KUKA CYBERTECH maintenance troubleshooting

Practical replacement of involute teeth and motors

The involute teeth are a critical transmission component between the motor and the input shaft of the gearbox. During inspection, it is necessary to remove the motor, clean the teeth, and check for wear and tear; If the teeth are damaged, the input shaft of the motor or gearbox must be replaced, and the replacement of the gearbox input shaft requires contacting KUKA Service. Operation points:

A1: Standard use 4 M8x22-8.8-A2K hex socket screws, while F and HO versions use M8x25-A4-80. Be careful not to tilt when removing the motor; Apply Microlube GL 261 to the teeth; Check the O-ring.

A2: First, fix the connecting rod arm with a sling to prevent the arm from falling down after disassembling the motor; The screw specifications are the same as A1.

A3: First, fix the robot arm with a sling; Standard use 4 M8x20-8.8, F and HO versions use M8x20-A4-80; Pay attention to the spacer sleeve.

A4/A5: Standard use 4 M5x14-8.8-A2K, F and HO versions use M5x14-A4-80; Pay attention to the connecting shaft, locking washer, and wave spring; Apply Microlube GL 261 to the connecting shaft teeth; After installation, the connecting shaft should have a slight axial clearance.

A6: A4, A5, and inline writer need to be disassembled first; The inline hoist weighs approximately 23 kg and must be reliably lifted; Standard use 4 M3x12-8.8, F and HO versions use M3x12-10.9; Apply Microlube GL 261 to the teeth.

After replacing the motor, it is necessary to perform Mastering on the corresponding shaft and test the program in T1 mode. After replacing A4/A5/A6, it is usually necessary to master A4, A5, and A6 simultaneously.

Details of oil change and cable group lubrication

When changing the oil, A1 uses an oil pump with a union nut torque of about 45.0 Nm and an M18x1.5 plug torque of about 20.0 Nm; A2 uses an M18x1.5 plug torque of about 20.0 Nm; A3 uses an M10x1 plug torque of about 7.5 Nm; A4 uses an M10x1 plug torque of about 7.5 Nm; A5/A6 uses an M10x1 plug torque of about 7.5 Nm. Before draining the oil, release the pressure first, measure the discharge amount after draining, and the filling amount should be based on the actual discharge amount. When lubricating cable group A1, first remove 5 M5x10-10.9 round head screws and 2 M4 hex nuts, remove the cover and brush strip; Use a brush to apply Optitemp RB2 to the outside of the hose, the contact surface with the base, and the inside of the cover; After reassembly, wipe off excess grease and move A1 to evenly distribute the grease.

F variant casting plate special maintenance

The protection focus of KR 20 R1810 F is on positive pressure and PURGE. The overpressure inside the arm is 0.01 MPa (0.1 bar) ± 10%, and the compressed air must be free of oil, water, and filtered, in accordance with ISO 8573-1 Class 4. PURGE has a maximum pressure of 0.01 MPa, an input pressure of 0.1-1.2 MPa, a pressure regulator of 0.005-0.07 MPa, and an air interface of 6 mm. The thermal load is 10 s/min at 180 ° C, and the wrist is coated with heat-resistant silver paint. The entire machine is coated with special paint and protective varnish. If positive pressure is lost, dust and coolant will enter the arm, accelerating the wear of bearings and teeth; Therefore, every maintenance should check for leaks in the air circuit, pressure regulator, and pipelines.

Installation, transportation, and electrical interfaces

Transportation location: A1 0 °, A2-138 °, A3 139 °, A4 0 °, A5 90 °, A6 0 °. Use slings or forklifts, unauthorized lifting is prohibited. Install base S31 weighing approximately 25.4 kg, using 4 M20x55-8.8 bolts and 6 chemical anchor bolts; Machine frame installation 0000-268-113 weighs approximately 1.05 kg and uses 4 M20x55-8.8 bolts. Tighten the base bolts again after 100 hours. Interface A1 is located at the rear of the base and includes X30 motor, X31 data, X32 mastering, XP7.1/XP8.1 external axis PURGE（F variant）。 The grounding conductor is 16 mm ², and the torque of the M8 nut is approximately 15.0 Nm. The connecting cable lengths are 4 m, 7 m, 15 m, 25 m, 35 m, and 50 m, with a maximum of 50 m and a maximum extension of once.

Fault Handling Checklist

Emergency stop, power off, padlock, and power check first.

Check the alarm: motor, brake RDC、 Data cables and safety circuits.

Mechanical inspection: oil level, oil leakage, involute teeth, O-ring, connecting shaft, cable assembly, positive pressure.

Check parameters: load, center of gravity, inertia, installation angle, program magnification.

After replacement: Mastering, T1 testing, stop distance retest.

Record: Fault time, frequency, axle number, temperature, load, maintenance content.

The reliability of the KUKA KR CYBERTECH series is based on standardized maintenance. By controlling the stopping distance, involute teeth, gear oil, cable assembly, zero point calibration, base bolts, and F variant positive pressure, most on-site faults can be detected in advance. For engineers, the true idea of "replacing discontinued modules" is not to wait until they break before replacing them, but to use verifiable parameters and standard steps to turn every maintenance into a traceable quality record.