KUKA KR 1000 titan PA troubleshooting

Rack installation is used for steel structures, brackets, or KUKA linear slides. First, install the center pin and sword pin, and fix them with M8x65 and M8x80 hexagonal bolts with a tightening torque of about 24.9 Nm. Then install the robot, use 12 M30x90-8.8-A2K bolts and tighten them to 1330 Nm. Connect the motor cables X30.1, X30.2, and X30.3, and the data cables KR C4 and KR C5 are X31 and XF31, respectively. The grounding and potential balance must be reliably connected and checked according to VDE 0100 and EN 60204-1.

The transportation positions are A1 0 °, A2-130 °, A3 130 °, A4 0 °, A5 90 °, A6 0 °. The minimum load capacity for forklift transportation is 6 tons; the minimum load capacity for transport frame transportation is 8 tons, including about 5600 kg without equipment. Avoid vibration and collision during transportation, otherwise it may cause insignificant damage, especially to the motor and balance weight. Before resuming operation, check whether the robot is fixed, whether there is external damage, whether the motor and balance weight are abnormal, whether the protective device is intact, whether the power supply system is matched, whether the grounding is reliable, whether the plug is locked, and whether there are foreign objects or loose parts.

Maintenance cycle and oil change specifications

The maintenance intervals are based on nodes such as 100 hours, 2000 hours, 6 months, 10000 hours, etc. Check the fastening bolts after 100 hours of operation. Lubricate the 4 oil nozzles of the main bearing every 2000 hours or at the latest 6 months, with A1 at 0 °,+30 °, and+60 ° positions, a total of 12 times, each time 8 cm ³, for a total of 96 cm ³, using LGEP 2 grease. Check the balance weight pressure every 6 months. If the oil pressure is lower than the set value of 5 bar, supplement Hyspin ZZ 46 hydraulic oil. The maintenance interval for the F variant can be extended to 10000 hours.

Gear oil replacement: A1 uses Optigear ALR 320, add 25 L for the first time; A2 uses Optigear Synt. ALR 150, add 24 L for the first time; A3 uses 12 L for the first time; A4 uses 10 L for the first time; A5 uses 3 L for the first time; A6 uses 10 L for the first time. When changing the oil, the amount of oil discharged depends on the discharge time and oil temperature, and the refilling amount should be the actual discharge amount. If the discharge volume is less than 70% of the specified oil volume, rinse once with the discharged oil; If it is less than 50%, rinse twice. Move the shaft at manual speed throughout the entire shaft range during flushing.

A1 oil change: Move A1 to -90 ° C, the gearbox is at operating temperature. Release the pressure first, then remove the magnetic plug, connect the oil drain hose, and drain the oil. Inject from below when refueling, check the oil level between the two markings, and recheck after 5 minutes. A2 oil change: Open the exhaust nuts on both sides, remove the oil drain hose, drain the oil, and add oil from below until the oil comes out from both joints. A3 oil change: Remove the sealing cover of the maintenance valve, connect the oil drain hose, and after draining the oil, add oil from the lower hose until the oil level is visible at the upper part. A4/A5/A6 oil change: Remove the upper and lower M27x2 magnetic plugs respectively, drain the oil, and add oil from the upper hole. Tighten the lower plug with a torque of 30 Nm and the upper plug with the same torque of 30 Nm. All magnetic plugs must be cleaned and checked for sealing, and any damage must be replaced. There is a risk of burns when the oil temperature is high, and the oil chamber may be under pressure. It is necessary to release the pressure first and wear protective equipment.

Balance weight inspection and replacement

This series adopts hydraulic pneumatic balance weight, and the system includes 2 diaphragm accumulators, hydraulic cylinders, pressure gauges, and safety valves. The accumulators are filled with nitrogen gas. When checking, manually move A2 to -90 °, wait for 1 minute, press emergency stop, and read the pressure gauge. KR 1000 1300 titan PA and PA-F should be 130 bar ± 15 bar at 20 ℃; KR 1000 L950 titan PA and PA-F should be 120 bar ± 15 bar. If the values do not match, a dedicated pressure gauge should be used for measurement and KUKA should be contacted. Check if the lead seal of the safety valve is intact, and if the accessories are damaged, clean, and sealed.

When replacing the balance weight, it weighs approximately 150 kg and is under pressure. First, move A2 to a vertical position and secure it. Remove the protective cap, connect the hose, and drain the hydraulic oil into the collection container until the pressure gauge reads zero. Remove the pin, cover plate, and bolts, fix the counterweight with a sling and crane, and then remove the pin shaft. During installation, clean and rust proof, insert the pin shaft, use M16x230-8.8 hexagon socket bolts and conical spring washers, tighten with a torque of 195 Nm. Check the pressure after installation. Attention: Do not continue to move the balance weight in the negative direction, otherwise it may damage the balance weight, pull rod or turntable. If the balance weight forms an air cushion after storage, remove the exhaust valve protective cover, maintain a safe distance, move A2 ± 30 °, and then reinstall the protective cover.