ROBOT

KR 30 K, KR 60 K

Adjustment Instructions

Manipulator

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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 Adjusting toothed belt tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.1 Measuring and adjusting toothed belt tension on wrist axis motor units A 4 and A 5 . . . . . 7
2.2 Measuring and adjusting toothed belt tension on in--line wrist A 5 and A 6 . . . . . . . . . . . . . . 11

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Adjustment Instructions

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 1 General

Valid for KR 30 K/1

KR 60 K/1
KR 60 L45K/1
KR 60 L30K/1

1 General

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

Apart from adjustment of the toothed belts, the robot does not require any further mechanical
adjustment. See Operating Handbook, Software KR C2, Chapter Start--up, Section Robot
Mastering/Unmastering for adjustment operations on the electrical/electronic equipment of
the robot system.
Two axes (A 5 and A 6) of the in--line wrist are driven via toothed belts, as are two of the three
drive shafts in the arm (for A 4 and A 5). The tension of these toothed belts is to be checked
or adjusted in accordance with the following procedure after removal or installation of related
assemblies and at the maintenance intervals specified in the robot Doc. Module Mainte-
nance.

When a new toothed belt is installed, the belt tension must be rechecked after
approximately 100 hours of operation and adjusted again if necessary.

Tools and additional equipment must be removed before the adjustment process is started
if they are likely to impede the adjustment work.
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 hand symbol, as many of these
marked texts refer to the preceding job step.

Example:
(1) Perform the measurement ten times.

The five highest measured values must lie within a range of 5 Hz. The median of these
five measurements is the frequency that is sought.

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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 pad-
lock to prevent unauthorized persons from switching it on again.

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 2 Adjusting toothed belt tension

2 Adjusting toothed belt tension

2.1 Measuring and adjusting toothed belt tension on wrist axis motor units
A 4 and A 5

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

Only the adjustment of the toothed belt stage of axis 4 is described. The procedure is, how-
ever, essentially the same for axis 5 (Fig. 1).

Before starting the adjustment work, it must be ensured that the toothed belts
are relieved of any weight, i.e. axis 4 must be vertical and in its zero position. No
tools may be installed on axis 6.

If the toothed belts are to be 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.

There are two methods available for measuring and adjusting the tension of the toothed belts
on the wrist axis motor units.

D Method 1 (frequency measurement)

(1) If necessary, tighten the toothed belt to the tension that is felt to be correct; only when
replacing a toothed belt.
(2) Remove plug (Fig. 1/4).
(3) Pluck toothed belt with a hook or pin as near as possible to middle of free length of belt.
Hold microphone (Fig. 2/2) approximately 3 mm away from back of toothed belt at the
same point. Record indicated frequency (Fig. 3/3).
(4) Perform the measurement ten times.

The five highest measured values must lie within a range of 5 Hz. The median of these
five measurements is the frequency that is sought.
If the frequency thus determined is higher than the specified value (Fig. 4), the belt ten-
sion must be reduced. If the measured frequency is too low, the tension must be in-
creased (see steps 5 to 6).
The required frequencies are specified in Fig. 4.
No useful measurements will be achieved if the toothed belt tension is very low or if the
toothed belt is not plucked with sufficient force.
(5) Slacken the four Allen screws (Fig. 1/2) until motor unit A 4 can be shifted without play.
(6) Turn tensioning screw (1) until required toothed belt tension is achieved (see Fig. 4).
(7) Tighten the four Allen screws (2).
(8) Measure toothed belt tension again as per steps 3 and 4, and repeat the adjustment
procedure if necessary.

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Adjustment Instructions

1 2 3 4

A4 A6

A5

Fig. 1 Adjusting the toothed belt tension on wrist axis motor unit A 4

(9) Tighten the four Allen screws (2) in diagonally opposite sequence with torque wrench,
increasing the tightening torque in several stages to the specified value (MA = 23 Nm).
(10) Insert plug (4).

Directions for use of the frequency meter (Fig. 2):

Range switch

Before the measurement is started, the range switch (Fig. 3/6) must be set to the position
specified in Figure 4, e.g. position 1 for axis 4.

Range switch positions:

1 = 50 to 100 Hz
2 = 80 to 160 Hz
3 = 125 to 500 Hz

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 2 Adjusting toothed belt tension (continued)

1 Frequency meter
2 Microphone

Fig. 2 Frequency meter

Amplification control

Before the measurement is started, the amplification control switch (Fig. 3/5) must also be
set to a starting value of 7.
The Signal LED (1) lights up as soon as a belt vibration is transmitted to the frequency
meter; it stays lit up for the duration of the vibration (approx. 0.2 s). If this LED lights up for
a considerably shorter time, the amplification must be increased or the belt is to be plucked
with greater force.
If it also lights up before there is any vibration, this is caused by background noise.

3 4

2 5
1 Signal LED 1 6
2 On/Off switch
3 Frequency display
4 Overload LED 7
(overamplification)
5 Amplification control
6 Range switch
7 Microphone socket

Fig. 3 Frequency meter, front plate

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Adjustment Instructions

Axis Required frequency Range switch

position
Axis 4 93 to 98 Hz 1
Axis 5 93 to 98 Hz 1

Fig. 4 Required frequencies for toothed belt tension on wrist axis motor units

D Method 2 (spring balance)

(1) Slacken tensioning screw (Fig. 5/1) and unscrew it by several turns.
(2) Slacken the four Allen screws (2) until motor unit A 4 (3) can be shifted without play.
(3) Place rope sling (4) around motor unit A 4 (3) and pull motor unit outwards horizontally
with a spring balance (5), applying a force of 130 N. The rope sling must be in full contact
with the flange of motor unit A 4.

In the case of motor unit A 5, the force on the spring balance is to be applied vertically
downwards.

(4) While maintaining the force on the spring balance, tighten tensioning screw (1) until
motor unit A 4 is fixed in this position and unable to move once the force is no longer
applied.
(5) Tighten the four Allen screws (2) in diagonally opposite sequence with torque wrench,
increasing the tightening torque in several stages to the specified value (MA = 23 Nm).
(6) Remove spring balance (5) and rope sling (4).

1 2 3

A4 A6

A5

5 4

Fig. 5 Adjusting the toothed belt tension on wrist axis motor unit A 4

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 2 Adjusting toothed belt tension (continued)

2.2 Measuring and adjusting toothed belt tension on in--line wrist

A 5 and A 6

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

Only the adjustment of the toothed belt stage of axis 5 is described. The procedure is,
however, essentially the same for axis 6. The toothed belts (Fig. 6/3, 4) of axes 5 and 6 are
accessible after the cover (2) has been removed.

Before starting the adjustment work, it must be ensured that the toothed belts
are relieved of any weight, i.e. axis 4 must be vertical and in its zero position. No
tools may be installed on axis 6.

If the toothed belt is to be adjusted on an operable robot, the main switch on the
control cabinet must be turned to the OFF position and secured with a pad-
lock to prevent unauthorized persons from switching it on again.

(1) Remove 13 M5x20 Allen screws (Fig. 6/1) and lock washers and take off cover (2).

2 1

Fig. 6 Cover

(2) Switch on belt tension measuring device (Fig. 7/1).

(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.

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Adjustment Instructions

Fig. 7 Belt tension measuring device

If the value indicated in Fig. 8 is not obtained, steps 5 to 9 are to be carried out.

Axis Toothed belt Frequency

A5 12 AT5/920--E5/8 1305 Hz
A6 10 AT5/780--E5/8 1855 Hz

Fig. 8 Toothed belt tension

(5) Slacken hexagon nut (Fig. 9/1) on eccentric shaft (4).

(6) Push socket wrench onto hexagon (3) and turn eccentric shaft (4) in required direction.

The directions for tight and loose are given on plate (2).

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 (4) 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 Fig. 8 is
obtained.

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 2 Adjusting toothed belt tension (continued)

A5

A6

4 3 2

Fig. 9 Adjusting the toothed belt tension

(10) Mount cover (Fig. 6/2) and fasten it with 13 M5x20 Allen screws (1) and lock washers.
1

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