KUKA KR CYBERTECH CR maintenance troubleshooting

A4/A5: Disassemble 4 M5x14-A4-80 pieces; Pay attention to the connecting shaft and compression spring; If there is a back up ring on the old motor shaft, it must be discarded and cannot be reused; Apply Microlube GL 261 to the connecting shaft teeth; After installation, the connecting shaft should have a slight axial clearance.

A6: A4, A5, and inline writer need to be disassembled first; The inline hoist weighs approximately 23 kg and must be reliably lifted; Remove 4 M3x12-10.9 pieces; Apply Microlube GL 261 to the teeth.

After replacing the motor, it is necessary to perform Mastering on the corresponding shaft and test the program in T1 mode. After replacing A4/A5/A6, it is usually necessary to master A4, A5, and A6 simultaneously.

Common Fault 3: Gear Oil Leakage and Oil Change Specification

Performance: There are oil stains near A1, A2, A3, A4, A5/A6, and the temperature is high during operation.

Reason: seal aging, screw plug not tightened according to torque, incorrect oil quantity, installation angle leading to incomplete oil discharge.

Solution: Replace the gear oil according to the shaft. The recommended oil is Cassida Fluid GL150. First filling amount: A1 is about 1.20 L, A2 is about 0.80 L, A3 is about 0.32 L, A4 is about 0.32 L, A5/A6 is about 0.37 L. The replacement cycle is according to the maintenance table, usually 2000 hours (based on KUKA Xpert). Oil discharge must be carried out at operating temperature and the discharge volume measured. If the discharge volume is less than 70% of the specified amount, it should be rinsed once; If it is less than 50%, rinse twice. The filling amount shall be based on the actual discharge amount. Be aware that the oil chamber may be under pressure, and release the pressure before opening the drain plug. The torque of M18x1.5 magnetic plug is about 20 Nm, M10x1 plug is about 7.5 Nm, and A1 union nut is about 45 Nm. After changing the oil, check for leaks and observe abnormalities during T1 operation.

Common Fault 4: Cable group wear and A1 lubrication

The A1 cable group moves with axis 1 inside the base, and long-term operation may result in hose wear and dust accumulation. The document requires regular inspection and lubrication of cable group A1. Before operation, remove the base cover: remove 2 M4 hex nuts and 5 M5x10-10.9 round head screws, and remove the cover and brush strip. Apply PETAMO GHY 133 N grease to the outer surface of the hose, the contact surface with the base, and the inner side of the cover with a brush, approximately 0.3 kg. If damage is found to the hose, the cable assembly must be replaced. After reassembly, wipe off excess grease and move A1 to evenly distribute the grease. For cleanroom applications, excessive lubricating grease may adsorb particles, so it is necessary to control the amount and clean the overflow.

Common fault five: Zero point loss and Mastering

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

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

Solution: Prioritize using EMD or a dial gauge for standard Mastering. Mastering positions for KR 20 R1810 CR: A1 27 °, A2 90 °, A3 90 °, A4 0 °, A5 0 °, A6 0 °. After replacing the motor, checking the involute teeth, and replacing the connecting shaft, the Mastering must be redone. If the release device is used to manually move the motor, the shaft will lose its zero point and must be re Mastered. The accuracy of emergency Mastering is relatively low, and standard methods should be used to recalibrate as soon as possible afterwards.

Common Fault 6: Connector, Grounding, and Cable Layout

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

Solution: Check the motor cables, data cables, and grounding conductors. KR C4 uses X20-X30, X21-X31; KR C5 uses XD20.1... XD20.6-XD30, XD10.1/XD10.2-XD30, XF21-XF31. The cross-sectional area of the grounding conductor is 16 mm ², and the torque of the M8 nut is about 23 Nm. When the cable bending radius is fixed and laid, the motor cable should not be less than 150 mm, and the data cable should not be less than 60 mm. The maximum length is 50 m, and it can be extended up to once. The cable shall not bear tensile force and shall be laid separately from the power line. For cleanroom robots, cable layout should also avoid generating particles, and zip ties or accessories should not be installed arbitrarily.

Installation, transportation, and foundation load

Transportation location: A1 0 °, A2-138 °, A3 139 °, A4 0 °, A5 90 °, A6 0 °. Use slings or forklifts, unauthorized lifting is prohibited. Install base S31 weighing approximately 25.4 kg, using 4 M20x55-8.8 bolts and 6 chemical anchor bolts; Machine frame installation 0000-268-113 weighs approximately 1.05 kg and uses 4 M20x55-8.8 bolts. Tighten the base bolts again after 100 hours. Basic load: floor Fv normal 4038 N、max 4443 N，Fh 2336/2988 N，Mk 3334/4177 Nm，Mr 1965/2361 Nm； Ceiling Fv 4104/4535 N, Fh 2272/2793 N, Mk 3642/4553 Nm, Mr 2017/2314 Nm; Wall Fv 4265/4661 N, Fh 1464/2268 N, Mk 4603/5124 Nm, Mr 1739/2368 Nm. Flange load: operating at F (a) 970 N, F (r) 960 N, M (k) 249 Nm, M (g) 107 Nm; Emergency stop F (a) 1115 N, F (r) 1280 N, M (k) 326 Nm, M (g) 164 Nm. The tool must be able to withstand these loads.