KUKA TITAN-2 Ultra Assembly and Maintenance Guide

Zero point loss or positioning deviation: After replacing the motor, reducer, cable, or battery, it is necessary to recalibrate the zero point using EMD/MEMD. After calibration, the program should be tested in T1 mode.

Unable to reset after emergency stop or safety door triggering: Confirm that the safety function has been restored, the emergency stop device has been released, and the safety fence is closed. If the safety function is removed or disabled, it is strictly prohibited to operate the robot.

When starting, the exhaust cap of the balance system pops out: Follow the exhaust procedure, move A2 ± 30 °, and then reinstall the protective cap.

Robot overturning or foundation cracking: Check the grade, thickness, chemical anchor bolt torque, and grouting quality of the foundation concrete. The typical values of the basic load are: normal vertical force of 79500 N, maximum 97000 N; normal horizontal force of 21000 N, maximum 52000 N; normal overturning moment of 146000 Nm, maximum 230000 Nm; normal torque around axis 1 of 26500 Nm, maximum 56500 Nm.

Casting Environment PURGE Options

For the F variant, the PURGE option is an important means of extending its lifespan. The system consists of plastic hoses, pressure regulating valves, brackets, and labels, installed behind interface A1. The preset working pressure is 0.01 MPa (0.1 bar) ± 10%, the air consumption is about 0.1 m ³/h, and the air interface is a 6 mm quick plug connector. During installation, it is necessary to remove the interface board, install the quick connector and pressure regulating valve, connect the air pipe, and paste the label. During debugging, conduct a T1 mode trial run and observe for any abnormalities. Daily maintenance mainly relies on visual inspection, and any damage found should be replaced in a timely manner.

Safety and stopping distance

The TITAN-2 ultra is equipped with mechanical end stops for shaft 1 and shaft 2, but only for machine protection. Personnel protection relies on the Safe Robot function of the controller or optional mechanical axis limitations (axis 1 to axis 3). The workspace must be limited to the minimum necessary range, and the danger zone is determined by both the workspace and the stopping distance. The stopping distance and stopping time vary depending on the model, load, speed, and wear. For detailed data, please refer to the product stopping distance and time information in KUKA Xpert. External protections such as safety fences, safety gates, and light curtains must be located outside the danger zone. In manual mode, T1 speed does not exceed 250 mm/s; T2 allows for higher speeds, but prohibits teaching and programming. Automatic mode is only allowed to operate when all safety devices are functioning properly and there is no one in the danger zone.

Disassembly, storage, and scrapping

Before dismantling, the robot needs to be moved to the transport position, disconnect the peripheral connections, motor cables, data cables, and grounding conductors, remove 12 hexagonal bolts, and lift it vertically off the installation surface. The storage environment should be dry, dust-free, avoid temperature fluctuations, ventilated and condensed, and use non shedding coverings. When stored for a long time, the electrical interface and hose interface should be sealed, and desiccants should be placed if necessary.

When scrapped, they are classified by material: cast iron and light alloy castings, copper cables, steel gears and fasteners, electronic components (RDC, EDS, etc.), plastic parts (ABS, NBR, PA, PE, PU, PUR). The motor can be treated as electrical waste without disassembly. The hydraulic pneumatic balance system must be depressurized before entering the scrap process.