1、 KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en Page 1 of 140 ROBOT KR 30-3 KR 60-3 KR 30 HA KR 60 HA Seminar workbook of Mechanical Servicing Issued:September 2005 Copyright Copyright 2005 KUKA Roboter GmbH Zugspitzstrae 140 D-86165 Augsburg This documentation or excerpts therefrom may not be reprodu
2、ced or disclosed to third parties without the express permission of the publishers.Other functions not described in this documentation may be operable in the controller.The user has no claims to these functions,however,in the case of a replacement or service work.We have checked the content of this
3、documentation for conformity with the hardware and software described.Nevertheless,discrepancies cannot be precluded,for which reason we are not able to guarantee total conformity.The information in this documentation is checked on a regular basis,however,and necessary corrections will be incorporat
4、ed in subsequent editions.Subject to technical alterations without an effect on the function.KUKA Roboter GmbH accepts no liability whatsoever for any errors in technical information communicated orally or in writing in the training courses or contained in the documentation.Nor will liability be acc
5、epted for any resultant damage or consequential damage.Responsible for this training documentation:College Development(WSC-IC)Page 2 of 140 KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en Copyright Contents KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en Page 3 of 140 Contents 1.Overview Robot.5 2.Disasse
6、mbly.9 2.1.Wrist.9 2.2.Arm.13 2.3.Link arm.21 2.4.Rotating column.27 2.5.Base unit.35 2.6.Energy supply.37 2.7.Axis monitoring.51 3.Assembly.55 3.1.Base unit.55 3.2.Rotating column.57 3.3.Link arm.63 3.4.Arm.69 3.5.Wrist.75 3.6.Energy supply.81 3.7.Axis monitoring.95 4.Maintenance.99 4.1.Wrist axes.
7、99 4.2.Basic axes.109 5.Exercises.113 6.Tightening torques table.139 Overview Robot KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en Page 5 of 140 1.Overview Robot Overview Robot Page 6 of 140 KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en Overview Robot KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en Page 7
8、 of 140 I 25.10.2005 I College I MW I 1KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeMechanical servicing,KR 30-3Energy supply systemAxis range monitoringWristArmLink armRotatin
9、g columnBase frame43215671234567 Disassembly KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en Page 9 of 140 2.Disassembly 2.1.Wrist Disassembly Page 10 of 140 KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en I 25.10.2005 I College I MW I 1KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/4
10、5 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeWrist disassemblyUse the appropriate equipment to ensure that the wrist does not fall!I 25.10.2005 I College I MW I 2KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:
11、+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeLoosen and remove sixteen wrist fastening screws(M6 x 100/12.9).Wrist disassembly Disassembly KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en Page 11 of 140 I 25.10.2005 I College I MW I 3KUKA Roboter GmbH,Hery-Park 3
12、000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeWrist disassemblyThe wrist must not be tilted as it is being removed!Mind the contact surface of the wrist on the arm and also the wrist drive shaft.I 25.10.200
13、5 I College I MW I 4KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeRemove the wrist horizontally in the direction of the arrow and place it on a suitable support.Wrist disassembl
14、y23116 fastening screws M6 x 100/12.9WristArm213 Disassembly Page 12 of 140 KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en I 25.10.2005 I College I MW I 5KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA
15、 Roboter GmbH CollegeIf an arm extension is installed additional fastening screws(2)need to be removed.231Arm extension16 fastening screws M6 x 35/10.9 Arm213Wrist disassemblyArm extension I 25.10.2005 I College I MW I 6KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,F
16、ax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeRemove the extension section horizontally in the direction of the arrow and place it on a suitable support.Arm extension21316 fastening screws M6 x 35/10.9 Arm extensionArm213Wrist disassembly Disassembly KUKA R
17、oboter GmbH 2005/SM KR30-3 09.05.00 en Page 13 of 140 2.2.Arm Disassembly Page 14 of 140 KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en I 25.10.2005 I College I MW I 1KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copy
18、right by KUKA Roboter GmbH CollegeArm disassemblyUse the appropriate equipment to ensure that the arm does not fall!Unplug the motor and control connectors.I 25.10.2005 I College I MW I 2KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/ww
19、w.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeArm disassemblyWrist axis motors,axis 4 to axis 6Remove the three plugs on both sides of the arm and under the motor of axis 4.Disassembly KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en Page 15 of 140 I 25.10.2005 I College I MW I 3KUKA Roboter G
20、mbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH College32411Arm disassemblyWrist axis motors,axis 4 to axis 6Unscrew adjusting screws(1)by several turns,remove fastening screws(2)and remove motors.Wri
21、st axis motor A 4Wrist axis motor A 543Adjusting screws8 motor fastening screws M6 x 25/8.821 I 25.10.2005 I College I MW I 4KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeArm di
22、sassemblyWrist axis motors,axis 4 to axis 6When removing the motors their respective toothed belts in the arm must be taken off at the same time.21Toothed belt,wrist axis motor A 4Toothed belt,wrist axis motor A 521 Disassembly Page 16 of 140 KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en I 25.10.2005
23、 I College I MW I 5KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeArm disassemblyWrist axis motors,axis 4 to axis 6Remove fastening screws(2)on the axis 6 motor(1)and take the mo
24、tor out12Wrist axis motor A 64 motor fastening screws M8 x 18/8.821Attention must be paid to any loose disc springs!I 25.10.2005 I College I MW I 6KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Robo
25、ter GmbH CollegeArm disassemblyMotor A 3Unscrew fastening screws(3)and remove motor(2).Secure the arm so that it cannot move!ArmMotor A 34 motor fastening screws M12 x 30/8.8213123 Disassembly KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en Page 17 of 140 I 25.10.2005 I College I MW I 7KUKA Roboter Gmb
26、H,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeArm disassemblyLoosen and remove fastening screws(2).12Arm6 fastening screws M16 x 100/10.912 I 25.10.2005 I College I MW I 8KUKA Roboter GmbH,Hery
27、-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeArm disassemblyLoosen and remove fastening screws(2).Arm18 fastening screws M10 x 90/10.9 1212 Disassembly Page 18 of 140 KUKA Roboter GmbH 2005/SM KR30-
28、3 09.05.00 en I 25.10.2005 I College I MW I 9KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeArm disassemblyTake off support ring(3).6 fastening screws M16 x 100/10.918 fastening
29、screws M10 x 90/10.9 Support ring213123 I 25.10.2005 I College I MW I 10KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeArm disassemblyPush the arm out of its location and careful
30、ly swing it away.Push the arm out of its location and carefully swing it away.The arm must not be tilted while it is being lifted off.Disassembly KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en Page 19 of 140 I 25.10.2005 I College I MW I 11KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0
31、)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeArm disassemblyGrease the toothing of the shafts with Microlube GL261.Motor A 6Motor A 6RingDisc springs213123 Disassembly KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en Page 21 of 140 2.3.Link a
32、rm Disassembly Page 22 of 140 KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en I 25.10.2005 I College I MW I 1KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeLink arm disassembly I 25
33、.10.2005 I College I MW I 2KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeLink arm disassemblyUse the appropriate equipment to ensure that the link arm does not fall!Disassembly
34、KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en Page 23 of 140 I 25.10.2005 I College I MW I 3KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeLink arm disassemblyMotor A 2Unplug the
35、motor and signal connectors.Remove fastening screws(2).Remove motor(1)and place it on a suitable support.Motor A 24 motor fastening screws M12 x 30/10.92121 I 25.10.2005 I College I MW I 4KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/w
36、ww.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeLink arm disassemblyLoosen and remove the six fastening screws(M16 x 100/10.9).Disassembly Page 24 of 140 KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en I 25.10.2005 I College I MW I 5KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(
37、0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeLink arm disassemblyLoosen and remove the eighteen fastening screws(M10 x 100/10.9).I 25.10.2005 I College I MW I 6KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-190
38、6,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeLink arm disassemblyThe link arm must not be tilted while it is being lifted off.6 fastening screws M16 x 100/10.918 fastening screws M10 x 100/10.9 Support ring322131 Disassembly KUKA Roboter GmbH 2005/SM KR
39、30-3 09.05.00 en Page 25 of 140 I 25.10.2005 I College I MW I 7KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeLink arm disassemblyCarefully lift off the link arm and place it on
40、a suitable support.I 25.10.2005 I College I MW I 8KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeLink arm disassemblyGear unit A 2To remove the motor unit,remove the screws(2)and
41、 take off the fixed stop(1).Fixed stop with rubber buffer4 fastening screws M12 x 100/10.92121 Disassembly Page 26 of 140 KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en I 25.10.2005 I College I MW I 9KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-23
42、40,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeLink arm disassemblyGear unit A 219 fastening screws M12 x 50/10.9Fixed stop with rubber buffer4 fastening screws M12 x 100/10.9213Remove fixed stop(2),and loosen and remove fastening screws(3).321 I 25.10.2005 I College I MW I 10KUK
43、A Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeLink arm disassemblyGear unit A 2Secure the gear unit with appropriate equipment,lift off and place on a suitable support.Disassembly
44、KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en Page 27 of 140 2.4.Rotating column Disassembly Page 28 of 140 KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en I 25.10.2005 I College I MW I 1KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.ku
45、ka-roboter.de Copyright by KUKA Roboter GmbH CollegeRotating column disassembly I 25.10.2005 I College I MW I 2KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeRotating column disa
46、ssemblyUnscrew the eight screws on the upper cover and remove cover.3123Lower coverUpper cover8 screws M6 x 12/8.8213 Disassembly KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en Page 29 of 140 I 25.10.2005 I College I MW I 3KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,
47、Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeRotating column disassembly122Lower cover4 hexagon nuts M6-8Screw M5 x 8/8.8Remove four hexagon nuts(2)and locking screws and one fastening screw from the lower cover(1).3213 I 25.10.2005 I College I MW I 4KUKA
48、 Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA Roboter GmbH CollegeRotating column disassemblyUnscrew the screws from the holder,remove the holders and the ring segment from the rotating column.1236 scr
49、ews M6 x 12/8.83 holders6 screws M6 x 12/8.8213 Disassembly Page 30 of 140 KUKA Roboter GmbH 2005/SM KR30-3 09.05.00 en I 25.10.2005 I College I MW I 5KUKA Roboter GmbH,Hery-Park 3000,D-86368 Gersthofen,Tel.:+49(0)8 21/45 33-1906,Fax:+49(0)8 21/45 33-2340,http:/www.kuka-roboter.de Copyright by KUKA
50、Roboter GmbH CollegeRotating column disassemblyLoosen and remove fastening screws(1)from the motor.Carefully lift out the motor(2)and place it on a suitable support.Motor A 14 motor fastening screws M12 x 30/10.9Motor A 1Rotating column213132 I 25.10.2005 I College I MW I 6KUKA Roboter GmbH,Hery-Par
