ROBOT

(V)KR 100 HA

Adjustment Instructions

Robot with In--Line Wrist 125/150/200 IV

Issued: 04 Feb 2008 Version: 02

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 Adjustment Instructions

e Copyright KUKA Roboter GmbH

This documentation or excerpts therefrom may not be reproduced 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 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 incorporated in subsequent editions.
Subject to technical alterations without an effect on the function.

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Contents

1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2 Measuring and adjusting the toothed belt tension . . . . . . . . . . . . . . . . . . 6

2.1 Measuring and adjusting the toothed belt tension of A 5/A 6 . . . . . . . . . . . . . . . . . . . . . . . . . 6

3 Pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.1 Draining the counterbalancing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Filling and adjusting the counterbalancing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Checking and adjusting the oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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 Valid for (V)KR 100 HA (V)KR 100 HA--C
(V)KR 100 L90 HA
(V)KR 100 L80 HA

1 General

With a view to avoiding accidents when work is carried out on the robot, the
pertinent regulations are to be observed.

The description of the adjustment operations is subdivided 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. Many
of these marked texts refer to the preceding job step.

Example:
(9) Remove M5x20 Allen screws (Fig. 1/1) and lock washers
and take off in--line wrist (2).

The in--line wrist weighs 90 kg.

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 robot control cabinet to “OFF” and secure it with a
padlock to prevent unauthorized persons from switching it on again.

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2 Measuring and adjusting the toothed belt tension

The Doc. Module “Safety, General” and the robot Doc. Module “Adjustment
Instructions” (Section 1) must be observed!

When measuring or adjusting the toothed belt tension, it must be ensured that
for toothed belt A 5, rotational axis 5 and for toothed belt A 6, rotational axis 6
are vertical. This torque--neutral position is required in order to prevent different
strand forces from occurring, which would invalidate the measurement.

If the toothed belt tension is measured immediately after the robot has stopped
operating, it is liable to have an elevated surface temperature, in which case
appropriate safety measures must be taken.

2.1 Measuring and adjusting the toothed belt tension of A 5/A 6

If the toothed belt is to be measured and adjusted on an operable robot, the

main switch on the control cabinet must be turned to the “OFF” position and
secured with a padlock to prevent unauthorized persons from switching it on
again.

(1) Remove 13 M5x20 Allen screws (Fig. 1/1) and lock washers and take off cover (2).

Fig. 1 Cover

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 (2) Switch on belt tension measuring device (Fig. 2/1).
(3) Pluck toothed belt and hold sensor (2) at a distance of 2 to 3 mm from the vibrating
toothed belt. Read measurement on the belt tension measuring device.
(4) Repeat the measurement three times.

Fig. 2 Belt tension measuring device

If the value indicated in Fig. 3 is not obtained, steps 5 to 9 are to be

carried out.

Axis Toothed belt Frequency

A5 18AT5/1050--E5/8 140 Hz
A6 14AT5/860--E5/8 215 Hz

Fig. 3 Toothed belt tension

(5) Unscrew the hexagon nut (Fig. 4/1) on eccentric shaft (2) and replace it with a new one.
(6) Push socket wrench onto hexagon (3) and turn eccentric shaft (2) in required direction.

The directions for “tight” and “loose” are given on the in--line wrist.

(7) Tighten hexagon nut (1) with 18 Nm, at the same time securing the eccentric shaft (2)
to prevent it from turning.

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 (8) Measure toothed belt tension again as per steps 2 to 4.
(9) Repeat measuring and adjustment procedure if necessary until the value in Fig. 3 is
obtained.

A5

1 3

A6

Fig. 4 Adjusting the toothed belt tension

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3 Pressure adjustment
For the KR 100 HA--C robot variant the counterbalancing system must be adjusted in the
following cases:
G if the pressure in the counterbalancing system lies outside the permitted limits,
G after exchanging any part of the counterbalancing system, or
G after exchanging the entire counterbalancing system.

Section 1 of this Doc. Module and the Doc. Module “Safety, General” must be
observed!

3.1 Draining the counterbalancing system

The counterbalancing system is depressurized on the oil side by draining the hydraulic oil,
as described below.
(10) Ceiling--mounted robots, inverted: Move link arm into a vertical position (Fig. 5). The
arm may be in any position.
Ceiling--mounted robots, upright: Move link arm into the --133° position (Fig. 5). The
arm may be in any position.

It must be ensured that the link arm is not able to move either during or after a
reduction in the oil pressure.

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.

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 Fig. 5 Position for depressurizing robot

(11) Remove sealing cap (Fig. 6/6; with ceiling--mounted robots 1) and sealing cap (4) and
then connect hose (2) to screw coupling.
(12) Open screw coupling and drain hydraulic oil into a suitable receptacle (3).

The draining process is complete when the pressure gauge (5) reads zero and no more
hydraulic oil flows into the receptacle.

Store used hydraulic oil in accordance with the regulations and dispose of it
with minimum environmental impact.

Fig. 6 Draining hydraulic oil

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3.2 Filling and adjusting the counterbalancing system
To fill the counterbalancing system with hydraulic oil and gas, the robot must be brought into
the required position for the mounting arrangement concerned, if it is not in the position
described in Section 3.1.
(1) For ceiling--mounted robots, inverted: Move link arm into the --133° position (Fig. 5).
The arm may be in any position.
For ceiling--mounted robots, upright: Move link arm into vertical position (Fig. 5).
The arm may be in any position.

It must be ensured that the link arm is not able to move.

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.

D Filling with nitrogen and adjusting gas pressure

Before the diaphragm accumulator can be filled with nitrogen, the

counterbalancing system must be depressurized on the oil side (see Section
3.1).

(2) Connect hose (Fig. 7/4) to screw coupling (6) for ceiling--mounted robots or (3) for
floor--mounted robots, and drain hydraulic oil.

The oil side of the diaphragm accumulator is now open and can be vented during
subsequent filling of the gas side.

(3) Remove protective cap (2) from the diaphragm accumulator (5) and unscrew Allen
screw (1) slightly (without a torque wrench, by a quarter of a turn at the most).

6
1
5 2
4

Fig. 7 Topping up nitrogen

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 For safety reasons, the Allen screw (1) may under no circumstances be
unscrewed by more than a quarter of a turn without the filling and testing device
being connected. The pressure in the diaphragm accumulator may never be
adjusted without the filling and testing device.

No gas must be allowed to escape. If, in spite of care being taken, gas does
escape (hissing sound!), the sealing ring of Allen screw (1) must be replaced
with the diaphragm accumulator depressurized.

(4) Connect the filling and testing device on the gas connection (Fig. 8/2) of the
diaphragm--type accumulator (1). Turn gas valve rod (6) counterclockwise, thereby
opening the gas connection via the Allen screw (3) (a full turn after the start of pointer
deflection).

The pressure gauge (4) indicates the nitrogen pressure in the diaphragm accumulator
(1).
If the nitrogen pressure is too high according to Fig. 10, step (5) must be carried out.
If the nitrogen pressure is too low, step (7) is required.
Then in either case, continue with step (11).

(5) Discharging nitrogen.

(6) Open pressure relief valve (5) and discharge nitrogen until the specified pressure is
reached.

The reading on the pressure gauge (4) must be rechecked after 2 to 3 minutes and the
nitrogen pressure corrected if necessary.

1 2 3 4 5 6

Fig. 8 Changing the gas pressure

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 (7) Topping up nitrogen.
(8) Open shut--off valve (8) on the nitrogen cylinder (9) and raise the nitrogen pressure to
200 bar.
(9) Close the shut--off valve (8).
(10) Open pressure relief valve (5) and discharge nitrogen until the pressure specified in
Fig. 10 is reached.

The reading on the pressure gage (4) must be rechecked after 2 to 3 minutes and the
nitrogen pressure corrected if necessary.

(11) Turn the Allen screw (3) clockwise by means of the gas valve rod (6) and tighten it.
Then open the pressure relief valve (5) and discharge the remaining pressure in the
tube (7).
(12) Disconnect filling and testing device from diaphragm accumulator (1).

The filling and testing device may only be disconnected if the Allen screw (4)
has been tightened firmly by means of the gas valve rod (1).

(13) Firmly retighten Allen screw (3) (tightening torque MA = 20 Nm).

(14) Check that the gas valve is not leaking.
(15) Screw on protective cap.
(16) Remove tube (7) from the nitrogen cylinder (9).

D Filling with hydraulic oil and adjusting oil pressure

The values specified in Fig. 10 must be observed when topping up the hydraulic oil.

(17) Unscrew sealing cap on check valve (Fig. 9/6) and connect hydraulic hose (5) of the
oil pump (4).
(18) Unscrew sealing cap on screw coupling (8) for floor--mounted robots or (1) for
ceiling--mounted robots, and connect hose (2) (unless the hose is still connected from
the previous “gas--filling” stage).

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 (19) Slightly open valve of upper screw coupling (8 or 1) (= vent valve), put hydraulic pump
(4) into operation and allow hydraulic oil to flow out into the oil receptacle (3) until no
more bubbles escape.

Hydraulic pressure 20 bar

Flow rate 0,5 l/min

The reservoir of the hydraulic pump (6) must only be filled with filtered Aral
Vitam GF 46 (filter gage 3 µm).

The tube (2) must be immersed in the liquid of the oil receptacle (3) to allow the
bubbles to be observed.

(20) Close valve of screw coupling (8).

(21) Continue to operate hydraulic pump (4) until the oil pressure on the pressure gauge (7)
is approx. 10 bar above the specified value (Fig. 10).

1
5
2

4 3

Fig. 9 Filling with hydraulic oil

(22) Lower pump pressure to “0”.

The oil pressure must be checked after approx. 10 minutes and lowered to the
specified value (see Fig. 10) by opening the screw coupling.

(23) Unscrew hydraulic hose (Fig. 9/5) and screw sealing cap onto check valve (6).
(24) Unscrew hose (2) and screw sealing cap onto screw coupling (8).
(25) Check hydropneumatic counterbalancing system for leaks.

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 Robot type Ceiling--mounted robot

Gas pressure P0 Oil pressure P1 Oil pressure P2

Link arm into vertical Link arm into --133° position
position

KR 100 HA--C 50 bar 90 bar 81 bar

Fig. 10 Settings for the counterbalancing system (standard settings by manufacturer)

3.3 Checking and adjusting the oil pressure

The procedure for checking the oil pressure when performing maintenance work, -- i.e. when
the counterbalancing system has not been replaced -- is as follows:
(1) Ceiling--mounted robots, inverted: Move link arm into a vertical position (Fig. 5). The
arm may be in any position.
Ceiling--mounted robots, upright: Move link arm into the --133° position (Fig. 5). The
arm may be in any position.

It must be ensured that the link arm is not able to move.

Turn main switch on the robot control cabinet to “OFF” and secure it with a pad-
lock to prevent unauthorized persons from switching it on again.

(2) Read the pressure gauge on the counterbalancing system and compare the reading
with the correct value in Fig. 10.

Lower limit value: 5 bar below specified value

If adjustment to the correct value is required after checking the oil pressure then -- even if
the counterbalancing system has not been replaced -- the counterbalancing system must be
drained and then refilled. The procedure is described in Sections 3.1 and 3.2.
1

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