KUKA TITAN-2 Ultra Assembly and Maintenance Guide



KUKA TITAN-2 Ultra Assembly and Maintenance Guide

In the field of heavy-duty industrial robots, the KUKA KR TITAN-2 ultra series is a core model designed for high load and large arm deployment scenarios. This series includes models such as KR 1000 R4200-2 F, KR 1250 R3700-2 F, KR 1500 R3200-2, and KR 1500 R3200-2 F. The rated load covers 1000 kg to 1500 kg, with a maximum load of 1858 kg and a maximum arm span of 4218 mm. For engineers in the stage of solution search and troubleshooting, mastering the assembly points, maintenance cycles, and common problem handling is the key to ensuring stable operation of the production line.

Product family and F variant positioning

The KR TITAN-2 ultra series are all 6-axis articulated arm robots, using light alloy and cast iron structures, equipped with AC servo motors and two sets of hydraulic and pneumatic balancing systems. Its repeated positioning accuracy is ± 0.08 mm, and the protection level generally reaches IP65. The wrist can reach IP65/IP67, suitable for harsh working conditions such as casting, handling, and machine tool loading and unloading.

Among them, the F variant is designed specifically for casting environments and has higher protection requirements. The F-variant wrist can withstand a short-term heat load of 180 ° C (10 seconds/minute) and is protected by special coating and additional varnish, providing stronger resistance to dust, lubricants, coolant, and water vapor. If corrosive media are present on site, the pH value should be controlled between 7.0 and 9.0. In addition, the F variant can be equipped with the PURGE positive pressure protection option, which applies a slight positive pressure to the arm to prevent pollutants from entering and maintain the protection level for a long time.

The basic data for each model is as follows: KR 1000 R4200-2 F weighs approximately 4750 kg and has a working envelope of 193.8 m ³; KR 1250 R3700-2 F weighs approximately 4820 kg and has a working envelope of 117.4 m ³; The KR 1500 R3200-2 and KR 1500 R3200-2 F weigh approximately 4640-4650 kg, with a working envelope of 79.6 m ³. All models use KR C5-2 or KR C5 controllers, with installation surface dimensions of 1422 mm × 1300 mm and a hollow base shaft A1 diameter of 151 mm.

Installation foundation: from concrete to frame

The installation foundation of heavy-duty robots directly determines their operational stability. TITAN-2 ultra offers two installation methods: mounting base C1300 and rack mounting.

The installation base C1300 weighs approximately 1051 kg and includes a base plate, chemical anchor bolts, and fasteners, suitable for direct fixation on concrete foundations. The concrete grade should be at least C20/25, and the minimum thickness of the foundation depends on the edge distance and reinforcement: about 180 mm without edge reinforcement, and about 200-250 mm with edge reinforcement. If there is an intermediate layer between the bottom plate and the concrete, the intermediate layer must be in full contact with a compressive strength of not less than 25 N/mm ².

The installation steps include: cleaning the foundation, lifting the base plate, leveling with 4 M30x90 leveling screws, marking the position, applying leveling compound, curing, drilling chemical anchor bolt holes and implanting. The chemical anchor bolt nut needs to be tightened to 60 Nm, and the annular gap must be filled with injected resin. Then install the positioning pin and M8x65 bolt, lift the robot and lower it vertically to avoid damaging the positioning pin. Finally, use 12 M30x90-8.8 hexagonal bolts with conical spring washers, and tighten diagonally alternately and step by step to the specified torque.

Rack installation is suitable for steel structures, booster frames, or KUKA linear units. The installation surface needs to be pre drilled with holes, fixed with 12 M30x90-8.8 hexagonal bolts and conical spring washers, and equipped with a cylindrical pin and a flat head pin for positioning. During lifting, it is also necessary to maintain verticality to prevent damage to the pins. Regardless of the method, stability is confirmed by the integrator or debugging personnel.

Cable connection and grounding

The connecting cable is responsible for the power and data transmission between the robot and the control cabinet. The interface A1 of TITAN-2 ultra is located at the rear of the base and includes two motor cables XD30 and XD30.1, data cable XF31, grounding conductor, and optional external shaft interfaces XG7.1/XG8.1.

The cable length can be selected from 7 m, 10 m, 14 m, 20 m, 25 m, 35 m, and 50 m, with a maximum of 50 m and a maximum of one extension allowed. When used dynamically, the minimum bending radius for motor cables is 150 mm, for data cables it is 60 mm, and the operating temperature range is -10 ° C to 55 ° C. Motor cables and data cables must be laid separately in metal cable trays to prevent electromagnetic interference. The cross-sectional area of the grounding conductor is 16 mm ², and both ends are equipped with M8 ring cable lugs with a tightening torque of 23.0 Nm. After the connection is completed, the equipotential bonding needs to be checked according to VDE 0100 and EN 60204-1.

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.

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.