Troubleshooting of KUKA KR FORTEC-2 ultra

Oil drainage and filling must be carried out at operating temperature, with pressure relief first. When draining A1 oil, use M22x1.5 magnetic plug to exhaust, remove the sealing cover of the service valve, connect M26x1.5 oil pipe, drain the oil and measure. Fill from below until the lower edge of the inspection hole, with a torque of 25 Nm for M22 plug and 45 Nm for service valve. A2 and A3 are similar. A4 uses upper and lower M18x1.5 plugs, and after draining the oil, adds a torque of 20 Nm. A5/A6 share the oil chamber and need to be filled separately: A4 drains oil at+90 °, drains the lower part at 0 °, adds oil at -90 °, A5 adds about one-third, A6 adds excess, M18 plug torque is 20 Nm. If the drained oil is less than 70% of the specified amount, it needs to be flushed once with drained oil; Less than 50%, rinse twice and move the entire axis range at a jog speed during the rinsing process.

Double Balance System Inspection and Replacement

When checking, manually move A2 to -90 ° and wait for 1 minute. Prepare pressure gauge: Install adapter and sensor, connect CH1, press F4 to turn on the machine. Measure the temperature of the component with a digital thermometer, which should be 20 ° C. Remove the M16x2 protective cover, connect the sensor, wait for 3 minutes, and read the minimum pressure. KR 480 R3400-2、KR 480 R3400-2 F、KR 560 R3100-2、KR 560 R3100-2 F、KR 560 R3100-2 HI  The minimum pressure is 143.6 bar; KR 640 R2800-2, KR 640 R2800-2 F, KR 640 R2800-2 HI are 131 bar; KR 480 R3700-2, KR 480 R3700-2 F, KR 800 R2800-2, KR 800 R2800-2 F are at 152.6 bar. If the value is lower than this or there is a deviation in the application, the balance system must be replaced. Clean the valve, reinstall the protective cover, and check for accessory leaks and bellows.

When replacing, the robot should be in the mechanical zero position, A2 should be movable, and fixed on the ground. The weight of the balance system is about 40 kg. Use two ropes to suspend the connecting rod, loosen the worm clamp, push the bellows, move the connecting rod to the appropriate position, insert the clamping sleeve, and clamp the piston rod. Hang the balance system with ropes, remove 4 M8x20-10.9 Allen screws and retaining plates, insert the pin locator, use M16 pin puller to pull out the pin by about 25 mm, and remove the balance system. Before installing the new pressure filling balance system, remove the anti-corrosion coating, move the connecting rod to about -90 °, insert the connecting rod, install it on the rotating column pin, apply Drei Bond 1342, M12x30-10.9 and M8x20-10.9 and tighten with torque, apply LGEP 2 to the thrust ring, pay attention to the installation position, insert the pin, install the retaining plate, M8x20 screw and sealing plug. After replacement, the pressure must be checked and a functional test must be conducted. Both balance systems must be replaced simultaneously.

Replacement of motor, connecting shaft and linear wrist

A1 motor replacement: Remove XDM1 and XG1 connectors, remove 4 M12x25-8.8 Allen screws, install Load Lifting Attachment, torque 15 Nm for M8x20 screws, lift the motor and remove. The F variant requires replacement of the seal. Remove the spacer ring. Clean the teeth of the new motor, apply Microlube GL 261, install 30x5 O-ring, and install a new seal for the F variant. Insert the motor, tighten 4 M12x25-8.8 in diagonal order, connect the plug, and perform mastering. The replacement of A2 and A3 motors is similar. First, fix the connecting rod or arm, remove XDM2/XG2 or XDM3/XG3, hang the motor, remove 4 M12x25-8.8, take them out, install a new motor, and connect them, mastering。 A4/A5 motor replacement: Remove XDM4/XG4 or XDM5/XG5, remove 4 M10x25-8.8, take out the motor and connecting shaft, and remove the connecting shaft and sine spring. Replace the seal with the F variant. Remove the bushings M8x30-8.8 and 17x3 O-rings. Clean the new motor, install the bushing and 17x3 O-ring, use the centering bushing, tighten M8x30, install 21x2 O-ring, and install a new seal for the F variant. Insert the connecting shaft, install the sine spring, insert the motor, tighten the 4 screws in diagonal order, and connect, mastering。 The replacement of A6 motor is more complex, requiring the disassembly of A4/A5, connecting plate, and linear arm before disassembling A6. The installation should be carried out in reverse. The connecting shafts A4/A5 must be replaced in pairs. Remove the motor and connecting shaft, replace the O-ring, and install a new connecting shaft. For KR 480 R3400-2 and KR 480 R3700-2, the adapter connecting shaft needs to be replaced, and all four connecting shafts must be replaced simultaneously. Linear wrist replacement: Remove A4/A5, remove the connecting plate, remove 24 or 26 M10x200-10.9, take out the linear wrist, remove A6, prepare a new linear wrist, clean the teeth, apply Microlube GL 261, install, tighten M10x200-10.9 with torque, install the connecting plate, connect the cable, install A4/A5, master. IW500 flange screw M12 12.9 torque 125 Nm, IW800 flange screw M16 10.9 torque 250 Nm.

Common troubleshooting ideas