KUKA KR 360 FORTEC Inspection and Maintenance Guide

Maintenance cycle and oil management

The maintenance cycle is based on technical data and operating conditions. Check the torque of the fastening bolts and nuts 100 hours after startup. O-rings A4 and A5 require regular lubrication: the standard robot takes about 10000 hours, the F variant takes about 5000 hours, and Microlube GL 261 is used. Balance system bearing lubrication: 5000 hours or at least once a year; If A2 frequently has a short stroke of less than 40 ° and the interval is shortened to 3000 hours, use LGEV2/5, with each lubrication point approximately 10 cm ³.

Balance system pressure check: Manually move A2 to -90 ° and wait for 1 minute. The pressure for ground robots should be 140 bar ± 15 bar (20 ° C), and for ceiling robots it should be 230 bar ± 15 bar (20 ° C). If there is abnormal pressure or deviation in application, a dedicated pressure gauge should be used for measurement and KUKA Service should be consulted. Check for leaks in the bellows, fittings, accumulator, and hoses.

Inspection of drive shafts A4 to A6: first at 15000 hours or 6 years, and annually thereafter. Remove the installation cover and O-ring, visually inspect for wear and bluing. Apply a tensile force of 20 N to the universal joint and check the axial and rotational clearances. If the gap is greater than 0.8 mm, the drive shaft must be stopped and replaced. The rotational clearance of connecting shaft A5 shall also not exceed 0.8 mm.

Gear oil replacement: standard robot 20000 hours or 5 years; F variant 10000 hours or 5 years. The oil is Optigear Synt. ALR 150. Capacity: A1 ground 10.0 L, ceiling 13.9 L; A2 10.0 L; A3 3.5 L； A4 2.2 L； A5 2.5 L； A6 5.2 L。 Oil discharge must be carried out at operating temperature, first release pressure. Measure the amount of discharged oil. If it is less than 70% of the specified amount, rinse it once with discharged oil; If it is less than 50%, rinse twice and move the entire axis range at a jog speed during the rinsing process. Torque after filling: A1 oil pipe nut 40 Nm, magnetic plug 25 Nm; A2 magnetic plug 25 Nm; A3 to A6 magnetic plug 20 Nm. The lubrication cycle of the cable assembly is 20000 hours or 5 years, using Optitemp RB2 for approximately 200 cm ³. The replacement cycle of the balance system is 10 years.

Maintenance and replacement of balance system

The balance system inspection includes pressure, leakage, bellows, joints, and bearings. When replacing ground robots, the robot should be in mechanical zero position, A2 should be movable, and firmly fixed on the ground. First, fix the piston rod between the hydraulic cylinder and the hinge joint with a clamping sleeve, and then lift the balance system with a crane. Remove 6 Allen screws and retaining plate, remove M10x35 screws, insert pin locator, use M16 puller to pull out the pin by about 25 mm, and then remove the balance system.

Remove corrosion protection before installing the new balance system and move A2 to approximately -85 °. Align the pin on the rotating column during installation, apply Drei Bond 1342, and tighten M10x35 and 6 M8x20 Allen screws to the torque. When replacing the ceiling robot, it is necessary to first remove it from the ceiling and fix it on the ground. The weight of the balancing system is about 97 kg. First, release the pressure, and then follow similar steps for disassembly and installation. After replacement, the pressure must be checked and a functional test must be conducted.

Motor and transmission shaft replacement

A1 to A3 motor replacement: Power off and lock, remove XM/XP connector, fix connecting rod or arm with lifting device, remove 4 Allen screws, and take out the motor. Clean the motor and gearbox teeth, apply Microlube GL 261, check the O-ring, install a new seal, tighten the M12x25-8.8 Allen screws in diagonal order, reconnect the plug, and finally perform mastering.

A4 to A6 motor and drive shaft replacement: arm in horizontal position, wrist axis at zero position. Remove the installation cover and O-ring, remove the XM4 to XM6 and XP4 to XP6 connectors, remove 4 M10x30-8.8 Allen screws from each motor, and take out the motor and drive shaft. The transmission shaft is divided into setscrew type and O-ring type. The Setscrew type needs to be cleaned and coated with Drei Bond 1342. After tightening, loosen it back 45 degrees to allow the Setscrew to fit into the V-shaped groove. The O-ring type requires the installation of axial retainers, washers, M8x20 screws, spacers, and O-rings. The distance between the motor shaft and the drive shaft should be measured to be 16 mm, and it should automatically return to its original position after light pulling. Perform mastering and braking tests after installation.

Common troubleshooting ideas

Unexpected shutdown or safety stop: Check the emergency stop, enable switch, safety door, mode selection, external safety stop, safety configuration, and brake status.

Low or fluctuating pressure in the balance cylinder: Check the pressure gauge, accumulator, hoses, fittings, and leaks. Ground pressure is 140 bar, ceiling pressure is 230 bar. If there is a large deviation, consult KUKA Service.