KUKA KR CYBERTECH CR HO (KR   20   R1810-HO) assembly instructions

HO meaning: Sanitary Oil, the version of sanitary oil, aimed at the secondary food industry; Filling the gearbox with food grade gear oil Cassida Fluid GL150; Support installation at any tilt angle for ground, wall, and ceiling, compatible with KR C4, KR C5 S controllers; Belonging to the CYBERTECH family 20kg load body, the manual covers safety, technical parameters, planning, transportation, installation and commissioning, complete maintenance, motor/wrist repair, shutdown disposal, options, and appendices for a complete set of body assembly and maintenance content.

Product Description

Robot system composition: robotic arm body, controller, power/data cables, teaching pendant, software, tools and options.

Mechanical arm body structure: 6-axis series joint, assembly including straight wrist inline wrist, linkage arm, rotating column, base frame, and complete electrical wiring.

A1-A3 is equipped with mechanical terminal hard blocks, only used for equipment protection; Personnel protection relies on the SafeRobot safety function of the controller, or by selecting the A1-A3 adjustable mechanical shaft limit.

Straight wrist: A4-A6 integrated wrist, A6 motor arranged inside the upper arm; A4/A5 rely on the drive shaft for transmission; The flange complies with ISO 9409-1 standard.

Key features of HO version: All gearboxes are filled with food grade Cassida Fluid GL150 sanitary gear oil, and the body components are suitable for secondary production conditions of food; The Combo junction box at the rear of the base integrates an RDC unit; All motors and signal cables use quick plug connectors.

Permitted use and prohibited misuse

✅ Allow: secondary food industry workpiece handling and processing; Strictly adhere to environmental conditions and maintenance cycles.

❌ Prohibited: climbing, carrying people and animals, outdoor activities, explosion-proof areas, radioactive activities, and underground operations; The main body cannot directly contact food materials; Unauthorized use will result in the loss of warranty.

Robots belong to partially completed machinery and cannot be put into operation independently; The system integrator completes the entire system, issues an EC conformity declaration, and affixes the CE mark.

Available options: Release device for brake release, transport fork groove, lifting equipment, A1-A3 mechanical shaft limit, pipeline package; Supports PURGE-A/B positive pressure blowing kit.

Technical Data (KR   20   R1810-HO)

Basic parameters of the ontology

Project KR   20   R1810-HO

6 axes fully controlled

Rated load of 20 kg; maximum load of 23.9 kg

Maximum reach distance 1813mm

Repetitive positioning accuracy ISO 9283 ± 0.04 mm

The self weight of the body is about 250 kg

Protection level: IP65 for the body and IP67 for the wrist

Noise<75 dB (A)

Installation method: Ground, wall mounted, suspended ceiling, with any inclination angle of ± 180 °

Gear oil Cassida Fluid GL150 (food hygiene grade)

Operating at a temperature of 5-45 ℃; Storage -20~60 ℃

Compatible controller KR C4/KR C5 S

Axis motion parameters

Motion range: A1 ± 185 °; A2‑185°~+65°； A3‑138°~+175°； A4/A6 ±350°； A5 ±130°

Rated load maximum shaft speed: A1   200 °/s; A2   175 °/s; A3   190 °/s; A4   430 °/s; A5   430 °/s; A6   630 °/s

Mastering zero position; Tilt installation will limit the range of motion of the A1 axis, and the WorkVisual software must fill in the actual installation tilt angle, otherwise overload and accidental motion may damage the robot.

Load parameters: wrist flange ZH8/12/16/20, ISO 9409-1; Load center of gravity, moment of inertia, load curve diagram; Distinguish between normal operation and emergency stop conditions, flange bearing axial force, radial force, overturning moment, and torsional moment; Additional loads are allowed to be added to the boom, connecting rod arm, and rotating column.

Base load: Output vertical force, horizontal force, overturning moment, and A1 torque for ground, ceiling, and wall mounted working conditions respectively; The structural verification must take the maximum value of the emergency stop condition to prevent overturning and falling.

Cable parameters: distinguish between KR-C4 and KR-C5-S sets of cables; The standard length of the cable is 4-50 meters, with a maximum total length of 50 meters and a maximum of one extension allowed; Specify the minimum bending radius; Independent protective grounding; Complete interface pin diagram of A1 base, including PURGE blowing air source interface.

Stop distance and stop time: distinguish between STOP0 cutting off the brake and STOP1 safe stop; For A1-A3, provide stop angle and stop time curves for different arm extension ratios (33%/66%/100%), program magnification POV, and different loads; The brake will wear out, it is recommended to conduct an annual on-site review of the actual stopping distance.

Refer to KUKA Xpert for information on the body nameplate and REACH regulations.

Planning and Design

Accelerated wear conditions: long-term temperature limit operation, abrasive dust environment, sustained performance limit, single axis high duty cycle, monotonic reciprocating short stroke, wrist long-term static, external process force; Consult KUKA for the above working conditions to shorten the maintenance cycle; The body comes with overheating and overload monitoring, and automatically shuts down when exceeding the limit.

Two base schemes

Centering option base S310: concrete floor; Concrete grade C20/25; Bottom plate, chemical anchor bolt, positioning pin; It is prohibited to add a soundproof leveling layer between the base and concrete, and a foundation section drawing should be provided.

Rack mounted installation: customer steel structure, KUKA linear slide table; 4 M20 bolts+2 locating pins; The installation requires strict requirements for flatness, roughness, and structural stiffness.

Cable planning: The minimum static bending radius for motor cables is 150   mm, and for signal cables it is 60   mm. Power cables and signal cables are laid separately in metal cable trays to ensure EMC electromagnetic compatibility; Double protection grounding; Cable layout eliminates tripping risks; Cables are prohibited from withstanding tensile forces.

A1 Base Interface Definition: Motor X30/XD30, Data X31/XF31, Mastering Calibration Interface, External Shaft Interface, PURGE Purging Air Source Interface Drawing.

Transportation

Forced transportation posture (must be maintained throughout the entire process, and the posture must not be changed before being fixed to the base to prevent tipping)

A1=0°，A2=‑138°，A3=139°，A4=0°，A5=90°，A6=0°

Shipping Method

Forklift: Optional fork slots must be installed;

Crane: Use KUKA specialized lifting equipment and M10 lifting rings, with lifting points distributed around rotating columns and bases;

Prohibit lifting from non-standard lifting points; Avoid impact and vibration; Dismantle the lifting ring/fork groove in place; Provide the overall dimensions and center of gravity position for the transportation of the entire machine.

Startup Debugging and Restarting

The complete process of covering the installation of fixed base flooring, rack mounted flooring/wall mounted/suspended ceiling.

Prerequisite: The robot is in a transport position, the base steel structure is completed, and the lifting equipment is in place.

General installation steps

Lift into place and install the positioning pin;

M20 bolts are tightened diagonally in multiple stages to the specified torque;

Connect double protection grounding (torque 15   Nm);

Connect motor cables and data cables; The sound of a click on the connector indicates locking, and the lock buckle can rotate 90 degrees to prevent accidental unlocking; Distinguish between KR-C4 and KR-C5-S wiring;

Fill in the actual installation posture and inclination angle of the robot using WorkVisual software; If PURGE blowing is selected, adjust the compressed air pressure;

Install tools, power on, jog in T1 mode, perform axis Mastering zero calibration, and perform overall functional testing.

After 100 hours of operation, all anchor bolt torques must be rechecked.

Provide a complete schematic diagram of the wiring of KR C4 and KR C5 S motor cables, data cables, and grounding cable pins.

Maintenance

Only allow maintenance projects recorded in the manual to be executed; The remaining repairs will be entrusted to KUKA authorized personnel; Emergency stop, lock and power off before maintenance; The maintenance cycle is shortened when the operating oil temperature exceeds 60 ℃; The HO model uses food grade Cassida Fluid GL150 gear oil.

Maintenance cycle summary table

Periodic homework content consumables

After being put into operation, only one 100 hour recheck of the torque of all bolts on the base will be conducted

5000 hours visual inspection of A1 flexible pipeline package for damage -

Apply lubricating grease PETAMO GHY 133 N to the 10000 h A1 cable package

20000 hours or at the latest 5 years, A1-A6 axis gradual flowering key inspection and fat supplementation; Change all gearbox oil Cassida Fluid GL150 food grade gear oil; Microlube GL261 grease; Drei Bond 5204HV sealant

Suggest KUKA to conduct a comprehensive on-site inspection of the entire machine after 7 years or changes in operating conditions.

Key maintenance process

A1 cable package lubrication: Remove the base cover plate, visually inspect the corrugated tube, apply lubricating grease with a brush, restore the cover plate, and jog A1 to evenly distribute the grease.

Gradual flowering key inspection and lubrication of each axis motor (A1-A6)

Before disassembling the motor, the corresponding shaft must be mechanically locked with a sling fixture to prevent the arm from falling;

Remove the motor, clean the gradually blooming key, and check for wear and tear; Damage must be replaced; Thin and continuous application of Microlube GL261;

Apply Drei Bond 5204HV to the O-ring/sealing surface; tighten the bolts diagonally in steps; Connect the plug back; The axis must undergo Mastering zero calibration.

The disassembly of A6 motor is complex: it is necessary to first remove A4 and A5 motors, and then remove the entire straight row wrist before removing A6 motor.

General rules for gearbox oil change: The gearbox is at operating temperature; Measure the actual amount of oil released during oil discharge; The gearbox must be flushed if the oil release rate is less than 70% of the rated value; Rinse twice with less than 50%, and move the entire stroke during rinsing; Magnetic plug inspection for metal debris; Tighten the plug according to the specified torque; Oil change completed T1 mode jog operation, check for leaks.

Initial oil filling amount for each gearbox: A1=1.20   L; A2=0.80   L; A3=0.32   L; A4=0.32   L; A5/A6=0.37   L.

Robot cleaning: Prohibit high-pressure water guns and direct blowing of compressed air on bearing seals; Use water-soluble neutral cleaning agents; Power off operation to prevent liquid from entering the electrical chamber.

Maintenance

Manual description: A1-A6 motor replacement, straight row wrist assembly replacement, A4/A5 drive shaft replacement.

General safety for motor replacement: power off, lock the main switch, wait for 5 minutes for high voltage discharge; Before disassembling the motor, the corresponding shaft must be mechanically locked to prevent the arm from accidentally falling;

Motor installation: Check that the gradual flowering key is not damaged and apply Microlube GL261 evenly; The O-ring seal must be replaced if it is damaged; Tighten the bolts diagonally in steps; After installation, the axis must undergo Mastering zero calibration and T1 mode trial operation.

Special difficulties:

Dismantling of A2/A3 motors, fixing the connecting rod arm/boom with a sling to prevent self weight from falling;

A6 motor: The A4 and A5 motors must be removed first, and the entire straight arm must be dismantled before the A6 motor can be removed;

Replacement of straight row wrist assembly: It is necessary to remove the A4/A5/A6 motors and the lifting device supporting the wrist (about 23 kg) in sequence, and disassemble and replace the entire set.

Overview of Electrical Wiring; Repairs must use KUKA original spare parts; Complete verification of all safety functions after maintenance is completed.

Suspension, Storage, and Disposal

Shutdown disassembly: The robot moves to the designated transport posture; Install lifting rings and slings; Disconnect all cables; Lift the crane off the main body.

Storage: Maintain transportation posture, clean the robot, provide rust prevention protection, and meet temperature and humidity storage conditions.

Scrap disposal: The HO version requires special disposal of food grade waste oil in accordance with local regulations; Lubricating oil, electronic components, and metal structures shall be classified and disposed of in accordance with local environmental regulations.

Options

Release device: manual movement of the robotic arm in power-off state; Provide a complete explanation of the installation process and safety constraints for a non actuated mobile robotic arm.

PURGE-A and PURGE-B blowing kits are used for positive pressure protection inside the cavity.

Forklift transport components, lifting equipment, A1-A3 mechanical shaft limit, pipeline package.