Troubleshooting of KUKA KR FORTEC-2 ultra

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 balancing system: Check the pressure gauge, accumulator, hoses, fittings, and leaks. Refer to the minimum pressure value of the reference model. If it is lower than this value, it should be replaced.

A2 abnormal noise, sinking or vibration: Check the bearings, pressure, mechanical limit and connecting rod fixation of the double balance system.

Wrist abnormal noise or positioning drift: Check the connecting shaft teeth, straight wrist teeth, bearings, and lubrication status; If worn or discolored, replace the connecting shaft or straight wrist.

Gear oil leakage: Check the magnetic plug, oil pipe, service valve, O-ring, and gearbox seal, and tighten according to torque.

Motor overheating: Check the load, duty cycle, ambient temperature, cooling, brake holding, and motor current to confirm that the load data has been input into the controller.

Cable wear or interference: Check the cable group, bending radius, shielding, separate laying, and A1 cable group lubrication.

Zero point loss: Mastering A1 to A6 again.

Abnormal braking: Conduct a braking test to check the parameters of the brake, motor, and controller.

Automatic mode cannot start: check safety door, operate safety signal, external emergency stop, confirm button, and mode selection.

Abnormal noise after replacing the straight wrist: Check if the teeth are damaged, M10x200 torque, A4/A5 are in zero position, and if the mastering is correct.

After replacing the balance system, the pressure is unstable: check the hydraulic oil filling amount, accumulator pre charge pressure, exhaust and leakage.

Abnormal noise after replacing the connecting shaft: Check for damage to the sine spring, O-ring, teeth, and torque.

F variant seal leakage: Replace the seal, use Drei Bond 5204HV, and pay attention to the bonding of the connecting plate.

Insufficient lubrication of cable assembly: Use Optitemp RB2 for approximately 50g at a 20000 hour or 5-year cycle, and move A1 to evenly distribute the grease.

Inconsistent pressure in the dual balance system: Both must be checked simultaneously. If one is abnormal, the other also needs to be evaluated and replaced.

Key points of standards and compliance

KR FORTEC-2 ultra is subject to the Machinery Directive 2006/42/EC, EMC Directive 2014/30/EU, Pressure Equipment Directive 2014/68/EU, and EN 60204-1、EN ISO 10218-1、EN ISO 12100、EN ISO 13849-1/-2、EN ISO 13850、NFPA 79、UL 1740  Waiting for standards. The F variant has higher dust, lubricant, coolant, and water vapor resistance, while the HI variant is designed for high inertia applications. Industrial robots must be integrated into a complete system and undergo compliance assessment before they can operate. The balance system contains nitrogen and hydraulic oil, and must be depressurized before disposal. Only pressure free balance systems are allowed to be scrapped.

Overall, the reliability of KUKA KR FORTEC-2 ultra depends on the installation foundation, dual balancing system, gear oil, connecting shaft, motor, and safety circuit. Regularly checking pressure, oil level, teeth, clearance, and torque can detect abnormalities in the early stages of faults. When encountering abnormal pressure, abnormal noise, leakage or shutdown, first lock it safely, and then investigate according to the levels of power supply, safety circuit, double balance system, connecting shaft, gear oil and motor. This can reduce unplanned downtime and maintain stable operation of overloaded robots under harsh working conditions.