MA KP3-V2H-2 en

Positioner
KP3-V2H-2
Assembly Instructions
Issued: 12.11.2020
MA KP3-V2H-2 V1
KUKA Deutschland GmbH
KP3-V2H-2
© Copyright 2020
KUKA Deutschland GmbH
Zugspitzstraße 140
D-86165 Augsburg
Germany
This documentation or excerpts therefrom may not be reproduced or disclosed to third parties
without the express permission of KUKA Deutschland GmbH.
Other functions not described in this documentation may be operable in the controller. The user
has no claims to these functions, however, in the case of a replacement or service work.
We have checked the content of this documentation for conformity with the hardware and soft-
ware described. Nevertheless, discrepancies cannot be precluded, for which reason we are not
able to guarantee total conformity. The information in this documentation is checked on a regu-
lar basis, however, and necessary corrections will be incorporated in the subsequent edition.
Subject to technical alterations without an effect on the function.
KIM-PS5-DOC
Translation of the original documentation
Publication: Pub MA KP3-V2H-2 (PDF) en

PB14956
Book structure: MA KP3-V2H-2 V1.1

BS13515
Version: MA KP3-V2H-2 V1
2/155 | www.kuka.com MA KP3-V2H-2 V1 | Issued: 12.11.2020

KP3-V2H-2
Contents
1 Introduction.............................................................................................. 7
1.1 Target group.......................................................................................................... 7
1.2 Positioning system documentation........................................................................ 7
1.3 Representation of warnings and notes................................................................. 7
1.4 Terms used............................................................................................................ 8
2 Product description................................................................................. 11
2.1 Overview of the positioner.................................................................................... 11
2.2 Description of the positioner................................................................................. 11
2.3 Control and integration.......................................................................................... 13
2.4 Intended use and misuse...................................................................................... 14
3 Safety......................................................................................................... 17
3.1 General.................................................................................................................. 17
3.1.1 Disclaimer.............................................................................................................. 17
3.1.2 EC declaration of conformity and declaration of incorporation............................ 18
3.1.3 Terms in the “Safety” chapter............................................................................... 18
3.2 Personnel............................................................................................................... 20
3.3 Workspace, safety zone and danger zone........................................................... 21
3.4 Overview of protective equipment........................................................................ 21
3.4.1 Mechanical end stops........................................................................................... 22
3.4.2 Mechanical axis limitation (optional)..................................................................... 22
3.4.3 Options for moving the manipulator without drive energy................................... 22
3.4.4 Labeling on the industrial robot............................................................................ 23
3.5 Safety measures.................................................................................................... 23
3.5.1 General safety measures...................................................................................... 23
3.5.2 Transportation........................................................................................................ 25
3.5.3 Start-up and recommissioning.............................................................................. 25
3.5.4 Manual mode......................................................................................................... 27
3.5.5 Automatic mode..................................................................................................... 28
3.5.6 Maintenance and repair........................................................................................ 28
3.5.7 Decommissioning, storage and disposal.............................................................. 30
4 Technical data.......................................................................................... 31
4.1 Technical data, overview....................................................................................... 31
4.2 Technical data, KP3-V2H500 R600 L2600-2........................................................ 31
4.2.1 Basic data, KP3-V2H500 R600 L2600-2.............................................................. 31
4.2.2 Axis data, KP3-V2H500 R600 L2600-2................................................................ 33
4.2.3 Payloads, KP3-V2H500 R600 L2600-2................................................................ 35
4.2.4 Foundation loads, KP3-V2H500 R600 L2600-2................................................... 36
4.3 Technical data, KP3-V2H1000 R600 L2000-2...................................................... 38
4.3.1 Basic data, KP3-V2H1000 R600 L2000-2............................................................ 38
4.3.2 Axis data, KP3-V2H1000 R600 L2000-2.............................................................. 39
4.3.3 Payloads, KP3-V2H1000 R600 L2000-2.............................................................. 42
4.3.4 Foundation loads, KP3-V2H1000 R600 L2000-2................................................. 42
4.4 Technical data, KP3-V2H1000 R800 L2600-2...................................................... 44
4.4.1 Basic data, KP3-V2H1000 R800 L2600-2............................................................ 44
MA KP3-V2H-2 V1 | Issued: 12.11.2020 www.kuka.com | 3/155

KP3-V2H-2
4.4.2 Axis data, KP3-V2H1000 R800 L2600-2.............................................................. 45

4.4.3 Payloads, KP3-V2H1000 R800 L2600-2.............................................................. 48
4.4.4 Foundation loads, KP3-V2H1000 R800 L2600-2................................................. 48
4.5 Plates and labels................................................................................................... 49
4.6 REACH duty to communicate information acc. to Art. 33................................... 52
4.7 Stopping distances................................................................................................ 52
5 Planning.................................................................................................... 53
5.1 Information for planning........................................................................................ 53
5.2 Mounting base with centering............................................................................... 53
5.3 Machine frame mounting....................................................................................... 56
5.4 Dimensions of face plates..................................................................................... 58
5.5 Counterbearing variants........................................................................................ 59
5.6 Connecting cables and interfaces......................................................................... 60
6 Transportation.......................................................................................... 63
6.1 Transporting the positioner.................................................................................... 63
7 Start-up and recommissioning............................................................... 65

7.1 Starting up the positioner (mounting base).......................................................... 65
7.1.1 Installing the positioner with a mounting base..................................................... 67
7.1.2 Connecting the connecting cables........................................................................ 68
7.1.3 Machine data......................................................................................................... 69
7.1.4 Mastering the positioner........................................................................................ 69
7.1.5 Concluding work.................................................................................................... 72
7.2 Starting up the positioner (machine frame mounting).......................................... 72
7.2.1 Installing the positioner with machine frame mounting........................................ 74
7.2.2 Connecting the connecting cables........................................................................ 75
7.2.3 Machine data......................................................................................................... 76
7.2.4 Mastering the positioner........................................................................................ 76
7.2.5 Concluding work.................................................................................................... 79
7.3 Description of the connecting cables.................................................................... 79
8 Maintenance.............................................................................................. 81
8.1 Maintenance overview........................................................................................... 81
8.1.1 Maintenance table................................................................................................. 81
8.2 Cleaning the positioner......................................................................................... 83
8.2.1 Cleaning................................................................................................................. 84
8.2.2 Concluding work.................................................................................................... 84
9 Repair........................................................................................................ 85
9.1 Exchanging motor A1............................................................................................ 85
9.1.1 Removing covers from the main beam................................................................ 87
9.1.2 Removing motor A1.............................................................................................. 87
9.1.3 Installing motor A1................................................................................................ 88
9.1.4 Installing covers on the main beam..................................................................... 89
9.1.5 Concluding work.................................................................................................... 90
9.2.1 Removing the drive unit covers............................................................................ 92
9.2.2 Removing motor A2.............................................................................................. 93

KP3-V2H-2
9.2.4 Installing the drive unit covers.............................................................................. 95

9.2.5 Concluding work.................................................................................................... 96
9.3.1 Removing the drive unit covers............................................................................ 98
9.3.2 Removing motor A3.............................................................................................. 99
9.3.4 Installing the drive unit covers.............................................................................. 101
9.3.5 Concluding work.................................................................................................... 102
9.4 Description of the electrical installations.............................................................. 102
10 Decommissioning, storage and disposal............................................. 109

10.1 Decommissioning................................................................................................... 109
10.1.1 Moving the positioner into its transport position.................................................. 110
10.1.2 Removing the positioner....................................................................................... 110
10.1.3 Concluding work.................................................................................................... 111
10.2 Storage.................................................................................................................. 111
10.2.1 Removing the positioner....................................................................................... 113
10.2.2 Cleaning................................................................................................................. 114
10.2.3 Preparing for storage............................................................................................ 114
10.2.4 Concluding work.................................................................................................... 114
10.3 Disposal................................................................................................................. 114
11 Options...................................................................................................... 117
11.1 Anti-glare equipment (optional)............................................................................. 117
11.1.1 Putting the anti-glare equipment into operation, distance between face plates
2000 mm................................................................................................................ 120
11.1.1.1 Fastening the anti-glare equipment...................................................................... 121
11.1.1.2 Concluding work.................................................................................................... 126
11.1.2 Putting the anti-glare equipment into operation, distance between face plates
2600 mm................................................................................................................ 126
11.1.2.1 Fastening the anti-glare equipment...................................................................... 127
11.1.2.2 Concluding work.................................................................................................... 132
11.1.3 Decommissioning................................................................................................... 132
11.1.3.1 Moving the positioner into its transport position.................................................. 133
11.1.3.2 Removing the anti-glare equipment...................................................................... 133
11.1.3.3 Concluding work.................................................................................................... 134
11.2 Weld current return, infinitely rotating (optional).................................................. 134
11.2.1 Exchanging the current collector.......................................................................... 138
11.2.1.1 Removing the cover on the drive side................................................................. 139
11.2.1.2 Removing the current collector on the drive side................................................ 140
11.2.1.3 Installing the current collector on the drive side.................................................. 142
11.2.1.4 Mounting the cover on the drive side................................................................... 143
11.2.1.5 Concluding work.................................................................................................... 143
11.3 Position monitoring................................................................................................ 143
12 Appendix................................................................................................... 147
12.1 Tightening torques................................................................................................. 147
12.2 Auxiliary and operating materials used................................................................ 148
12.3 Applied standards and regulations....................................................................... 148
13 KUKA Service........................................................................................... 151

KP3-V2H-2
13.1 Requesting support............................................................................................... 151

13.2 KUKA Customer Support...................................................................................... 151
Index 153

KP3-V2H-2
Introduction
1 Introduction
1.1 Target group
This documentation is aimed at users with the following knowledge and

skills:
• Advanced knowledge of mechanical engineering
• Advanced knowledge of electrical and electronic systems
• Advanced knowledge of programming external axes
• Advanced knowledge of machine data
• Knowledge of the robot controller system
For optimal use of KUKA products, we recommend the training courses

offered by KUKA College. Information about the training program can be
found at www.kuka.com or can be obtained directly from our subsidia-
ries.
1.2 Positioning system documentation
The positioner documentation consists of the following parts:

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

Introduction KP3-V2H-2
These warnings contain references to safety-relevant information or gen-

eral safety measures.
These warnings do not refer to individual hazards or individual precau-
tionary measures.
This warning draws attention to procedures which serve to prevent or rem-

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

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

The stopping distance is part of the danger zone.
Drive unit A combination of motor and gear unit.
Workspace Area within which the robot may move. The workspace is derived
from the individual axis ranges.
EMD Electronic Mastering Device
Danger zone The danger zone consists of the workspace and the stopping dis-
tances of the manipulator and external axes (optional).
KCP KUKA Control Panel

Teach pendant for the KR C2/KR C2 edition2005
The KCP has all the operator control and display functions required
for operating and programming the industrial robot.
KP KUKA Positioner
Kinematic system that is controlled by the robot controller as an ex-
ternal axis.
KR C KUKA Robot Control

Robot controller
KUKA smartPAD see “smartPAD”
KUKA smartPAD-2 see “smartPAD”

KP3-V2H-2
Introduction
Manipulator The robot arm and the associated electrical installations
RDC Resolver Digital Converter

The resolver digital converter is used to acquire motor data (e.g.
position data, motor temperatures).
Safety zone The safety zone is situated outside the danger zone.
smartPAD Programming device for the robot controller

The smartPAD has all the operator control and display functions re-
quired for operating and programming the industrial robot. 2 models
exist:
• smartPAD
• smartPAD-2
In turn, for each model there are variants, e.g. with different lengths
of connecting cables.
For robot controllers of the KR C5 series, only the model “smart-
PAD-2” is used.
For other robot controllers, the designation “KUKA smartPAD” or
“smartPAD” always refers to both models unless an explicit distinc-
tion is made.
PLC Programmable Logic Controller

Used in systems as a higher-level master module in the bus sys-
tem.
Stop category 0 The drives are deactivated immediately and the brakes are applied.
The manipulator and any external axes (optional) perform path-ori-
ented braking.
Note: This stop category is called STOP 0 in this document.
Stop category 1 The manipulator and any external axes (optional) perform path-
maintaining braking.
• Operating mode T1: the drives are deactivated as soon as the

robot has stopped, but no later than after 680 ms.
• Operating modes T2, AUT (KR C controller), AUT EXT (KR C
controller), EXT (VKR C controller):
The drives are switched off after 1.5 s.
Stop category 2 The drives are not deactivated and the brakes are not applied. The
manipulator and any external axes (optional) are braked with a
path-maintaining braking ramp.
T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)
T2 Test mode, Manual High Velocity (> 250 mm/s permissible)
External axis Axis of motion that does not belong to the manipulator, yet is con-
trolled with the robot controller. e.g. KUKA linear unit, turn-tilt table,
Posiflex

Introduction KP3-V2H-2

KP3-V2H-2
Product description
2 Product description
2.1 Overview of the positioner
The KP3-V2H-2 product family comprises the following positioners:

• KP3-V2H500 R600 L2600-2
• KP3-V2H1000 R600 L2000-2
• KP3-V2H1000 R800 L2600-2
Fig. 2-1: Overview of the positioner
2.2 Description of the positioner
Overview
The positioner has 3 axes, which are controlled via the robot controller. A
customer-specific or project-specific fixture is mounted by means of a me-
chanical interface (e.g. locating holes and threaded holes). The system
may optionally have an energy supply system integrated into it (e.g. for
compressed air, electrical current).
In the document, the axes of the positioner are designated Axis 1 (A1),
Axis 2 (A2) and Axis 3 (A3). In the actual application, A1, A2, A3 might
already be assigned to different system components.

Product description KP3-V2H-2
Fig. 2-2: Principal components
1 Counterbearing unit of planetary axis

2 Planetary axis (cross-member)
3 Main beam
4 Drive unit of planetary axis
5 Main support
6 Interface A1
7 Base frame
Base frame
The base frame forms the basis of the positioner and houses motor A1.
Fastened to the base frame is the central support, which supports the
main axis. Also located on the base frame is the interface for the motor
and data cables and the energy supply system (optional).
Main beam
The main beam forms the main axis and supports the two planetary axes
on its arms.
Planetary axes
The planetary axes consist of drive with motor, gear unit, counterbearing
and face plates; the workpiece fixtures are mounted on the face plates.
The face plates are electrically insulated.
Electrical installations
The electrical installations include all the motor and data cables for the
motors of axes 1 to 3. The complete electrical installations consist of ca-
ble set A1 - A3.
The electrical installations also include holders and the RDC, which is fas-
tened to the main beam.
All connections are implemented as connectors in order to enable the mo-
tors to be exchanged quickly and reliably. The electrical installations also

KP3-V2H-2
include a protective circuit. The ground conductors to the positioner are
Product description
connected to the base frame by means of ring cable lugs and setscrews.
Accessories
Only accessories authorized by KUKA Deutschland GmbH for this posi-

tioner may be used. All items of equipment must possess the appropriate
certification and EC declarations of conformity.
Options
The positioner can be equipped and operated with various options, e.g. an
energy supply system and/or support strips. The option is described in
separate documentation.
The following options are also available:
• Anti-glare equipment (>>> 11.1 "Anti-glare equipment (optional)"
Page 117)
• Weld current return, infinitely rotating (>>> 11.2 "Weld current return,
infinitely rotating (optional)" Page 134)
• Position monitoring (>>> 11.3 "Position monitoring" Page 143)
2.3 Control and integration
Description
The drive units of the positioner are operated as external axes of the ro-
bot controller. The following couplings are possible:
• Asynchronous operation. There is no mathematical coupling with the
robot.
• Mathematical coupling of one or more drive units into the robot kine-
matic system.
Root point calibration is required for the mathematical coupling.
Further information about calibration of an external kinematic system is

contained in the Operating and Programming Instructions for System In-
tegrators.
An example of a mathematical coupling is depicted in the following dia-

gram.

Fig. 2-3: Robot with external axes and extended kinematic system
With mathematical coupling, the robot constantly follows the movement of

the coupled external axes. The mathematical coupling can simplify the
programming for complex processes, e.g. arc welding. Using this method,
a constant defined orientation can be maintained during a CP motion, for
example.
2.4 Intended use and misuse
Intended use
The positioner is intended to move and position loads and workpieces.

Use is only permitted under the specified environmental conditions.
Operation of the positioner in accordance with its intended use also re-
quires compliance with the operating and assembly instructions for the in-
dividual components, with particular reference to the maintenance specifi-
cations.
Misuse
Any use or application deviating from the intended use is deemed to be

misuse and is not allowed. It will result in the loss of warranty and liability
claims. KUKA is not liable for any damage resulting from such misuse.
This includes e.g.:
• Use as a climbing aid
• Operation outside the specified operating parameters
• Operation without the required safety equipment
• Transportation of persons and animals
• Outdoor operation.
• Use in a potentially explosive area
• Use in radioactive environments
• Operation in underground mining
NOTICE
Deviations from the operating conditions specified in the technical data
or the use of special functions or applications can lead to premature
wear. KUKA Deutschland GmbH must be consulted.

KP3-V2H-2
Product description
The positioner is an integral part of an overall system and may only be
operated in a CE-compliant system.


KP3-V2H-2
Safety
3 Safety
3.1 General
• This “Safety” chapter refers to a mechanical component of an indus-

trial robot.
• If the mechanical component is used together with a KUKA robot
controller, the “Safety” chapter of the operating instructions or as-
sembly instructions of the robot controller must be used!
This contains all the information provided in this “Safety” chapter. It
also contains additional safety information relating to the robot con-
troller which must be observed.
• Where this “Safety” chapter uses the term “industrial robot”, this also
refers to the individual mechanical component if applicable.
3.1.1 Disclaimer
The device described in this document is either an industrial robot or a

component thereof.
Components of the industrial robot:
• Manipulator
• Robot controller
• Teach pendant
• Connecting cables
• External axes (optional)
e.g. linear unit, turn-tilt table, positioner
• Software
• Options, accessories
The industrial robot is built using state-of-the-art technology and in accord-
ance with the recognized safety rules. Nevertheless, misuse of the indus-
trial robot may constitute a risk to life and limb or cause damage to the
industrial robot and to other material property.
The industrial robot may only be used in perfect technical condition in ac-
cordance with its intended use and only by safety-conscious persons who
are fully aware of the risks involved in its operation. Use of the industrial
robot is subject to compliance with this document and with the declaration
of incorporation supplied together with the industrial robot. Any functional
disorders, especially those affecting safety, must be rectified immediately.
Safety information
Information about safety may not be construed against the manufacturer.

Even if all safety instructions are followed, this is not a guarantee that the
industrial robot will not cause personal injuries or material damage.
No modifications may be carried out to the industrial robot without the au-
thorization of the manufacturer. Unauthorized modifications will result in
the loss of warranty and liability claims.
Additional components (tools, software, etc.), not supplied by the manufac-
turer, may be integrated into the industrial robot. The user is liable for any
damage these components may cause to the industrial robot or to other
material property.
In addition to the Safety chapter, this document contains further safety in-
structions. These must also be observed.

Safety KP3-V2H-2
3.1.2 EC declaration of conformity and declaration of incorporation
The industrial robot constitutes partly completed machinery as defined by

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

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

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

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

KP3-V2H-2
Safety
Service life The service life of a safety-relevant component begins at the time
of delivery of the component to the customer.
The service life is not affected by whether the component is used
or not, as safety-relevant components are also subject to aging dur-
ing storage.
Danger zone The danger zone consists of the workspace and the stopping dis-
tances of the manipulator and external axes (optional).
KCP KUKA Control Panel

Teach pendant for the KR C2/KR C2 edition2005
The KCP has all the operator control and display functions required
for operating and programming the industrial robot.
KUKA smartPAD see “smartPAD”
KUKA smartPAD-2 see “smartPAD”
Manipulator The robot arm and the associated electrical installations
Safety zone The safety zone is situated outside the danger zone.
Safety options Generic term for options which make it possible to configure addi-
tional safe monitoring functions in addition to the standard safety
functions.
Example: SafeOperation
smartPAD Programming device for the robot controller

The smartPAD has all the operator control and display functions re-
quired for operating and programming the industrial robot. 2 models
exist:
• smartPAD
• smartPAD-2
In turn, for each model there are variants, e.g. with different lengths
of connecting cables.
For robot controllers of the KR C5 series, only the model “smart-
PAD-2” is used.
For other robot controllers, the designation “KUKA smartPAD” or
“smartPAD” always refers to both models unless an explicit distinc-
tion is made.
Stop category 0 The drives are deactivated immediately and the brakes are applied.
The manipulator and any external axes (optional) perform path-ori-
ented braking.
Stop category 1 The manipulator and any external axes (optional) perform path-
maintaining braking.


Safety KP3-V2H-2
Stop category 1 – The manipulator and any external axes (optional) perform path-ori-
Drive Ramp Stop ented braking.

Note: This stop category is called STOP 1 - DRS in this document.
Stop category 2 The drives are not deactivated and the brakes are not applied. The
manipulator and any external axes (optional) are braked with a
path-maintaining braking ramp.
System integrator The system integrator is responsible for safely integrating the indus-
(plant integrator) trial robot into a complete system and commissioning it.
T1 Test mode, Manual Reduced Velocity (<= 250 mm/s)
T2 Test mode, Manual High Velocity (> 250 mm/s permissible)
External axis Axis of motion that does not belong to the manipulator, yet is con-
trolled with the robot controller. e.g. KUKA linear unit, turn-tilt table,
Posiflex
3.2 Personnel
The following persons or groups of persons are defined for the industrial
robot:
• User
• Personnel
Qualification of personnel
Work on the system must only be performed by personnel that is able
to assess the tasks to be carried out and detect potential hazards.
Death, severe injuries or damage to property may otherwise result. The
following qualifications are required:
• Adequate specialist training, knowledge and experience
• Knowledge of the relevant operating or assembly instructions, knowl-
edge of the relevant standards
• All persons working with the industrial robot must have read and un-
derstood the industrial robot documentation, including the safety
chapter.
User
The user must observe the labor laws and regulations. This includes e.g.:
• The user must comply with his monitoring obligations.

• The user must carry out briefing at defined intervals.
• The user must comply with the regulations relating to personal protec-
tive equipment (PSA).

KP3-V2H-2
Safety
Personnel
Personnel must be instructed, before any work is commenced, in the type

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

• Connecting the industrial robot
• Performing risk assessment
• Implementing the required safety functions and safeguards
• Issuing the EC declaration of conformity
• Attaching the CE mark
• Creating the operating instructions for the system
Operators
The operator must meet the following preconditions:

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

space must be safeguarded using appropriate safeguards.
The safeguards (e.g. safety gate) must be situated inside the safety zone.
In the case of a stop, the manipulator and external axes (optional) are
braked and come to a stop within the danger zone.
The danger zone consists of the workspace and the stopping distances of
the manipulator and external axes (optional). It must be safeguarded by
means of physical safeguards to prevent danger to persons or the risk of
material damage.
3.4 Overview of protective equipment
The protective equipment of the mechanical component may include:
• Mechanical end stops

Safety KP3-V2H-2
• Mechanical axis limitation (optional)

• Release device (optional)
• Brake release device (optional)
• Labeling of danger areas
Not all equipment is relevant for every mechanical component.
3.4.1 Mechanical end stops
Depending on the robot variant, the axis ranges of the main and wrist ax-
es of the manipulator are partially limited by mechanical end stops.
Additional mechanical end stops can be installed on the external axes.
WARNING
Danger to life and limb following collision with obstacle
If the manipulator or an external axis hits an obstruction or a mechani-
cal end stop or mechanical axis limitation, the manipulator can no
longer be operated safely. Death, injuries or damage to property may re-
sult.
• Put manipulator out of operation.
• KUKA must be consulted before it is put back into operation.
3.4.2 Mechanical axis limitation (optional)
Some manipulators can be fitted with mechanical axis limitation systems

in axes A1 to A3. The axis limitation systems restrict the working range to
the required minimum. This increases personal safety and protection of
the system.
In the case of manipulators that are not designed to be fitted with me-
chanical axis limitation, the workspace must be laid out in such a way that
there is no danger to persons or material property, even in the absence of
mechanical axis limitation.
If this is not possible, the workspace must be limited by means of photo-
electric barriers, photoelectric curtains or obstacles on the system side.
There must be no shearing or crushing hazards at the loading and trans-
fer areas.
This option is not available for all robot models. Information on specific
robot models can be obtained from the manufacturer.
3.4.3 Options for moving the manipulator without drive energy
Qualification of personnel with regard to behavior in emergency

situations
In emergencies or other exceptional situations, it may be necessary to
move the manipulator without drive energy.
• Personnel must be trained in how to move the manipulator without
drive energy.
Description
The following options are available for moving the manipulator without
drive energy after an accident or malfunction:

KP3-V2H-2
Safety
• Release device (optional)
The release device can be used for the main axis drive motors and,
depending on the robot variant, also for the wrist axis drive motors.
• Brake release device (option)
The brake release device is designed for robot variants whose motors
are not freely accessible.
• Moving the wrist axes directly by hand
There is no release device available for the wrist axes of variants in
the low payload category. This is not necessary because the wrist ax-
es can be moved directly by hand.
Information about the options available for the various robot models and
about how to use them can be found in the assembly and operating in-
structions for the robot or can be requested from the manufacturer.
NOTICE
Damage to property due to moving the manipulator without drive
energy
Moving the manipulator without drive energy can damage the motor
brakes of the axes concerned.
• Only move the manipulator without drive energy in emergencies,
e.g. for rescuing persons.
• The motor must be replaced if the brake has been damaged.
3.4.4 Labeling on the industrial robot
All plates, labels, symbols and marks constitute safety-relevant parts of

the industrial robot. They must not be modified or removed.
Labeling on the industrial robot consists of:
• Identification plates
• Warning signs
• Safety symbols
• Designation labels
• Cable markings
• Rating plates
Further information is contained in the technical data of the operating in-

structions or assembly instructions of the components of the industrial
robot.
3.5 Safety measures
3.5.1 General safety measures
The industrial robot may only be used in perfect technical condition in ac-
cordance with its intended use and only by safety-conscious persons. Op-
erator errors can result in personal injury and damage to property.
It is important to be prepared for possible movements of the industrial ro-
bot even after the robot controller has been switched off and locked out.
Incorrect installation (e.g. overload) or mechanical defects (e.g. brake de-
fect) can cause the manipulator or external axes to sag. If work is to be
carried out on a switched-off industrial robot, the manipulator and external
axes must first be moved into a position in which they are unable to move

KP3-V2H-2
on their own, whether the payload is mounted or not. If this is not possi-
Safety
ble, the manipulator and external axes must be secured by appropriate

means.
DANGER
Risk of fatal injury due to non-operational safety functions or exter-
nal safeguards
In the absence of operational safety functions or safeguards, the indus-
trial robot can cause death, severe injuries or damage to property.
• If safety functions or safeguards are dismantled or deactivated, do
not operate the industrial robot.
DANGER
Danger to life and limb of persons under the robot arm
Sagging or falling parts can cause death or serious injuries. This applies
at all times, e.g. also for assembly tasks or with the controller switched
off.
• Never loiter under the robot arm.
CAUTION
Risk of burns from hot motors
The motors reach temperatures during operation which can cause
burns.
• Avoid contact.
• Take appropriate safety precautions, e.g. wear protective gloves.
KCP/smartPAD
The user must ensure that the industrial robot is only operated with the
KCP/smartPAD by authorized persons.
If more than one KCP/smartPAD is used in the overall system, it must be
ensured that each device is unambiguously assigned to the corresponding
industrial robot. They must not be interchanged.
WARNING
The operator must ensure that decoupled KCPs/smartPADs are immedi-
ately removed from the system and stored out of sight and reach of per-
sonnel working on the industrial robot. This serves to prevent operation-
al and non-operational EMERGENCY STOP devices from becoming in-
terchanged.
Failure to observe this precaution may result in death, severe injuries or
considerable damage to property.
External keyboard, external mouse
An external keyboard and/or external mouse may only be used if the fol-
lowing conditions are met:
• Start-up or maintenance work is being carried out.

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

KP3-V2H-2
Safety
Modifications
After modifications to the industrial robot, checks must be carried out to

ensure the required safety level. The valid national or regional work safety
regulations must be observed for this check. The correct functioning of all
safety functions must also be tested.
New or modified programs must always be tested first in Manual Reduced
Velocity mode (T1).
After modifications to the industrial robot, existing programs must always
be tested first in Manual Reduced Velocity mode (T1). This applies to all
components of the industrial robot and includes e.g. modifications of the
external axes or to the software and configuration settings.
Faults
The following tasks must be carried out in the case of faults in the indus-
trial robot:
• Switch off the robot controller and secure it (e.g. with a padlock) to
prevent unauthorized persons from switching it on again.
• Indicate the fault by means of a label with a corresponding warning
(tagout).
• Keep a record of the faults.
• Eliminate the fault and carry out a function test.
3.5.2 Transportation
Manipulator
The prescribed transport position of the manipulator must be observed.

Transportation must be carried out in accordance with the operating in-
structions or assembly instructions of the robot.
Avoid vibrations and impacts during transportation in order to prevent
damage to the manipulator.
Robot controller
The prescribed transport position of the robot controller must be observed.

Transportation must be carried out in accordance with the operating in-
structions or assembly instructions of the robot controller.
Avoid vibrations and impacts during transportation in order to prevent
damage to the robot controller.
External axis (optional)
The prescribed transport position of the external axis (e.g. KUKA linear
unit, turn-tilt table, positioner) must be observed. Transportation must be
carried out in accordance with the operating instructions or assembly in-
structions of the external axis.
3.5.3 Start-up and recommissioning
Before starting up systems and devices for the first time, a check must be
carried out to ensure that the systems and devices are complete and op-
erational, that they can be operated safely and that any damage is detec-
ted.
The valid national or regional work safety regulations must be observed
for this check. The correct functioning of all safety circuits must also be
tested.

Safety KP3-V2H-2
The passwords for logging onto the KUKA System Software as “Expert”
and “Administrator” must be changed before start-up and must only be
communicated to authorized personnel.
WARNING
Danger to life and limb due to incorrectly assigned cables
The robot controller is preconfigured for the specific industrial robot. The
manipulator and other components can receive incorrect data if they are
connected to a different robot controller. Death, severe injuries or dam-
age to property may result.
• Only connect the manipulator to the corresponding robot controller.
Do not impair safety functions

Additional components (e.g. cables and hoses) not supplied by KUKA
may be integrated into the industrial robot. If the safety functions are not
taken into consideration, this may result in death, severe injuries or
damage to property.
• Additional components must not impair or disable safety functions.
NOTICE
Damage to property due to condensation
If the internal cabinet temperature of the robot controller differs greatly
from the ambient temperature, condensation can form. This may result
in damage to property.
• Wait until the internal cabinet temperature has adapted to the ambi-
ent temperature in order to avoid condensation.
Function test
The following tests must be carried out before start-up and recommission-
ing:
It must be ensured that:
• The industrial robot is correctly installed and fastened in accordance

with the specifications in the documentation.
• There is no damage to the robot that could be attributed to external
forces. Example: Dents or abrasion that could be caused by an impact
or collision.
WARNING
Danger to life and limb resulting from external forces
External forces, such as an impact or a collision, can cause non-
visible damage. For example, it can lead to a gradual loss of drive
power from the motor, resulting in unintended movements of the ma-
nipulator.
Death, severe injuries or damage to property may result from non-
visible damage.
‒ Check the robot for damage that could have been caused by ex-
ternal forces, e.g. dents or abrasion of paintwork.
Check the motor and counterbalancing system particularly care-
fully.
‒ In the case of damage, the affected components must be ex-
changed.
• There are no foreign bodies or loose parts on the industrial robot.

• All required safety equipment is correctly installed and operational.

KP3-V2H-2
Safety
• The power supply ratings of the industrial robot correspond to the
local supply voltage and mains type.
• The ground conductor and the equipotential bonding cable are suffi-
ciently rated and correctly connected.
• The connecting cables are correctly connected and the connectors are
locked.
3.5.4 Manual mode
Manual mode is the mode for setup work. Setup work is all the tasks that
have to be carried out on the industrial robot to enable automatic opera-
tion. Setup work includes:
• Jog mode
• Teaching
• Programming
• Program verification
The following must be taken into consideration in manual mode:
• If the drives are not required, they must be switched off to prevent the
manipulator or the external axes (optional) from being moved uninten-
tionally.
• New or modified programs must always be tested first in Manual Re-
duced Velocity mode (T1).
• The manipulator, tooling or external axes (optional) must never touch
or project beyond the safety fence.
• Workpieces, tooling and other objects must not become jammed as a
result of the industrial robot motion, nor must they lead to
short-circuits or be liable to fall off.
• All setup work must be carried out, where possible, from outside the
safeguarded area.
If the setup work has to be carried out inside the safeguarded area, the
following must be taken into consideration:
In Manual Reduced Velocity mode (T1):
• If it can be avoided, there must be no other persons inside the safe-

guarded area.
If it is necessary for there to be several persons inside the safeguar-
ded area, the following must be observed:
‒ Each person must have an enabling device.
‒ All persons must have an unimpeded view of the industrial robot.
‒ Eye-contact between all persons must be possible at all times.
• The operator must be so positioned that he can see into the danger
area and get out of harm’s way.
In Manual High Velocity mode (T2):
• This mode may only be used if the application requires a test at a ve-
locity higher than possible in T1 mode.
• Teaching and programming are not permissible in this operating mode.
• Before commencing the test, the operator must ensure that the ena-
bling devices are operational.
• The operator must be positioned outside the danger zone.
• There must be no other persons inside the safeguarded area. It is the
responsibility of the operator to ensure this.

Safety KP3-V2H-2
3.5.5 Automatic mode
Automatic mode is only permissible in compliance with the following safety

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

• There are no persons in the system.
• The defined working procedures are adhered to.
If the manipulator or an external axis (optional) comes to a standstill for
no apparent reason, the danger zone must not be entered until an EMER-
GENCY STOP has been triggered.
3.5.6 Maintenance and repair
After maintenance and repair work, checks must be carried out to ensure
the required safety level. The valid national or regional work safety regula-
tions must be observed for this check. The correct functioning of all safety
functions must also be tested.
The purpose of maintenance and repair work is to ensure that the system
is kept operational or, in the event of a fault, to return the system to an
operational state. Repair work includes troubleshooting in addition to the
actual repair itself.
The following safety measures must be carried out when working on the
industrial robot:
• Carry out work outside the danger zone. If work inside the danger
zone is necessary, the user must define additional safety measures to
ensure the safe protection of personnel.
• Switch off the industrial robot and secure it (e.g. with a padlock) to
prevent it from being switched on again. If it is necessary to carry out
work with the robot controller switched on, the user must define addi-
tional safety measures to ensure the safe protection of personnel.
• If it is necessary to carry out work with the robot controller switched
on, this may only be done in operating mode T1.
• Label the system with a sign indicating that work is in progress. This
sign must remain in place, even during temporary interruptions to the
work.
• The EMERGENCY STOP devices must remain active. If safety func-
tions or safeguards are deactivated during maintenance or repair work,
they must be reactivated immediately after the work is completed.
DANGER
Danger to life and limb due to live parts
The robot system must be disconnected from the mains power supply
prior to work on live parts. It is not sufficient to trigger an EMERGENCY
STOP or safety stop, because parts remain live. Death or severe inju-
ries may result.
• Before commencing work on live parts, turn off the main switch and
secure it against being switched on again.
If the controller variant in question does not have a main switch
(e.g. KR C5 micro), turn off the device switch then disconnect the
power cable and secure it so it cannot be reconnected.
• Then check to ensure that the system is deenergized.
• Inform the individuals involved that the robot controller is switched
off. (e.g. by affixing a warning sign)

KP3-V2H-2
Faulty components must be replaced using new components with the
Safety
same article numbers or equivalent components approved by the manu-
facturer for this purpose.
Cleaning and preventive maintenance work is to be carried out in accord-
ance with the operating instructions.
Robot controller
Even when the robot controller is switched off, parts connected to periph-
eral devices may still carry voltage. The external power sources must
therefore be switched off if work is to be carried out on the robot control-
ler.
The ESD regulations must be adhered to when working on components in
the robot controller.
Voltages in excess of 50 V (up to 600 V) can be present in various com-
ponents for several minutes after the robot controller has been switched
off! To prevent life-threatening injuries, no work may be carried out on the
industrial robot in this time.
Water and dust must be prevented from entering the robot controller.
Counterbalancing system
Some robot variants are equipped with a hydropneumatic, spring or gas

cylinder counterbalancing system.
• Counterbalancing system classified below category I: is subject to
the Pressure Equipment Directive but exempt from application of the
Pressure Equipment Directive according to Art. 4, para. 3 and there-
fore not CE marked.
• Counterbalancing system classified as category I or higher: is
subject to the Pressure Equipment Directive and CE marked as a
component (see rating plate of the counterbalancing system). The
pressure equipment is placed on the market in conjunction with partly
completed machinery. Conformity is expressed on the declaration of
incorporation according to the Machinery Directive.
The user must comply with the applicable national laws, regulations and
standards pertaining to pressure equipment.
• In Germany, the counterbalancing system is work equipment according
to the German Ordinance on Industrial Safety and Health (BetrSichV).
Inspection intervals in Germany in accordance with the Ordinance on
Industrial Safety and Health, Sections 14 and 15. Inspection by the
user before commissioning at the installation site.
• Inspection intervals in all other countries must be researched and ob-
served. As a rule, however, at least the maintenance intervals speci-
fied by KUKA must be observed. Shorter intervals are not permitted.
The following safety measures must be carried out when working on the
counterbalancing system:
• The assemblies supported by the counterbalancing systems must be
secured.
• Work on the counterbalancing systems must only be carried out by
qualified personnel.
Hazardous substances
The following safety measures must be carried out when handling hazard-
ous substances:
• Avoid prolonged and repeated intensive contact with the skin.
• Avoid breathing in oil spray or vapors.

Safety KP3-V2H-2
• Clean skin and apply skin cream.
Use current safety data sheets

Knowledge of the safety data sheets of the substances and mixtures
used is a prerequisite for the safe use of KUKA products. Death,
injuries or damage to property may otherwise result.
• Request up-to-date safety data sheets from the manufacturers of
hazardous substances regularly.
3.5.7 Decommissioning, storage and disposal
The industrial robot must be decommissioned, stored and disposed of in

accordance with the applicable national laws, regulations and standards.

KP3-V2H-2
Technical data
4 Technical data
4.1 Technical data, overview
The technical data for the individual positioner types can be found in the
following sections:
Positioner Technical data
KP3-V2H500 R600 • Technical data
L2600-2
(>>> 4.2 "Technical data, KP3-V2H500 R600 L2600-2" Page 31)
• Plates and labels
(>>> 4.5 "Plates and labels" Page 49)
• Stopping distances and times
(>>> 4.7 "Stopping distances" Page 52)
L2000-2
(>>> 4.3 "Technical data, KP3-V2H1000 R600 L2000-2"
Page 38)
L2600-2
(>>> 4.4 "Technical data, KP3-V2H1000 R800 L2600-2"
Page 44)
4.2 Technical data, KP3-V2H500 R600 L2600-2
4.2.1 Basic data, KP3-V2H500 R600 L2600-2
Basic data
KP3-V2H500 R600 L2600-2

Number of axes 3
Weight approx. 1420 kg
Rated payload 500 kg
Protection rating (IEC 60529) IP67
Sound level < 78 dB (A)
Mounting position Floor
Default color Base frame: black (RAL 9005);
Moving parts: KUKA Industrial Or-
ange (RAL 2009);
Cover: KUKA Industrial Orange
(RAL 2009)
Controller KR C4

Technical data KP3-V2H-2
KP3-V2H500 R600 L2600-2

Footprint 754 mm x 754 mm
Hole pattern: mounting surface for S780
kinematic system
Pose repeatability
A1 0.0023 °
A2 0.009 °
A3 0.009 °
Hollow shaft diameter

A1 140 mm (partially occupied by mo-
tor cables)
A2 -
A3 -
Counterbearing A2 67 mm
Ambient conditions
Humidity class (EN 60204) -

Classification of environmental 3K3
conditions (EN 60721-3-3)
Ambient temperature
During operation 0 °C to 55 °C (273 K to 328 K)
During storage/transportation -40 °C to 60 °C (233 K to 333 K)
Connecting cables
Cable designation Connector designa- Interface on posi-

tion tioner
robot controller -
positioner
Motor cable X7.1 - XM7 6-contact circular
power connector, size
X8.1 - XM8
1
X9.1 - XM9
Data cable X21.1 -X31.1 17-contact signal cou-
pling circular connec-
tor
Ground conductor / - M8 ring cable lug at
equipotential bonding both ends
8 mm2
(optional)
Cable lengths 7 m, 15 m, 25 m
Max. cable length 50 m
Number of extensions 1
For detailed specifications of the connecting cables, see “Description of
the connecting cables”.

KP3-V2H-2
Technical data
4.2.2 Axis data, KP3-V2H500 R600 L2600-2
Axis data
Loading height 950 mm

Tool radius 600 mm
Distance between face plates 2600 mm
Motion range
A1 ±185 °
A2 Infinite
A3 Infinite
Motion range with energy supply system
A1 ±185 °
A2 ±190 °
A3 ±190 °
Turning time 180°
A1 3.1 s
A2 1.8 s
A3 1.8 s
Turning time 360°
A1 5.5 s
A2 2.8 s
A3 2.8 s
NOTICE
If the positioner is moved through 360° at maximum speed, this may re-
sult in damage to the positioner. To prevent this, the speed should be
reduced.
Direction of rotation
The orientation of a rotational axis is defined on the motor side (drive):

• “+” clockwise
• “-” counterclockwise
The direction of motion and the arrangement of the individual axes may
be noted from the following diagram (>>> Fig. 4-1):

Fig. 4-1: Direction of rotation of the axes
Mastering positions
Mastering position
A1 -60 °
A2 0 °
A3 0 °
Working envelope
The following diagrams show the shape and size of the working envelope
for these variants of this product family.

KP3-V2H-2
Technical data
Fig. 4-2: Working envelope, side view, KP3-V2H500 R600 L2600-2
1 Height: 1150 mm:

2 Loading height: 950 mm
3 Distance A2-A3 horizontal: 1655 mm
4 Tool radius: 600 mm
Fig. 4-3: Working envelope, top view, KP3-V2H500 R600 L2600-2
5 Interference circle radius A1: 1948 mm
4.2.3 Payloads, KP3-V2H500 R600 L2600-2
Payloads
Maximum load torque

A1 -
A2 736 Nm

A3 736 Nm
Mass moment of inertia
A1 -
A2 261 kgm²
A3 261 kgm²
4.2.4 Foundation loads, KP3-V2H500 R600 L2600-2
Description
The specified forces and torques already include the payload and the iner-
tia force (weight) of the positioner.
Vertical force F(v)
F(v normal) 24626 N
F(v max) 25526 N
Tilting moment M(k)
M(k normal) 6965 Nm
M(k max) 6965 Nm
Torque about axis 1 M(r)
M(r normal) 8790 Nm
M(r max) 15487 Nm
Vertical force F(v), tilting torque M(k), torque about axis 1 M(r)
*Tilting torque M(k) only occurs during start-up or change of fixture.

KP3-V2H-2
Technical data
Fig. 4-4: Foundation loads
WARNING
Normal loads and maximum loads for the foundations are specified in
the table.
The maximum loads must be referred to when dimensioning the founda-
tions and must be adhered to for safety reasons. Failure to observe this
can result in personal injury and damage to property.
The normal loads are average expected foundation loads. The actual
loads are dependent on the program and on the robot loads and may
therefore be greater or less than the normal loads.
The supplementary loads (A1 and A2) are not taken into consideration
in the calculation of the mounting base load. These supplementary
loads must be taken into consideration for Fv.

Basic data
KP3-V2H1000 R600 L2000-2

Number of axes 3
ange (RAL 2009);
(RAL 2009)
Controller KR C4
kinematic system
Pose repeatability
A1 0.0023 °
A2 0.009 °
A3 0.009 °

tor cables)
A2 -
A3 -
Ambient conditions

Ambient temperature

KP3-V2H-2
Technical data
Connecting cables

tion tioner
robot controller -
positioner
X8.1 - XM8
1
X9.1 - XM9
tor
8 mm2
(optional)
4.3.2 Axis data, KP3-V2H1000 R600 L2000-2
Axis data

Tool radius 600 mm
Motion range
A1 ±185 °
A2 Infinite
A3 Infinite
A1 ±185 °
A2 ±190 °
A3 ±190 °
Turning time 180°
A1 3.8 s
A2 1.8 s
A3 1.8 s
Turning time 360°
A1 6.8 s
A2 2.8 s
A3 2.8 s

NOTICE
reduced.

Mastering positions
Mastering position
A1 -60 °
A2 0 °
A3 0 °

KP3-V2H-2
Technical data
Working envelope
1 Height: 1200 mm:


4.3.3 Payloads, KP3-V2H1000 R600 L2000-2
Payloads
Maximum load torque

A1 -
A2 1472 Nm
A3 1472 Nm
A1 -
A2 523 kgm²
A3 523 kgm²
Description
Vertical force F(v)
F(v normal) 36250 N
F(v max) 37510 N
Tilting moment M(k)
M(k normal) 13910 Nm
M(k max) 13910 Nm
M(r normal) 9837 Nm
M(r max) 17271 Nm

KP3-V2H-2
Technical data
WARNING
the table.

Basic data
KP3-V2H1000 R800 L2600-2

Number of axes 3
ange (RAL 2009);
(RAL 2009)
Controller KR C4
kinematic system
Pose repeatability
A1 0.0023 °
A2 0.009 °
A3 0.009 °

tor cables)
A2 -
A3 -
Ambient conditions

Ambient temperature

KP3-V2H-2
Technical data
Connecting cables

tion tioner
robot controller -
positioner
X8.1 - XM8
1
X9.1 - XM9
tor
8 mm2
(optional)
4.4.2 Axis data, KP3-V2H1000 R800 L2600-2
Axis data

Tool radius 800 mm
Motion range
A1 ±185 °
A2 Infinite
A3 Infinite
A1 ±185 °
A2 ±190 °
A3 ±190 °
Turning time 180°
A1 3.8 s
A2 1.8 s
A3 1.8 s
Turning time 360°
A1 6.8 s
A2 2.8 s
A3 2.8 s

NOTICE
reduced.

Mastering positions
Mastering position
A1 -60 °
A2 0 °
A3 0 °

KP3-V2H-2
Technical data
Working envelope
1 Height: 1200 mm:


4.4.3 Payloads, KP3-V2H1000 R800 L2600-2
Payloads
Maximum load torque

A1 -
A2 1472 Nm
A3 1472 Nm
A1 -
A2 523 kgm²
A3 523 kgm²
Description
Vertical force F(v)
F(v normal) 36250 N
F(v max) 37510 N
Tilting moment M(k)
M(k normal) 13910 Nm
M(k max) 13910 Nm
M(r normal) 9837 Nm
M(r max) 17271 Nm

KP3-V2H-2
Technical data
WARNING
the table.
4.5 Plates and labels
Description
The following plates, labels and signs are attached to the positioner. They
must not be removed or rendered illegible. Illegible plates, labels and
signs must be replaced.

Fig. 4-13: Location of plates and labels
Item Description
1
Direction of translation/rotation
The label shows the plus and minus directions of the corre-
sponding translational/rotational axis.
2
Axis designation
3
Secure the axis

Before exchanging any motor, secure the corresponding axis
through safeguarding by suitable means/devices to protect
against possible movement. The axis can move. Risk of crush-
ing!
4
Do not slacken screwed connection

Do not slacken screwed connection! Observe safety instructions
and assembly instructions!

KP3-V2H-2
Technical data
Item Description
5
High voltage
Any improper handling can lead to contact with current-carrying
components. Electric shock hazard!
6
Hot surface
During operation of the robot, surface temperatures may be
reached that could result in burn injuries. Protective gloves must
be worn!
7
Work on the positioner

Before start-up, transportation or maintenance, read and follow
the assembly and operating instructions.
8
Danger zone
Entering the danger zone of the positioner is prohibited if the
positioner is in operation or ready for operation. Risk of injury!
9
Identification plate
Content according to Machinery Directive.
The QR code contains a link to product information in KUKA
Xpert.

Item Description
10
Axis designation
4.6 REACH duty to communicate information acc. to Art. 33
As of June 2007, the Regulation (EC) 1907/2006 of the European Parlia-

ment and of the Council dated 18 December 2006 on the registration,
evaluation and authorization of chemicals (REACH Regulation) is in force.
Detailed REACH information can be found in the product information in
KUKA Xpert.
4.7 Stopping distances
General information
• The stopping distance is the angle traveled by the positioner from the
moment the stop signal is triggered until the positioner comes to a
complete standstill.
• Stop category:
‒ Stop category 0 » STOP 0
according to IEC 60204-1
• The values specified for Stop 0 are guide values determined by
means of tests and simulation. They are average values. The actual
stopping distances and stopping times may differ due to internal and
external influences on the braking torque. It is therefore advisable to
determine the exact stopping distances and stopping times where nec-
essary under the real conditions of the actual positioner application.
• Measuring technique
The stopping distances were measured using the robot-internal meas-
uring technique.
• The wear on the brakes varies depending on the operating mode, ro-
bot application and the number of STOP 0 stops triggered. It is there-
fore advisable to check the stopping distance at least once a year.
Description
The table shows the stopping distances after a STOP 0 (category 0 stop)
is triggered.
Stopping distance (°)
Positioner STOP 0
A1 A2/A3
KP3-V2H500 R600
30.84 72
L2600-2
KP3-V2H1000 R600
L2000-2
24 72
KP3-V2H1000 R800
L2600-2

KP3-V2H-2
Planning
5 Planning
5.1 Information for planning
In the planning and design phase, care must be taken regarding the func-
tions or applications to be executed by the kinematic system. The follow-
ing conditions can lead to premature wear. They necessitate shorter main-
tenance intervals and/or earlier exchange of components. In addition, the
permissible operating parameters specified in the technical data must be
taken into account and observed during planning.
• Continuous operation near temperature limits or in abrasive environ-
ments
• Continuous operation close to the performance limits, e.g. high rpm of
an axis
• High duty cycle of individual axes
• Monotonous motion profiles, e.g. short, frequently recurring axis mo-
tions
• External forces (process forces) acting on the robot
If one or more of these conditions are to apply during operation of the kin-
ematic system, KUKA Deutschland GmbH must be consulted.
If the positioner reaches its corresponding operation limit or if it is operat-
ed near the limit for a period of time, the built-in monitoring functions
come into effect and the positioner is automatically switched off.
This protective function can limit the availability of the robot system.
5.2 Mounting base with centering
Description
The mounting base with centering is used when the kinematic system is
fastened to the floor, i.e. directly on a concrete foundation.
The mounting base with centering consists of:
• Bedplates
• Resin-bonded anchors (chemical anchors)
• Fastening elements
This mounting variant requires a level and smooth surface on a concrete
foundation with adequate load bearing capacity. The concrete foundation
must be able to accommodate the forces occurring during operation.
There must be no layers of insulation or screed between the bedplates
and the concrete foundation.
The minimum dimensions must be observed.

Planning KP3-V2H-2
Fig. 5-1: Mounting base
1 Bedplate (4x)
2 Locating pin, cylindrical
3 M24x65-8.8-A2K hexagon screw with conical spring washer (8x)
4 Resin-bonded anchor (12x)
5 M20 tapped hole for leveling screws (4x)
6 Locating pin, flat-sided
Grade of concrete for foundations
When producing foundations from concrete, observe the load-bearing ca-

pacity of the ground and the country-specific construction regulations.
There must be no layers of insulation or screed between the bedplate/
bedplates and the concrete foundation. The quality of the concrete must
meet the requirements of the following standard:
• C20/25 according to DIN EN 206-1:2001/DIN 1045-2:2008
WARNING
Danger to life and limb due to incorrect mounting
If not mounted correctly, the kinematic system may topple over or fall
down. Death, severe injury or damage to property may result.
• Only install the kinematic system using the mounting base or ma-
chine frame mounting.
• The stability must be ensured by the integrator or start-up techni-
cian.
Dimensioned drawing
The following illustration (>>> Fig. 5-2) provides all the necessary informa-
tion on the mounting base, together with the required foundation data. The
specified foundation dimensions refer to the safe transmission of the foun-
dation loads into the foundation and not to the stability of the foundation.

KP3-V2H-2
Planning
Fig. 5-2: Mounting base, dimensioned drawing
1 Concrete foundation
2 M24x65-8.8-A2K hexagon bolt (8x)
To ensure that the anchor forces are safely transmitted to the foundation,
observe the dimensions for concrete foundations specified in the following
illustration.
NOTICE
The dimensions specified for the distance to the edge are valid for non-
reinforced or normally reinforced concrete without verification of
concrete edge failure. For safety against concrete edge failure in ac-
cordance with ETAG 001 Annex C, the concrete foundation must be
provided with an appropriate edge reinforcement.

Planning KP3-V2H-2
Fig. 5-3: Foundation cross-section
1 Locating pin 3 Bedplate

2 Hexagon bolt with lock wash- 4 Concrete foundation
er
A: min. distance to edge B: min. concrete thickness

360 mm 180 mm
340 mm 200 mm
300 mm 250 mm
5.3 Machine frame mounting
Description
The “machine frame mounting” assembly is used when the kinematic sys-
tem is fastened to a steel structure, a booster frame (pedestal) or a KUKA
linear unit. It must be ensured that the substructure is able to withstand
safely the forces occurring during operation (foundation loads). The follow-
ing diagram contains all the necessary information that must be observed
when preparing the mounting surface (>>> Fig. 5-4).
The machine frame mounting assembly consists of:
• Locating pins
• Hexagon bolts with conical spring washers

KP3-V2H-2
Planning
Fig. 5-4: Machine frame mounting
Dimensioned drawing
The following illustration (>>> Fig. 5-5) provides all the necessary informa-
tion on machine frame mounting, together with the required foundation da-
ta.

Planning KP3-V2H-2
Fig. 5-5: Machine frame mounting, dimensioned drawing
5.4 Dimensions of face plates
Face plate on drive
The dimensions of the face plates on the drive are specified in the follow-
ing diagram (>>> Fig. 5-6).

KP3-V2H-2
Planning
Fig. 5-6: Dimensions, face plate on drive
1 Mounting borehole for support strip (optional)
Counterbearing face plate
The dimensions of the face plate on the counterbearing are specified in

the following diagram (>>> Fig. 5-7).
Fig. 5-7: Dimensions, face plate on counterbearing
5.5 Counterbearing variants
The following counterbearing variants are available:

Planning KP3-V2H-2
• Counterbearing, self-aligning with length compensation

• Counterbearing with length compensation
The counterbearing has self-aligning bearings and a length compensation
function for +/- 5 mm (>>> Fig. 5-8).
Fig. 5-8: Counterbearing length compensation
1 Counterbearing, self-aligning with length compensation

2 Counterbearing with length compensation
5.6 Connecting cables and interfaces
Connecting cables
The connecting cables comprise all the cables for transferring energy and
signals between the positioner, the robot and the robot controller. They
are connected on the positioner side with connectors at interface A1. Con-
nection to the controller is always the same, irrespective of the controller
variant.
Cable lengths of 7 m, 15 m and 25 m are available as standard. The
maximum length of the connecting cables must not exceed 50 m. The
maximum number of connectors is 1, i.e. a maximum of 2 connecting ca-
bles may be combined with each other.
For the connecting cables, an additional ground conductor is always re-
quired to provide a low-resistance connection between the positioner and
the control cabinet in accordance with DIN EN 60204. The ground con-
ductor is connected via ring cable lugs. The threaded bolts for connecting
the two ground conductors are located on the base frame of the position-
er.
The following points must be observed when planning and routing the
connecting cables:
• The bending radius for fixed routing must not be less than 150 mm for
motor cables and 60 mm for data cables.
• Protect cables against exposure to mechanical stress.
• Route the cables without mechanical stress – no tensile forces on the
connectors.
• Cables are only to be installed indoors.

KP3-V2H-2
Planning
• Observe the permissible temperature range (fixed installation) of
263 K (-10 °C) to 343 K (+55 °C).
• Route the motor cables and the data cables separately in metal ducts.
If necessary, take additional measures to ensure electromagnetic com-
patibility (EMC).
Interface A1
Interface A1 is located at the rear of the base frame.
Fig. 5-9: Interface A1
1 Data cable RDC X21.1 for cascading

2 Motor cable XM7
3 Motor cable XM8
4 Motor cable XM9
5 Data cable RDC X31.1
Interface for energy supply system
The robot can be equipped with an energy supply system between A1

and A2/A3. The interface A1 required for this is located at the rear of the
base frame of the positioner. Depending on the application, the interfaces
differ in design and scope. They can be equipped, for example, with con-
nections for cables and hoses. Detailed information on the connector pin
allocation, threaded unions, etc. is given in separate documentation.

Planning KP3-V2H-2

KP3-V2H-2
Transportation
6 Transportation
6.1 Transporting the positioner
Description
Move the positioner into its transport position each time it is transported. It
must be ensured that the positioner is stable while it is being transported.
The positioner must remain in its transport position until it has been fas-
tened in position. Before the positioner is lifted, it must be ensured that it
is free from obstructions. Remove all transport safeguards, such as nails
and screws, in advance. First remove any rust or glue on contact surfa-
ces.
The center of gravity must be taken into account during transportation.
WARNING
The positioner may tip over during transportation. Risk of personal injury
and damage to property.
If the positioner is transported using lifting tackle (optional), special care
must be exercised to prevent it from tipping. Additional safeguarding
measures must be taken. It is forbidden to pick up the positioner in any
other way using a crane.
WARNING
Use of unsuitable handling equipment may result in damage to the posi-
tioner or injury to persons. Only use authorized handling equipment with
a sufficient load-bearing capacity. The positioner may only be transpor-
ted in the manner specified here.
NOTICE
There must be no fixtures and tools on the positioner during transporta-
tion, as material damage could otherwise result. The KUKA options (e.g.
support strips) may remain on the positioner during transportation.
Transport position
The positioner must be in the transport position before it is transported,

i.e. it must not be tilted for transporting purposes.
Fig. 6-1: Transport position
Transport dimensions
The dimensions for the positioner can be noted from the following draw-
ings. The position of the center of gravity and the weight vary according
to the specific configuration. The specified dimensions refer to the posi-
tioner without equipment.

Transportation KP3-V2H-2
Fig. 6-2: Transport dimensions, positioner without dismantling
Positioner A B C
KP3-V2H500 R600 L2600-2 3519 mm 2004 mm 1151 mm
KP3-V2H1000 R600 L2000-2 2856 mm 2099 mm
1200 mm
KP3-V2H1000 R800 L2600-2 3455 mm 2499 mm
Further information can be found in the Section ‘Axis data’.
Transportation by fork lift truck
For transport by fork lift truck (>>> Fig. 6-3), four fork slots are mounted
on the base frame. The positioner can be picked up by the fork lift truck
from the front and from the rear. The base frame must not be damaged
when inserting the forks into the fork slots. The fork lift truck must have a
sufficient carrying capacity and an adequate fork length.
NOTICE
Damage to property due to overloading of the fork slots
Overloading the fork slots during transportation can cause damage to
property.
• Avoid overloading the fork slots through undue inward or outward
movement of hydraulically adjustable forks of the fork lift truck.
Fig. 6-3: Transportation by fork lift truck

KP3-V2H-2
Start-up and recommissioning

7 Start-up and recommissioning
The procedure for start-up and recommissioning comprises the following
steps:
Description Information
Installation with mounting Start-up (mounting base)
base
(>>> 7.1 "Starting up the positioner (mounting base)"
Page 65)
Installation with machine Start-up (machine frame mounting)
frame mounting
(>>> 7.2 "Starting up the positioner (machine frame mount-
ing)" Page 72)
7.1 Starting up the positioner (mounting base)
Description
The mounting base is used for installing positioners on a foundation.

It is fastened to a suitable concrete foundation using a bedplate / bed-
plates and resin-bonded anchors.
If the surface of the concrete foundation is not sufficiently smooth and
even, the differences must be evened out with a suitable leveling com-
pound.
When using a Dynamic Set and resin-bonded anchors, use only compo-
nents and resin capsules from the same manufacturer. No diamond tools
or core drills may be used for drilling the anchor holes; for preference,
drilling tools supplied by the anchor manufacturer are to be used. The
manufacturer’s instructions for the use of resin-bonded anchors must also
be observed.
The installation and start-up of the robot controller, the tools mounted and
the applications are not described here.
Equipment
The following equipment is required:

Designation Article number
Lifting tackle/rope sling with sufficient -
load-bearing capacity
Crane with sufficient load-bearing capaci- -
ty
Fork lift truck with a sufficient load-bear- -
ing capacity
Drill with a ø 18 mm bit -
Setting tool approved by the anchor -
manufacturer
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 2 to 20 Nm
Torque wrench -
min. 400 to 700 Nm

Start-up and recommissioning KP3-V2H-2
Material
The following material is required:

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

torques" Page 147)
These are valid for screws and nuts where no other specifications are giv-
en.
Screws of strength class 10.9 and higher as well as screws with test cer-
tification may only be tightened once with the rated tightening torque.
When the screws are first slackened they must be replaced with new
ones.
Precondition
• The installation site is accessible with a fork lift truck.

• The positioner is in the transport position.
• The substructure has been checked for sufficient safety.
• The concrete foundation must have the required dimensions and
cross-section.
• The surface of the foundation must be smooth and even.
• Have the leveling compound readily at hand.
• Any tools or other system components which would hinder the work
have been removed.
• The connecting cables and ground conductors are routed to the posi-
tioner and installed.
Work safety
WARNING
Danger to life and limb due to unintended positioner motions
Unintended positioner motions may result in death, severe injuries and
damage to property.
• Secure the positioner by pressing the EMERGENCY STOP device.
• Warn all persons concerned before starting to put it back into opera-
tion.
WARNING
WARNING
and damage to property
If the positioner is transported by fork lift truck, the forks must be inser-
ted in the fork slots. It is forbidden to pick up the robot in any other way
using a fork lift truck or lifting tackle!

KP3-V2H-2

7.1.1 Installing the positioner with a mounting base
Procedure
1. Clean the concrete foundation.

2. Screw 2 locating pins into the bedplates and check that they are fitted
securely (>>> Fig. 7-1).
3. Lift the positioner with the fork lift truck and move it to the installation
site.
4. Clean the lower mounting surface on the positioner.
5. Fasten the 4 bedplates to the positioner using 2 M24x65-8.8 hexagon
bolts and conical spring washers for each one. Ensure that an entirely
vertical position is maintained in order to prevent damage to the locat-
ing pins.
6. Tighten 8 M24x65-8.8 hexagon bolts with torque wrench. Increase the
tightening torque to the specified value in several stages.
Fig. 7-1: Mounting base
1 Bedplate (4x)
3 M24x65-8.8-A2K hexagon screw with conical spring washer (8x)
4 Resin-bonded anchor (12x)
5 M20 tapped hole for leveling screws (4x)
7. Determine the position of the positioner on the foundation in relation to

the working envelope.
8. Set the positioner down on the foundation in its installation position.
9. Check the surface of the concrete foundation against the specified val-
ue:
• If the surface is sufficiently smooth and even, continue with step
15.
• If the surface is not sufficiently smooth and even, continue with
step 10.
If the evenness of the foundation is outside the specified tolerances,
this can cause strain or result in loosening of the mounting base.
10. Lift the positioner with a fork lift truck.

11. Apply sufficient leveling compound to the underside of the bedplates

(toothed spatula).
The area under the hexagon bolt for fastening the positioner must be
kept free from leveling compound.
12. Set down the positioner and align horizontally with leveling screws if
necessary.
13. Remove excess leveling compound. The maximum height of the level-
ing compound must not be exceeded. Observe the manufacturer’s
specifications.
14. Allow the leveling compound to set in accordance with the manufactur-
er's instructions.
15. Drill 12 anchor holes in accordance with the manufacturer’s specifica-
tions and fit the anchors as specified in the instructions for use.
The instructions for use are enclosed with the anchors and must be
followed precisely.
Fig. 7-2: Installing the positioner
1 Bedplate (4x)
2 M24x65-8.8-A2K hexagon bolt with conical spring washer (8x)
3 Locating pin
7.1.2 Connecting the connecting cables
Procedure
1. Fasten the ground conductor between the robot controller and the po-
sitioner to the ground conductor connection with 1 M8 hexagon nut in-
cluding conical spring washer; tightening torque MA= 23.0 Nm.
2. Connect data cable X31.1.
3. Connect motor cables XM7.1, XM8.1 and XM9.1.
When connecting the motor cable connectors, it must be ensured that
the connectors on the controller and on the robot are locked correctly.
Correct locking is indicated by an audible click. It is indicated optically
by the fact that the red rings on each of the locking buttons are not
visible and are pushed in completely.
4. Check the equipotential bonding in accordance with VDE 0100 and
EN 60204-1.

KP3-V2H-2

Further information is contained in the operating and assembly in-
structions of the robot controller.
Fig. 7-3: Connecting the connecting cables (example)
1 Ground conductor (optional)

2 Data cable X31.1
3 Connection XM9, motor cable XM9.1 (A3)
7.1.3 Machine data
Description
In the case of commissioning with the KR C4, the positioner must be con-
figured with the aid of WorkVisual.
WARNING
The positioner must not be moved if incorrect machine data are loaded.
Personal injuries or damage to property may result in this case.
Further information about WorkVisual is contained in the WorkVisual

documentation and about configuration of the machine data in the oper-
ating and assembly instructions Configuration of Kinematic Systems.
Further information is contained in the operating and programming in-

structions for the corresponding KUKA System Software (KSS).
7.1.4 Mastering the positioner
Description
The mastering of positioners is analogous to that of robot axes. During

mastering, the positioner is moved to the mechanical zero position, and
the encoder value for each axis is saved. In this way, the mechanical zero
position and the electronic zero position are made to coincide.
When mastering positioners, the axes must be mastered in ascending or-
der.
Mastering methods
The positioner can be mastered using one of the following methods:

• With the EMD

• With the dial gauge
EMD mastering is recommended.

structions.
Pre-mastering position
The pre-mastering position is a prerequisite for every mastering procedure

carried out with the EMD. Each axis is moved so that the probe pin is
positioned in front of the reference notch. When mastering with the EMD,
an axis is always moved to the mechanical zero position from “+” to “-”.
Fig. 7-4: Mastering run
1 Pre-mastering position 5 Gauge cartridge

2 Motion direction of axis 6 Probe pin
3 Mechanical zero position 7 Reference notch
4 EMD
Position of the gauge cartridges
The EMD is fastened to the corresponding gauge cartridge. The following

figure (>>> Fig. 7-5) shows the positions of the gauge cartridges.

KP3-V2H-2

Fig. 7-5: Position of the gauge cartridges
1 Gauge cartridge A3 3 Gauge cartridge A2

2 Gauge cartridge A1
Mechanical zero position
The mechanical zero position of A1 is given when A1 has moved 60° in

the minus direction .
Fig. 7-6: Mechanical zero position, A1
The mechanical zero position of A2 and A3 has been reached when the
mounting boreholes for the support strip (optional) in the face plate are
parallel to the bolt-on surface of the base frame (>>> Fig. 7-7).

Fig. 7-7: Mechanical zero position, A2 and A3
1 Face plate
3 Base frame
4 Bolt-on surface
7.1.5 Concluding work
The following concluding work must be carried out:

• If applicable, mount the tool.
• Start up the robot system in accordance with the chapter “Start-up and
recommissioning” in the operating instructions for the robot controller.
• Put the robot system into operation in accordance with the chapter
“Start-up and recommissioning” of the operating and programming in-
structions for the KUKA System Software (KSS).
7.2 Starting up the positioner (machine frame mounting)
Description
The following sections describe the installation of the positioner using ma-
chine frame mounting.

KP3-V2H-2
8 Allen screws with lock washers are used for fastening it to a machine

frame. A cylindrical pin and a flat-sided pin are provided to ensure correct
positioning.
The machine frame mounting is used for installing positioners on a mount-
ing surface prepared by the customer or on an adapter plate (optional).
The positioner must be rotated for wall and ceiling mounting. In doing so,
it must be secured such that an uncontrolled rotational motion or toppling
is impossible. When rotating the positioner, care must be taken not to
damage the connectors, installation material and/or energy supply system
(optional). The wall-mounted or ceiling-mounted installation is analogous
to installation of the floor-mounted robot.
NOTICE
If a fixture is used, the positioner must be secured in such a way that
slipping is impossible. Only approved fixtures with an adequate carrying
capacity may be used. Damage to property may otherwise result.
The installation and start-up of the robot controller, the tools mounted and
the applications are not described here.
Move the positioner into its transport position each time it is transported. It
must be ensured that the robot is stable while it is being transported. The
positioner must remain in its transport position until it has been fastened
to the foundation. Before the positioner is lifted, it must be ensured that it
is free from obstructions. Remove all transport safeguards, such as nails
and screws, in advance. First remove any corrosion or adhesive on con-
tact surfaces.
Equipment

Fork lift truck with a sufficient load-bear- -
ing capacity
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Torque wrench -
min. 2 to 20 Nm
Torque wrench -
min. 400 to 700 Nm
Material

Machine frame mounting 0000-310-641 1
Tightening torques

torques" Page 147)
en.
ones.

Precondition
• The installation site is accessible with a fork lift truck.

• The positioner is in the transport position.
• The substructure has been checked for sufficient safety.
• The mounting surface has been prepared.
• Any tools or other system components which would hinder the work
have been removed.
• The connecting cables and ground conductors are routed to the posi-
tioner and installed.
Work safety
WARNING
damage to property.
tion.
WARNING
WARNING
and damage to property.
If the positioner is transported using lifting tackle (optional), special care
must be exercised to prevent it from tipping. Additional safeguarding
measures must be taken. It is forbidden to pick up the positioner in any
other way using a crane.
7.2.1 Installing the positioner with machine frame mounting
Procedure
1. Clean the mounting surface.

2. Check the hole pattern on the mounting surface.
3. Screw 2 locating pins into the mounting surface and check that they
are fitted securely.
4. Lift the positioner with the fork lift truck and move it to the installation
site.
5. Clean the lower mounting surface on the positioner.
6. Lower the positioner vertically onto the installation surface. Ensure that
an entirely vertical position is maintained in order to prevent damage
to the locating pins.
7. Insert 8 M24x65-8.8 Allen screws with conical spring washers.
8. Tighten 8 M24x65-8.8 Allen screws with a torque wrench in diagonally
opposite sequence. Increase the tightening torque to the specified val-
ue in several stages.
9. For each fork slot, unscrew 2 M16x50-8.8 Allen screws with conical
spring washers and remove the 4 fork slots.

KP3-V2H-2

Fig. 7-8: Machine frame mounting
7.2.2 Connecting the connecting cables
Procedure
1. Fasten the ground conductor between the robot controller and the po-
sitioner to the ground conductor connection with 1 M8 hexagon nut in-
cluding conical spring washer; tightening torque MA= 23.0 Nm.
2. Connect data cable X31.1.
3. Connect motor cables XM7.1, XM8.1 and XM9.1.
When connecting the motor cable connectors, it must be ensured that
the connectors on the controller and on the robot are locked correctly.
Correct locking is indicated by an audible click. It is indicated optically
by the fact that the red rings on each of the locking buttons are not
visible and are pushed in completely.
4. Check the equipotential bonding in accordance with VDE 0100 and
EN 60204-1.
Further information is contained in the operating and assembly in-
structions of the robot controller.
Fig. 7-9: Connecting the connecting cables (example)
1 Ground conductor (optional)

2 Data cable X31.1

7.2.3 Machine data
Description
In the case of commissioning with the KR C4, the positioner must be con-
figured with the aid of WorkVisual.
WARNING
The positioner must not be moved if incorrect machine data are loaded.
Personal injuries or damage to property may result in this case.
Further information about WorkVisual is contained in the WorkVisual

documentation and about configuration of the machine data in the oper-
ating and assembly instructions Configuration of Kinematic Systems.

structions for the corresponding KUKA System Software (KSS).
7.2.4 Mastering the positioner
Description
The mastering of positioners is analogous to that of robot axes. During

mastering, the positioner is moved to the mechanical zero position, and
the encoder value for each axis is saved. In this way, the mechanical zero
position and the electronic zero position are made to coincide.
When mastering positioners, the axes must be mastered in ascending or-
der.
Mastering methods
The positioner can be mastered using one of the following methods:

• With the EMD
• With the dial gauge
EMD mastering is recommended.

structions.
Pre-mastering position
The pre-mastering position is a prerequisite for every mastering procedure

carried out with the EMD. Each axis is moved so that the probe pin is
positioned in front of the reference notch. When mastering with the EMD,
an axis is always moved to the mechanical zero position from “+” to “-”.

KP3-V2H-2

Fig. 7-10: Mastering run
1 Pre-mastering position 5 Gauge cartridge

2 Motion direction of axis 6 Probe pin
3 Mechanical zero position 7 Reference notch
4 EMD
Position of the gauge cartridges
The EMD is fastened to the corresponding gauge cartridge. The following

figure (>>> Fig. 7-11) shows the positions of the gauge cartridges.
Fig. 7-11: Position of the gauge cartridges
1 Gauge cartridge A3 3 Gauge cartridge A2

2 Gauge cartridge A1
Mechanical zero position
The mechanical zero position of A1 is given when A1 has moved 60° in

the minus direction .

Fig. 7-12: Mechanical zero position, A1
The mechanical zero position of A2 and A3 has been reached when the
mounting boreholes for the support strip (optional) in the face plate are
parallel to the bolt-on surface of the base frame (>>> Fig. 7-13).
Fig. 7-13: Mechanical zero position, A2 and A3
1 Face plate

KP3-V2H-2

3 Base frame
4 Bolt-on surface

• If applicable, mount the tool.
• Start up the robot system in accordance with the chapter “Start-up and
recommissioning” in the operating instructions for the robot controller.
• Put the robot system into operation in accordance with the chapter
“Start-up and recommissioning” of the operating and programming in-
structions for the KUKA System Software (KSS).
7.3 Description of the connecting cables
Configuration
The connecting cables are used to transfer power and data between the
robot controller and the positioner.
The connecting cables comprise:
• Motor cable
• Data cable
• Ground conductor/equipotential bonding (optional)
Interface

tion tioner
robot controller -
positioner
X8.1 - XM8
1
X9.1 - XM9
Data cable X21.1 - X31.1 17-contact signal cou-
tor
8 mm2
(optional)

Standard connecting cable
Fig. 7-14: Connecting cables, overview

KP3-V2H-2
Maintenance
8 Maintenance
Only maintenance and repair work described in this document may be
performed.
Work that exceeds this scope may only be carried out by personnel spe-
cially trained by KUKA. Information about KUKA College and its training
program can be found at www.kuka.com or can be obtained directly from
our subsidiaries.
In the case of support and repair services provided by KUKA, KUKA Serv-
ice must be informed in advance about potential contamination or haz-
ards.
Non-compliance nullifies warranty and liability claims.
8.1 Maintenance overview
Description
The maintenance intervals given in the tables are valid for the operating
conditions specified in the technical data (>>> 4 "Technical data"
Page 31). KUKA must be consulted in the event of deviations in working
conditions or the use of special functions or applications.
Further information can be found in the section “Information for plan-
ning” (>>> 5.1 "Information for planning" Page 53).
A general inspection of the positioner is recommended after 7 years or if

its use is changed. Please contact KUKA Service for this.
If the positioner is fitted with a KUKA energy supply system (optional), ad-
ditional maintenance work must be carried out.
NOTICE
Only lubricants approved by KUKA Deutschland GmbH may be used.
Non-approved lubricants may cause premature wear and failure of as-
semblies.
Precondition
• The positioner controller must be switched off and secured to prevent

unauthorized persons from switching it on again.
• The power cable must be de-energized.
• The positioner and the installed tools and fixtures must be mechanical-
ly secured to prevent unintentional motions.
• Remove the tools and any additional items of equipment if they im-
pede maintenance work.
WARNING
When work is carried out on the positioner, turn the main switch on the
control cabinet to “OFF” and secure it with a padlock to prevent unau-
thorized persons from switching it on again.
8.1.1 Maintenance table
Maintenance symbols
The overview may contain maintenance symbols that are not relevant
for the maintenance work on this product. The maintenance illustrations
provide an overview of the relevant maintenance work.

Maintenance KP3-V2H-2
Oil change
Lubricate with grease gun
Lubricate with brush
Lubricate with spray grease
Tighten screw/nut
Check component, visual inspection
Clean component
Exchange battery
Exchange component
Check toothed belt tension
Fig. 8-1: Maintenance diagram
Interval Item Activity

100 h* 1 Check all fastening screws with a torque wrench.
Exchange damaged screws and washers.
Retighten if necessary.
* Once only, after initial start-up or recommission-
ing.
6 months 1 Check all fastening screws with a torque wrench.
Exchange damaged screws and washers.
Retighten if necessary.

KP3-V2H-2
Maintenance
6 months Visually check for damage to mechanical and elec-
trical components.
7 years The gear units of A1, A2 and A3 are maintenance-
free for 7 years. Once this period has expired,
these gear units must be inspected and exchanged
if necessary.
8.2 Cleaning the positioner
Description
The positioner must be cleaned in compliance with the instructions given

here in order to prevent damage. These instructions only refer to the posi-
tioner.
Equipment

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

Cleaning agent - -
solvent-free, water-soluble, non-flamma-
ble, non-aggressive, no steam, no refrig-
erants
Overview
Work step Activity

1 Cleaning
(>>> 8.2.1 "Cleaning" Page 84)
2 Concluding work
(>>> 8.2.2 "Concluding work" Page 84)
Precondition
• The robot controller is switched off.

• The positioner is freely accessible.

Maintenance KP3-V2H-2
Work safety
NOTICE
The following must be taken into consideration when carrying out clean-
ing work (material damage may otherwise result):
• Cleaning must be in accordance with the corresponding cleaning in-
structions.
• Do not use high-pressure cleaners.
• It must be ensured that no cleaning agent enters electrical or me-
chanical system components.
8.2.1 Cleaning
Procedure
1. Shut down the positioner.

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

• Remove cleaning agents and equipment from the workspace of the
positioner.
• Dispose of cleaning agents in accordance with the pertinent regula-
tions.
• Replace any damaged or illegible plates and covers.
• Check any protective and safety equipment that had been removed for
correct operation.

KP3-V2H-2
Repair
9 Repair
Only maintenance and repair work described in this document may be
performed.
Work that exceeds this scope may only be carried out by personnel spe-
cially trained by KUKA. Information about KUKA College and its training
program can be found at www.kuka.com or can be obtained directly from
our subsidiaries.
In the case of support and repair services provided by KUKA, KUKA Serv-
ice must be informed in advance about potential contamination or haz-
ards.
Non-compliance nullifies warranty and liability claims.
9.1 Exchanging motor A1
Description
The following sections describe the procedure for exchanging the motor
on a positioner.
When using KUKA anti-glare equipment, this does not have to be re-
moved for exchanging motor A1.
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Hexagon socket set -
Torque wrench -
min. 20 Nm to 100 Nm
Torque wrench -
min. 2 Nm to 20 Nm
SEMD/MEMD mastering set 0000-228-936
Material

SPP motor 5.5kW L0 ME 0000-334-485 1
Procurement of spare parts
Defective components must only be replaced with original spare parts

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

Repair KP3-V2H-2
Tightening torques

torques" Page 147)
en.
ones.
Precondition

• The power cable must be deenergized.
• The positioner must be mechanically secured to prevent unintentional
motions.
• There is no fixture and no tool mounted on the positioner.
Work safety
WARNING
Danger to life and limb due to live components
Components may remain energized after the positioner has been
switched off. Death, severe injuries or damage to property may result.
• Switch off the positioner at the main switch and secure it to prevent
• Disconnect the power cable from the supply.
• After switching off, wait at least 5 minutes and then check to ensure
that the controller and power cable are deenergized.
WARNING
damage to property.
tion.
CAUTION
Risk of burns on hot surfaces
High motor surface temperatures immediately after the positioner has
stopped operating can lead to burns. Injuries may result.
• Protective gloves must be worn.
WARNING
Risk of crushing during removal and installation of motor
When removing or installing the motor, there is a risk of injury by crush-
ing. This could result in hand injuries.
• Wear protective gloves.

KP3-V2H-2
Repair
NOTICE
Wear and premature failure due to damage to toothing
Damage to the toothing of the motor and gear unit can lead to in-
creased wear and premature failure of the components.
• During cleaning, ensure that the toothing is not damaged.
• Before installation, check the toothing of the motor and gear unit for
damage.
9.1.1 Removing covers from the main beam
Description
There are 5 covers on the main beam.
Procedure
1. Unscrew 4 M6x12-8.8 Allen screws from each cover.

2. Remove the covers from the main beam.
Fig. 9-1: Covers on the main beam
1 Main beam
2 Cover
3 M6x12-8.8 Allen screw
9.1.2 Removing motor A1
Procedure
1. Release and unplug connectors XM7 and XP7 from the sockets of
motor A1.
2. Unscrew 4 M12x25-8.8 Allen screws from motor A1.
3. Release and lift out motor A1. Do not tilt when lifting out.

Repair KP3-V2H-2
Fig. 9-2: Motor A1

2 Motor A1
3 Connector XP7
4 Connector XM7
4. If the motor is not to be reinstalled, it must be disposed of correctly or

put into storage.
9.1.3 Installing motor A1
Procedure
1. If a new motor is to be installed, remove any corrosion protection it

may have prior to installation.
2. Clean the toothing of the motor and the gear unit before installation
and apply a thin but continuous coat of Microlube GL 261 grease.
3. Clean the mounting surface of motor A1 on the gear unit.
4. Check the condition of the O-ring on the motor shaft.
5. Position sockets XM7 and XP7 as shown.
6. Insert motor A1. Do not tilt during installation.
Insertion of motor can be facilitated by turning it gently about its ro-
tational axis.
7. Insert 4 M12x25-8.8 Allen screws.

8. Plug connectors XM7 and XP7 into the sockets.

KP3-V2H-2
Repair
Fig. 9-3: Motor A1

2 Motor A1
3 Connector XP7
4 Connector XM7
9.1.4 Installing covers on the main beam
Description
There are 5 covers on the main beam.
Procedure
1. Place covers on the main beam and align them.

2. Fasten covers with 4 M6x12-8.8 Allen screws each.

Repair KP3-V2H-2
Fig. 9-4: Covers on the main beam
1 Main beam
2 Cover

• Move A1 of the positioner and look out for irregularities.
• Carry out mastering of A1.
Detailed information about mastering is contained in the operating
and programming instructions for end users or system integrators.
Description
on a positioner.
Equipment

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

KP3-V2H-2
Repair
Torque wrench -
min. 2 Nm to 20 Nm
Material

Payload: 500 kg 0000-362-745 1
SPP motor 2.5kW L0 ME 250-750kg
Payload: 1000 kg 0000-362-740 1

bility claims.
Tightening torques

torques" Page 147)
en.
ones.
Precondition

motions.

Repair KP3-V2H-2
Work safety
WARNING
WARNING
damage to property.
tion.
CAUTION
WARNING
NOTICE
damage.
9.2.1 Removing the drive unit covers
Description
The covers on A2 and A3 are identical and are removed in the same way.
The following instructions only describe the removal of one cover.
Depending on the task, either one or both covers must be removed.
Procedure
• Unscrew 3 M6x10-A2-70 round head screws from the cover. Carefully

remove the cover. Ensure that the motor cables are not damaged.

KP3-V2H-2
Repair
Fig. 9-5: Cover on drive side
1 Motor A2/A3
2 M6x10-A2-70 round head screws
3 Cover
Procedure
1. Release and unplug connectors XM8 and XP8 from the sockets of
motor A2.
3. Unfasten and remove motor A2. Do not tilt while removing.

Repair KP3-V2H-2
Fig. 9-6: Motor A2

2 Motor A2
3 Connector XP8
4 Connector XM8

put into storage.
Procedure

tational axis.


KP3-V2H-2
Repair
Fig. 9-7: Motor A2

2 Motor A2
3 Connector XP8
4 Connector XM8
9.2.4 Installing the drive unit covers
Description
The covers on A2 and A3 are identical and are installed in the same way.
The following instructions only describe the installation of one cover.
Depending on the task, either one or both covers must be installed.
Procedure
• Place the cover on the positioner and fasten using 3 M6x10-A2-70

round head screws. Ensure that the motor cables are not damaged.

Repair KP3-V2H-2
1 Motor A2/A3
3 Cover

Description
on a positioner.
Equipment

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

KP3-V2H-2
Repair
Material

Payload: 500 kg 0000-362-745 1
Payload: 1000 kg 0000-362-740 1

bility claims.
Tightening torques

torques" Page 147)
en.
ones.
Precondition

motions.
Work safety
WARNING

Repair KP3-V2H-2
WARNING
damage to property.
tion.
CAUTION
WARNING
NOTICE
damage.
9.3.1 Removing the drive unit covers
Description
The covers on A2 and A3 are identical and are removed in the same way.
The following instructions only describe the removal of one cover.
Depending on the task, either one or both covers must be removed.
Procedure
• Unscrew 3 M6x10-A2-70 round head screws from the cover. Carefully

remove the cover. Ensure that the motor cables are not damaged.

KP3-V2H-2
Repair
1 Motor A2/A3
3 Cover
Procedure
1. Release and unplug connectors X9 and XP9 from the sockets of mo-
tor A2.
3. Unfasten and remove motor A3. Do not tilt while removing.

Repair KP3-V2H-2
Fig. 9-10: Motor A3

2 Motor A3
3 Connector XP9
4 Connector XM9

put into storage.
Procedure

tational axis.


KP3-V2H-2
Repair
Fig. 9-11: Motor A3

2 Motor A3
3 Connector XP9
4 Connector XM9
9.3.4 Installing the drive unit covers
Description
The covers on A2 and A3 are identical and are installed in the same way.
The following instructions only describe the installation of one cover.
Depending on the task, either one or both covers must be installed.
Procedure
• Place the cover on the positioner and fasten using 3 M6x10-A2-70

round head screws. Ensure that the motor cables are not damaged.

Repair KP3-V2H-2
1 Motor A2/A3
3 Cover

9.4 Description of the electrical installations
Overview
The electrical installations of the positioner consist of:

• Cable set
• Junction box for data cable, RDC
• Interface A1
Description
The electrical installations include all the supply and control cables for the
motors of axes 1 to 3. All the connections on the motors are screwed
plug-and-socket connections. The assembly consists of the cable set, the
RDC box (optional) and interface A1. The interface for the connecting ca-
bles is located on the base frame. The motor and data cables are connec-
ted here via plug-in connections.

KP3-V2H-2
The motor cables are routed directly from interface A1 to the motors (XM
Repair
connectors). The data cables are routed to the motors (XP connectors) as
follows:
• From interface A1 directly to the motors
or
• From interface A1 to the RDC box to the motors
The protective circuit is also integrated into the cable set. The ground con-
ductor is connected to the base frame via a ground conductor bolt.
The selected cable routing ensures that the cables are guided without
strain or kinking throughout the entire motion range of the positioner.
Fig. 9-13: Overview of electrical installations
1 Motor A3 4 Motor A2
2 RDC 5 Interface A1
3 Motor A1
Fig. 9-14: Interface A1 (example)
1 Ground conductor
2 Connection panel, cable set
3 Connection panel, energy supply system

Repair KP3-V2H-2
Connection panel, cable set
Fig. 9-15: Connection panel example
Cables
The motors of the positioner each have 2 connectors for the electrical
connection:
• Motor cable connector (motor and brake)
• Data cable connector (control signals and temperature monitoring)
Fig. 9-16: Motor on positioner, example
1 Motor 3 Data cable connector

2 Motor cable connector

KP3-V2H-2
Repair
Wiring diagrams
Cable designation Connection Figure

Interface 2nd RDC Motor
A1
Motor cable A1 XM7.1 - XM7 (>>> Fig. 9-17)
Motor cable A2 XM8.1 - XM8
Motor cable A3 XM9.1 - XM9
Data cable A1 - X1 XP7 (>>> Fig. 9-18)
Data cable A2 - X2 XP8
Data cable A3 - X3 XP9
Data cable (RDC option) X31.1 X18 - (>>> Fig. 9-19)
X15
Ground conductor Ring cable lug (>>> Fig. 9-20)
Fig. 9-17: Motor cable, KR C4, one robot, from interface A1 to motor

Repair KP3-V2H-2
Fig. 9-18: Data cable, KR C4, one robot, from RDC to motor

KP3-V2H-2
Fig. 9-19: Data cable, KR C4, one robot, from interface A1 to RDC Repair

Repair KP3-V2H-2
Fig. 9-20: Wiring diagram, protective circuit

KP3-V2H-2
Decommissioning, storage and disposal

10 Decommissioning, storage and disposal
10.1 Decommissioning
Description
This section describes all the work required for decommissioning the posi-
tioner if it is to be removed from the system. After decommissioning, it is
prepared for storage or for transportation to a different location.
Following its removal, the positioner can be transported by means of lifting
tackle and crane (>>> 6 "Transportation" Page 63).
Equipment

Lifting tackle / rope sling with sufficient -
load-bearing capacity
ty
Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Precondition
• The removal site is accessible for transportation by fork lift truck.

• There is no hazard posed by system components.
Work safety
WARNING
When carrying out the following work, the positioner must be moved
several times between the individual work steps. Unintentional move-
ments of the positioner can cause death, serious injury or material dam-
age.
• While work is being carried out on the positioner, it must always be
secured by activating the EMERGENCY STOP device.
• If work is carried out on an operational positioner that is switched
on, the positioner must only be moved at reduced velocity. It must
be possible to stop the robot at any time by activating an EMER-
GENCY STOP device. Operation must be limited to what is abso-
lutely necessary.
• Warn all persons concerned before switching on and moving the po-
sitioner.
WARNING
If the positioner is caught on the mounting surface, it may come free
abruptly, endangering persons and property.
The positioner must stand loosely on the mounting surface; completely
remove all fastening materials and any adhesives.

Decommissioning, storage and disposal KP3-V2H-2
10.1.1 Moving the positioner into its transport position
Procedure
1. Secure positioner.
2. Remove tools and equipment.
3. Put the positioner into operation and move it into the transport posi-
tion.
4. Secure the positioner by pressing the E-STOP device and then shut
down the positioner.
10.1.2 Removing the positioner
Procedure
1. Release and disconnect the peripheral connections.

2. Release and unplug connecting cables to the robot controller
(>>> Fig. 10-2).
3. Unscrew the M8 hexagon nut from the ground conductor, take off the
washers and lock washers and pull off the ground conductor.
4. Unscrew and remove 8 M24x65-8.8 hexagon bolts and conical spring
washers.
5. Lift the positioner vertically off the mounting surface and transport it
away.
Take care not to damage the two pins when lifting off the robot.
WARNING
The positioner must stand loosely on the mounting surface; com-
pletely remove all fastening materials and any adhesives.

KP3-V2H-2

Fig. 10-2: Removing the positioner (example)
1 Data cable X31.1

2 Motor cable XM7.1 (A1)
5 Fork slots
6 Hexagon bolts
7 Pin
8 Ground conductor

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

• Virtually dry and free of dust
• Avoid temperature fluctuations
• Avoid wind and drafts
• Avoid condensation
• No exposure to direct sunlight

• Maintain the permissible temperature ranges for storage

• The packaging film cannot be damaged.
Equipment

ty
Torque wrench -
min. 2 to 20 Nm
Permissible cleaning tools (e.g. cloths, -
brushes)
Material

Covers - -
that cannot detach themselves and which
can withstand the expected environmen-
tal conditions.
Cleaning agent - -
solvent-free, water-soluble, non-flamma-
ble, non-aggressive, no steam, no refrig-
erants
Precondition
• Loose parts or parts that might knock against other parts have been
removed from the positioner.
• Tools and equipment have been removed.
Work safety
WARNING
When carrying out the following work, the positioner must be moved
several times between the individual work steps. Unintentional move-
ments of the positioner can cause death, serious injury or material dam-
age.
• While work is being carried out on the positioner, it must always be
secured by activating the EMERGENCY STOP device.
• If work is carried out on an operational positioner that is switched
on, the positioner must only be moved at reduced velocity. It must
be possible to stop the robot at any time by activating an EMER-
GENCY STOP device. Operation must be limited to what is abso-
lutely necessary.
• Warn all persons concerned before switching on and moving the po-
sitioner.

KP3-V2H-2

10.2.1 Removing the positioner
Procedure
1. Release and disconnect the peripheral connections.

2. Release and unplug connecting cables to the robot controller
(>>> Fig. 10-3).
3. Unscrew the M8 hexagon nut from the ground conductor, take off the
washers and lock washers and pull off the ground conductor.
4. Unscrew and remove 8 M24x65-8.8 hexagon bolts and conical spring
washers.
5. Lift the positioner vertically off the mounting surface and transport it
away.
Take care not to damage the two pins when lifting off the robot.
WARNING
The positioner must stand loosely on the mounting surface; com-
pletely remove all fastening materials and any adhesives.
Fig. 10-3: Removing the positioner (example)
1 Data cable X31.1

5 Fork slots
6 Hexagon bolts
7 Pin
8 Ground conductor

10.2.2 Cleaning
Procedure
1. Shut down the positioner.

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

2. Remove any foreign bodies.
3. Remove any corrosion.
4. Attach all covers to the positioner and check that the seals are cor-
rectly in place.
5. Seal off electrical connections with suitable covers.
6. Seal hose connections by suitable means.
7. Cover the positioner with plastic sheeting and seal it at the base
frame against dust.
If necessary, add a desiccant beneath the plastic sheeting.
No concluding work is required.
10.3 Disposal
Description
When the positioner reaches the end of its useful life, it can be removed
from the system and dismantled, and the materials can be disposed of
properly by type.
The following table provides an overview of the materials used in the po-
sitioner. All plastic components are marked with a material designation
and must be disposed of accordingly.
Subassembly, com- Additional informa-
Material
ponent tion
Metals
Cast aluminum Cross-members, plan-
etary axes
Copper Cables, wires
Steel Gear units, spindles,
screws, washers

KP3-V2H-2

Material
ponent tion
Cast steel Base frame
Electrical parts
Motors Dispose of motors
without dismantling.
Plastics
ABS Enclosure panels, cov-
ers
EPDM Seals, covers
ETFE Flexible tube
NBR O-rings, shaft seals
PA Hinged clamps
PTFE Sealing rings
PU Hoses
PUR Cable sheaths
Auxiliary substances and consumables
Gear oil Gear units Optigear Synt. ALR
150 gear oil
Lubricating grease Cabling Lubricating grease Op-
titemp RB2
Up-to-date safety data sheets must be requested from the manufacturers
of auxiliary and operating materials. Further information about the auxiliary
substances and consumables used can be found under:
(>>> 12.2 "Auxiliary and operating materials used" Page 148)


KP3-V2H-2
Options
11 Options
11.1 Anti-glare equipment (optional)
Description
The anti-glare equipment is fastened to the positioner and serves as a

safeguard during welding work.
Fig. 11-1: Anti-glare equipment
1 Bracket (2x)
2 Anti-glare plate
3 Support, left/right
4 Reinforcement, left/right
5 Upright element (2x)
Basic data
Designation Article number Weight

Distance between face plates 0000-360-788 approx.
2000 mm: 105.5 kg
antiglare KP3-V2H 1000 R600
L2000 -2
Distance between face plates 0000-360-333 approx.
2600 mm: 129.6 kg
Antiglare KP3-V2H 1000 R800
L2600 -2
Further information about the ambient conditions is contained in the as-

sembly instructions for the positioner and robot controller.
Dimensions of anti-glare equipment, L=2000 mm
The following figure (>>> Fig. 11-2) shows the dimensions of the antiglare
KP3-V2H 1000 R600 L2000 -2.

Options KP3-V2H-2
Fig. 11-2: Anti-glare equipment dimensions, L=2000 mm
Dimensions of anti-glare equipment, L=2600 mm
The following figure (>>> Fig. 11-3) shows the dimensions of the Antiglare
KP3-V2H 1000 R800 L2600 -2.
Fig. 11-3: Anti-glare equipment dimensions, L=2600 mm
Transportation
The components must be suitably and properly packaged prior to trans-

portation. The components must be protected against damage with shock-
resistant and break-proof packaging.
The following measures are to be taken before assemblies and individual
components are transported:
• Clean components.
• Assign small parts to their respective components in plastic bags to
prevent them from getting lost.
• Protect components against impacts and slipping; fill gaps with suita-
ble approved padding materials.
Mark transport cases and packing according to the sensitivity of their con-
tents (e.g. TOP, FRAGILE, DO NOT BEND) and attach labels to ensure

KP3-V2H-2
correct transportation (e.g. indication of center of gravity). In addition to
Options
these measures, the regulations and conditions of the company entrusted
with the transportation are to be observed.
• Distance between face plates 2000 mm

(>>> 11.1.1 "Putting the anti-glare equipment into operation, distance
between face plates 2000 mm" Page 120)
• Distance between face plates 2600 mm
(>>> 11.1.2 "Putting the anti-glare equipment into operation, distance
between face plates 2600 mm" Page 126)
Maintenance
conditions specified in the technical data. KUKA Deutschland GmbH must
be consulted in the case of discrepancies!
Fig. 11-4: Maintenance work (example)

6 months 1 Check all screwed connections (tightening torques).
Decommissioning
(>>> 11.1.3 "Decommissioning" Page 132)
Storage
If components are to be put into long-term storage, the following points

must be observed:
• Clean the components and protect against corrosion.

Options KP3-V2H-2
• The place of storage must be as dry and dust-free as possible.

• Protect mechanical components against damage.
• Avoid temperature fluctuations.
• Avoid wind and drafts.
• Avoid condensation.
• Use appropriate packaging that can withstand the expected environ-
mental conditions.
• Do not leave any loose parts on the product, especially ones that
might knock against other parts.
• Do not expose to direct sunlight.
• Observe and comply with the permissible temperature ranges for stor-
age.
• Select a storage location in which the packaging materials cannot be
damaged.
Disposal
When the assembly reaches the end of its useful life, it can be removed
and dismantled, and the materials can be disposed of properly by type.
The following table provides an overview of the materials used. All plastic
components are marked with a material designation and must be disposed
of accordingly.
Material
ponent tion
Metals
Steel Screws, washers, sup-
ports, reinforcements,
panels, brackets
11.1.1 Putting the anti-glare equipment into operation, distance between face
plates 2000 mm
Description
The following instructions describe the installation of the anti-glare equip-

ment.
Equipment

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

KP3-V2H1000 R600 L2000-2 0000-363-263 1

KP3-V2H-2
Options
Tightening torques

torques" Page 147)
en.
ones.
Precondition

• The power cable is deenergized.
motions.
Work safety
WARNING
damage to property.
tion.
11.1.1.1 Fastening the anti-glare equipment
Procedure
1. Position the left-hand support and the left-hand reinforcement on the

cross-member (>>> Fig. 11-5).
2. Fasten the support and reinforcement with 2 M8x16-8.8 Allen screws
and conical spring washers.
4. Position the right-hand support and the right-hand reinforcement on
the cross-member.

Options KP3-V2H-2
Fig. 11-5: Supports and reinforcements
1 Cross-member
2 Support, left
3 Support, right
4 M8x16-8.8 Allen screw (2x)
5 Reinforcement, left
7. Join 2 anti-glare plates together. For this, screw in 4 M8x18-8.8 Allen

screws, each with 2 conical spring washers, and 4 M8 hexagon nuts
and tighten them (>>> Fig. 11-6).

KP3-V2H-2
Options
Fig. 11-6: Pre-assembly of anti-glare plates
1 Anti-glare plate
2 M8x18-8.8 Allen screws (4x)
Conical spring washers (8x)
M8 hexagon nuts (4x)
8. Position the pre-assembled plates between the supports on the main

beam (>>> Fig. 11-7).
9. Fasten the plates to each support with 4 M8x16-8.8 Allen screws and
conical spring washers.

Options KP3-V2H-2
Fig. 11-7: Anti-glare plates
1 Support, right/left
2 M8x18-8.8 Allen screws (4x) with conical spring washers (4x)
3 Main beam
4 Anti-glare plate
11. Position 1 upright element on the side of each support (>>> Fig. 11-8).
12. Fasten the upright elements to the supports with 4 M8x16-8.8 Allen
screws and conical spring washers in each case.
14. Fasten the upright elements and reinforcements with 2 M8x16-8.8 Al-
len screws and conical spring washers in each case.

KP3-V2H-2
Options
Fig. 11-8: Upright element
1 Upright element
3 Cross-member
16. Fasten 1 bracket each to the upright elements and anti-glare plates
using 6 M8x16-8.8 Allen screws and conical spring washers in each
case (>>> Fig. 11-9).

Options KP3-V2H-2
Fig. 11-9: Bracket
3 Bracket
4 Upright element
11.1.1.2 Concluding work

• Carry out a test run in T1 mode and look out for irregularities.
11.1.2 Putting the anti-glare equipment into operation, distance between face
plates 2600 mm
Description
The following instructions describe the installation of the anti-glare equip-

ment.
Equipment

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

KP3-V2H-2
Options
Material

Antiglare KP3-V2H 1000 R800 L2600 -2 0000-360-333 1
Tightening torques

torques" Page 147)
en.
ones.
Precondition

motions.
Work safety
WARNING
damage to property.
tion.
11.1.2.1 Fastening the anti-glare equipment
Procedure
1. Position the left-hand support and the left-hand reinforcement on the

cross-member (>>> Fig. 11-10).
4. Position the right-hand support and the right-hand reinforcement on
the cross-member.

Options KP3-V2H-2
Fig. 11-10: Supports and reinforcements
1 Cross-member
2 Support, left
3 Support, right
5 Reinforcement, left
7. Join 3 anti-glare plates together. For this, screw in 4 M8x18-8.8 Allen

screws, each with 2 conical spring washers, at each joint and 8 M8
hexagon nuts and tighten them (>>> Fig. 11-11).

KP3-V2H-2
Options
Fig. 11-11: Pre-assembly of anti-glare plates
1 Anti-glare plate
8. Position the pre-assembled plates between the supports on the main

beam (>>> Fig. 11-12).
9. Fasten the plates to each support with 4 M8x16-8.8 Allen screws and
conical spring washers.

Options KP3-V2H-2
Fig. 11-12: Anti-glare plates
2 M8x18-8.8 Allen screws (4x) with conical spring washers (4x)
3 Main beam
4 Anti-glare plate
11. Position 1 upright element on the side of each support

(>>> Fig. 11-13).
12. Fasten the upright elements to the supports with 4 M8x16-8.8 Allen
screws and conical spring washers in each case.
14. Fasten the upright elements and reinforcements with 2 M8x16-8.8 Al-
len screws and conical spring washers in each case.

KP3-V2H-2
Options
Fig. 11-13: Upright element
1 Upright element
3 Cross-member
16. Fasten 1 bracket each to the upright elements and anti-glare plates
using 6 M8x16-8.8 Allen screws and conical spring washers in each
case. (>>> Fig. 11-14)

Options KP3-V2H-2
Fig. 11-14: Bracket
3 Bracket
4 Upright element

• Carry out a test run in T1 mode and look out for irregularities.
11.1.3 Decommissioning
Description
This section describes all the tasks which are necessary for decommis-
sioning the anti-glare equipment. After decommissioning, it is prepared for
storage or for transportation to a different location.
Equipment

Set of Allen keys -
1.5; 2; 2.5; 3; 4; 5; 6; 8; 10 mm
Precondition


KP3-V2H-2
Options
motions.
Precondition

motions.
Work safety
WARNING
damage to property.
tion.
11.1.3.1 Moving the positioner into its transport position
Procedure
1. Secure positioner.
2. Remove tools and equipment.
3. Put the positioner into operation and move it into the transport posi-
tion.
4. Secure the positioner by pressing the E-STOP device and then shut
down the positioner.
11.1.3.2 Removing the anti-glare equipment
Procedure
1. Unscrew 6 M8x16-8.8 Allen screws from both brackets and remove

the brackets (>>> Fig. 11-16).
2. Unscrew 2 M8x16-8.8 Allen screws from the reinforcements for each
upright element.

Options KP3-V2H-2
3. Unscrew 4 M8x16-8.8 Allen screws from the supports for each upright
element and remove the upright elements.
4. Unscrew 4 M8x16-8.8 Allen screws from each of the supports and re-
move the anti-glare plates.
5. Unscrew 4 M8x16-8.8 Allen screws each from each of the reinforce-
ments and supports and remove the reinforcements and supports.
Fig. 11-16: Removing the anti-glare equipment (example)

2 Anti-glare plate
3 Bracket
4 Upright element
5 Support
6 Reinforcement
7 M8x18-8.8 Allen screw with conical spring washer

• Prepare the positioner for storage if it is not to be reinstalled.
11.2 Weld current return, infinitely rotating (optional)
Description
The infinitely rotating weld current return is an option for the positioner. It
is used to carry out ground return during welding via a sliding contact.
The energy generated during the weld process is picked up and dis-
charged via the weld current return.

KP3-V2H-2
Using this weld current return allows the respective rotational axis to be
Options
designed as an infinitely rotating axis.
This weld current return consists of the following components:
• Current collector:
‒ Contact surface of plunger holder
‒ Plunger holder with integrated compression spring
‒ Connection plate
‒ Holder
‒ Insulating plate
• Fastening materials
• Grounding cables
If the infinitely rotating weld current return is used in combination with an
energy supply system, the range of motion is limited to ±190°.
Fig. 11-17: Components, infinitely rotating weld current return, exam-

ple
1 Current collector 4 Plunger holder

2 Insulating plate 5 Connection plate
3 Holder 6 Grounding cables
Basic data
Weight, current collector approx. 3 kg

Article number, Welding current 0000-355-920
collector DS (drive)
Article number, Welding current 0000-380-922
collector CB (counterbearing)
Current rating under continuous max. 500 A
load

sembly instructions for the robot and robot controller.
Dimensions
The following diagram shows the dimensions of the current collector for:

Options KP3-V2H-2
Fig. 11-18: Dimensions, current collector
Planning
Up to three welding robots can be connected to interface A1.
Fig. 11-19: Interface A1
1 Connection, weld current return, 3rd robot, Dinse DIX BE 70/95

2 Connection, weld current return, 1st robot, Dinse DIX BE 70/95
3 Data cable RDC X21.1 for cascading
4 Motor cable XM7
5 Motor cable XM8
6 Motor cable XM9

KP3-V2H-2
Options
7 Data cable RDC X31.1
8 Connection, weld current return, 2nd robot, Dinse DIX BE 70/95
Transportation

Start-up and recommissioning may only be carried out by KUKA Deutsch-

land GmbH or trained specialist personnel.
Maintenance
Fig. 11-20: Maintenance chart, current collector, example

6 months 1 Check tightening torques for screws.
6 months 2 Visual inspection: Check the contact surfaces of the plunger holder.
• The contact surface must be smooth and even.

• The recesses on the contact surface must be visible.
• If unevenness is detected, the current collector must be ex-
changed.
(>>> 11.2.1 "Exchanging the current collector" Page 138)

Options KP3-V2H-2

6 months 3 Check that compression spring moves freely.
(Compression spring is not visible from outside.)
• Compression spring must move freely.

• If it does not move freely, the current collector must be ex-
changed.
Repair
Disposal
When the cover reaches the end of its useful life, it can be removed and
disposed of. The materials must be disposed of in accordance with the
pertinent regulations or recycled.
The following table provides an overview of the materials used.
Material
ponent tion
Metals
Copper Cables, wires -
Steel Connection plate, -
screws, washers, hold-
ers
Plunger holder Dispose of plunger
holder without disman-
tling.
Plastics
HGW2082 Insulating plate -
PUR Cable sheaths -
11.2.1 Exchanging the current collector
Description
The following sections describe the procedure for exchanging the current
collector on a positioner.
Equipment

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

KP3-V2H-2
Options
Welding current collector DS 0000-355-920 1
Tightening torques

torques" Page 147)
en.
ones.
Precondition

motions.
Work safety
WARNING
11.2.1.1 Removing the cover on the drive side
Procedure
1. Unscrew 3 M6x10-A2K-70 round head screws from the cover.

2. Remove the cover.

Options KP3-V2H-2
1 M6x10-A2K-70 round head screw

2 Cover
11.2.1.2 Removing the current collector on the drive side
Procedure
1. Unscrew the cable gland from the copper bar.

2. Take the cable gland and cable off the copper bar.

KP3-V2H-2
Options
Fig. 11-22: Cable gland on current collector
1 Copper bar
2 Cable gland
3 Grounding cable
3. Unscrew 2 M8x25-8.8-A2K Allen screws including 2 washers and 2 in-

sulating bushings from the current collector.
4. Take the current collector carefully out of the housing.
Fig. 11-23: Current collector
1 M8x25-8.8-A2K Allen screw with washer and insulating bushing

2 Copper bar
3 Housing

KP3-V2H-2
11.2.1.3 Installing the current collector on the drive side

Options
Procedure
1. Position the current collector in the housing and fasten with 2

M8x25-8.8-A2K Allen screws including 2 washers and 2 insulating
bushings. Ensure that the installation position is correct.
Fig. 11-24: Current collector
1 M8x25-8.8-A2K Allen screw with washer and insulating bushing

2 Copper bar
3 Housing
2. Place the cable on the copper bar and fasten it with the cable gland.
Fig. 11-25: Cable gland on current collector
1 Copper bar
2 Cable gland
3 Grounding cable

KP3-V2H-2
11.2.1.4 Mounting the cover on the drive side
Options
Procedure
1. Attach cover to housing and align it.

2. Fasten the cover using 3 M6x10-A2K-70 round head screws.
1 M6x10-A2K-70 round head screw

2 Cover

• Move the positioner and look out for irregularities.
• Run the program in T1 mode and look out for irregularities.
• Carry out a function test.
11.3 Position monitoring
The positioner can be equipped with safe position monitoring on the main
axis in order to detect the working position of the main axis. The signal
can be sent to a controller or PLC.
The position monitoring consists of the following components:
• Safety switch
• Actuator for safety switch
• Bus module (PROFINET)
• Cables and hoses M12
• Plates

Options KP3-V2H-2
• Fastening materials
Fig. 11-27: Position monitoring
1 Guard plate
2 Mounting plate
3 Safety switch
4 Cable M12
5 Actuator for safety switch
6 Bus module (PROFINET)
Basic data
Designation Article number Weight

Position sensing 0000-354-776 approx.
3.5 kg

sembly instructions for the robot and robot controller.
Transportation


KP3-V2H-2
Options
Start-up and recommissioning may only be carried out by KUKA Deutsch-

land GmbH or trained specialist personnel.
Maintenance
conditions specified in the technical data. KUKA Deutschland GmbH must
be consulted in the case of discrepancies!
Fig. 11-28: Maintenance work

6 months 1 Check all screwed connections (tightening torques).
Disposal
When the cover reaches the end of its useful life, it can be removed and
disposed of. The materials must be disposed of in accordance with the
pertinent regulations or recycled.
The following table provides an overview of the materials used.
Material
ponent tion
Metals
Copper Cables, wires -
Steel Plates, screws, wash- -
ers
Electrical parts
Safety switch, actuator Dispose of as electri-
for safety switch cal scrap without dis-
assembling
Plastics
PUR Cable sheaths -

Options KP3-V2H-2

KP3-V2H-2
Appendix
12 Appendix
12.1 Tightening torques
Tightening torques
The following tightening torques (Nm) are valid for screws and nuts where
no other specifications are given.
The specified values apply to lightly oiled black (e.g. phosphated) and
coated (e.g. mech. galv., zinc flake plating, screw locking elements)
screws and nuts.
Strength class
Thread 8.8 10.9 12.9
M1.6 0.17 Nm 0.24 Nm 0.28 Nm
M2 0.35 Nm 0.48 Nm 0.56 Nm
M2.5 0.68 Nm 0.93 Nm 1.10 Nm
M3 1.2 Nm 1.6 Nm 2.0 Nm
M4 2.8 Nm 3.8 Nm 4.4 Nm
M5 5.6 Nm 7.5 Nm 9.0 Nm
M6 9.5 Nm 12.5 Nm 15.0 Nm
M8 23.0 Nm 31.0 Nm 36.0 Nm
M10 45.0 Nm 60.0 Nm 70.0 Nm
M12 78.0 Nm 104.0 Nm 125.0 Nm
M14 125.0 Nm 165.0 Nm 195.0 Nm
M16 195.0 Nm 250.0 Nm 305.0 Nm
M20 370.0 Nm 500.0 Nm 600.0 Nm
M24 640.0 Nm 860.0 Nm 1030.0 Nm
M30 1330.0 Nm 1700.0 Nm 2000.0 Nm
Strength class
Thread 8.8 10.9
ISO7991 ISO7380, ISO07381
Allen screw Fillister head
screw
M3 0.8 Nm 0.8 Nm
M4 1.9 Nm 1.9 Nm
M5 3.8 Nm 3.8 Nm
Strength class
Thread 10.9
DIN7984
Pan head screws
M4 2.8 Nm
Tighten M5 domed cap nuts with a torque of 4.2 Nm.

Appendix KP3-V2H-2
12.2 Auxiliary and operating materials used
Product designation / Use Manufacturer designation /

Article number Address
Optigear Synt. Gear oil Castrol Industries - divisie BP Euro-

ALR 150_EEA pa SE - BP Belgium
Amocolaan 2
0000-362-835 for Europe-
2440 Geel
an Economic Area
Belgium
Optigear Synt.
ALR 150_USA
0000-361-461 for USA,
Canada, Mexico
Optigear Synt.
ALR 150_CHN
0000-361-473 for China
Optigear Synt.
ALR 150_APA
0000-361-476 for Asia/
Pacific Area
Article numbers for further
regions can be found in
KUKA Xpert.
Optitemp RB 2 Lubricating grease Deutsche BP Aktiengesellschaft - In-

dustrial Lubricants & Services
0000-101-456
Erkelenzer Strasse 20
D-41179
Mönchengladbach
Germany
To ensure safe use of our products, we recommend regularly requesting

up-to-date safety data sheets from the manufacturers of auxiliary and
operating materials.
12.3 Applied standards and regulations
Name/Edition Definition
2006/42/EC:2006 Machinery Directive:

Directive 2006/42/EC of the European Parliament and of the Coun-
cil of 17 May 2006 on machinery, and amending Directive 95/16/EC
(recast)
2014/68/EU:2014 Pressure Equipment Directive:

Directive 2014/68/EU of the European Parliament and of the Coun-
cil dated 15 May 2014 on the approximation of the laws of the
Member States concerning pressure equipment
(Only applicable for robots with hydropneumatic counterbalancing
system.)
EN 60204-1:2006/ Safety of machinery:

A1:2009
Electrical equipment of machines - Part 1: General requirements

KP3-V2H-2
Appendix
EN 61000-6-2:2005 Electromagnetic compatibility (EMC):
Part 6-2: Generic standards; Immunity for industrial environments
EN 61000-6-4:2007 + Electromagnetic compatibility (EMC):

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

Ergonomic design principles - Part 1: Terms and general principles
EN ISO 10218-1:2011 Industrial robots – Safety requirements:

Part 1: Robots
Note: Content equivalent to ANSI/RIA R.15.06-2012, Part 1
EN ISO 12100:2010 Safety of machinery:

General principles of design, risk assessment and risk reduction
EN ISO 13849-1:2015 Safety of machinery:

Safety-related parts of control systems - Part 1: General principles
of design
EN ISO 13849-2:2012 Safety of machinery:

Safety-related parts of control systems - Part 2: Validation
EN ISO 13850:2015 Safety of machinery:

Emergency stop - Principles for design

Appendix KP3-V2H-2

KP3-V2H-2
KUKA Service
13 KUKA Service
13.1 Requesting support
Introduction
This documentation provides information on operation and operator con-

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

quest:
• Description of the problem, including information about the duration
and frequency of the fault
• As comprehensive information as possible about the hardware and
software components of the overall system
The following list gives an indication of the information which is rele-
vant in many cases:
‒ Model and serial number of the kinematic system, e.g. the manip-
ulator
‒ Model and serial number of the controller
‒ Model and serial number of the energy supply system
‒ Designation and version of the system software
‒ Designations and versions of other software components or modifi-
cations
‒ Diagnostic package KRCDiag
Additionally for KUKA Sunrise: existing projects including applica-
tions
For versions of KUKA System Software older than V8: archive of
the software (KRCDiag is not yet available here.)
‒ Application used
‒ External axes used
13.2 KUKA Customer Support
The contact details of the local subsidiaries can be found at:

www.kuka.com/customer-service-contacts

KUKA Service KP3-V2H-2

KP3-V2H-2
Index Disposal..........................................30, 109, 114

Documentation, positioning system................. 7
2006/42/EC:2006.......................................... 148
Drive unit.......................................................... 8
2014/68/EU:2014.......................................... 148
95/16/EC....................................................... 148
E
A EC declaration of conformity......................... 18
Electrical installations.............................12, 102
Accessories.............................................. 13, 17
Electromagnetic compatibility (EMC)........... 149
ANSI/RIA R.15.06-2012............................... 149
Electromagnetic compatibility (EMC):.......... 149
Anti-glare equipment (optional).................... 117
Anti-glare equipment, putting into operation, EMC Directive.................................................18
distance between face plates 2000 mm..... 120 EMD.................................................................. 8
Anti-glare equipment, putting into operation, EN 60204-1:2006/A1:2009........................... 148
distance between face plates 2600 mm..... 126 EN 61000-6-2:2005...................................... 149
Appendix....................................................... 147 EN 61000-6-4:2007 + A1:2011.................... 149
Automatic mode..............................................28 EN 614-1:2006+A1:2009..............................149
Auxiliary materials used............................... 148 EN ISO 10218-1:2011.................................. 149
Axis data............................................33, 39, 45 EN ISO 12100:2010..................................... 149
Axis data, KP3-V2H1000 R600 L2000-2.......39 EN ISO 13849-1:2015..................................149
Axis data, KP3-V2H1000 R800 L2600-2.......45 EN ISO 13849-2:2012..................................149
EN ISO 13850:2015..................................... 149
Axis data, KP3-V2H500 R600 L2600-2.........33
Energy supply system.................................... 11
Axis limitation, mechanical............................. 22
External axes..................................................17
Axis range.................................................. 8, 18
External axis...............................................9, 20
B
Base frame..................................................... 12
F
Face plates, dimensions................................ 58
Basic data, KP3-V2H1000 R600 L2000-2.....38
Faults.............................................................. 25
Basic data, KP3-V2H1000 R800 L2600-2.....44
Foundation loads, KP3-V2H1000 R600
Basic data, KP3-V2H500 R600 L2600-2.......31
L2000-2...........................................................42
Brake defect................................................... 24
Brake release device......................................23
L2600-2...........................................................48
Braking distance.........................................8, 18
L2600-2...........................................................36
Function test................................................... 26
C
CE mark..........................................................18
Center of gravity.............................................63
Cleaning work.................................................29
G
General safety measures............................... 23
Connecting cable, standard........................... 80
Connecting cables..........17, 32, 39, 45, 60, 79
Connecting cables interface...........................79
Connecting cables, connecting................68, 75 H
Counterbalancing system............................... 29 Handling equipment...........................63, 66, 74
Cover on drive side, mounting.................... 143 Hazardous substances................................... 29
Cover on drive side, removing.................... 139
Current collector on drive side, removing... 140
Current collector, exchanging...................... 138 I
Industrial robot................................................17
Installation with mounting base..................... 67
D Interface A1.................................................... 61
Danger zone...............................................8, 19 Interface, energy supply system....................61
Declaration of conformity............................... 18 Interfaces........................................................ 60
Declaration of incorporation.....................17, 18 Introduction....................................................... 7
Decommissioning...........................30, 109, 132
Description, positioner.................................... 11
Dimensions, transport.....................................63 K
Directives...................................................... 148 KCP......................................................8, 19, 24
Disclaimer....................................................... 17 Keyboard, external......................................... 24

KP3-V2H-2
KP..................................................................... 8 Positioner, cleaning........................................ 83

KR C................................................................. 8 Positioner, mastering................................69, 76
KUKA Customer Support............................. 151 Positioner, removing............................. 110, 113
KUKA Service...............................................151 Preparing for storage....................................114
KUKA smartPAD........................................ 8, 19 Pressure Equipment Directive............... 29, 148
KUKA smartPAD-2..................................... 8, 19 Preventive maintenance work........................ 29
Product description......................................... 11
Protective equipment, overview..................... 21
L PSA.................................................................20
Labeling.......................................................... 23
Linear unit.......................................................17
Low Voltage Directive.....................................18 R
RDC.................................................................. 9
Reaction distance.......................................8, 18
M Recommissioning..................................... 25, 65
Machine data............................................69, 76 Regulations................................................... 148
Machine frame mounting................................56 Release device............................................... 23
Machine frame mounting, installing............... 74 Repair....................................................... 28, 85
Machinery Directive................................18, 148 Robot controller.............................................. 17
Main beam......................................................12
Maintenance............................................. 28, 81
Maintenance overview....................................81 S
Maintenance symbols.....................................81 Safety..............................................................17
Maintenance table.......................................... 81 Safety instructions............................................ 7
Manipulator.......................................... 9, 17, 19 Safety of machinery.............................148, 149
Manual mode..................................................27 Safety options.................................................19
Material designation......................................114 Safety zone..........................................9, 19, 21
Mechanical end stops.................................... 22 Safety, general................................................17
Misuse.............................................................14 Service life...................................................... 19
Motor A1, exchanging.................................... 85 smartPAD............................................. 9, 19, 24
Motor A2, exchanging.................................... 90 Software..........................................................17
Motor A3, exchanging.................................... 96 Spare parts........................................ 85, 91, 97
Mounting base................................................ 67 Standards......................................................148
Mounting base with centering........................53 Start-up.....................................................25, 65
Mouse, external.............................................. 24 Start-up, positioner (machine frame
mounting)........................................................ 72
Start-up, positioner (mounting base)............. 65
O STOP 0................................................ 9, 19, 52
Operating materials used............................. 148 STOP 1...................................................... 9, 19
Operators........................................................ 21 STOP 2...................................................... 9, 20
Optigear Synt. ALR 150...............................148 Stop category 0......................................... 9, 19
Options............................................. 13, 17, 117 Stop category 1......................................... 9, 19
Optitemp RB 2..............................................148 Stop category 2......................................... 9, 20
Overload......................................................... 24 Stop category 1, Drive Ramp Stop............... 20
Overview, positioner....................................... 11 STOP 1 - DRS............................................... 20
Stopping distance.......................................8, 18
Stopping distances......................................... 52
Storage........................................... 30, 109, 111
P Support request............................................ 151
Payloads, KP3-V2H1000 R600 L2000-2....... 42
System integrator.............................. 18, 20, 21
Payloads, KP3-V2H1000 R800 L2600-2....... 48
Payloads, KP3-V2H500 R600 L2600-2......... 35
Personal protective equipment...................... 20
Personnel........................................................20 T
Planning.......................................................... 53 T1 (operating mode).................................. 9, 20
Plant integrator............................................... 20 T2 (operating mode).................................. 9, 20
Plates and labels............................................49 Teach pendant................................................ 17
PLC................................................................... 9 Technical data.................................................31
Position monitoring....................................... 143 Technical data, KP3-V2H1000 R600
Positioner........................................................ 17 L2000-2...........................................................38

KP3-V2H-2
Technical data, KP3-V2H1000 R800

L2600-2...........................................................44
Technical data, KP3-V2H500 R600 L2600-2 31
Technical data, overview................................ 31
Terms used....................................................... 8
Terms, safety.................................................. 18
Tightening torques........................................147
Training................................................ 7, 81, 85
Transport position.................................... 63, 73
Transportation.......................................... 25, 63
Turn-tilt table...................................................17
U
Use
Intended..................................................... 14
User.......................................................... 18, 20
W
Warnings........................................................... 7
Weld current return, infinitely rotating
(optional).......................................................134
Workspace........................................... 8, 18, 21

MA KP3-V2H-2 en

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Positioner

Publication: Pub MA KP3-V2H-2 (PDF) en

Book structure: MA KP3-V2H-2 V1.1

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4.4.2 Axis data, KP3-V2H1000 R800 L2600-2.............................................................. 45

7 Start-up and recommissioning............................................................... 65

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9.2.4 Installing the drive unit covers.............................................................................. 95

10 Decommissioning, storage and disposal............................................. 109

13 KUKA Service........................................................................................... 151

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13.1 Requesting support............................................................................................... 151

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1.1 Target group

This documentation is aimed at users with the following knowledge and

For optimal use of KUKA products, we recommend the training courses

1.2 Positioning system documentation

The positioner documentation consists of the following parts:

1.3 Representation of warnings and notes

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These warnings contain references to safety-relevant information or gen-

This warning draws attention to procedures which serve to prevent or rem-

Procedures marked with this warning must be followed exactly.

These notices serve to make your work easier or contain references to

1.4 Terms used

Stopping distance Stopping distance = reaction distance + braking distance

Drive unit A combination of motor and gear unit.

EMD Electronic Mastering Device

KCP KUKA Control Panel

KR C KUKA Robot Control

KUKA smartPAD see “smartPAD”

KUKA smartPAD-2 see “smartPAD”

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RDC Resolver Digital Converter

smartPAD Programming device for the robot controller

PLC Programmable Logic Controller

• Operating mode T1: the drives are deactivated as soon as the

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

T2 Test mode, Manual High Velocity (> 250 mm/s permissible)

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2.1 Overview of the positioner

The KP3-V2H-2 product family comprises the following positioners:

Fig. 2-1: Overview of the positioner

2.2 Description of the positioner

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Fig. 2-2: Principal components

1 Counterbearing unit of planetary axis

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include a protective circuit. The ground conductors to the positioner are

Only accessories authorized by KUKA Deutschland GmbH for this posi-

2.3 Control and integration

Further information about calibration of an external kinematic system is

An example of a mathematical coupling is depicted in the following dia-

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With mathematical coupling, the robot constantly follows the movement of

2.4 Intended use and misuse

The positioner is intended to move and position loads and workpieces.

Any use or application deviating from the intended use is deemed to be

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