KUKA KR18 R1450-3 PP Operation and Maintenance Essentials

Transportation, installation, and connection of cables

Before transportation, the robot must be placed in the transportation position: A1 0 °, A2-127 °, A3 140 °, A4 0 °, A5 115 °, A6 0 °. The transportation position must be maintained until it is fixed. Remove obstacles, transport fasteners, rust, and adhesives before transportation. Avoid vibration and impact. Forklifts or lifting equipment can be used, and rope lifting equipment can be used to wrap around the connecting arm and turntable, with all sides long enough to not damage the robot. The installation tool may change the center of gravity. It is prohibited to use other methods of lifting with a crane, stand under the robot, and prevent tipping. The transportation dimensions and center of gravity vary with configuration, and the dimensions provided in the document do not include equipment.

The ground installation uses a centering installation base S220, which is fixed to the concrete foundation through a bottom plate and chemical anchor bolts. The surface of the concrete foundation must be smooth and level, with sufficient load-bearing capacity. There should be no insulation layer or mortar layer between the bottom plate and the concrete, and the concrete quality should be at least C20/25. If there is unevenness, use leveling material, but there should be no leveling material below the hexagonal bolt. Chemical anchor bolts can only use resin pipes and anchor bolts from the same manufacturer, and diamond tools or coring drills are not allowed. Follow the manufacturer's instructions. Clean the foundation during installation, screw two parallel pins into the base plate, lift the robot to clean the lower installation surface, and use four M16x50-12.9 hex screws with tapered spring washers to fix the base plate vertically and avoid damaging the positioning pins. Place it on the installation base, check the level, and if necessary, lift and apply leveling material. After drying, drill 4 anchor bolt holes and install anchor bolts. The tightening torque of the four fixed bolts on the base is 195.0 Nm. Check after the first 100 hours and annually thereafter. Rack fixation is used for steel structures, boosters, or KUKA linear slides, as well as for ceiling installations, ensuring that the bottom structure can withstand operating forces. The rack fixing components include locating pins, hexagonal bolts with tapered spring washers, using 4 M16x50-12.9 hex screws and 2 parallel pins 10x30.

Connect the cable on the robot side through interface A1. Cable lengths of 4 m, 7 m, 10 m, 25 m, maximum 25 m. Motor cable XD20.1/XD0.2-XD30, shell size 20; Data cable XF21-X31, M12 Y encoding; Grounding wire/equipotential connection M8 ring terminal. Interface A1 is located at the rear of the base, including motor cable X30 and data cable X31. The energy supply system interface is located on the A1 interface board. When connecting, use one M4 hex nut with a conical spring washer for the grounding wire, with a torque of 1.2 Nm; the optional system component grounding wire is also 1.2 Nm; connect the data cable XF21 to X31 to ensure locking; Connect motor cables XD20.1/XD20.2 to X30, ensuring that the control cabinet and robot side connectors are locked; Check the equipotential connection according to VDE 0100 and EN 60204-1. Cables should be protected from tripping and secured with cable trays or neatly coiled to avoid sharp edges, tools, or other material damage.

Maintenance cycle and lubrication oil change

The maintenance table is applicable to the working conditions specified in the technical data. If the working conditions deviate or special functions are used, KUKA must be consulted. Suggest conducting a comprehensive inspection after 7 years or modifying the usage. If equipped with KUKA energy supply system, additional maintenance is required. Only auxiliary materials approved by KUKA can be used, otherwise early wear and component failure may occur. The maintenance point must be accessible and remove obstructing tools. Emergency stop protection must be used when working on robots; If working on an electrified robot, only slow down movement is allowed, emergency stop can be made at any time, and the operation is limited to the necessary range. If the oil temperature exceeds 60 ° C, the maintenance interval must be shortened.

Maintenance project: First check the tightening torque of the four fixed bolts on the installation base after 100 hours, MA=195.0 Nm； Lubricate the inside of A2, A3, and A5 cover plates for 5000 hours or at least annually, using Optitemp RB2 cable grease 10g; replace the A5 toothed belt for 5000 hours or at least annually; Check the torque of the four fixed bolts on the installation base every year, MA=195.0 Nm； Replace A2 gearbox oil every 20000 hours or at least every 5 years, using Optigear Synt. ALR 150 with an initial filling amount of 0.25 L; replace A1 gearbox oil every 20000 hours or at least every 5 years, using Optigear Synt. ALR 150 with an initial filling amount of 0.36 L. Auxiliary materials include Drei Bond 1305, 1342, 1385, 5204HV adhesive and sealant, Harmonic Drive grease 4B No.2, Kl ü beralfa MR 3-500 UV，Loctite 510，Optitemp RB2，PETAMO GHY 133 N，Optigear Synt. ALR 150  Regional version. Request the latest safety data sheet before use.