KUKA QUANTEC-2 HO Maintenance Guide

Oil change and lubrication

The oil change cycle of the HO type is similar to that of the standard type, but the oil type is different. Maintenance table regulations: After 100 hours of operation, check the fastening bolts with a torque of 640 Nm; lubricate the balance cylinder bearings every 5000 hours or at the latest 1 year, using approximately 10 cm ³ of LGEP 2 grease; Check the balance cylinder pressure every 5000 hours; Replace gear oil every 20000 hours or no later than 5 years. If there is frequent short distance exercise, the maintenance interval can be shortened to 3000 hours.

Oil change volume: A1 about 5.70 L, A2 about 2.10 L, A3 about 1.40 L, A4 about 2.10 L, A5/A6 about 1.40 L (wrist ZH210) or 1.90 L (wrist ZH300). All use Cassida Fluid GL150. When changing the oil, the gearbox should be at operating temperature, and the discharge amount depends on the discharge time and oil temperature. The refilling amount must be consistent with the emission amount. If the emission amount is less than 70% of the specified oil amount, it needs to be flushed once with discharge oil; If it is less than 50%, rinse twice. Move the axis within the full axis range at a jog speed during flushing.

The tightening torque of the magnetic plug is 25 Nm for A1, 20 Nm for A2, 20 Nm for both the upper and lower parts of A3, 40 Nm for both the upper and lower parts of A4, and 20 Nm for A5/A6. When operating, pay attention to hot oil burns and oil chamber pressure, and exhaust before discharging. When cleaning robots, neutral cleaning agents must be used, which are solvent-free, water-soluble, non flammable, steam free, refrigerant free, chlorine free, and non strong acid and alkali free. Do not use high-pressure cleaners, do not use compressed air to clean bearings and sealing points, and prevent cleaning agents from entering electrical or mechanical components.

Balance cylinder inspection and replacement

The balance cylinder is a hydraulic and pneumatic component between the turntable and the connecting rod arm, used to reduce the torque of shaft 2. During inspection, manually run A2 to -90 °, wait for 1 minute, press emergency stop, and read the pressure gauge. KR 120 R2700-2 HO and KR 150 R3100-2 HO should have a pressure of 150 bar ± 15 bar at 20 ° C; KR 240 R2900-2 HO should be 176 bar ± 15 bar. If the pressure is abnormal, a dedicated pressure gauge should be used for retesting and KUKA service should be contacted. Check if the attachments are dirty, damaged, or leaking, and clean or replace them if necessary. Check the bellows and clamps, and replace them by professionals if necessary.

Replacing the balance cylinder is a high-risk operation. The balance cylinder weighs about 40 kg and is under pressure. Wear protective gloves and secure with slings and cranes during homework to prevent falls and accidental movements. The steps include: loosening the threaded clamp and pushing back the corrugated pipe; Move the connecting rod arm forward and install it into the clamping sleeve; Move the connecting rod arm in the negative direction to clamp the bushing; Fix the balance cylinder and connecting rod arm with a sling; Remove the cover plate and turntable bolts; Use a bolt fastener and a bolt puller to remove the bolt; Push the balance cylinder out of the turntable bolt; Lift it to a safe location. Install the new balance cylinder in reverse order. After completion, check the pressure and put it back into operation.

CBS HO Filter

CBS HO filter is a ventilation filter installed on the balance weight, used for balancing cylinder breathing in food environments. The maintenance schedule stipulates a visual inspection every 5000 hours, and if the filter turns black, it should be replaced. Open the valve cover during installation, insert the straight male coupling and reducing coupling, tighten and install the ventilation filter. When disassembling, first remove the ventilation filter, loosen the coupling, and close the valve cover. After replacement, it is necessary to test run in T1 mode and observe for any abnormalities. Filter blockage can cause poor breathing in the balance cylinder, which may lead to pressure fluctuations or leaks. Therefore, food factories should include it in regular inspections.

Motor and wrist replacement

Before replacing the motor, it is necessary to comply with electrical safety regulations: cut off the power supply, lock and prevent restart, confirm no voltage, ground and short-circuit, cover or isolate adjacent live parts. Simultaneously press the emergency stop button to prevent the robot from accidentally moving. When the motor is just stopped, the surface temperature is high and protective gloves should be worn; There is a risk of crushing during disassembly and assembly, and protective gloves should also be worn.

A1 motor replacement: Remove XM1 and XP1, unscrew 4 M12x25-8.8 screws, and lift out the motor. Clean the teeth before installing the new motor, apply a small amount of Microlube GL 261, and check the O-ring. Install the screws and tighten them diagonally step by step. Connect plug, zero point calibration, T1 test.

A2 motor replacement: First, fix the connecting rod arm with a sling, remove XM2 and XP2, hang A2 motor, unscrew 4 M12x25-8.8 screws, and pull out the motor. Clean the teeth, apply lubricating grease, install screws, and tighten diagonally during installation. Connect the plug, remove the stopper, calibrate the zero point, and conduct T1 testing.