21/09/2025 By CNCBUL UK EDITOR Off

What Should I Pay Attention To When Buying a Second-Hand / used DMG Automation Gildemeister Kuka KR60?

If you’re looking to buy a second-hand KUKA KR60 robot (potentially mounted or integrated by DMG/Gildemeister or similar), there are many things you should check closely. Robots have different wear modes and failure points than machine tools, but many of the same principles (mechanical condition, electronics, support, etc.) apply. Below is a guide: what to know, what to inspect, what to ask, and red flags.

What the KUKA KR60 Is / What You Should Know

Before buying, make sure you know exactly which KR60 variant you are considering. Key specs and variant details will matter.

Payload: The “60” means ~60 kg payload (varies slightly depending on model / wrist, mount).
Reach / Arm length: Depending on the exact configuration, arm span, and mounting (mounted on floor, ceiling, in DMG system etc.).
Degrees of freedom, axes configuration (6-axis robot arm).
Controller version (KR C2, KR C4, KR C5 etc.), software version, firmware.
What the robot was used for: application (welding, machining, material handling, painting, cutting, etc.) affects which parts are worn more.

Knowing the exact model helps you check for correct spare parts, support, and expected life.

What to Pay Attention To / Inspect

When evaluating a used KR60, these are the major components and test-points to check. Some require running the robot, others visual / documentation checks.

Component / Area	What to Inspect or Test	Why It Matters / What Can Go Wrong
Mechanical Condition of Arm and Joints	• Inspect all joints (shoulder, elbow, wrist) for looseness, play, backlash. • Observe if there are abnormal noises (grinding, squeaking, knocking) when moving through full range. • Check for visible wear or damage on gears, pinions, bearings in joints. • Inspect the wrist for signs of overload, impact damage. • Check housing/cover plates for wear, rust, dents etc.	Worn joint bearings or gearboxes lead to lost accuracy, increased maintenance, or even failure. A damaged wrist or badly used joints degrade performance.
Encoders, Feedback, Calibration	• Verify encoder readings are consistent, free of jumps. • Check for any calibration drift: ask for recent calibration / reference position records. • Move to specific positions multiple times; check repeatability. • Check if any axis has backlash or hysteresis in movement.	Encoder faults or drift reduce precision; applications needing tight positional repeatability will suffer. Faulty feedback can cause motion errors or even crashes.
Controller & Software / Firmware	• Identify which controller version (KR C2, C4, C5, etc.) is installed. • Check software/firmware version; whether updates are available / applied. • Inspect teach pendant; ensure display, buttons, joint control (manual control) works. • Check diagnostics, error logs, fault history. • Confirm whether any features you need (e.g. safety modules, I/O, communication protocols) are present and working.	A modern controller helps reliability, compatibility. Older controllers may be obsolete; missing features I/O or safety could require costly retrofits. Fault history can reveal recurring failures.
Drive & Motor Systems	• Inspect servo motors (for each axis); check for signs of overheating, unusual vibrations, noise. • Inspect cables, connectors, especially in joints (which move). • Check gearboxes: oil level, leakage, condition; inspect seals. • Check brakes (if present) for wear and effectiveness. • Run the robot through full motion (joint motion, combined motions) under load (if possible) to see if performance degrades.	Motor/drive failures are expensive. Wiring wear, backlash or slippage in gearboxes can produce positional errors. Brakes, if weak, cause drift or safety problems. Repeated heavy usage may have stressed motors or gear reducers.
Mechanical Interfaces & Mounting	• Inspect base mounting: is it rigid, stable; have there been any base or weld damage. • If mounting involves a DMG cell, check that fixtures, tooling interfaces, end-effectors are correct and in good shape • End effector / tool mount (weld torch, gripper, spindle etc.): check tool changer (if present) functioning, mechanical integrity, alignment. • Payload: verify whether the robot has been used close to its maximum payload frequently (this shortens life).	Overloading or frequent use near limits wears joints/gears faster. If base or mounting has damage, alignment may be off. Bad tooling interface causes mispositioning or safety risk.
Environmental / Usage History	• What environment was the robot used in? (clean, dusty, wet, temperature extremes, chemical exposure etc.) • How many hours total, how many cycles, how much idle time vs active motion. • Was robot exposed to impacts, shocks, or if there have been crashes (e.g. tools hitting parts, workpiece collision). • Maintenance history: regular lubrication of joints, replacing worn gearboxes, cleaning, replacement of belts or seals etc. • How many hours on motors, how much load.	A robot used in harsh environment or with crashes needs more refurbishment. Maintenance determines longevity. Hidden damage may have occurred even if visually small.
Electrical / Wiring / Cabling	• Inspect all cables (power, feedback, I/O) especially in moving joints to see wear, chafing, insulation damage. • Inspect cable chains (if used) for wear, deformation, correct function. • Check connectors, the teach pendant cable, whether connectors are tight and corrosion-free. • Check grounding, enclosure sealing (dust/water ingress protection). • Power supply stability; check if the robot has had electrical surges, downtime etc.	Damaged or stressed cables often cause intermittent faults or failures. Poor grounding or ingress leads to corrosion, shorts. Power issues can degrade motors/drives.
Safety Features & Compliance	• Emergency stop buttons and circuits: do they work everywhere required. • Safety interlocks, safety rated limits, collision detection (if installed). • Whether robot meets necessary certifications / safety standards in your country (CE, etc.) • Whether safety guarding, protective fences, light curtains or area scanners are included & functional. • Condition of warning labels, safety signs. • Whether the controller has safety-rated I/O modules if needed (e.g. rated safety circuits).	Safety is critical for legal, insurance, and operator safety. Missing or broken safety systems can both be dangerous and require expensive upgrades. Also, lacking certifications or compliance may block usage.
Performance Tests & Accuracy / Repeatability	• Move to several positions in the workspace, note the repeatability. • If possible, test with a known payload: see whether accuracy changes under load. • Joint-singularities or extended reach positions: check whether errors increase. • Time-based stress: let the robot run some hours and see whether performance drift or heating appears. • Operational speed vs precision: test motion at required speeds to ensure no oscillation or overshoot.	Real accuracy matters: robots tend to degrade incrementally. Tests under load & full motion are more revealing than just idle motion. Also heating may cause drift.
Support & Spare Parts Availability	• Check that spare parts for that model are available (gearboxes, motors, encoders, controller modules, etc.). • Check what condition the controller software is in, whether there are licensing or service issues. • Is there local or regional support / service for that robot / model? • Manuals and documentation (wiring diagrams, maintenance manuals etc.) should be included. • Any history of firmware or safety module obsolescence.	If parts are hard to get, downtime & cost can skyrocket. Controller software that can’t be updated or that requires impossible licenses is a risk. Lack of documentation complicates repair.
Physical Condition & Visual Inspection	• Check for rust, splashes, physical damage to links, covers, base. • Condition of joints: grease fittings, sealing boots. • Stem surfaces (axis arms) for gouges, scratches. • Paint, but more importantly whether corrosion or physical wear is present. • Cleanliness: how well has the robot been cleaned; presence of contaminants in motors / joints. • Check fans, enclosures: cooling fans working, ventilation not blocked.	Visual issues often hint at neglect. Damaged seals or boots allow contaminants in. Overheating due to blocked cooling leads to damage.
Electrical Safety & Power Requirements	• Voltage, phase, frequency: ensure compatible with your facility. • Inspect power supply, transformer (if used), surge protection. • Check for overcurrent protection, fusing, safety switches. • Is the robot grounded properly? • Cable routing safe; no pinch points, trapped cables or tight bends.	Ensuring correct power setup avoids damage or safety hazards. Poor wiring or weak safety protections can be risky.
Usage Limits & Lifetime	• What is the robot’s duty cycle? How many cycles per day, how many days/year? • What has been the typical load (payload, speed)? • How many running hours vs idle hours? In robotics, joints & motors degrade with hours and load more than just calendar age. • Any refurbishment done (gearboxes, motors, joints, paints etc.).	Knowing realistic remaining lifespan helps price appropriately. Refurbished robots may offer better value if done properly.

Questions to Ask the Seller

To properly evaluate, ask the seller for detailed information. Some of these you may want in writing / video / running robot:

Model number, serial number, controller type, software version
(So you can check what spare parts are used, compatibility, support.)
Full usage history
- Total run hours (joint cycles, weight loads) – What tasks it performed (heavy load, high speed, precision etc.) – Idle time vs active time.
Maintenance & service history
- Has the robot been maintained per KUKA specifications? – Are there records of replacing gearboxes, motors, encoders, lubricants etc. – Any major repairs or incident history (crashes, collisions etc.).
Accuracy / calibration records
- Are there last calibration / accuracy check data? – Date of last calibration. – Has the robot been used for tasks requiring high positional accuracy? Any drift noted.
Condition of joint gearboxes, motors, encoders
- Ask whether there’s wear in specific joints that are heavily used (wrist, shoulder etc.). – Any unusual noise or vibration under load.
Accessories / End-Effectors included
- Is the teach pendant included, cable etc.? – End effector tooling (gripper, welding torch, spindle etc.). – Mounting hardware, brackets, base plates etc.
Safety / compliance
- Any safety certificates; interlocks; emergency stops. – Any modifications made affecting safety. – Is the robot compliant with safety/emission regulations in your country.
Environmental History
- Was robot in dust / humidity / chemical exposure? Clean room or shop floor? – Temperature extremes? – Level of cleanliness and whether joints/gearboxes were cleaned/lubricated regularly.
Electrical / Cabling Condition
- Status of all wiring, cable chains; whether any cable bends/frays/pinches. – Are connectors original or replaced; condition of insulation.
Proof of performance
- Can you see the robot in operation? Run through motions, do some test programs. – Can you test under load? – Can you see repeatability / positional accuracy in real work.
Support / Spare Part Costs
- What is cost / lead time for common parts (gears, drives, encoders etc.) – Are there local support centers for KUKA in your area. – Are manuals, firmware updates, software licenses readily available.

Red Flags & When to Be Very Cautious

These are issues that could significantly increase cost, reduce performance, or make the purchase risky:

Joints with noticeable backlash, wear, or noise.
Gearboxes or motors that overheat during operation or have been heavily used near overload.
Worn or damaged cable chains; exposed cables that seem frayed or repaired.
Cracks, rust, or structural damage, especially in critical load bearing parts of the arm or base.
Controller hardware that’s aged or obsolete, or with unsupported software.
Missing safety features, or safety modules in disrepair.
Robot used in a harsh environment (coolant / welding spray / chemicals / scorching heat) without proper protection.
Inconsistent or missing maintenance records.
No test under load, no calibration data.
Hidden damage from drops / transport, which may misalign joints or gearbox axes.