Troubleshooting KUKA KR 1000 Titan

Replace gear oil every 20000 hours or 5 years. A1 uses Optigear ALR 320 with an initial volume of 25.0 L; A2 uses Optigear Synt. ALR 150 with an initial volume of 24.0 L; A3 is 12.0 L; A4 is 10.0 L; A5 is 3.0 L; A6 is 10.0 L. The oil change interval for the F variant is shortened to 10000 hours. Lubricate the A1 cable assembly every 20000 hours or 5 years using Optitemp RB2, approximately 100 g. If the oil temperature exceeds 60 ° C, the maintenance interval must be shortened and KUKA Service consulted.

Gear oil drainage must be carried out at operating temperature, first release pressure. A1 oil discharge requires moving A1 to -90 °, releasing the M22x1.5 magnetic plugs of the two motor towers for exhaust, and connecting the oil pipe to the service valve for oil discharge. Fill from below, the oil level should be between the two marks on the oil level indicator, recheck after 5 minutes, and the torque of the ventilation plug should be 12.5 Nm. For A2 oil discharge, loosen the two oil pipe joints and fill from below until the oil is discharged from both sides of the joints. A3 uses two service valves for oil discharge and filling. A4/A5/A6 are three independent oil chambers, using M27x2 magnetic plugs, with a torque of 30 Nm after filling. If the amount of discharged oil is less than 70% of the specified amount, it needs to be flushed once with discharged oil; 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 the balance system, manually move A2 to -90 ° and wait for 1 minute. The ground robot pressure for KR 1000 titan and KR 1000 titan F should be 130 bar ± 15 bar (20 ° C). The ground robot pressure for KR 1000 L750 titan and KR 1000 L750 titan F should be 120 bar ± 15 bar (20 ° C). If there is abnormal pressure or deviation in application, a dedicated pressure gauge should be used for measurement and KUKA Service should be consulted. Check the hydraulic system, fittings, hoses, accumulator, and safety valve to confirm that there are no leaks, damage, or dirt.

When replacing the balance system, the robot should be in mechanical zero position, A2 should be movable, and firmly fixed on the ground. The weight of the balancing system is approximately 150 kg, and approved lifting devices must be used to prevent falls and uncontrolled movements. First, loosen the bellows clamp, move the connecting rod so that the clamping sleeve can be inserted between the hydraulic cylinder and the hinge joint, and clamp the piston rod. Lift the balance system with a crane, release pressure, pull out the pin, and remove the balance system. Before installing the new balance system, remove the anti-corrosion and move the connecting rod to about -85 ° or a suitable position. Insert the hinge joint, spacer ring, and pin, paying attention to the positioning pin on the pin entering the groove. The torque of the M16x230-8.8 screw is 195 Nm. After installation, the pressure must be checked and a functional test must be conducted. Before disposing of the balance system, pressure must be released, and only pressure free balance systems are allowed to be scrapped.

Motor and linear wrist replacement

When replacing the A4/A5/A6 motor, power off and lock it first, remove the XM/XP connector, fix the motor with a sling, remove the 4 M12x30-8.8 Allen screws, and take out the motor. The F variant requires replacement of the seal between the motor and arm. Clean the motor teeth and drive shaft, apply Microlube GL 261, check the O-ring, tighten 4 Allen screws in diagonal order to 78 Nm, reconnect the plug, and perform mastering. A1 motor weighs about 32 kg, A2 motor weighs about 44 kg. When replacing, attention should be paid to lifting and hot surfaces.

The replacement of the straight wrist belongs to the major repair level. The weight of the straight arm is about 570 kg, and a crane or lifting device with sufficient load-bearing capacity must be used. Remove 22 M16x180-10.9 black Allen screws, note that there are still two pan head screws on the same hole circle that cannot be loosened. When pulling out the straight wrist, do not tilt it, and the gap between the arm and the straight wrist should be even. Clean all teeth and apply Microlube GL 261 before installation, ensuring that A4 and A6 are in the zero position. After inserting the straight wrist, gradually tighten the 22 M16x180-10.9 screws in diagonal order to 250 Nm. After installation, perform A4, A5, A6 mastering, T1 trial run to check for abnormal noise and leakage.

The release device is used to move A1 and A2 without driving energy in emergency situations. Before use, turn off the controller and lock it, remove the corresponding motor, install a ratchet, hexagonal socket or drive shaft, and manually move the shaft. After moving, all axes must be re masterned, brake tested, and tested under T1.

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 balance cylinder: Check the pressure gauge, accumulator, hoses, fittings, and leaks. KR 1000 titan should be 130 bar, L750 should be 120 bar. If there is a large deviation, consult KUKA Service.