KUKA KR 20 R1810 HO maintenance troubleshooting

Cable group A1 is worn or has abnormal noise

Performance: The hose inside the base is worn, dust accumulates, and there is friction noise during movement.

Reason: Insufficient lubrication, aging of hoses, long-term high-frequency exercise.

Solution: Remove the base cover, inspect the hose, clean it, and apply PETAMO GHY 133 N grease to the outer surface of the hose, the contact surface with the base, and the inner side of the cover, weighing approximately 0.3 kg. If the hose is damaged, the cable assembly must be replaced. After reassembly, wipe off excess grease and move A1 to evenly distribute the grease. In food grade environments, the overflow of lubricating grease may adsorb particles and must be cleaned thoroughly.

Zero point loss or Mastering abnormality

Performance: teaching point offset, program unable to reproduce, abnormal axis angle display.

Reason: Replacement of motor, manual release of brake, loss of encoder data, collision.

Solution: Prioritize using EMD or a dial gauge for standard Mastering. The Mastering positions of this model are A1 27 °, A2 90 °, A3 90 °, A4 0 °, A5 0 °, A6 0 °. After replacing the motor, checking the involute teeth, and replacing the connecting shaft, the Mastering must be redone.

Connector, grounding, and cable layout faults

Performance: The controller reports motor/data line faults, intermittent shutdowns, and abnormal shielding.

Solution: Check the motor cables, data cables, and grounding conductors. KR C4 uses X20-X30, X21-X31; KR C5 uses XD20.1... XD20.6-XD30, XD10.1/XD10.2-XD30, XF21-XF31. The cross-sectional area of the grounding conductor is 16 mm ², and the torque of the M8 nut is about 15.0 Nm. When the cable bending radius is fixed and laid, the motor cable should not be less than 150 mm, and the data cable should not be less than 60 mm. The maximum length is 50 m, and it can be extended up to once. The cable shall not bear tensile force and shall be laid separately from the power line.

Food grade cleaning and PURGE abnormalities

Performance: Arm contamination, dust ingress, residue after cleaning, PURGE gas path blockage.

Reason: Improper cleaning agent, high-pressure water entering the seal, insufficient PURGE pressure, pipeline leakage.

Treatment: Only neutral, solvent-free, water-soluble, non flammable, non strong acid and alkali, and chlorine free cleaning agents can be used for cleaning. Prohibit high-pressure cleaning machines and use compressed air to blow bearings and sealing points, ensuring that cleaning agents do not enter electrical or mechanical components. PURGE option A/B is only used for cleaning and is prohibited from use during operation to prevent particle emissions. The gas source should be oil-free, waterless, and filtered, and the pressure regulator should be set correctly.

Wear of connecting shaft or large clearance between A4/A5 movements

Performance: A4/A5 abnormal noise, positioning drift, and increased reverse clearance.

Reason: Tooth wear, insufficient lubrication, and damage to the tooth surface during installation.

Solution: The connecting shafts must be replaced in pairs. Clean the teeth and apply Microlube GL 261 before installation. Pay attention to locking washers and wave springs during installation. A6 replacement requires the dismantling of A4, A5, and the inline hoist, which weighs approximately 23 kg and must be reliably lifted.

Planned maintenance: Block faults before they occur

Core nodes for the maintenance table of KR 20 R1810 HO:

100 hours: Check the torque of the fixing bolts on the installation base.

2500 hours: Check if the visible hose is damaged.

5000 hours: Lubricate cable group A1 using PETAMO GHY 133 N.

2000 hours: Check A1-A6 involute teeth and grease them; Replace A1, A2, A3, A4, A5/A6 gear oil.

Before maintenance, the maintenance point must be accessible and any obstructing tools and accessories must be removed. If the oil temperature exceeds 60 ° C for a long time, the maintenance interval should be shortened and KUKA should be consulted. All accessories must use approved products, otherwise it may lead to early wear and tear. Special attention should be paid to the food grade version: cleaning agents, lubricants, and gear oils must be compatible with the food production environment and cannot be replaced arbitrarily.

Practical replacement of involute teeth and motors

The involute teeth are a critical transmission component between the motor and the input shaft of the gearbox. During inspection, it is necessary to remove the motor, clean the teeth, and check for wear and tear; If the teeth are damaged, the input shaft of the motor or gearbox must be replaced, and the replacement of the gearbox input shaft requires contacting KUKA Service. Operation points:

A1: The HO version uses 4 M8x25-A4-80 hex socket screws. Be careful not to tilt when removing the motor; Apply Microlube GL 261 to the teeth; Check the O-ring; Pay attention to the sealing components during installation.

A2: First, fix the connecting rod arm with a sling to prevent the arm from falling down after disassembling the motor; The screw specifications are the same as A1.

A3: First, fix the robot arm with a sling; The HO version uses 4 M8x20-A4-80 chips; Pay attention to the spacer sleeve and O-ring.