Troubleshooting of KUKA KR FORTEC-2

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 screw plugs, and after draining the oil, adds oil with a torque of 20 Nm. A5/A6 share the oil chamber in IW300-2 and need to be added separately: A4 drains oil at+90 °, drains the lower part at 0 °, adds oil at -90 °, A5 adds about one-third, A6 adds excess, and M18 screw plug torque is 20 Nm. In IW500, A5 and A6 are independent oil chambers, drain oil at+90 °, drain the rear part at 0 °/-85 °, add oil at -90 °, and add oil separately. M18 screw plug torque is 20 Nm. If the amount of discharged oil is less than 70% of the specified amount, it needs to be flushed with discharged oil once; Less than 50%, rinse twice and move the entire axis range at a jog speed during the rinsing process.

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 of 152.6 bar (20 ° C). 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, remove the plug, insert the pin locator, use an M16 pin puller to pull out the pin by about 25 mm, and remove the balance system. Remove anti-corrosion before installing the new pressure filling balance system, 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, 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.

Motor and linear wrist replacement

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. A2 motor replacement is similar. First, fix the connecting rod, remove XDM2 and XG2, hang the motor, remove 4 M12x25-8.8, take them out, install a new motor, and connect them, mastering。 A3 motor replacement is similar, requiring a fixed arm. A4/A5 motor replacement: Remove XDM4, XG4 or XDM5, XG5, remove 4 M8x25-8.8 (IW300-2) or M10x25-8.8 (IW500), take out the motor and connecting shaft, 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. Linear wrist replacement: Remove A4/A5, remove the connecting plate, remove 20 or 24 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. The replacement of connecting shafts must be carried out in pairs. Remove the motor and connecting shaft, replace the O-ring, and install a new connecting shaft. KR 240 R3700-2 still needs to replace the adapter connecting shaft.

Common troubleshooting ideas

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. The minimum pressure is 152.6 bar (20 ° C), and if it is lower than this value, it should be replaced.