KUKA Robot Automation Maintenance checklist: Robot System

(Malaysia) Sdn Bhd

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Order data
End customer AWISAR Customer PPKS
Engineer
Customer no. Customer no. JT / Hafis
Plant / site of Demak Laut,Kuching Sarawak Contact person Mr. Zuraimi Maintenance date
use 7/9/2018
Contact +60 16- 8690730 Order no.

Robot data
Robot type KR 16-2 Serial no. 863602 Robot Name KR 16-2
Controller KRC2 Serial no. 74484 Station Name
Operating hours 99.30 hrs Year of manuf. Application
Mounting position Floor Ceiling Wall Pedestal Special variant Foundry FoundryPlus Arctic

Type of servicing
Basic inspection Wrist maintenance Main axis maintenance Backlash measurement
Minor electr. maintenance Major electr. maintenance Data backup on spare HDD Inspection SafeOperation

Basic inspection
Not
Manipulator Activity Done Not OK
relevant Comments / Results / Article no.
Evaluation of
Evaluation Heavy fouling
degree of fouling
Test run / visual inspection
Gear units
Axis 1 Normal
Axis 2 Normal
Running noises
Axis 3 Normal
Sealing
Axis 4 Normal
Gear backlash
Axis 5 Normal
Axis 6 Normal
Check
Axis 1 Mastering done.
Axis 2 Mastering done.
Perform mastering Axis 3 Mastering done.
Axis 4 Mastering done.
Axis 5 Mastering done.
Axis 6 Mastering done.
Cleaning Done
Rotating column
Lubrication Done
Visual inspection
Internal energy supply Normal
Ext. energy supply, A1-3 Normal
Energy supply
Ext. energy supply, A3-6 Normal
(Hose packages)
Lubrication
Internal energy supply Normal
Ext. energy supply, A1-3 Normal

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KUKA Robot Automation Maintenance checklist: Robot System
(Malaysia) Sdn Bhd
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Basic inspection
Not
Manipulator Activity Done Not OK
relevant Comments / Results / Article no.
Robot fastening Visual inspection Normal
Connectors Check Normal
Mechanical damage Visual inspection Normal
Counterbalancing Visual inspection
Not Related
system, mechanical Running noises
Motors, axes 1-6 Visual inspection Normal
Not
Robot controller Activity Done Not OK
relevant Comments / Results / Article no.
Archiving Memory dump on HDD Done, Normal
CD-ROM drive Function test Normal
Floppy disk Function test Normal
USB Function test Normal
Internal cabinet fan Check Cleaned
External cabinet fan Check Cleaned
PC fan Check Cleaned
E-STOP Function test Normal
Visual inspection
Display Normal
KCP
Cable Normal
Keyboard Some buttons not functioning
Enabling device Function test Normal
Battery Voltage test Exchanged
Power supply unit Voltage test Normal
Cabinet seals Check Normal
Microfilter (KRC2) Exchange if necessary Normal
Connectors Check Normal
Service sticker Attach Normal

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KUKA Robot Automation Maintenance checklist: Robot System
(Malaysia) Sdn Bhd
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Wrist axis maintenance

Not rele-
Manipulator Activity Done Not OK
vant Comments / Results / Article no.
Axis 4 gear unit Oil change Done
Axis 5 gear unit Oil change Done
Axis 6 gear unit Oil change Done

Minor electrical maintenance

Not rele-
Robot controller Activity Done Not OK
vant Comments / Results / Article no.
Cleaning
Control cabinet Inside Cleaned
Heat exchanger Cleaned

Major electrical maintenance

Not rele-
Robot controller Activity OK Not OK
vant Comments / Results / Article no.
Cabinet seals Exchange if necessary Normal
Internal cabinet fan Exchange if necessary Normal
External cabinet fan Exchange if necessary Normal
PC fan Exchange if necessary Normal
Motherboard battery Exchange if necessary Exchanged

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(Malaysia) Sdn Bhd
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Reference:

Figure 1.0: Draining the gear oil from Axis-1. Figure 2.0: Draining the gear oil from Axis-2.

Figure 3.0: Draining the gear oil from Axis-3. Figure 4.0: Draining the gear oil from Axis-4.

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KUKA Robot Automation Maintenance checklist: Robot System
(Malaysia) Sdn Bhd
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Figure 5.0: Draining the gear oil from Axis-5. Figure 6.0: : Draining the gear oil from axis-6.

Figure 7.0: Filling new gear oil into Axis-1. Figure 8.0: Filling new gear oil into Axis-2.

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KUKA Robot Automation Maintenance checklist: Robot System
(Malaysia) Sdn Bhd
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Figure 9.0: Filling new gear oil into Axis-3. Figure 10.0: Filling new gear oil into axis-4.

Figure 11.0: Filling new gear oil on axis-5 Figure 12.0: Filling new gear oil on axis-6.

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KUKA Robot Automation Maintenance checklist: Robot System
(Malaysia) Sdn Bhd
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Figure 13.0: Applied grease on rotating column. Figure 14.0: Cleaning the controller.

Figure 15.0: Changed wrist belt Axis-4 & tensioned. Figure 16.0 : Changed wrist belt Axis-5 &
tensioned.

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KUKA Robot Automation Maintenance checklist: Robot System
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Figure 17.0: Changed the backup batteries (2pcs). Figure 18.0: Changed the motherboard battery.

Note:

1. Troubleshooting for KCP no display problem: fixed after changed new KVGA card (S/N: 74658).
2. Backup of archive and image done. System date and time updated as well.
3. The Haas system that the controller linking to currently having malfunction and will be off automat-
ically 15 seconds after powered on, therefore the communication testing is not possible for this.
4. KCP having some buttons not functioning, suggest to change a new one.

Next service

Due in: September 2020

Recommended work
Basic inspection Wrist maintenance Main axis maintenance Backlash measurement

Minor electr. maintenance Major electr. Maintenance Data backup on spare HDD Inspection of SafeOperation

Date: Name: Signature:

13/9/2018 Mohamad Hafis Mohamad Hafis

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