KUKA TITAN-2 Ultra Assembly and Maintenance Guide

Balance system and starting exhaust

The TITAN-2 ultra is equipped with two sets of hydraulic and pneumatic balancing systems, installed between the rotating column and the left and right connecting rod arms, for balancing the load torque of shaft 2. Each system includes two accumulators, hydraulic cylinders, hoses, and accumulator safety valves, which fall within the scope of pressure equipment instructions.

After long-term storage, the robot may accumulate air cushions in the balance system. If there is sudden exhaust during startup, the safety valve protective cap may pop out, causing injury. Therefore, when starting or re debugging for the first time, the exhaust procedure must be executed: first remove the protective cap of the balance system exhaust valve, maintain a safe distance, move the A2 axis ± 30 °, and then reinstall the protective cap. If the balance system needs to be scrapped, it must be depressurized first, and only non pressurized balance systems are allowed to be disposed of.

Key points of transportation and lifting

The robot must be placed in the transport position before transportation. The transportation positions of KR 1000 R4200-2 F are A1-90 °, A2-120 °, A3-80 °, A4 0 °, A5-70 °, A6 0 °; other models are A1 0 °, A2-120 °, A3-80 °, A4 0 °, A5-70 °, A6 0 °. Vibration and impact should be avoided during transportation.

There is a forklift slot on the base frame, which can be lifted by a forklift from the front and rear directions. The rated load of the forklift should be at least 5 tons, and the length of the fork should be sufficient. Alternatively, a lifting device can be selected, which can be installed on the rotating column using three M30 rotating lifting ring screws and lifted by a crane. All lifting straps must be arranged according to the diagram during hoisting to avoid damaging the cable assembly. If the robot is equipped with tools or energy supply systems, they should be removed if necessary to prevent sling damage to the equipment. It is strictly prohibited to use other methods to pick up robots with cranes.

Maintenance cycle and oil management

The maintenance interval of TITAN-2 ultra varies by model and is closely related to oil temperature, load, and motion trajectory. If the oil temperature exceeds 60 ° C, the maintenance interval must be shortened and KUKA service must be consulted.

General inspection: After 100 hours of initial startup or re debugging, it is necessary to check the tightening torque of the fastening screws and nuts. Afterwards, execute according to the table of each model.

KR 1000 R4200-2 F and KR 1250 R3700-2 F: Replace A1 cross roller bearing grease LGEP 2 every 2500 hours or 6 months, with a dosage of 8 × 60 g. Lubricate the balance system bearings on both sides of the rotating column and connecting rod arm, with each lubrication point of 10 cm ³. If shaft 2 frequently trips short (less than 40 °), the interval is 3000 hours; Check the balance system pressure and leakage every 2500 hours or 1 year. Replace gear oil every 10000 hours or 5 years: A5/A6 with Optigear Synt. ALR 150, 10.00 L; A4 uses 10.50 L; A3 uses 28.00 L; A2 uses 32.00 L; A1 input stage and gear unit use Optigear ALR 320, gear unit 12.00 L, input stage 2 × 1.80 L. At the same time, lubricate the A1 cable set using Optitemp RB2 50 g. The balance system is replaced every 10 years.

KR 1500 R3200-2: Maintenance interval extended to 5000 hours or 1 year, A1 bearing grease and lubrication balance system replaced; Replace gear oil after 20000 hours or 5 years; The balance system is replaced every 10 years.

KR 1500 R3200-2 F: Similar to KR 1000/1250 F, replace A1 bearing grease and lubrication balance system after 2500 hours or 6 months; Change oil after 10000 hours or 5 years; Replace the balance system in 10 years.

During maintenance, KUKA approved auxiliary materials and consumables must be used. Common oil products include Optigear Synt. ALR 150、Optigear ALR 320、LGEP 2、Hyspin ZZ 46、Optitemp RB2、Microlube GL 261、PETAMO GHY 133 N  Wait. The latest safety data sheet should be requested from the manufacturer.

Common faults and troubleshooting ideas

Abnormal or leaking pressure in the balance system: Check the accumulator pressure, hydraulic cylinder, and hose connections. If the pressure is insufficient, it may cause an imbalance in the torque of shaft 2, resulting in motion shaking or sinking. Check and replenish Hyspin ZZ 46 hydraulic oil according to the maintenance schedule.

Abnormal noise or wear of A1 bearings: After long-term high load operation, the lubricating grease of A1 cross roller bearings may deteriorate. Replace LGEP 2 periodically and check the bearing clearance.

High gearbox oil temperature: Oil temperature exceeding 60 ° C will accelerate oil aging. Check if the load exceeds the rated value, if the ambient temperature is too high, and if the oil level is normal. If necessary, shorten the oil change cycle.

Cable wear or signal interference: Check whether the motor cable and data cable are laid separately, whether the bending radius meets the standard, and whether the connector is locked. The casting environment should be equipped with PURGE positive pressure protection to prevent dust and coolant from entering.