KUKA KR 20 SCARA CS Robot Selection and Maintenance Guide

Transportation position: A1=-90 °, A2=-90 °, A3=-100 mm, A4=0 °. Forklift transportation is used for the original packaging state; Lifting and transportation (optional) must use Qingling DF fixed plate (0000-433-013) and fixed plate B (0000-433-014): 5 M6x20-12.9 (9.5 Nm) are used to fasten the two fixed plates, and 3 M10x17 lifting rings (9.5 Nm) are installed. The rope length must be greater than 1500 mm and follow the path shown in the diagram. No other lifting methods are allowed. The center of gravity positions of the R800/R1000/R1200 three arm arms are different (such as the R1200 center of gravity distance of 922.1 mm), and the transportation dimension table must be checked according to the model before lifting.

Maintenance cycle table - the complete timeline of this series

Cycle task consumables

Tighten 4 M12/M14 mounting bolts for 100 hours (only once) -

100 km or 1500 h lubricated ball screw spline THK AFB-LF approximately 10 g

4000 hours or 1 year replacement of corrugated pipe (KUKA authorized personnel) 2525 corrugated pipe 0000-446-917

4000 hours or 1 year replacement of toothed belt A3/A4 (KUKA authorized personnel) A3: 0000-434-702, A4: 0000-434-704

4000 hours or 1 year cable group coated with Optitemp RB2 grease, approximately 20 g

1-Year Battery Replacement Standard 0000-339-818/CR 0000-439-232

Tighten installation bolts for 1 year -

Replace Optigear ALR 320 with A1 reducer oil after 20000 hours or 5 years, initial installation 0.37 L

Key points for screw lubrication: Press and hold the brake release button on arm A2 to move A3 to the upper limit position (do not hit the limit block) → Release button → Activate emergency stop → Remove old grease → Brush THK AFB-LF → Move to the lower limit position again and repeat. The CR version requires dismantling the top 8 M4x8-8.8 screws to move the bellows down, lubricating them, and then reinstalling them (2.8 Nm). Clean up excess grease and empty A3/A4 to evenly distribute the grease.

Tension calibration of toothed belt: After replacement, use a frequency meter TSM alpha 2 (0071-053-386) in conjunction with a tensioning fixture to measure. Move the belt and sensor 2-3 mm away from the vibration belt. Readings: A3 belt (150MTS3M927) target 59-70 Hz, A4 belt (150MTS5M1000) target 83-90 Hz. Adjust the M5x25-12.9 adjustment screw to meet the standard. If the fluctuation value after adjustment deviates within 30% of the table, it is considered normal. Before calibration, it is necessary to "break in": adjust A4 axis ± 20 ° back and forth 2-3 times, adjust A3 axis upper and lower limits back and forth 2-3 times, and then retest - skipping break in and locking directly will cause tension drift after operation. During assembly, the A4 belt is inserted into the lead screw from above and moved down with the transition pulley assembly. The belt must mesh correctly with the pulley. M6x25-12.9 is tightened diagonally in steps to 15 Nm after A3 moves vertically 3 times. Note that when loosening the A3 motor or A3 belt, the load may cause A3 to suddenly fall down, so A3 must be fixed first.

Key points for battery replacement: 10 M4x12-8.8 battery boxes on the front of the base, remove the cover → screw 2 M5 screws into the threaded holes of the battery box and pull out the battery box → insert the new battery into the empty connector first and then remove the old battery occupying connector → cut the zip tie to remove the old battery → reinstall the new battery, only use zip ties to tie the battery body, do not tie the battery cable → reinstall (2.8 Nm). At the end, it is necessary to check whether the zero point is lost, and if necessary, recalibrate A1/A2/A3/A4.

Key points for A1 oil change: The gear unit must be at operating temperature and A1 level. Remove 10 M4x12-8.8 cable box covers → replace the oil drain pipe with the lower M10x1 magnetic plug → ventilate and drain the upper 2 M10x1 magnetic plugs → measure the amount of oil discharged and recharge according to this amount - if the amount discharged is less than 70%, rinse the gearbox with the discharged oil once and recharge it; Less than 50% (if installed at an angle) needs to be flushed twice, during which the full stroke motion axis of the jog speed is required. Clean the magnetic plug and inspect the sealing components. Tighten to 7.5 Nm and perform a leak test.

Cleaning boundary: prohibit high-pressure cleaning equipment, prohibit compressed air blowing bearings and sealing points; Only solvent-free, water-soluble, non flammable, and non corrosive cleaning agents are allowed; Cleaning agents are strictly prohibited from entering electrical and mechanical system components; After cleaning the corroded area, apply anti-corrosion agent again.

Zero point calibration - Differences between standard version and CR version

After replacing components such as motors, reducers, cables, batteries, etc., the zero point may shift and must be recalibrated:

A1/A2: Prioritize using the calibration fixture (Calibration_1A/A20000-396-617), insert it into the calibration slot for alignment, and select Set Current on the ControlStudio calibration page; When there is no fixture, two calibration slots can be visually aligned, but there may be errors in relying on manual judgment.