KUKA QUANTEC-2 PA maintenance troubleshooting

Key points of transportation and installation

Before transportation, the robot must be placed in the transportation position: A1 0 °, A2-137 °, A3 160 °, A4-A5 67 °, A6 0 °. During transportation, vibration and impact should be avoided until the robot is firmly 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. G3 leg strap adjustable chain needs to be adjusted to the vertical suspension of the robot, and attention should be paid not to let adjacent balance cylinders bear the load. 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. Optional 150mm mounting base S780 with 16 chemical anchor bolts.

Rack installation is used for steel structures, mounting brackets, or KUKA linear guides. 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 and Han 3A Q12 data cable from X21 to X31. KR C5 uses 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 to 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 uses a circular cable terminal with an M8 nut torque of 23.0 Nm. The equipotential connection is checked according to VDE 0100 and EN 60204-1. The motor cable connector requires the insertion of 4 fastening screws with a torque of 3.0 Nm.

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, and optional air path interface. 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 lubrication cycle

The maintenance cycle is related to the working conditions. Under normal circumstances, check the fastening bolts 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; Replace gear oil every 20000 hours or no later than 5 years; Replace the balance cylinder every 10 years. If there is frequent short distance exercise, the maintenance interval can be shortened to 3000 hours.

In terms of oil change volume, A1 is about 5.70 L, A2 is about 2.10 L, A3 is about 1.40 L, A5 is about 0.56 L, A6 is about 0.93 L. All use Optigear Synt. ALR 150 gear oil. 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. Magnetic plug tightening torque: A1 is 25 Nm, A2 is 20 Nm, A3 is both 20 Nm, A5/A6 is 20 Nm. A1 uses M22x1.5 magnetic plug for oil discharge, and after filling, the union nut torque is 45 Nm. When operating, pay attention to hot oil burns and oil chamber pressure, and exhaust before draining oil. When cleaning robots, neutral cleaning agents must be used, which are solvent-free, water-soluble, non flammable, steam free, and refrigerant free. High pressure cleaners are prohibited.