KUKA KR AGILUS-3 ultra maintenance troubleshooting

Insufficient lubrication leads to wear inside the cover

Performance: There is dryness, abnormal noise, and dust accumulation inside the A2, A3, and A5 covers.

Reason: The lubricating grease is aging and has not been replenished for a long time.

Treatment: Lubricate the interior of A2, A3, and A5 covers every 5000 hours or 1 year using Optitemp RB2, approximately 10g. After greasing, wipe off excess grease to avoid dust adsorption.

Zero point loss or Mastering abnormality

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

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

Solution: Prioritize using EMD or a dial gauge for standard Mastering. Zero position: A1 0 °, A2-90 °, A3 90 °, A4 0 °, A5 0 °, A6 0 °. After replacing the toothed belt or motor, it is necessary to re Mastering and test the program in T1 mode.

Loose or vibrating base installation

Performance: Robot shaking during operation, abnormal noise from the feet, and poor repeated positioning.

Reason: Insufficient torque of base bolts, cracking of concrete foundation, and failure of chemical anchor bolts.

Processing: The installation bases of KR 10 R1100-3 and KR 13 R900-3 use 4 M10x35-8.8 bolts with a torque of approximately 45 Nm; KR 16 R1100-3 uses 4 M16x50-12.9 bolts with a torque of approximately 195 Nm. Check after the first 100 hours and annually thereafter. The basic concrete grade must be at least C20/25, and chemical anchor bolts must be used in conjunction with the same brand.

Cable, connector, and grounding faults

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

Solution: Check motor cables XD20.1/XD20.2 to XD30, and data cables XF21 to X31. The cross-sectional area of the grounding conductor is 4 mm ², with M4 ring terminals and a torque of approximately 1.2 Nm. The connector must be locked, the cable must not withstand tension, and the bending radius must be sufficient to avoid contact with sharp edges. The AIR CTR GIG version also needs to check X41, X74, X94, X30, X31, X32, PURGE, and fuse F41-F3A (3 A fast melting).

Abnormal gas path of energy supply system

Performance: Insufficient air pressure, abnormal valve action, and PURGE blockage in AIR1-AIR4.

Reason: The gas source contains water and oil, insufficient pressure, pipeline leakage, and blown fuses.

Solution: Check that the maximum pressure of AIR1-AIR4 is 7 bar, and the vacuum can reach atmospheric pressure minus 0.95 bar; PURGE has a maximum pressure of 0.3 bar, and the air needs to be oil-free, dry, and filtered, in compliance with ISO 8573-1:2010 (7:4:4). X41 power supply 24 V/3 A, maximum digital output 0.5 A, maximum short-circuit current 2 A. Valve working pressure 3-7 bar, switching frequency 10 Hz.

Planned maintenance: Block faults before they occur

The core nodes for maintaining a table are as follows:

After 100 hours: Check the torque of the fixing bolts on the installation base. KR 10/13 is 45 Nm, KR 16 is 195 Nm.

5000 hours or 1 year: lubricate the interior of A2, A3, A5 covers using Optitemp RB2 for approximately 10 g; replace the A3/A5 toothed belt (according to the model).

1 year: Check the torque of the base bolts.

20000 hours or 5 years: Replace A1 and A2 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.

Oil Change and Lubrication Practice

A1 gear oil: KR 16 R1100-3, first add approximately 0.36 L, with a cycle of 20000 hours or 5 years. A2 gear oil: KR 10 R1100-3 approximately 0.17 L, KR 13 R900-3 approximately 0.17 L, KR 16 R1100-3 approximately 0.25 L, with a cycle of 20000 hours or 5 years. All oil products are Optigear Synt. ALR 150. When draining oil, the robot should be in a suitable posture to ensure that the oil can be completely drained; The filling amount shall be based on the actual discharge amount. Lubricating grease: Optitemp RB2 is used inside the A2/A3/A5 covers, with a weight of approximately 10 g each time. After replacing the toothed belt, the tension and engagement should be checked and observed during operation at T1.

Installation, transportation, and cable connection

Transportation location: KR 10 R1100-3 and KR 13 R900-3 are at A1 0 °, A2-105 °, A3 158 °, A4 0 °, A5 37 °, A6 0 °; KR 16 R1100-3 is at A1 0 °, A2-120 °, A3 140 °, A4 0 °, A5 115 °, A6 0 °. Use slings or forklifts, unauthorized lifting is prohibited. The installation methods include base installation, machine frame installation, wall installation, and ceiling installation. Wall installation requires a 90 ° rotation, ceiling installation requires a 180 ° rotation, and LLA installation equipment is used. Installation base: KR 10/13 is S192, approximately 20.7 kg, with 4 M10x35-8.8 and a torque of 45 Nm; KR 16 is S220, approximately 27 kg, with 4 M16x50-12.9 and a torque of 195 Nm. Machine frame installation: KR 10/13 is approximately 0.152 kg, with 4 M10x35-8.8 and a torque of 45 Nm; KR 16 is approximately 0.514 kg, with 4 M16x50-12.9 and a torque of 195 Nm. The connecting cable lengths are 1 m, 4 m, 5 m, 7 m, 10 m, 15 m, and 25 m, with a maximum of 25 m. Interface A1 is located at the rear of the base and includes X30 motor, X31 data, X32 MEMD, X76 or X41 I/O, X74/X 94 data, AIR1-AIR4 air circuit PURGE。 Grounding conductor 4 mm ², M4 terminal, torque 1.2 Nm.