210系列机器人维护手册

1、ROBOT(V)KR 150, 180, 210; (V)KR 150, 180, 210, 240-2; (V)KR 150 WMaintenanceManipulatorwithoutWristIssued:22 Dec 2005Version:08Ro/Me/05/33.01 01.01.08 en1 of 18e CopyrightKUKARoboterGmbHThis documentationor excerptstherefrom may not be reproduced or disclosed to third partieswithoutthe expresspermis

2、sionof the publishers.Other functionsnot described in thisdocumentationmay be operablein the controller.Theuser has no claim to these functions, however,inthe caseof a replacement or servicework.We havecheckedthe contentof thisdocumentationfor conformitywith the hardwareandsoftwaredescribed.Neverthe

3、less, discrepanciescannotbe precluded, for whichreason we are not ableto guaranteetotal conformity.The information in this documentationis checkedon aregularbasis,however, and necessarycorrectionswillbe incorporatedin subsequenteditions.Subjectto technicalalterationswithoutan effecton thefunction.Ro

4、/Me/05/33.0101.01.08en2 of 18Contents1General42Lubrication62.1Oil change on main axis gear units92.1.1Oil change on axis 1 gear unit102.1.2Oil change on axis 2 gear unit112.1.3Oil change on axis 3 gear unit123Other maintenance154Cleaningand preventivemaintenance175Safety precautionswhen handlinglubr

5、icants18Ro/Me/05/33.01 01.01.08 en3 of 18MaintenanceValid for(V)KR 150(V)KR 150 W(V)KR150-2(V)KR 150 L 130(V)KR150 L 130-2(V)KR 150 L 110(V)KR150 L 110-2(V)KR 180(V)KR180-2(V)KR 180 L 150(V)KR180 L 150-2(V)KR 180 L 130(V)KR180 L 130-2(V)KR 210(V)KR210-2(V)KR 210 L 180(V)KR210 L 180-2(V)KR 210 L 150(

6、V)KR210 L 150-2(V)KR240-2(V)KR240 L 210-2(V)KR240 L 180-21GeneralThis description applies analogously to all of the robots listed above, regardless of the robot variant or model shown in the illustrations.The Doc. Module“ Safety,General”is to be observed!Before any maintenance work is started, any a

7、ttached tools or additional equipment that would hinder maintenance must be dismounted.Explanationofthesymbolsusedin connectionwithmaintenanceintervals in the“ Lubricationand “” Othermaintenancetables”below.means: maintenanceintervalmeans: recommendedmaintenanceLubricationis performed either at the

8、specified maintenanceintervals or every 5 years aftercommissioningby the customer- whicheveris reached first.With maintenance intervals of 20 000 hours, the first maintenance (oil change)is performedeither after20 000operating hoursor 5 yearsafter commissioning bythe customer -whicheveris reachedfir

9、st.If the robot is fitted with an energy supply system(option) A 1 - A 2 or A 1 - A 5, additionalmaintenancework is recommended.It is imperativethat lubricationis carried out every5 years, as prescribed(oil ageing).The maintenance intervals given in the tables are valid for the operating conditions

10、specified in the robot Doc. Module “ Technical Data ”In. case of variations from normal conditions (e.g. increased dust or water content in the environment of the robot, abnormal temperatures), the KUKA design department must be consulted.Ro/Me/05/33.0101.01.08 en4 of 181General(continued)Explanatio

11、nof symbols:1Maintenance pointMaintenance point, visible on drawingMaintenance point, hidden on drawing1.0 lOil change, to be repeated at specific intervals; with indication of oil capacityLubricate with grease gunLubricate with brushTighten screw (nut)The description of maintenance operations is su

12、bdivided into job steps with numbers in brackets appearing before them. The text which immediately follows these steps must also be read if it is specially marked by a warning triangle or either of the hand symbols , as many of these marked texts refer to the preceding job step.Example:(1) Pour spec

13、ified amount of oil into the filler hole at (10). Only KUKA- -approved lubricants may be used.Some of the specially marked texts refer exclusively to everything that follows - until the instruction is expressly revoked or the work is completed at the end of a section.Example:Turn main switch on the

14、robot control cabinet to “ OFF”and secure it with a padlock to prevent unauthorized persons from switching it on again.Ro/Me/05/33.01 01.01.08 en5 of 18Maintenance2LubricationSection1 of this Doc. Moduleis to be observed!Turn main switch on the robot control cabinet to “ OFF”and secure it with a pad

15、lock to prevent unauthorized persons from switching it on again.Utmost caution must be exercised when handling cable grease. The use of protective clothing (at least protective gloves, for example) is strongly recommended.All accident prevention regulations and Section 5 of this Doc. Module must be

16、observed.Store used oil and grease in accordance with regulations and dispose of them with minimum environmental impact.Ro/Me/05/33.0101.01.08 en6 of 182Lubrication (continued)D “Lubrication ”tableMaintenance pointMaintenanceActivityRemarks(see Fig. 1)intervalLubricant(hours)ManufacturerAmount00KUKA

17、 Art. no.00000012Gear with bearings A 1DOil changeOptigear RMOOptimol, approx. 7.1 l 2)KUKA Art. no.00-106-431Bearings of counter- -DLubricatebalancing system onGrease LGEP2link arm 1)SKF, approx. 10 g pernippleKUKA Art. no.00-108-474Change oil as described in Section 2.1.1.Pump grease into nipples

18、until clean grease emerges. Remove old grease.Gear with bearings A 2Gear with bearings A 3Energy supply system(option)A1-A2A1-A3A1-A5DOil changeOptigear RMOOptimol, approx. 3.0 l 2)KUKA Art. no.00-106-431DOil changeOptigear RMOOptimol, approx. 1.9 l 2)KUKA Art. no.00-106-431V Checking, greasing Opti

19、temp RB1 Optimol, approx. 1000 g KUKA Art. no.00-101-456Change oil as described in Section 2.1.2.Change oil as described in Section 2.1.3.Verify externally the gliding quality of the flexible tube A 1; if necessary clean the flexible tube and the sliding surface. Apply grease with a cloth. If the gl

20、iding quality of the cables and hoses in the flexible tube is no longer suf-ficient, inform the KUKA Service department and let re-lubricate.D Normal maintenance interval V recommended maintenance1) In the case of frequently recurring, short-distancemovements about axis 2, the maintenance interval i

21、s 3000 hours.2) The oil quantities specified are the actual amounts of oil in the gear unit at first fillingRo/Me/05/33.01 01.01.08 en7 of 18Maintenance7,1 l3,0 l1.9 l12345Fig. 1LubricationWhen draining the oil, it is important to remember that the quantity drained is dependent on time and temperatu

22、re.The quantity of oil drained must be determined, as only this quantity may be used when refilling.Ro/Me/05/33.0101.01.08 en8 of 182Lubrication(continued)2.1Oil changeon main axis gear unitsSection2 of this Doc. Moduleis to be observed!The oil is to be changed only at operating temperature.Ro/Me/05

23、/33.01 01.01.08 en9 of 18MaintenanceIf the oil changeis carriedout immediatelyafter the robothas stoppedoperating,the oil temperatureis liableto be high,in whichcase appropriatesafety measuresmustbe taken.2.1.1Oil changeon axis 1 gear unitSection2.1 of this Doc. Moduleis to be observed!D Drain oil(1

24、) Remove four M8x12 Allen screws (Fig. 2/4) including lock washers, take off cover (5) and pull out drain hose (6).(2) Unscrew sealing cap (7) on drain hose (6) and place a suitable receptacle under the drain hole.(3) Remove screw plug (3) and catch oil as it drains out.The oil takes about 15 minute

25、s to drain completely.Store used oil in accordance with regulations and dispose of it with minimum environmental impact.(4) Screw sealing cap (7) onto drain hose (6) and tighten it.D Fill with oil(1) Pour specified amount of oil into filler hole of screw plug (3). Only KUKA- -approved lubricants may

26、 be used.Use a hose (2) approx. 1 m long with a straight M33x2 union (8) together with a funnel(1) which fits into the free end of the hose (2).(2) Insert and tighten screw plug (3).(3) Check sealing cap (7) for leaks.(4) Fit cover (5) and fasten it with four M8x12 Allen screws (4) and lock washers.

27、(5) Connect any peripheral supply lines required.Ro/Me/05/33.0101.01.08 en10 of 1882Lubrication(continued)1234576Fig. 2Oil changeon axis 12.1.2Oil changeon axis 2 gear unitSection2.1 of this Doc. Moduleis to be observed!DDrain oil(1) Remove sealing cap (Fig. 3/4) and place a suitable receptacle (6)

28、under the drain hole.(2) Remove screw plug (3) and catch oil as it drains out.The oil takes about 15 minutes to drain completely.Store used oil in accordance with regulations and dispose of it with minimum environmental impact.(3)Replace and tighten sealing cap (4) (tightening torque MA = 40 Nm).Ro/

29、Me/05/33.01 01.01.08 en11 of 18MaintenanceDFill with oil(1) Pour specified amount of oil into the filler hole at (3).Only KUKA- -approvedlubricantsmay be used.It is easier to pour in the oil if a hose (2) with an M22x1.5 connection (5) and a funnel(1) are used for this purpose.(2) Insert and tighten

30、 screw plug (3) (M A = 40 Nm).(3) Check sealing cap (4) for leaks.125364Fig. 3Oil changeon axis 22.1.3Oil changeon axis 3 gear unitSection2.1 of this Doc. Moduleis to be observed!DDrain oilBefore performing the next step, it must be ensured that it is not possible for anyone to be injured within the

31、 range of the slowly turning robot.The robot may only be moved at jog speed, with all applicable safety rules and regulations being observed.(1) Put robot into operation and move axis 3 until screw plugs (Fig. 4/2, 6) are aligned vertically.Ro/Me/05/33.0101.01.08 en12 of 182Lubrication(continued)Tur

32、n main switch on the robot control cabinet to “ OFF”and secure it with a padlock to prevent unauthorized persons from switching it on again.(2) Remove screw plug (6) and place a suitable receptacle (5) under the drain hole.It is easier to drain the oil if a hose (4) with an M18x1.5 connecting nipple

33、 (3) is used.(3) Remove screw plug (2) and catch oil as it drains out. The oil takes about 10 minutes to drain completely.Store used oil in accordance with regulations and dispose of it with minimum environmental impact.(4) Insert and tighten screw plug (6) (tightening torque MA = 10 Nm).DFill with

34、oil(1) Pour specified amount of oil into the filler hole at (2).Only KUKA- -approvedlubricantsmay be used.It is easier to pour in the oil if a funnel is used for this purpose.(2) Insert and tighten screw plug (2) (M A = 40 Nm).(3) Check screw plugs (2, 6) for leaks.Ro/Me/05/33.01 01.01.08 en13 of 18

35、Maintenance126345Fig. 4Oil changeon axis 3Ro/Me/05/33.0101.01.08 en14 of 183Other maintenance3Other maintenanceSection1 of this Doc. Moduleis to be observed!Turn main switch on the robot control cabinet to “ OFF”and secure it with a padlock to prevent unauthorized persons from switching it on again.

36、D “Other Maintenance ” tableMaintenance pointMaintenanceActivityRemarks(see Fig. 5)interval(hours)00001Robot mounting baseDChecking tightening torquesSee robot Doc. Modulefor bolts and anchor nuts“ Installation,Connection,Exchange ”.Ro/Me/05/33.01 01.01.08 en15 of 18Maintenance1Fig. 5Other maintenan

37、ceRo/Me/05/33.0101.01.08 en16 of 184Cleaningand preventivemaintenance4Cleaningand preventivemaintenanceTurn mainswitch on the robotcontrol cabinet to “ OFF”and secureit withapadlockto preventunauthorizedpersons fromswitchingit on again. Thisalsoappliestoanycleaningwork,whichthoughnotperformeddirectl

38、yon therobotis carriedoutwithinorclosetoitsworkingrange.Cleaning and preventive maintenance work is to be carried out in accordance with the following instructions:- Clean robot with a cloth soaked with washing agent.- Clean cables, plastic parts and hoses with solvent-free washing agents.The manufa

39、cturerinstructionss are to be observed when using washing agents.- Remove any lubricant that has escaped using washing agent. If a large amount of lubricant has emerged, trace and remedy the cause.It must be ensured that no washing fluid enters bearings, seals, electrical equipment or the mechanical

40、 counterbalancing system.If washing agent does enter bearings, these must be re-greased or re-oiled.- Remove any corrosion and - where permissible - protect the affected areas with paint, grease or oil.- Apply a thin coat of oil to bare metal parts.- Replace damaged, illegible or missing inscriptions, labels and plates.Do not use compressedair to clean the system,as this couldcause dirt topenetrateand damage seals, bearingsand electricalcomponents.Used cleaning agents a