KUKA KR QUANTEC-2 Maintenance Troubleshooting Guide

Key points of transportation and installation

The robot must be placed in the transport position before transportation. The transport poses of KR QUANTEC-2 are A1 0 °, A2-137 °, A3 160 °, A4 0 °, A5-105 °, A6 0 °. Vibration and impact should be avoided during transport until the robot is securely fixed. When transporting by forklift, four fork slots are installed on the base, and the forklift can start from the front and rear sides. The minimum load capacity of the forks is about 2.0 tons. When using transportation lifting equipment, connect the two front fork slots and the rotating column, and arrange all lifting equipment according to the diagram to prevent the robot from overturning or being damaged. It is prohibited to use cranes to lift robots in other ways.

Ground installation usually uses the S780 mounting base with centering. The base consists of a base plate, chemical anchor bolts, and fasteners, and requires a flat concrete foundation with sufficient bearing capacity. The recommended concrete grade is above C20/25. If there is an insulation layer or leveling layer between the bottom plate and the concrete, it must be in full contact and have sufficient compressive strength. The basic dimensions, margins, and concrete thickness need to be confirmed according to the drawing. Chemical anchor bolt construction must use the same manufacturer's resin and anchor bolt, and diamond drill bits or core drills should not be used. The drilling tools provided by the anchor bolt manufacturer should be prioritized. During installation, first fix the base plate and positioning pin, then place the robot on the foundation, drill 12 anchor bolt holes, install chemical anchor bolts, and connect the cables after curing. Tighten 8 M24x65-8.8 hex bolts step by step to the specified torque. The optional 150mm mounting base S780 uses 16 chemical anchor bolts.

Rack installation is used for steel structures, mounting brackets or KUKA linear guides, and can also be used for top mounting. The installation surface needs to be prepared according to the diagram, using two locating pins and eight M24x65-8.8 hexagonal bolts, and tightened step by step to the specified torque. During top installation, it is also necessary to ensure that the bottom structure can withstand the foundation load.

Connecting cables and interfaces

The connecting cables include motor cables, data cables, and grounding wires. KR C4 uses Han 16HP motor cable from X20 to X30, Han 3A Q12 data cable from X21 to X31, with a grounding wire of 16 mm ². KR C5 and KR C5-2 use 6 motor plugs XD20.1 to XD20.6, 2 brake plugs XD10.1 and XD10.2 to XD30, and data cables XF21 to XF31. The cable length can be selected from 7 m, 10 m, 15 m, 20 m, 25 m, 30 m, 35 m, 50 m, with a maximum of 50 m and a maximum of one extension allowed. When fixed laying, the bending radius of motor cables should not be less than 150 mm, and that of data cables should not be less than 60 mm. The cables should be installed in metal cable trays, and the motor and data cables should be laid separately to avoid stretching, sharp edges, and tripping risks.

The grounding wire must be connected using a circular cable terminal, with an M8 nut torque of 23.0 Nm. The equipotential connection should be checked according to VDE 0100 and EN 60204-1. Interface A1 is located at the rear of the base and includes motor cable X30, data cable X31, grounding conductor, optional external shaft interfaces XP7.1 and XP8.1. If the robot is equipped with a pipeline package, there may be additional air and cable interfaces between A1 to A3 and A3 to A6.

Oil change and maintenance cycle

The maintenance cycle is related to the working conditions. Under normal circumstances, check the tightening torque after 100 hours of operation; 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 using Hyspin ZZ 46 hydraulic oil; Replace gear oil every 20000 hours or no later than 5 years; Replace the balance cylinder every 10 years. The maintenance cycle of the F variant is shorter, with lubrication and pressure checks every 2500 hours or 1 year, and oil changes every 10000 hours or 5 years.

In terms of oil change volume, A1 has an oil change volume of about 5.70 L, A2 has an oil change volume of about 2.10 L, A3 has an oil change volume of about 1.40 L, A4 has an oil change volume of about 2.10 L, and A5/A6 has an oil change volume of about 1.40 L. The standard model uses Optigear Synt. ALR 150 gear oil. If the oil temperature exceeds 60 ° C for a long time, the maintenance cycle should be shortened.

When changing the oil, the gearbox should be in a warm state. The emission amount depends on the discharge time and oil temperature, and the refilling amount should be consistent with the discharge amount. If the discharge amount is less than 70% of the specified oil amount, the reducer should be flushed with discharge oil; If it is less than 50%, it should be rinsed twice. Move the axis at a jog speed throughout the entire axis range during flushing. The tightening torque of the magnetic plug should be confirmed according to the model and position. Pay attention to hot oil burns and oil chamber pressure during operation, and exhaust before draining the oil.