KUKA KR AGILUS-2 maintenance troubleshooting

Maintenance cycle and replacement of toothed belt

Maintenance interval: Check the fastening bolts and nuts after 100 hours; Check the tightening torque of the base for 1 year; Annual review of ESD requirements for EP variants; Replace A3 and A5 toothed belts after 5000 hours or at the latest 1 year. Before maintenance, it is necessary to ensure that the maintenance point is freely accessible and remove tools and additional equipment that hinder maintenance. Robots must be secured by emergency stop and prevented from unauthorized activation.

A3 toothed belt replacement: A3 toothed belt specifications, KR 6 is 12 HTD-5M/450 HP, KR 10 is 12 HTD-5M/475 HP, target frequency is 160 ± 5 Hz. Steps: First, place the robot at A2-90 ° and A3+90 °, fix the arm with a sling, and remove the 8 M4x8-8.8 hexagonal bolts on the A3 cover plate. Loosen 2 M4x16-10.9 hex bolts, 1 M4 lock nut, and 1 M4x20-8.8 hex bolt, and remove the old strap. Install a new belt and ensure proper engagement with the toothed belt pulley. Gently tighten the M4x20-8.8 hex bolt to adjust the tension, causing the lower A3 pulley to move downwards until the pre tightening is roughly correct. At the same time, tighten two new M4x16-10.9 hex bolts until the lower pulley cannot move on its own. Measure with TSM alpha 2 frequency meter, with a sensor distance of 2 to 3 mm from the band, move the band side, and read the frequency. If the frequency does not reach 160 ± 5 Hz, fine tune the M4x20-8.8 hexagonal bolt, repeat the measurement, and tighten 2 M4x16-10.9 internal hexagonal bolts after reaching it. Remove the fixed device and run the robot to move A3 within ± 20 ° range 2 to 3 times. When controlling measurements, any position can be used without tools; If there are tools available, A3 should not be affected by gravity, such as A2-90 °, A3 0 °, or A2 0 °, A3-90 °. Measure the frequency on both sides, take the average, and if it is not within 160 ± 5 Hz, repeat the adjustment. Finally, tighten the two M4x16-10.9 hex bolts and secure the M4x20-8.8 hex bolts with M4 locking nuts. Install the cover plate, clean the foam pad, and tighten 8 M4x8-8.8 hexagonal socket bolts. After completion, calibrate A3 and run the program to check T1.

A5 toothed belt replacement: The specification of the A5 toothed belt is 6 HTD-5M/325 HP, with a target frequency of 180 ± 5 Hz. Steps: First, fix A5, remove the tool or fixing tool, or place the arm in a horizontal position with A4+90 ° or -90 °, or place the arm in a vertical position with A5 0 °. Remove the 9 M4x10-8.8 hexagonal bolts from the A5 cover plate. Loosen 2 M4x12-8.8 hex bolts and 1 M4x16-8.8 hex bolt (adjusting screw), and remove the old strap. Install a new belt and ensure proper engagement with the toothed belt pulley. Gently tighten the adjusting screw M4x20-8.8 to move the A5 pulley in the A4 direction until the preload is roughly correct. Then, lightly tighten the 2 M4x12-8.8 hex bolts to prevent the pulley from moving. Measure with a frequency meter, with a sensor distance of 2 to 3 mm from the belt, move the belt side, and read the frequency. If the frequency does not reach 180 ± 5 Hz, loosen the 2 M4x12-8.8 hexagon socket bolts, adjust the tension with adjusting screws, repeat the measurement, and tighten the 2 M4x12-8.8 hexagon socket bolts after reaching the desired frequency. Remove the tool fixing device. Operate the robot to move A5 within a range of ± 20 ° 2 to 3 times. When controlling measurements, if there are tools available, A5 should not be affected by gravity, such as keeping the arm level and A4+90 ° or -90 °; If there are no tools, any position can be used. Measure the frequency on both sides of the band, take the average, and if it is not within 180 ± 5 Hz, repeat the adjustment. Finally, tighten the two M4x12-8.8 hexagon socket bolts and secure the adjusting screws with M4 locking nuts. Install the cover plate, clean the foam pad, and tighten 9 M4x10-8.8 hexagonal socket bolts. After completion, calibrate A5 and A6, and run the program to check T1.

Replacement of fine fuses and troubleshooting of electrical faults

The fine fuse is located on interface board A1, with specifications of 3 A, 250 V, fast break, 5x20 mm. Before replacement, the controller must be turned off and prevented from restarting. Follow ESD regulations and unplug the motor cable connector. The controller equipment switch does not have grid isolation function. Before operation, the power cable must be disconnected and stored outside the line of sight and reach of the operator, with warning signs hung. Follow 5 safety steps when doing homework. When replacing, rotate the thin fuse 90 ° to unscrew the interface board, insert the new fuse and manually tighten it 90 °. No further finishing work is required after completion.

Common electrical fault troubleshooting ideas:

Robot unable to enable or emergency stop failure: Check if smartPAD/KCP is correctly connected and assigned to the corresponding robot, disconnect the device and immediately remove it from the system.

Digital output or valve not functioning: Check if X41 power supply is overloaded and if 3A fuse is tripped; If connected to a 3A device, no other outputs or valves can be switched.