KUKA CYBERTECH maintenance troubleshooting

Reason: seal aging, screw plug not tightened according to torque, incorrect oil quantity, installation angle leading to incomplete oil discharge.

Solution: Replace the gear oil according to the shaft. The recommended oil is Optigear Synt. ALR 150. The standard maintenance cycle is 2000 hours; the F variant is 10000 hours or 5 years. Initial filling amount: A1 is about 1.20 L, A2 is about 0.80 L, A3 is about 0.32 L, A4 is about 0.32 L, A5/A6 is about 0.37 L. Oil discharge must be carried out at operating temperature and the discharge amount must be measured. If the discharge volume is less than 70% of the specified amount, it should be rinsed once; If it is less than 50%, rinse twice. The filling amount shall be based on the actual discharge amount. Be aware that the oil chamber may be under pressure, and release the pressure before opening the drain plug. The torque of M18x1.5 magnetic plug is about 20 Nm, M10x1 plug is about 7.5 Nm, and A1 union nut is about 45 Nm.

Cable group A1 is worn or has abnormal noise

Performance: The hose inside the base is worn, dust accumulates, and there is friction noise during movement.

Reason: Insufficient lubrication, aging of hoses, long-term high-frequency exercise.

Solution: Remove the base cover, inspect the hose, clean it, and apply Optitemp RB2 grease to the outer surface of the hose, the contact surface with the base, and the inner side of the cover, weighing approximately 0.3 kg. If the hose is damaged, the cable assembly must be replaced. After reassembly, wipe off excess grease and move A1 to evenly distribute the grease.

Zero point loss or Mastering abnormality

Performance: teaching point offset, program unable to reproduce, abnormal axis angle display.

Reason: Replacement of motor, manual release of brake, loss of encoder data, collision.

Solution: Prioritize using EMD or a dial gauge for standard Mastering. The Mastering positions for this series are: A1 27 °, A2 90 °, A3 90 °, A4 0 °, A5 0 °, A6 0 °. After replacing the motor, checking the involute teeth, and replacing the connecting shaft, the Mastering must be redone.

Connector, grounding, and cable layout faults

Performance: The controller reports motor/data line faults, intermittent shutdowns, and abnormal shielding.

Solution: Check the motor cables, data cables, and grounding conductors. KR C4 uses X20-X30, X21-X31; KR C5 uses XD20.1... XD20.6-XD30, XD10.1/XD10.2-XD30, XF21-XF31. The cross-sectional area of the grounding conductor is 16 mm ², and the torque of the M8 nut is about 15.0 Nm. When the cable bending radius is fixed and laid, the motor cable should not be less than 150 mm, and the data cable should not be less than 60 mm. The maximum length is 50 m, and it can be extended up to once. The cable shall not bear tensile force and shall be laid separately from the power line.

F variant positive pressure loss or PURGE abnormality

Performance: Pollution inside the arm, entry of dust, accelerated wear of bearings and teeth.

Reason: The gas source contains water and oil, insufficient pressure, pipeline leakage, and the pressure regulator is not set.

Solution: Check for an overpressure of 0.01 MPa (0.1 bar) ± 10% inside the arm. The compressed air must be free of oil and water, in accordance with ISO 8573-1 Class 4. PURGE has a maximum pressure of 0.01 MPa, input pressure of 0.1-1.2 MPa, pressure regulator of 0.005-0.07 MPa, and air interface of 6 mm. Pressure loss can cause dust and coolant to enter, and must be repaired in a timely manner.

Wear of connecting shaft or large clearance between A4/A5 movements

Performance: A4/A5 abnormal noise, positioning drift, and increased reverse clearance.

Reason: Tooth wear, insufficient lubrication, and damage to the tooth surface during installation.

Solution: The connecting shafts must be replaced in pairs. Clean the teeth and apply Microlube GL 261 before installation. Pay attention to locking washers and wave springs during installation. A6 replacement requires the dismantling of A4, A5, and the inline hoist, which weighs approximately 23 kg and must be reliably lifted.

Planned maintenance: Block faults before they occur

Core nodes of standard maintenance table:

100 hours: Check the torque of the fixing bolts on the installation base.

2500 hours: Check if the visible hose is damaged.

5000 hours: Lubricate cable group A1 using Optitemp RB2.

2000 hours: Check A1-A6 involute teeth and grease them; Replace A1, A2, A3, A4, A5/A6 gear oil.

F variant maintains the core node of the table:

100 hours: Check the torque of the fixing bolts on the installation base.

2500 hours: Check for visible hoses.

5000 hours: Lubricate cable group A1 using Optitemp RB2 for approximately 200 cm ³.

10000 hours or 5 years: Check A1-A6 involute teeth and grease them; Replace A1, A2, A3, A4, A5/A6 gear oil.

Before maintenance, the maintenance point must be accessible and any obstructing tools and accessories must be removed. If the oil temperature exceeds 60 ° C for a long time, the maintenance interval should be shortened and KUKA should be consulted. All accessories must use approved products, otherwise it may lead to early wear and tear.