ROBOT

KR 350

Adjustment Instructions

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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 claim 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.

PD Interleaf

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Contents

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

2 Measuring and adjusting the toothed belt tension . . . . . . . . . . . . . . . . . . 7

2.1 Measuring and adjusting the toothed belt tension of A 5/A 6 . . . . . . . . . . . . . . . . . . . . . . . . . 7

3 Pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.1 Draining the counterbalancing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Filling and adjusting the counterbalancing system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.3 Checking and adjusting the oil pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Adjustment Instructions

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 1 General

Valid for KR 350/2

KR 350 L280/2
KR 350 L240/2

1 General

In the following description, only the KR 350 will be depicted in the illustrations. The
information in the description applies to all robot variants, however. Exceptions to this
will be clearly marked.

The Doc. Module “Safety, General” is to be observed!

If the adjustment work is carried out 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.

If adjustments and checks are to be carried out 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.

With regard to the manipulator, the operator must only carry out adjustments to the hydro-
pneumatic counterbalancing system for assisting axis 2 and to the toothed belts in the wrist,
insofar as maintenance specifications (see robot Doc. Module “Maintenance”) or special cir-
cumstances require this.
The counterbalancing system is filled with hydraulic oil and nitrogen. The pressure in this sys-
tem is correctly set for each robot when delivered to the customer and is suitable for load
conditions occurring during normal operation of the robot (cf Table 2).
Tools and additional equipment must be removed before the adjustment process is started
if they are likely to impede the adjustment work.

With a view to avoiding accidents when work is carried out on the counter-
balancing system, the pertinent regulations concerning the handling of
hydraulic oil and nitrogen 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, as
many of these marked texts refer to the preceding job step.

Example

(9) Disconnect filling and testing device from diaphragm accumulator.

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).

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Adjustment Instructions

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

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, the in--line wrist 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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Adjustment Instructions

(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 Table 1 is not obtained, steps 5 to 9 are to be carried out.

Axis Toothed belt Frequency

A6 18AT5/1050--E5/8 220 Hz
A5 22AT5/1230--E5/8 140 Hz

Table 1 Toothed belt tension

(5) Slacken hexagon nut (Fig. 3/1) on eccentric shaft (2).

(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.

When tightening the hexagon nut (1), make sure that adequate locking is
achieved.

(7) Tighten hexagon nut (1) with 18 Nm, holding the eccentric shaft (2) firmly to prevent it
from turning.
(8) Measure toothed belt tension again as per steps 2 and 4.
(9) Repeat measuring and adjustment procedure if necessary until the value in Table 1 is
obtained.

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 2 Measuring and adjusting the toothed belt tension (continued)

3
A5 A6

Fig. 3 Adjusting the toothed belt tension

(10) Mount cover (Fig. 1/2) and fasten it with 13 M5x20 Allen screws (1) and lock washers.

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Adjustment Instructions

3 Pressure adjustment

Section 1 of this Doc. Module is to be observed.

The following table gives reasons for adjustment of the pressure on the part of the operator
and specifies where the procedures concerned are described.

Reason Procedure
Excessive deviation of the
See Section 3.3.
pressure value

Replacement of a defective
counterbalancing system by a See Section 3.1 and 3.2
new one

Replacement of a floor version of

the counterbalancing system by
See Section 3.1 and 3.2
a ceiling version when the robot
installation position is altered

Load conditions lying far below

Please consult KUKA.
the normal range

3.1 Draining the counterbalancing system

The counterbalancing system is depressurized on the oil side by draining the hydraulic oil,
as described below.
(1) For floor--mounted robots: Move link arm into vertical position and secure it using a
crane (Fig. 4). The arm may be in any position.
For ceiling--mounted robots, inverted: Move link arm into vertical position (Fig. 5).
The arm may be in any position.
For ceiling--mounted robots, upright: Move link arm into vertical position and secure
it using a crane (Fig. 4). 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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 3 Pressure adjustment (continued)

90˚ ±2˚

Fig. 4 Position for depressurizing floor--mounted robots

and ceiling--mounted robots, upright

90˚ ±2˚

Fig. 5 Position for depressurizing ceiling--mounted robots, inverted

(2) Remove screw cap (Fig. 6/1, Fig. 7/1) and connect tube (3) to vent valve (2).
(3) Drain hydraulic oil into a suitable receptacle (4).

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

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Adjustment Instructions

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

1, 2

5
4

Fig. 6 Draining the hydraulic oil on floor--mounted robots

1, 2

Fig. 7 Draining the hydraulic oil on ceiling--mounted robots, inverted

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 3 Pressure adjustment (continued)

3.2 Filling and adjusting the counterbalancing system

To fill the counterbalancing system with 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 floor--mounted robots: Move link arm into vertical position and secure it using
lifting tackle and a crane (Fig. 4). The arm may be in any position.
For ceiling--mounted robots, inverted: Move link arm into vertical position (Fig. 5).
The arm may be in any position.
For ceiling--mounted robots, upright: Move link arm into vertical position and secure
it using lifting tackle and a crane (Fig. 4). 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 gas and adjusting gas pressure

Before the diaphragm accumulator can be filled with nitrogen, the counter-
balancing system must be depressurized on the oil side (see Section 3.1).

(2) Connect the tube used to drain the oil (see Section 3.1) for the mounting arrangement
of the robot concerned as shown in Fig. 6 or Fig. 7.

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

(3) Connect the filling and testing device (accessory) for the diaphragm accumulator to a
standard commercial nitrogen cylinder (9) via the tube (Fig. 8/7, Fig. 9/7 ) .

If the pressure in the nitrogen cylinder is higher than the permissible pressure of
the diaphragm accumulator, a pressure reducer and a safety valve set to the
permissible pressure must be fitted to the nitrogen cylinder.

For reasons of safety, the Allen screw (4) 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 (6) may never be
adjusted without the filling and testing device.

(4) Remove protective cap (5) from the diaphragm accumulator (6) and unscrew Allen
screw (4) slightly (without a torque wrench, by a quarter of a turn at the most).

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 (4) must be replaced.
This must only be done when the diaphragm accumulator is completely
depressurized.

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Adjustment Instructions

(5) Connect the filling and testing device to the gas connection of the diaphragm
accumulator (6). Turn gas valve rod (1) counterclockwise, thereby opening the gas
connection via the Allen screw (4) (a full turn after the start of pointer deflection).

The pressure gage (3) indicates the nitrogen pressure in the diaphragm
accumulator (6).
If the nitrogen pressure is too high according to Table 2, step 6 must be carried out.
If the nitrogen pressure is too low, step 8 is required.
Then in either case, continue with step 12.

(6) Discharging nitrogen. To do so:

(7) Open pressure relief valve (2) and discharge nitrogen until the specified pressure is
reached.

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

(8) Topping up nitrogen. To do so:

(9) Open shut--off valve (8) on the nitrogen cylinder (9) and raise the nitrogen pressure to
200 bar.
(10) Close shut--off valve (8).
(11) Open pressue relief valve (2) and discharge nitrogen until the pressure specified in
Table 2 is reached.

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

(12) Turn Allen screw (4) clockwise by means of the gas valve rod (1) and tighten it. Then
open pressure relief valve (2) and discharge the remaining pressure in the tube (7).
(13) Disconnect filling and testing device from diaphragm accumulator.

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).

(14) Firmly retighten Allen screw (4) (tightening torque MA = 20 Nm).

(15) Check that the gas valve is not leaking.
(16) Screw on protective cap (5).
(17) Remove tube (7) from the nitrogen cylinder (9).
The counterbalancing system is filled with oil directly after this procedure.

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 3 Pressure adjustment (continued)

1 2 3 4 5 6

Fig. 8 Changing the gas pressure on floor--mounted robots

1 2 3 4 5 6

Fig. 9 Changing the gas pressure on ceiling--mounted robots, inverted

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Adjustment Instructions

D Filling with oil and adjusting oil pressure

The counterbalancing system is filled with oil immediately after it has been filled with
gas and the gas pressure has been adjusted. The numbering of the steps is therefore
continued.

The following steps are ordered according to the mounting arrangement of the robot
concerned and its position for maintenance.

Step (18) for floor--mounted robots,

step (27) for ceiling--mounted robots, inverted and
step (35) for ceiling--mounted robots, upright.

For floor--mounted robots:

The values specified in Table 2 must be observed when topping up the hydraulic oil.

(18) Unscrew cap on filling connection (Fig. 10/3) and connect hydraulic tube (1).
(19) Unscrew cap on vent connection (2) and connect tube (4) unless the tube is still con-
nected from the previous “gas--filling” stage.
(20) Open valve on vent connection (2) (= vent valve) slightly, put hydraulic pump (6) into
operation and allow hydraulic oil to flow out into the oil receptacle (5) until no more
bubbles escape.

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

The tube (4) must be immersed in the liquid of the oil receptacle (5) to allow the
bubbles to be observed.

(21) Close vent valve at vent connection (2).

(22) Continue to operate hydraulic pump (6) until the oil pressure is approx. 10 bar above
the specified value (see Table 2). Then lower pump pressure to “0”.

The oil pressure must be checked after approx. 10 minutes and lowered to the
specified value (see Table 2) by opening the vent valve.

(23) Unscrew hydraulic tube (1) and screw cap back onto filling connection (3).
(24) Unscrew tube (4) and screw cap back onto vent connection (2).
(25) Check counterbalancing system for leaks.
(26) Remove lifting tackle and crane if applicable.

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 3 Pressure adjustment (continued)

For ceiling--mounted robots, inverted:

The values specified in Table 2 must be observed when topping up the hydraulic oil.

(27) Unscrew cap on filling connection (Fig. 11/3) and connect hydraulic tube (1).
(28) Unscrew cap on vent connection (2) and connect tube (4) unless the tube is still con-
nected from the previous “gas--filling” stage.
(29) Open valve on vent connection (2) (= vent valve) slightly, put hydraulic pump (6) into
operation and allow hydraulic oil to flow out into the oil receptacle (5) until no more
bubbles escape.

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

The tube (4) must be immersed in the liquid of the oil receptacle (5) to allow the
bubbles to be observed.

(30) Close vent valve at vent connection (2).

(31) Continue to operate hydraulic pump (6) until the oil pressure is approx. 10 bar above
the specified value (see Table 2). Then lower pump pressure to “0”.

The oil pressure must be checked after approx. 10 minutes and lowered to the speci-
fied value (see Table 2) by opening the vent valve on the vent connection.

(32) Unscrew hydraulic tube (1) and screw cap back onto filling connection (3).
(33) Unscrew tube (4) and screw cap back onto vent connection (2).
(34) Check counterbalancing system for leaks.

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Adjustment Instructions

1 2 3 4

6 5

Fig. 10 Oil filling for floor--mounted robots

1 2

6 5

Fig. 11 Oil filling for ceiling--mounted robots, inverted

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 3 Pressure adjustment (continued)

For ceiling--mounted robots, upright:

The values specified in Table 2 must be observed when topping up the hydraulic oil.

(35) Unscrew cap on filling connection (Fig. 12/2) and connect hydraulic tube (1).
(36) Unscrew cap on vent connection (3) and connect tube (4).
(37) Open valve on vent connection (3) (= vent valve) slightly, put hydraulic pump (6) into
operation and allow hydraulic oil to flow out into the oil receptacle (5) until no more
bubbles escape.

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

The tube (4) must be immersed in the liquid of the oil receptacle (5) to allow the
bubbles to be observed.

(38) Close vent valve at vent connection (3).

(39) Continue to operate hydraulic pump (6) until the oil pressure is approx. 10 bar above
the specified value (see Table 2). Then lower pump pressure to “0”.

The oil pressure must be checked after approx. 10 minutes and lowered to the
specified value (see Table 2) by opening the vent valve on the vent connection.

1 2 3

6 5

Fig. 12 Oil filling for ceiling--mounted robots, upright

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Adjustment Instructions

(40) Unscrew hydraulic tube (1) and screw cap back onto filling connection (2).
(41) Unscrew tube (4) and screw cap back onto vent connection (3).
(42) Check counterbalancing system for leaks.
(43) Remove lifting tackle and crane.

Robot type Floor--mounted robots Ceiling--mounted robots

Gas pressure Oil pressure Gas pressure Oil pressure

P0 P1 P0 P1

KR 350/2
incl. 80 bar 88 bar 50 bar 73 bar
supplementary load

KR 350 L280/2
incl. 80 bar 88 bar 50 bar 73 bar
supplementary load

KR 350 L240/2
incl. 80 bar 88 bar 50 bar 73 bar
supplementary load

Table 2 Settings for the counterbalancing system (standard settings by manufacturer)

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 3 Pressure adjustment (continued)

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) For floor--mounted robots: Move link arm into vertical position (Fig. 4). The arm may
be in any position.
For ceiling--mounted robots, inverted: Move link arm into vertical position (Fig. 5).
The arm may be in any position.
For ceiling--mounted robots, upright: Move link arm into vertical position (Fig. 4).
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.

(2) Read the pressure gage on the counterbalancing system and compare the reading with
the value specified in Table 2.

Lower limit value: 5 bar below specified value in Table 2.

If the value is in order, the robot can be put into operation.

(3) Adjust the oil pressure if necessary.

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.

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