Posts by nachoscritzon

    I have seen this problem before. Most likely it's a problem with the config.dat file.

    If you have a known good backup just pull the config.dat files from it, load them into the controller, and perform a cold start.

    Well - this leaves a million things that could be the culprit. Have you configured it properly in WorkVisual? What are the errors generated on the KCP in the status bar?

    Here's my experience:

    I was at a customer site and they were having problems with getting the External to turn. The WorkVisual project was configured properly, correct power supply, correct connections from the Compact Drive Box to the External Axis, correct connections between the Compact Drive Box and the KRC, etc....

    From the outside everything looked OK. But as soon as you tried to jog the External Axis I would get KSS Messages 15074, 15002, and 127 that all relate to the External Axis. Ruled out all of the Software and Tech Options.

    Open up the Compact Drive Box (it's like 10 phillips head screws that hold the top onto the bottom chassis) and look at the connections between the KPP and KSP and make sure that they're all seated properly. Then check the connections that go from the KSP out to the External Axis. In my case - the connections on the output side of the KSP were wired on the wrong side of the male terminal. Once I moved the wires to their proper location it worked great. I wish I still have the pictures, but I no longer work at KUKA Robotics and they were stored on my company laptop.

    Let me know what you've ruled out so far and we can go from there. I can dig out my external HDD and see what notes I had from that job tomorrow morning when I get out of work tonight.


    hi all,

    does anyone have a document, what i need to do after two years, to kuka robot KR60? machanical, electrical, and so on....

    thanks in advance :top:

    zeev -

    After (2) years you will need a technical inspection, wrist minor maintenance, and electrical minor maintenance.

      • Technical inspection is a thorough inspection of the robot connections, cleanliness of the robot arm, cleanliness of the controller, and a few other minor checks

      • Wrist minor maintenance is oil change of axes 4 through 6 or oil change of axis 4 and belt changes of axis 5 and 6

      • Electrical minor maintenance is removing the controller covers and cleaning the heat sinks and ballast resistors, changing the cabinet air inlet filters, and also replacement of the controller batteries

    Can any one help me with the X11 diagram for a KRC4 controller that, when plugged, all safety components connected to the robot system will be canceled. Is it similar to the X11 of KRC2 ed05 controller???

    bigboss -

    With the KRC4 controller - you don't have to go through all of that to bypass the safety components. You could also just unplug the X11 from the bottom of the controller and put the robot in "Startup" mode. Just a heads up if you don't have the spare harting connector with pins and wires to make a jumper.

    Hello people
    I have a KR150 L 120 and we found a mild oil leak from the A5 axis though there was no any collision at all with the neighbouring robot (safe robot configuration). I would like to know is there any way to check the healthiness of the gearboxes of all axis also is it necessary to change the gearbox of A5 alone. Currently the robot is around 4 years in production line.


    san_man -

    The easiest way to check if the gearboxes are still ok is to jog the robot and listen for any grinding and watch if the robot skips because of a bad/broken tooth in the gearbox. Also - with the robot in T1 and the motors not pulled in (do not have the dead man switch pulled in) - manually try to move each axis by hand. They should be nice and tight and not move more than a mm or so. If they move excessively then either the gearbox is going bad or the brakes in the servo motor are going bad.

    There's no way to check the level of oil that's currently in the gearbox. You would have to drain it and then measure how much comes out. You could check the color and smell of the oil though. It's green when new. When the oil is ready to be replaced it will be brown/black and smell pretty bad - kind of like when rear-end fluid has gone bad in a truck.

    I've attached a snip-it of what the capacities are for your robot for your reference. These numbers are for when the gearbox is completely bone dry. During an oil change of the gearboxes - we put back in the same amount that drained out. The oil is like syrup and not all of it drains out when doing an oil change - generally it's between 70% and 80% that comes out. A little more depending on how long you let it drain.

    As for replacing the axis 5 gearbox - that's something that KUKA most likely won't do in your facility. Normally - they would send out a refurbished wrist and you would send the leaking wrist back to KUKA for refurbishment. You would end up with new gearboxes on axes 4 through 6 then and it would be maintenance free for the next 10,000 hours.

    I just went through a bunch of these problems up at Ford Oakville. There are a few different things to check:

      • If you've replaced the card reader - make sure that the upper right pin isn't bent. If that pin is bent then you're SOL

      • Next check your actual PCMCIA adapter. Sometimes the pin holes wallow out when you plug it into the card reader it's bending the pins

      • Check the actual connection on the card reader to the board inside the cabinet. It's possible to plug these in off (1) row of pins. You'll still get "MC Inserted", but won't be able to do anything else

      • If you have a nearby robot that works - then swap the card reader out of that one and put it in the robot that's giving you trouble. This will rule out if the connections on the board inside the cabinet are still working properly or not