KUKA KR 3 D1200 HM Robot Operation and Maintenance Guide

Ceiling Installation - Core Process Different from Conventional Robots

KR 3 D1200 HM only supports ceiling installation, and the installation process includes multiple unique steps:

1. Installation foundation (optional, order number 0000-371-960): The user made rack must meet the load-bearing requirements. It is recommended to use square steel Ø 120 mm or Ø 150 mm material, and the rack must be stable enough to avoid shaking of the robotic arm during operation; There shall be no insulation or leveling layer between the base plate and the rack. Confirm that the surface of the base is flat and level before installation.

2. Minimum distance for anti-interference: When the robot leaves the factory, the upper arm is at a 45 ° angle. To avoid interference between the upper arm and the mounting plate, the design of the mounting plate must ensure that the minimum distance from the upper arm to the center point of the robot is 300 mm. Otherwise, the upper arm must be lowered through the brake release button before installation.

3. Layout suggestion: It is recommended to install the robot at a 30 ° angle to the conveyor line for better load balancing.

4. Tightening system: Three layer fastening - there are 12 M8 × 30-8.8 bolts (23 Nm) between the robotic arm and the installation base, 12 M8 × 30 bolts between the installation base and the hexagonal plate, and 12 M12 × 40-8.8 bolts (78 Nm) and 9 M16 × 40-8.8 bolts between the hexagonal plate and the frame. Three cylindrical positioning pins are used for positioning. Screws with a strength grade of 10.9 or above or with test certification are only allowed to be tightened once with the rated torque, and must be replaced with new screws after the first loosening - this rule is repeatedly emphasized in all maintenance operations.

5. On site installation of forearms: Unlike most factory produced machines, the forearms of KR 3 D1200 HM require on-site assembly: first install the spring assembly on the housing, and then assemble the two forearms separately with the upper arm and the moving platform (D20 ball head). The spring assembly stores a large amount of elastic potential energy, and it is strictly prohibited to pull it with full force; It is strictly prohibited to dismantle three forearms at the same time when disassembling the forearms, otherwise the moving platform may fall and cause compression injuries.

6. A4 cable laying: Connect cable group A4 and tighten it with an open-end wrench, equipped with Sanitary Usit sanitary washers and 6 M4 × 12 hexagonal flange bolts; Align the cable clamp according to the installation dimension diagram, tighten the upper arm and the moving platform with 4 M4 × 35 flange bolts each (torque 2.4 Nm), and confirm that the cable is not damaged when the upper arm and forearm move freely.

7. Move to horizontal position: Press the brake release button on the bottom of the base and manually adjust the A1 to A3 axes to horizontal.

Brake release: strict distinction between two methods

The document distinguishes between two ways of moving robotic arms without driving energy, which have completely different applicable scenarios:

Brake release button (standard): located on the bottom of the base, used for installation and debugging phase. The premise is that the controller is fully powered on and the system has been disabled. Press the button to release all axle brakes. Warning: The release of the brake may cause accidental loss of control and falling of the shaft. It is strictly prohibited to stand under the moving shaft.

Brake release device (optional): only used in exceptional situations after accidents or malfunctions, such as rescuing trapped personnel. The operation process must strictly follow: power off the controller and lock it with a padlock → unplug the motor cables XD20.1 and XD20.2 → connect the adapter box X20 → connect the brake release device → insert the handheld device X1 → select the shaft to be released through the selection switch → press the handheld device button. Different from the button mode, this device can selectively release the brake according to the axis, with significantly higher safety.

Maintenance cycle table and key vulnerable parts

Periodic tasks

Tighten the mounting base fastening bolts 100 hours after startup (only once): M8 × 30-8.8 torque 23 Nm, M12 × 40-8.8 torque 78 Nm

Replace the forearm bearing (order number 0000-394-673) after 5000 hours or up to 1 year; Replace the forearm shell (0000-394-674); Regularly clean the bearings with a cloth as needed

Visually inspect the forearm for 20000 hours or up to 5 years, and replace it if any damage or cracks are found (0000-376-891); Visually inspect cable group A4 and replace it with KUKA service if damaged (0000-376-893)

Key points for replacing bearings and shells: Each forearm should be equipped with 4 bearings at the connection between the moving platform and the upper arm, and 4 shells at the connection between the tension spring. The replacement process is to remove the forearm assembly → remove the bearing/housing → inspect → reinstall. When necessary, edible lubricating grease can be added to the bearings, but it must be ensured not to contaminate the product - this is the essential difference between HM sanitary and industrial types. Forearms must be replaced in pairs.