IRB 660 250/3.15 | ABB IRB 660 180/3.15, 250/3.15 Articulated robot Product manual

Product manual

Articulated robot

IRB 660 - 180/3.15

IRB 660 - 250/3.15

M2004

Product manual

IRB 660 - 180/3.15

IRB 660 - 250/3.15

M2004

Document ID: 3HAC025755-001

Revision: B

The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual.

Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein.

This manual and parts thereof must not be reproduced or copied without ABB's written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.

Additional copies of this manual may be obtained from ABB at its then current charge.

© Copyright 2006-2008 ABB All rights reserved.

ABB AB

Robotics Products

SE-721 68 Västerås

Sweden

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Safety 13

1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.2.2 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.2.2.1 Safety risks during installation and service work on robot . . . . . . . . . . . . . . . . . . . . . . . . 15

1.2.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.2.2.3 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.2.2.4 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.2.2.5 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.2.3 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.2.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.2.3.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.2.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.2.3.6 Safe use of the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.2.3.7 Work inside the robot's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.2.3.8 Translate the information on safety and information labels . . . . . . . . . . . . . . . . . . . . . . . 28

1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.3.2 DANGER - Moving robots are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.3.3 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.3.4 WARNING - The brake release buttons may be jammed after service work . . . . . . . . . . . . . . . . 33

1.3.5 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.3.6 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

2 Installation and commissioning 37

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2.2 Securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.3 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.3.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.3.2 Working range and type of motion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.3.3 Risk of tipping / stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

2.4 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.4.1 Lifting robot with fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.4.2 Lifting robot with roundslings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

2.4.3 Lifting robot with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

2.4.4 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2.4.5 Lifting the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

2.4.6 Securing the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

2.4.7 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

2.4.8 Fitting equipment on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

2.4.9 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

2.5 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

2.5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

2.5.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

2.5.3 Installation of position switch, axis 1 (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

3HAC025755-001 Revision: B 3


2.6 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

2.6.1 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

2.7 Making robot ready for operation (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

2.7.1 Commissioning (Foundry Prime). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

3 Maintenance 79

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

3.2 Maintenance schedule and expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

3.3.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

3.3.2 Inspection, oil level gearbox axes 2 - 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

3.3.3 Inspection, oil level gearbox axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

3.3.4 Inspection, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

3.3.5 Inspection, cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

3.3.6 Inspection, information labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

3.3.7 Inspection, mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

3.3.8 Inspection, additional mechanical stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

3.3.9 Inspection, dampers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

3.3.10 Inspection, position switch axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

3.3.11 Inspection, signal lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

3.4 Replacement/changing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

3.4.1 Type of oil in gearboxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

3.4.2 Oil change, gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

3.4.3 Oil change, gearbox axes 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

3.4.4 Oil change, gearbox axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

3.4.5 Replacement of SMB battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

3.5 Lubrication activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

3.5.1 Lubrication of bearing, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

3.6 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

3.6.1 Cleaning, robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

4 Repair 129

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

4.3 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

4.3.1 Replacement of cable harness, lower end (axes 1-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

4.3.2 Replacement of cable harness, upper end (incl. axis 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

4.3.3 Replacement of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

4.4 Upper and lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

4.4.1 Replacement of turning disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

4.4.2 Replacement of tilthouse unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

4.4.3 Replacement of upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

4.4.4 Replacement of linkage - upper rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

4.4.5 Replacement of linkage - lower rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

4.4.6 Replacement of linkage - link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

4.4.7 Replacement of parallel rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

4.4.8 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

4 3HAC025755-001 Revision: B


4.4.9 Replacement of parallel arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

4.5 Frame and base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

4.5.1 Replacement of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

4.5.2 Replacement of SMB unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

4.5.3 Replacement of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212

4.6.2 Replacement of motor, axes 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

4.6.3 Replacement of motor, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

4.7.1 Replacement of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

4.7.2 Replacement of gearbox, axes 2- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232

4.7.3 Replacement of gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

5 Calibration information 241

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241

5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242

5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244

5.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246

5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

6 Reference information 251

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

6.2 Applicable Safety Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252

6.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

6.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254

6.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

6.6 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

6.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

6.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

7 Spare parts and exploded views 263

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263

7.2 Spare parts - frame to base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

7.3 Spare parts - cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

7.4 Spare parts - customer harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

7.5 Spare parts - lower arm system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

7.6 Spare parts - parallel rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

7.7 Spare parts - Balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

7.8 Spare parts - frame to lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

7.9 Spare parts - shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

7.10 Spare parts - tilthouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

7.11 Spare parts - upper arm front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

7.12 Spare parts - Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

7.13 Spare parts - motor axis1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286

7.14 Spare parts - SMB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

8 Circuit diagram 291

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

Index 293




Overview

Overview

About this manual

This manual contains instructions for

• mechanical and electrical installation of the robot

• maintenance of the robot

• mechanical and electrical repair of the robot

Usage

This manual should be used during

• installation, from lifting the robot to its work site and securing it to the foundation to making it ready for operation

• maintenance work

• repair work.

Who should read this manual?

This manual is intended for:

• installation personnel

• maintenance personnel

• repair personnel.

Prerequisites

A maintenance/repair/ installation craftsman working with an ABB Robot must:

• be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work.

Organization of chapters

The manual is organized in the following chapters:

Chapter

Safety

Contents

Safety information that must be read through before performing any installation or service work on robot. Contains general safety aspects as well as more specific information about how to avoid personal injuries and damage to the product.

Required information about lifting and installation of the robot.

Installation and commissioning

Maintenance

Repair

Calibration Information

Decommissioning

Step-by-step procedures that describe how to perform maintenance of the robot. Based on a maintenance schedule that may be used in the work of planning periodical maintenance.

Step-by-step procedures that describe how to perform repair activities of the robot. Based on available spare parts.

Procedures that does not require specific calibration equipment.

Environmental information about the robot and its components.

3HAC025755-001 Revision: B

Continues on next page

7

Overview

Continued

References

Revisions

Document name

Product specification - IRB 660

Product manual - IRC5

Operating manual - IRC5 with FlexPendant

Operating manual - Calibration Pendulum

Operating manual - Service Information System

Application manual - Additional axes and stand alone controller

Technical reference manual - System parameters

Document ID

3HAC023932-001

3HAC021313-001

3HAC16590-1

3HAC16578-1

3HAC025709-001

3HAC021395-001

3HAC17076-1

Revision

-

A

B

Description

First edition

Detailed illustrations added in some procedures.

Art. no. on tools added.

Chapter "Replacement of tilthouse unit" has been changed in order to make it easier to follow the procedure.

Changes made in:

• Prerequisites in section Overview

• Oil change in section Maintenance


Product documentation, M2004

Product documentation, M2004

General

The robot documentation is divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any given delivery of robot products will not contain

all documents listed, only the ones pertaining to the equipment delivered.

However, all documents listed may be ordered from ABB. The documents listed are valid for

M2004 robot systems.

Product manuals

All hardware, robots and controllers, will be delivered with a Product manual that contains:

• Safety information

•

Installation and commissioning (descriptions of mechanical installation, electrical connections)

• Maintenance (descriptions of all required preventive maintenance procedures including intervals)

•

Repair (descriptions of all recommended repair procedures including spare parts)

• Additional procedures, if any (calibration, decommissioning)

•

Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards)

• Part list

•

Foldouts or exploded views

• Circuit diagrams

Technical reference manuals

The following manuals describe the robot software in general and contain relevant reference information:

•

RAPID Overview: An overview of the RAPID programming language.

• RAPID Instructions, Functions and Data types: Description and syntax for all

RAPID instructions, functions and data types.

•

System parameters: Description of system parameters and configuration workflows.

Application manuals

Specific applications (for example software or hardware options) are described in

Application manuals. An application manual can describe one or several applications.

An application manual generally contains information about:

• The purpose of the application (what it does and when it is useful)

•

What is included (for example cables, I/O boards, RAPID instructions, system parameters, CD with PC software)

• How to use the application

•

Examples of how to use the application



9

Product documentation, M2004

Continued

Operating manuals

This group of manuals is aimed at those having first hand operational contact with the robot, that is production cell operators, programmers and trouble shooters. The group of manuals includes:

•

Emergency safety information

•

General safety information

•

Getting started, IRC5

•

IRC5 with FlexPendant

•

RobotStudio

•

Introduction to RAPID

• Trouble shooting, for the controller and robot


How to read the product manual

How to read the product manual

Reading the procedures

The procedures contain references to figures, tools, material etc. The references are read as described below.

References to figures

The procedures often include references to components or attachment points located on the robot/controller. The components or attachment points are marked with italic text in the procedures and completed with a reference to the figure where the current component or attachment point is shown.

The denomination in the procedure for the component or attachment point corresponds to the denomination in the referenced figure.

The table below shows an example of a reference to a figure from a step in a procedure.

Action Note/Illustration

8.

Remove the rear attachment screws, gearbox. Shown in the figure

Location of gearbox on page xx

.

References to required equipment

The procedures often include references to equipment (spare parts, tools etc.) required for the different actions in the procedure. The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information, that is article number, dimensions.

The denomination in the procedure for the component or attachment point corresponds to the denomination in the referenced list.

The table below shows an example of a reference to a list of required equipment, from a step in a procedure.

Action

3.

Fit a new sealing, axis 2 to the gearbox.

Note/Illustration

Art. no. is specified in

Required equipment on page xx

.

Safety information

The manual includes a separate safety chapter that must be read through before proceeding with any service or installation procedures. All procedures also include specific safety information when dangerous steps are to be performed.

Read more in chapter

Safety on page 13

.


How to read the product manual


1 Safety

1.1. Introduction

1 Safety

1.1. Introduction

Overview

The safety information in this manual is divided in two categories:

• general safety aspects, important to attend to before performing any service work on

the robot. These are applicable for all service work and are found in section

General safety information on page 14

.

• specific safety information, pointed out in the procedure at the moment of the danger.

How to avoid and eliminate the danger is either detailed directly in the procedure, or

further detailed in separate instructions, found in section

Safety related instructions on page 29

.


1 Safety

1.2.1. Safety in the robot system

1.2 General safety information

1.2.1. Safety in the robot system

Validity and responsibility

The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment, which can influence the safety of the total system. To protect personnel, the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed.

The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that the safety devices necessary to protect people working with the robot system are designed and installed correctly.

Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, for example:

•

Operating Manual - IRC5 with FlexPendant (M2004)

•

Product Manual

Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot.

Limitation of liability

Any information given in this manual regarding safety, must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with.

Related information

Type of information Detailed in document

Installation of safety devices

Changing operating modes

Restricting the working space

Section

Product manual for the robot Installation and commissioning

Operating manual - IRC5 with

FlexPendant

(RobotWare 5.0)

Operating modes

Product manual for the robot Installation and commissioning


1 Safety

1.2.2.1. Safety risks during installation and service work on robot

1.2.2. Safety risks

1.2.2.1. Safety risks during installation and service work on robot

Overview

This section includes information of general safety risks to be considered when performing installation and service work on the robot.

General risks during installation and service

• The instructions in the Product Manual, chapter Installation and Commissioning must always be followed.

•

Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly.

• Those in charge of operations must make sure that safety instructions are available for the installation in question.

•

Those who install the robot must have the appropriate training for the robot system in question and in any safety matters associated with it.

Nation/region specific regulations

To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with.

Non-voltage related risks

•

Safety zones, which must be crossed before admittance, must be set up in front of the robot's working space. Light beams or sensitive mats are suitable devices.

•

Turntables or the like should be used to keep the operator out of the robot's working space.

•

The axes are affected by the force of gravity when the brakes are released. In addition to the risk of being hit by moving robot parts, you run the risk of being crushed by the parallel arm.

•

Energy, stored in the robot for the purpose of counterbalancing certain axes, may be released if the robot, or parts thereof, are dismantled.

•

When dismantling/assembling mechanical units, watch out for falling objects.

•

Be aware of stored heat energy in the controller.

• Never use the robot as a ladder, that is, do not climb on the robot motors or other part during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot.

To be observed by the supplier of the complete system

• The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function.

•

The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.



1 Safety

1.2.2.1. Safety risks during installation and service work on robot

Continued

Complete robot

Safety risk

Hot components!

Description

Removed parts may result in collapse of robot!

CAUTION!

Motors and gears are HOT after running the robot!

Touching motors and gears may result in burns!

With higher environment temperature more surfaces on the robot are getting HOT and may result in burns too!

WARNING!

Take any necessary measures to ensure that the robot does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Cabling

Safety risk

Cable packs are sensitive to mechanical damage!

Description

CAUTION!

The cable packs are sensitive to mechanical damage!

They must be handled with care, especially the connectors, in order to avoid damaging them!

Gearboxes and motors

Safety risk

Gears may be damaged if excessive force is used!

Description

CAUTION!

Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used!


1 Safety

1.2.2.2. Safety risks related to tools/workpieces

1.2.2.2. Safety risks related to tools/workpieces

Safe handling

It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating.

It should be possible to release parts by manual operation (valves).

Safe design

Grippers/end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller.

CAUTION!

Ensure that a gripper is prevented from dropping a workpiece, if such is used.


1 Safety

1.2.2.3. Safety risks related to pneumatic/hydraulic systems

1.2.2.3. Safety risks related to pneumatic/hydraulic systems

General

Special safety regulations apply to pneumatic and hydraulic systems.

Residual energy

• Residual energy may be present in these systems. After shutdown, particular care must be taken.

•

The pressure in pneumatic and hydraulic systems must be released before starting to repair them.

Safe design

•

Gravity may cause any parts or objects held by these systems to drop.

• Dump valves should be used in case of emergency.

•

Shot bolts should be used to prevent tools etc. from falling due to gravity.


1 Safety

1.2.2.4. Safety risks during operational disturbances

1.2.2.4. Safety risks during operational disturbances

General

•

The industrial robot is a flexible tool which can be used in many different industrial applications.

• All work must be carried out professionally and in accordance with the applicable safety regulations.

•

Care must be taken at all times.

Qualified personnel

• Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts.

Extraordinary risks

If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually.


1 Safety

1.2.2.5. Risks associated with live electric parts

1.2.2.5. Risks associated with live electric parts

Voltage related risks, general

•

Although troubleshooting may, on occasion, need to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.

• The mains supply to the robot must be connected in such a way that it can be turned off outside the robot’s working space.

Voltage related risks, IRC5 controller

A danger of high voltage is associated with, for example, the following parts:

• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the controller.

•

Units such as I/O modules, can be supplied with power from an external source.

• The mains supply/mains switch

•

The transformers

• The power unit

•

The control power supply (230 VAC)

• The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)

•

The drive unit (700 VDC)

• The drive system power supply (230 VAC)

•

The service outlets (115/230 VAC)

• The customer power supply (230 VAC)

•

The power supply unit for additional tools, or special power supply units for the machining process.

• The external voltage connected to the controller remains live even when the robot is disconnected from the mains.

•

Additional connections.

Voltage related risks, robot

A danger of high voltage is associated with the robot in:

• The power supply for the motors (up to 800 VDC).

•

The user connections for tools or other parts of the installation (max. 230 VAC, see chapter Installation and commissioning in the Product manual).

Voltage related risks, tools, material handling devices, etc

Tools, material handling devices, etc., may be live even if the robot system is in the

OFFposition. Power supply cables which are in motion during the working process may be damaged.


1 Safety

1.2.3.1. Safety fence dimensions

1.2.3. Safety actions

1.2.3.1. Safety fence dimensions

General

Install a safety cell around the robot to ensure safe robot installation and operation.

Dimensioning

Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed. Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell (see Product Specification - Description, Robot Motion).

Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot.


1 Safety

1.2.3.2. Fire extinguishing

1.2.3.2. Fire extinguishing

NOTE!

Use a CARBON DIOXIDE (CO

2

) extinguisher in the event of a fire in the robot system (robot or controller)!


1 Safety

1.2.3.3. Emergency release of the robot’s arm

1.2.3.3. Emergency release of the robot’s arm

Description

In an emergency situation, any of the robot's axes may be released manually by pushing the brake release buttons on the robot.

How to release the brakes is detailed in section:

•

Manually releasing the brakes on page 54

.

The robot arm may be moved manually on smaller robot models, but larger models may require using an overhead crane or similar.

Increased injury

Before releasing the brakes, make sure that the weight of the arms does not increase the pressure on the trapped person, further increasing any injury!


1 Safety

1.2.3.4. Brake testing

1.2.3.4. Brake testing

When to test

During operation the holding brake of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function.

How to test

The function of the holding brake of each axis motor may be checked as detailed below:

1. Run each robot axis to a position where the combined weight of the robot arm and any load is maximized (max. static load).

2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller.

3. Check that the axis maintains its position.

If the robot does not change position as the motors are switched off, then the brake function is adequate.


1 Safety

1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"

1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"

NOTE!

Do not change "Transm gear ratio" or other kinematic system parameters from the

FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s".


1 Safety

1.2.3.6. Safe use of the FlexPendant

1.2.3.6. Safe use of the FlexPendant

NOTE!

The enabling device is a push button located on the side of the FlexPendant which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.

To ensure safe use of the FlexPendant, the following must be implemented:

•

The enabling device must never be rendered inoperative in any way.

• During programming and testing, the enabling device must be released as soon as there is no need for the robot to move.

•

The programmer must always bring the FlexPendant with him/her, when entering the robot's working space. This is to prevent anyone else taking control of the robot without the programmer knowing.

Enabling device

The enabling device is a manually operated constant pressure push-button which, when continuously activated in one position only, allows potentially hazardous functions but does not initiate them. In any other position, hazardous functions are stopped safely.

The enabling device is of a specific type where you must press the push-button only half-way to activate it. In the fully in and fully out positions, robot operation is impossible.

Hold-to-run function

The hold-to-run function allows movement when a button connected to the function is actuated manually and immediately stops any movement when released. The hold-to-run function can only be used in manual mode.

How to operate the hold-to-run function is detailed in Operating manual - IRC5 with

FlexPendant.


1.2.3.7. Work inside the robot's working range

1 Safety

1.2.3.7. Work inside the robot's working range

WARNING!

If work must be carried out within the robot’s work envelope, the following points must be observed:

• The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel.

•

The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in position "manual mode with reduced speed". This should be the normal position when entering the working space. The position "manual mode with full speed (100%)" may only be used by trained personnel who are aware of the risks that this entails.

• Pay attention to the rotating axes of the robot! Keep a distance to the axes in order not to get entangled with hair or clothing. Also be aware of any danger that may be caused by rotating tools or other devices mounted on the robot or inside the cell.

•

Test the motor brake on each axis, according to section

Brake testing on page 24

.


1 Safety

1.2.3.8. Translate the information on safety and information labels

1.2.3.8. Translate the information on safety and information labels

Labels on the product

Both the robot and the controller are marked with several safety and information labels, containing important information about the product. The information is useful for all personnel handling the robot system, for example during installation, service or operation.

The labels are identified and located on the product as shown in section:

•

Inspection, information labels on page 97

Translation possibilities

The labels fitted to the product contain space for adding a fourth language underneath the three standard languages (English, German and French).

Add a local language to the label by:

• Using a transparent sticker over the standard label with text added in a fourth language. Drawings detailing the design (text, figure, dimensions) of the standard labels can be ordered from ABB. Notice that each label is identified according to the article number located in the lower corner of the label.

Example of transparent sticker

The figure below shows the location of the free space on one of the labels on the robot, where the fourth language can be added. The figure also shows a transparent sticker, containing the text in Swedish.

28 xx0500002517

A Free space for adding a fourth language


1 Safety

1.3.1. Safety signals, general

1.3 Safety related instructions

1.3.1. Safety signals, general

General

This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of:

• A caption specifying the danger level (DANGER, WARNING or CAUTION) and the type of danger.

•

A brief description of what will happen if the operator/service personnel do not eliminate the danger.

• An instruction of how to eliminate the danger to facilitate performing the activity at hand.

Danger levels

The table below defines the captions specifying the danger levels used throughout this manual.

Symbol

danger warning

Designation

DANGER

WARNING

ELECTRICAL

SHOCK

Signification

Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc.

Warns that an accident may occur if the instructions are not followed, that can lead to serious injury, possibly fatal, and/or great damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc.

The electrocution or electrical shock symbol indicates electrical hazards which could result in severe personal injury or death.

Electrical shock

CAUTION caution

Warns that an accident may occur if the instructions are not followed, that can result in injury and/or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment, where there is a risk of damaging the product or causing a breakdown.



29

1 Safety

1.3.1. Safety signals, general

Continued

Symbol Designation Signification

ELECTROSTATIC

DISCHARGE (ESD)

The electrostatic discharge (ESD) symbol indicates electrostatic hazards which could result in severe damage to the product.

Electrostatic discharge

(ESD)

NOTE Note symbols alert you to important facts and conditions.

Note

TIP Tip symbols direct you to specific instructions, where to find additional information or how to perform a certain operation in an easier way.

Tip


1 Safety

1.3.2. DANGER - Moving robots are potentially lethal!

1.3.2. DANGER - Moving robots are potentially lethal!

Description

Any moving robot is a potentially lethal machine.

When running the robot, it may perform unexpected and sometimes irrational movements.

Moreover, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the working range of the robot.

Elimination

Action Note

1. Before attempting to run the robot, make sure all emergency stop equipment is correctly installed and connected.

Emergency stop equipment such as gates, tread mats, light curtains, etc.

2. Usually the hold-to-run function is active only in manual full speed mode. To increase safety it is also possible to activate hold-to-run for manual reduced speed with a system parameter.

The hold-to-run function is used in manual mode, not in automatic mode.

3. Make sure no personnel are present within the working range of the robot before pressing the start button.

How to use the hold-to-run function in

RobotWare 5.0 is detailed in section How

to use the hold-to-run function in the

Operating manual - IRC5 with Flex-

Pendant.


1 Safety

1.3.3. DANGER - First test run may cause injury or damage!

1.3.3. DANGER - First test run may cause injury or damage!

Description

Since performing a service activity often requires disassembly of the robot there are several safety risks to take into consideration before the first test run.

Elimination

Follow the procedure below when performing the first test run after a service activity (repair, installation or maintenance):

Action

1. Remove all service tools and foreign objects from the robot and its working area!

2. Install all safety equipment properly!

3. Make sure all personnel are standing at a safe distance from the robot, that is out of its reach behind safety fences, etc!

4. Pay special attention to the function of the part previously serviced!


1 Safety

1.3.4. WARNING - The brake release buttons may be jammed after service work

1.3.4. WARNING - The brake release buttons may be jammed after service work

Description

The brake release unit has push buttons for brake release of each axis motor. When service work is performed inside the SMB recess that includes removal and refitting of the brake release unit, the brake release buttons may be jammed after refitting.

In case the power is turned on while a brake release button is jammed in depressed position, the affected motor brake is released! This may cause serious personal injuries and damage to the robot.

Elimination

To eliminate the danger after service work has been performed inside the SMB recess, follow the procedure below.

Action

1. Make sure the power is turned off.

2. Remove the push button guard, if necessary.

3. Check the push buttons of the brake release unit by pressing them down, one by one.

Make sure none of the buttons are jammed in the tube.

4. If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes!


1 Safety

1.3.5. WARNING - The unit is sensitive to ESD!

1.3.5. WARNING - The unit is sensitive to ESD!

Description

ESD (electrostatic discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges. This discharge may destroy sensitive electronics.

Elimination

Action Note

1. Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly.

2. Use an ESD protective floor mat.

The mat must be grounded through a currentlimiting resistor.

3. Use a dissipative table mat.

The mat should provide a controlled discharge of static voltages and must be grounded.

Location of wrist strap button

The wrist strap button is located in the right corner as shown in the illustration below.

xx0500002171

A Wrist strap button


1 Safety

1.3.6. WARNING - Safety risks during work with gearbox oil

1.3.6. WARNING - Safety risks during work with gearbox oil

Description

When handling the gearbox oil, there are several dangers to both personal injuries and product damages! Following safety information must be regarded before performing any work with the oil in the gearboxes!

Warnings and elimination

Warning Description Elimination / Action

Changing and draining gearbox oil may require handling hot oil of up to 90 °C!

Make sure that protective gear like goggles and gloves are always worn during this activity.

-

-

-

Hot oil!

-

Possible pressure build up in gearbox!

When opening the oil plug, there may be pressure present in the gearbox, causing oil to spray from the opening!

Open oil plug carefully and keep away from the opening. Do not overfill the gearbox when filling.

Do not overfill!

Overfilling of gearbox oil can lead to internal over-pressure inside the gearbox which in turn may:

• damage seals and gaskets

• completely press out seals and gaskets

• prevent the robot from moving freely.

Mixing types of oil may cause severe damage to the gearbox!

Make sure not to overfill the gearbox when filling with oil!

After filling, check the correct oil level.

When filling gearbox oil, do not mix different types of oil unless specified in the instruction.

Always use the type of oil specified by the manufacturer!

Do not mix types of oil!

Warm oil drains quicker than cold oil.

When changing gearbox oil, first run the robot for a time to heat up the oil.

-

Heat up the oil!

-

Specified amount depends on drained volume!

The specified amount of oil is based on the total volume of the gearbox. When changing the oil, the amount of refilled oil may differ from the specified amount, depending on how much oil has previously been drained from the gearbox.

After refilling, check the oil level.


1 Safety

1.3.6. WARNING - Safety risks during work with gearbox oil


2 Installation and commissioning

2.1. Introduction



General

This chapter contains information for installing the robot to the working site.

More detailed technical data, such as load diagram, permitted extra loads (equipment) and location of extra loads (equipment), may be found in the Product Specification for the robot.



2.2. Securing the robot

2.2. Securing the robot

General

This section describes how to secure the robot using the transport support.

DANGER!

Releasing the brakes is a hazardous action that may cause injury and damage property. It must be done with great care and only when absolutely necessary.

Securing the robot

38 xx0800000062

Action Note

1. Mount the transport support lower end to the robot using the recommended screw joint, (A) in figure.

Do not tightening the screw.

See attachment point for the specific robot in section

Transport position with a mounted tool

.




2.2. Securing the robot

Continued

Action Note

2. Jog the robot into a position as near above as possible to the recommended transport position for the specific robot. specified in section


.

CAUTION!

Do not try to jog the robot to the exact position (max distance 1mm).

3. Use the brake release for axis 3 to reach the final resting position on the transport support,

see section


.

See attachment point for the specific robot in section


4. Tightening all the attachment screws (A) and

(B) in figure with the brake release for axis 3 still activated starting with the lower end attachment screw.

CAUTION!

Do not attempt to tightening any attachment screw without first release the brakes, this can seriously damage the robot.

5. Use the brake release for axis 5 and 6 to reach the final resting position for the tool, see section




2.3.1. Pre-installation procedure

2.3 Unpacking

2.3.1. Pre-installation procedure

General

This section is intended for use when unpacking and installing the robot for the first time. It also contains information useful during later re-installation of the robot.

Checking the pre-requisites for installation

The checklist below details what must be observed before proceeding with the actual installation of the robot:

Action

1. Make sure only qualified installation personnel conforming to all national and local codes are allowed to perform the installation.

2. Visually inspect the robot to make sure it is not damaged.

3. Make sure the lifting device used is suitable to handle the weight of the robot as

specified in

Weight, robot on page 40

.

4. If the robot is not installed directly, it must be stored as described in

Storage conditions, robot on page 41

.

5. Make sure the expected operating environment of the robot conforms to the specifications as described in

Operating conditions, robot on page 41

.

6. Before taking the robot to its installation site, make sure the site conforms to

Loads on foundation, robot on page 40

,

Requirements, foundation on page 41

and

Protection classes, robot on page 41

.

7. Before moving the robot, please observe

Risk of tipping / stability on page 44

regarding

risk of tipping!

8. When these prerequisites are met, the robot may be taken to its installation site as described in section:

On-site installation on page 45

.

Weight, robot

The table below shows the weights of the different models:

Robot model

IRB 660 - 180/3.15

IRB 660 - 250/3.15

Weight

1750 kg

1750 kg

Loads on foundation, robot

The table below shows the various forces and torques working on the foundation during different kinds of operation, in relation to the base coordinate system.

Note! These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum at the same time!

40

Force

Force xy

Force z

Torque xy

Endurance load (operation)

± 8.0 kN

17.0 ±3.3 kN

± 23.2 kNm

Max. load (emergency stop)

± 15.9 kN

17.0 ±10.6 kN

± 40.6 kNm




2.3.1. Pre-installation procedure

Continued

Force

Torque z

Endurance load (operation)

± 10.1 kNm

Max. load (emergency stop)

± 14.4 kNm

Requirements, foundation

The table below shows the requirements for the foundation where the weight of the installed robot is included:

Requirement Value Note

Min. levelity

Max. tilt

0.5 mm

5° The limit for the maximum load on the robot is reduced if the robot is tilted.

Contact ABB for further information about acceptable loads.

Min. resonance frequency 22 Hz

Storage conditions, robot

The table below shows the allowed storage conditions for the robot:

Parameter

Min. ambient temperature

Max. ambient temperature

Max. ambient temperature (less than 24 hrs)

Max. ambient humidity

Value

-25° C

+55° C

+70° C

Max. 95% at constant temperature

Operating conditions, robot

The table below shows the allowed operating conditions for the robot:

Parameter

Min. ambient temperature

Max. ambient temperature

Max. ambient humidity

Value

0° C

1)

+50° C

Max. 95% at constant temperature

1)

At cold start (0° C - 5° C), see note in the product specification on how to warm up the robot.

Protection classes, robot

The table below shows the protection class of the robot:

Equipment Protection class

Robot IP 67



2.3.2. Working range and type of motion

2.3.2. Working range and type of motion

Working range

The following figures show the working ranges of the robot models. The extreme positions of the robot arm are specified at the wrist center (dimensions in mm).

IRB 660 - 180/3.15 and IRB 660 - 250/3.15

The illustration below shows the unrestricted working range of IRB 660 - 180/3.15 and IRB

660 - 250/3.15.

42 xx0500002274

H

J

Mechanical stop

Max working range

D

E

F

G

A

B

C

Position x (mm) Position z (mm)

1910

972

895

866

1160

3139

2809

1833

1966

870

207

-505

315

1837

Angle axis 2

(degrees)

50

85

85

50

0

-42

-42

Angle axis 3

(degrees)

0

-20

28

120

120

15

-20

The table below specifies the types and ranges of the robot motion in every axis.

Axis Type of motion Range of motion

1 Rotation motion -180° to +180°



Axis Type of motion

2

3

Arm motion

Arm motion

2-3 Arm motion

6 Turn motion


2.3.2. Working range and type of motion

Continued

Range of motion

-42° to +85°

-20° to +120°

20° to 160°

-300° to +300°



2.3.3. Risk of tipping / stability

2.3.3. Risk of tipping / stability

Risk of tipping

When the robot is not fastened to the foundation and standing still, the robot is not stable in the whole working area. Moving the arms will displace the center of gravity, which may cause the robot to tip over.

Do not change the robot position before securing it to the foundation!

Stabililty

The figure below shows the robot in its shipping position, which also is its most stable position. xx0500002275

WARNING!

The robot is likely to be mechanically unstable while not secured to the foundation!



2.4.1. Lifting robot with fork lift

2.4 On-site installation

2.4.1. Lifting robot with fork lift

General

The robot may be moved using a fork lift, provided that available special aids are used.

This section describes how to attach the fork lift equipment to the robot.

Attachment points

The attachment points for the fork lift equipment are shown in the figure below.

xx0500002276

A

B

C

Attachment points on adapter and horizontal attachment screws

Attachment points, horizontal attachment screws

Attachment points, vertical attachment screws

Required equipment

Equipment, etc.

Art. no.

Note

Fork lift set, incl. all required hardware

3HAC023044-001

3HAC023044-001

Standard toolkit -

See the figure

Fork lift set, 3HAC023044-

001 on page 46

.

The content is defined in section

Standard toolkit on page 258

.



45



Continued

Fork lift set, 3HAC023044-001

The fork lift set 3HAC023044-001, is fitted to the robot as shown in the figure below.

46 xx0500002277

A

B

C

D

E

Fork lift pocket (2 pcs, one long & one short)

Adapter (1 + 1 pcs)

Horizontal attachment screws (4 pcs/fork lift pocket)

Attachment screws for adapter (1 pc/adapter)

Vertical attachment screws (2 pcs)





Continued

Lifting the robot with fork lift

The section below details how to secure the fork lift set to the robot in order to lift and move the robot using the fork lift ONLY!

Action Note

1. Position the robot as shown in the figure to the right!

Release the brakes if required as

detailed in section


.

xx0500002275

2. Fit the two adapters to the robot and secure.

Attachment points on the robot are shown in the figure

Attachment points on page 45

.

Attachment screws, 2 pcs, M16 x 90.

Tightening torque: 60 Nm.

3. Strap up the axis 2 motor cable on the adapter.

3HAC025755-001 Revision: B xx0500002278

• A: Strap, velcro


47



Continued

4.

Action Note

CAUTION!

The fork lift pocket weighs 60 kg!

5. Secure the longer fork lift pocket to the adapter and frame with four of the horizontal

attachment screws and washers.

Make sure the original screws are always used (or replacements of equivalent quality: M16, quality 12.9)!

Attachment points on the robot are

shown in the figure


.

NOTE!

The vertically and the horizontally attached screws are identical, but tightened with different torques!

6. Make sure the securing screw is removed from the fork lift pocket! It is only used for robot model IRB 6650S.

xx0500002279

• A: Horizontal attachment screws, 4 pcs, M16 x 60.


• B: Adapter xx0700000655

• A: Securing screw must be removed!

48





Continued

Action

7. Secure the fork lift pocket to the robot with the two vertical attachment screws and washers.

Note

NOTE!

The vertically and the horizontally attached screws are identical, but tightened with different torques!

xx0500002284

• A: Vertical attachment screws, 2 pcs, M16x60.

• Tightening torque: 270 Nm.




.

8.

CAUTION!

The fork lift pocket weighs 22 kg!

9. Secure the shorter fork lift pocket on the other side of the robot with the four remaining

horizontal attachment screws.

4 pcs, M16x60.





.

10. Double-check that the pockets are properly secured to the robot! Insert the fork lift forks into the pockets.

11. Carefully lift the robot and move it to its installation site.

12.

WARNING!

Personnel must not, under any circumstances, be present under the suspended load!



2.4.2. Lifting robot with roundslings

2.4.2. Lifting robot with roundslings

General

The robot may be lifted with roundslings according to the illustration below. The illustration is identical with the label attached to the robot’s lower arm.

Attachment points

The figure below shows how to attach the roundslings to the robot.

50 xx0500002285

A Chain sling with shortener



D

E

B

C


2.4.2. Lifting robot with roundslings

Continued

Roundsling, robot

Roundsling, upper arm. Used to secure against rotation.

Note! No sharp edges!

Shackle

Sling specification

Sling type

Chain sling with shortener

Roundsling, robot

Roundsling, upper arm

Qty

4 pcs

4 pcs

1 pc

Lifting capacity

4 250 kg

2 000 kg

2 000 kg

Length / Note

0.605 m

0.8 m

1.0 m (2 pcs)

2 m

1 m

2 m

Secures against rotation.

Lifting with roundslings

Action

1. Attach the roundslings to the robot according to the figure


.

Note

NOTE!

For Cleanroom robots it is important to apply the roundslings:

• between robot harness and lower arm

• behind the side bracket, balancing cylinder.

2.

3.

CAUTION!

The robot weighs 1750 kg! All lifting equipment used must be sized accordingly!

WARNING!




2.4.3. Lifting robot with lifting slings

2.4.3. Lifting robot with lifting slings

General

This section contains a general overview of how to lift the complete robot using special lifting equipment. More detailed instructions are included with the equipment.

NOTE!

Move the robot to the recommended position shown in the figure below and in the instruction!

Attempting to lift a robot in any other position may result in the robot tipping over, causing severe damage or injury!

Illustration, lifting slings

The figure below shows how to lift the complete robot with lifting slings.

xx0500002460

C

D

A

B

E

F

Lifting device´s eye

Swivelling lifting eyes, 3 pcs

Chain

Lifting sling, short. Secures against rotation.

Lifting slings, long

Hook


Equipment

Lifting device, robot

Art. no.

3HAC15607-1

Note

Includes

• user instructions (3HAC15971-2).

52




2.4.3. Lifting robot with lifting slings

Continued

Slings attached directly onto robot

The section below details how to lift and move the robot using lifting slings when these are attached directly onto the robot frame.

Action Note

1. Run the overhead crane to a position above the robot.

2. Make sure the robot is positioned as shown in the figure on the right. If it is not, position it that way

Release the brakes if required as detailed in section


.

3.

xx0500002275

Shown in the figure

Illustration, lifting slings on page 52

.

NOTE!

If the robot is equipped with forklift pockets, it is necessary to remove these in order to reach the lower holes in the frame. These are used to attach the hooks of the lifting slings.

4. Fit the lifting device, robot to the robot as described in the enclosed instruction!

5.


Required equipment on page 52

.

6.

CAUTION!

The robot weighs 1750 kg! All lifting equipment used must be sized accordingly!

WARNING!


7. Raise the overhead crane to lift the robot. Make sure all hooks and attachments maintain their correct positions while lifting the robot!

Always move the robot at very low speeds, making sure it does not tip.



2.4.4. Manually releasing the brakes

2.4.4. Manually releasing the brakes

General

This section details how to release the holding brakes of each axis motor.

Location of brake release unit

The internal brake release unit is located at the frame, as shown in the figure below.

Note! Buttons no. 4 and 5 are not used!

xx0500002286

Internal brake release unit with push buttons

Releasing the brakes

The procedure below details how to release the holding brakes when the robot is equipped with an internal brake release unit.

Action

1. The internal brake release unit is equipped with six buttons for controlling the axes brakes. The buttons are numbered according to the numbers of the axes.

Note

The buttons are shown in the figure

Location of brake release unit on page 54

.

NOTE!

Axes 4 and 5 does not exist on IRB 660!

If the robot is not connected to the controller, power must be supplied to the connector R1.MP according to section

Supplying power to connector R1.MP on page 55

.

54




2.4.4. Manually releasing the brakes

Continued

Note Action

2.

DANGER!

When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways!

Make sure no personnel is near the robot arm!

3. Release the holding brake on a particular robot axis by pressing the corresponding button on the internal brake release panel and keeping it depressed.

The brake will function again as soon as the button is released.

Supplying power to connector R1.MP

If the robot is not connected to the controller, power must be supplied to connector R1.MP in the robot base in order to enable the brake release buttons on the robot.

Note

1.

Action

DANGER!

Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously!

2. Supply 0V on pin 12 and 24V on pin 11.

xx0300000565



2.4.5. Lifting the base plate

2.4.5. Lifting the base plate


Equipment

Lifting eye, M16

Lifting slings

Hole configuration

Art. no.

3HAC14457-4

Note

3 pcs

3 pcs

Length: approx. 2 m xx0200000096

A Attachment holes for lifting eyes (x3)

Lifting, base plate

1.

Action Note

CAUTION!

The base plate weighs 353 kg! All lifting equipment used must be sized accordingly!

2. Fit the lifting eyes in the three lifting holes.

3. Fit the lifting slings to the eyes and to the lifting device.

Shown in the figure

Hole configuration on page 56

.



2.4.6. Securing the base plate

2.4.6. Securing the base plate

General

This section details how to secure the base plate.

Base plate, dimensions

xx0100000105



57



Continued

58 xx0400000715

A Four holes for alternative clamping, 4x Ø18





Continued

Base plate, grooves and holes

The illustration below shows the orienting grooves and guide sleeve holes in the base plate.

xx0300000045

A

B

C

Guide sleeve holes (2 pcs)

Orienting grooves (3 pcs)

Levelling bolts, attachment holes (4 pcs)


Equipment Art. no. Note

Base plate

Standard toolkit

Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.

3HAC12937-9 Includes

• guide sleeves, 3HAC12937-3

• levelling screws, 9ADA120-79

• attachment screws and washers for securing the robot to the base plate.

A drawing of the base plate itself may be ordered from ABB Robotics!

- The content is defined in section


.

These procedures include references to the tools required.



59



Continued

Recommendations, quality

The table specifies any recommendations made by ABB:

Variable Recommendation

Recommended foundation quality 1 Steel fibre reinforced concrete foundation, 30 kg/m3, class K30, t=250 mm

Recommended foundation quality 2 Sturdy concrete foundation, double reinforced by ø10 mm steel bars, distance 140 mm, class K25, t=250

Recommended bolt quality and dimension

Hilti HDA-P, M20 x 250/50 (maximum thickness of base plate = 50 mm)

Hilti HDA-P, M20 x 250/100 (maximum thickness of base plate = 100 mm)

Base plate

This section details how to secure the base plate to the foundation.

Action

1. Make sure the foundation is level.

2.

Note

CAUTION!

The base plate weighs 353 kg! All lifting equipment used must be sized accordingly!

3. Orient the base plate in relation to the robot work location using the three grooves in the base plate.

Shown in the figure

Base plate, grooves and holes on page 59

.

4. Lift the base plate to its mounting position. Detailed in section

Lifting the base plate on page 56

.

5. Use the base plate as a template and drill 16 attachment holes as required by the selected bolt dimension.

If possible, observe the recommendations specified in section

Recommendations, quality on page 60

. ABB does not assume any responsibility for other foundation qualities, due to great variations in the foundation properties.

6. Fit the base plate and use the levelling bolts to level the base plate.

Shown in the figure

Base plate, grooves and holes on page 59

.

7. If required, fit strips of sheet metal underneath the base plate to fill any gaps.

8. Secure the base plate to the foundation with screws and sleeves.

9. Recheck the four robot contact surfaces on the base plate to make sure they are level and flat.

If they are not, pieces of sheet metal or similar may be used to bring the base plate to a level position.

Maximum allowed deviation: 0.5 mm



2.4.7. Orienting and securing the robot

2.4.7. Orienting and securing the robot

General

This section details how to orient and secure the robot to the base plate in order to run the robot safely. The requirements made on the foundations are shown in the following tables and figures.

Illustration, robot fitted to base plate

The illustration below shows the robot base fitted to the base plate.

xx0300000566

A

B

C

D

Robot attachment bolts and washers, 8 pcs (M24 x 140)

Orienting grooves in the robot base and in the base plate

Levelling screws

Base plate attachment screws

Attachment screws

The table below specifies the type of securing screws and washers to be used for securing the robot to the base plate/foundation.

Suitable screws, lightly lubricated: M24 x 140

Quality:

Suitable washer:

Tightening torque:

Quality 8.8

Thickness: 4 mm

Outer diameter: 44 mm

Inner diameter: 25 mm

725 Nm



61



Continued

Securing the robot

The procedure below details how to secure the robot to the base plate after fitting the plate to the foundation.

Action Note

1. Lift the robot.

2. Move the robot to the vicinity of its installation location.

3. Fit two guide sleeves to the guide sleeve holes in the base plate.

Detailed in section

Lifting robot with lifting slings on page 52

.

Detailed in section

Lifting robot with roundslings on page 50

.

4. Guide the robot gently using two M24 screws while lowering it into its mounting position.

5. Fit the bolts and washers in the base attachment holes.

NOTE!

One of the guide sleeve holes is elongated!

Make sure the robot base is correctly fitted onto the guide sleeves!

Specified in

Attachment screws on page 61

.

Shown in the figure

Illustration, robot fitted to base plate on page 61

.

6. Tighten the bolts in a criss-cross pattern to ensure that the base is not distorted.

NOTE!

Lightly lubricate the screws before assembly!

62





Continued

Hole configuration, base

The illustration below shows the hole configuration used when securing the robot.

xx0600002628

Cross section, guide sleeve hole

The illustration below shows the cross section of the guide sleeve holes.

xx0600002629



2.4.8. Fitting equipment on robot

2.4.8. Fitting equipment on robot

General

The robot features mounting holes for additional equipment.

Access to any of the following mounting holes may be obstructed by any additional cabling, equipment etc. fitted by the robot user. Make sure the required mounting holes are accessible when planning the robot cell.

NOTE!

No extra equipment may be fitted on the lower arm of the robot.

Illustration, fitting of extra equipment on upper arm

The illustration below shows the mounting holes available for fitting extra equipment on the upper arm.

For fitting of extra vacuum hose all holes shall be used (6 pcs). These holes can only be used for extra vacuum hose!

The max. weight of the vacuum hose and fastening device on the upper arm, is calculated to

10 kg.

Max. extra weight on the upper arm:

•

IRB 660 - 180/3.15 = 35 kg

• IRB 660 - 250/3.15 = 35 kg

Note! Extra weight on the upper arm, must be deducted from the max. handling capacity.

Example: If 35 extra kg is put on the upper arm, this means that the robot only can handle

180 - 35 = 145 kg or 250 - 35 = 215 kg (depending on model).

xx0500002289

A

B

C

Fitting holes, M10 (2 pcs)



64





Continued

Illustration, fitting of extra equipment on frame

The illustration below shows the mounting holes available for fitting extra equipment on the frame.

xx0500002505



65



Continued

Illustration, fitting on turning disk

The illustration below shows the mounting holes available for fitting equipment on the turning disk. xx0500002292

Mounting flange.

Fastener quality

When fitting tools on the turning disk (see the figures above), only use screws with quality

12.9. When fitting other equipment standard screws with quality 8.8 may be used.



2.4.9. Loads

2.4.9. Loads

General

Any loads mounted on the robot must be defined correctly and carefully (with regard to the position of center of gravity and mass moments of inertia) in order to avoid jolting movements and overloading motors, gears and structure.

CAUTION!

Incorrect defined loads may result in operational stops or major damage on the robot.

References

Load diagrams, permitted extra loads (equipment) and their positions are specified in the

Product Specification

. The loads must also be defined in the software as detailed in Operating

manual IRC5 with FlexPendant.

Stop time and braking distances

Robot motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB.



2.5.1. Introduction

2.5 Restricting the working range

2.5.1. Introduction

General

When installing the robot, make sure that it can move freely within its entire working space.

If there is a risk that it may collide with other objects, its working space should be limited.

The working range of the following axis may be restricted:

•

Axis 1, hardware (mechanical stop) and software (signal from adjustable position switch)

As standard configuration, axis 1 is allowed to move ± 180º. The working range may however be increased to ± 220º with option 561-1 "Extended working range axis 1". Notice that this option also requires installation of a position switch on axis 1.

This section describes how to install hardware that restricts the working range.

Notice that adjustments must also be made in the software. References to software manuals are given in the following installation procedures.



2.5.2. Mechanically restricting the working range of axis 1

2.5.2. Mechanically restricting the working range of axis 1

General

The working range of axis 1 is limited by fixed mechanical stops and can be reduced by adding additional mechanical stops giving 7.5 or 15 graduation, between 22.5° and 135° in both directions.

Mechanical stops, axis 1

The illustration below shows the mounting position of the stop pin and one of the additional mechanical stops available for axis 1.

xx0300000049

A

B

Additional mechanical stop

Stop pin


Equipment, etc.

Mechanical stop for axis 1, 7.5°

Mechanical stop for axis 1, 15°

Standard toolkit

Art. no.

3HAC11076-1

-

3HAC11076-2

Technical reference manual - System parameters (RobotWare 5.0)

-

Note

Includes attachment screws and an assembly drawing.

Includes attachment screws and an assembly drawing.

The content is defined in

section


.

Art. no. is specified in section

References on page 8

.



69


2.5.2. Mechanically restricting the working range of axis 1

Continued

Installation, mechanical stops axis 1

The procedure below details how to fit the mechanical stops of axis 1 to the robot. An assembly drawing is also enclosed with the product.

Note

1.

Action

DANGER!

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

2. Fit the additional mechanical stop to the frame according to the figure

Mechanical stops, axis 1 on page 69

.

3.


NOTE!

To utilize the option 561-1 "Extended working range axis 1" the software working range limitations must be re-defined. The motion configuration parameter "arm/rob1_1/Upper

Joint Bound" and "arm/rob1_1/Lower Joint

Bound" must be changed to 3.84 resp. -3.84.

The values are in radians that is 220 deg. =

3.84 rad.

The system parameters that must be changed in RobotWare 5.0 (Upper joint bound and Lower joint bound) are further detailed in Technical reference manual -

System parameters.

4.

WARNING!

If the mechanical stop is deformed after a hard collision, it must be replaced!



2.5.3. Installation of position switch, axis 1 (option)

2.5.3. Installation of position switch, axis 1 (option)

General

Position switches can be installed on axis 1. The position switches include cams as shown in the figure below.

The position switch sets may be delivered in one of two ways:

•

Fitted by ABB on delivery. In this case, the cams must still be fitted and locked by the user. For axis 1, the cover for the cams must also be fitted.

• As sets to be completely fitted to the robot and adjusted by the user.


Description

Position switch, axis 1

Art.no.

3HAC 15715-1

Note

Includes position switch and plate for customer connections.

Connector kit R1.SW1

Plate for customer connections

3HAC 17252-1

3HAC 025778-001 An additional connection plate must be fitted to the robot base, if not already installed.

Additional cabling to and inside the controller

-

Axis 1

The illustration below shows the position switch for axis 1. The switch is connected directly to the connector in the base, R1.SW1.

xx0100000158

A

B


Cam



71



Continued

E

F

C

D

Set screw, cam (cam stop)

Protection sheet

Rail

Rail attachment

Specifications

Maximum voltage/current for the position switches:

Parameter Value

Voltage

Current

Max. 50 VDC

Max. 1 A

Connections

The position switch is connected to different points on the robot system:

•

XT8, screw terminal in the controller cabinet when position switch cables are used.

• R1.SW1 at the robot base. Customer connection set is recommended. Art.no. is specified in


.

Further information about cables and connection points, see section

Robot cabling and connection points on page 76

.

Plate customer connections, at base

72 xx0500002301

A

B

Plate for customer connections

Attachment screws, 3 pcs, M6x16





Continued

Installation of cable harness for position switch

The procedure below details how to fit the complete cable harness for position switch axis 1 to the robot.

Note Action

1. Move the robot to its calibration position.

2.

DANGER!


3. Remove the rear cover (A) from the robot base.

4. Fit the position switch to the frame of the robot.

5. Run the cabling through the notch in the base of the robot next to the rear cover.

xx0500002306

3HAC025755-001 Revision: B xx0600002625

• A: Notch for pos.switch cable


73



Continued

Action

6. Connect the connector R1.SW1 to the position switch of axis 1 (D).

Note

7. Connect the connector R1.SW1 to the base of the robot (B).

8. Refit the rear cover to the robot base.

9. Recalibrate the robot!

xx0600002626

• A: Cable, pos.switch axis 1

• B: Connection point R1.SW1

• C: Notch for cable

• D: Position switch, axis 1

See figure above!

Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.

General calibration information is included in section

Calibration information on page 241

.

10.

DANGER!

Make sure all safety requirements are met when performing the first test run. These are further detailed in section

DANGER - First test run may cause injury or damage! on page 32

.

Fitting and adjusting cams and stops

The instruction below details how to fit and adjust the parts of the position switch:

Action

1. Cut the cam to a suitable length.

2. Cut the edge of the cam edge to max 30°!

Note

Use a sharp knife and rubber hammer or similair.

Shown in the figure

Illustration, cutting the cam on page 75

.

If the angle is larger, this may damage the position switch!

74





Continued

Action Note

3. Cut the part of the cam running in the profile to

90°!

Also see the figure

Illustration, cutting the cam on page 75

.

4. Make sure the ends of the profile are chamfered to enable the cam to run through the profile.

5. Fit the cam with the M5 screw and nut. Tighten the M5 screw to secure the cam.

Shown in the figure

Illustration, adjust and secure cams on page 75

.

Illustration, adjust and secure cams

The illustration below shows how to adjust and secure the position switch cams and profiles.

xx0100000113

A

B

C

Cam stop, M5 nut and M5 x 6 set screw

Adjustable cam

Profile

Illustration, cutting the cam

The illustration below shows how to cut the position switch cam.

xx010000114

A Remove the gray section



2.6.1. Robot cabling and connection points

2.6 Electrical connections

2.6.1. Robot cabling and connection points

General

Connect the robot and controller to each other after securing them to the foundation. The lists below specify which cables to use for each respective application.

Main cable categories

All cables between the robot and controller are divided into the following categories:

Cable category Description

Robot cables

Position switch cables

(option)

Handles power supply to and control of the robot's motors as well as feedback from the serial measurement board.

Specified in the table

Robot cables on page 76

.

Handles supply to and feedback from any position switches on the robot.

Specified in the table

Position switch cables, robot base to controller (option) on page 77

.

Customer cables (option) Handles communication with equipment fitted on the robot by the customer, including databus communication, low voltage signals and high voltage power supply + protective ground.

See the product manual for the controller

1)

.

External axes cables (option) Handles power supply to and control of the external axes' motors as well as feedback from the servo system.

See the Application manual - Additional axes and stand

alone controller (M2004)

1)

.

1)



.

The cable categories are divided into sub-categories, specified below:

Robot cables

These cables are included in the standard delivery. They are completely pre-manufactured and ready to plug in.

Cable sub-category Description

Robot cable, power

Robot cable, signals

Connection point, cabinet

Connection point, robot

R1.MP Transfers drive power from the drive units in the control cabinet to the robot motors.

XS1

Transfers resolver data from and power supply to the serial measurement board.

XS2 R1.SMB

Robot cable, power

76

Cable

Robot cable, power, 7 m


Art. no.

3HAC11818-1

3HAC11818-2




2.6.1. Robot cabling and connection points

Continued

Cable



Art. no.

3HAC11818-3

3HAC11818-4

Robot cable, signals

Cable

Robot cable, signal, shielded, 7 m




Art. no.

3HAC7998-1

3HAC7998-2

3HAC7998-3

3HAC7998-4

Position switch cables, robot base to controller (option)

These cables are not included in the standard delivery, but are included in the delivery if the position switch option is ordered. The position switches can also be ordered without cables.

The cables are completely pre-manufactured and ready to plug in.

Cabling to be installed on the robot is specified in section

Installation of position switch, axis

1 (option) on page 71

.

Cabling between robot base and controller

In a M2004 robot system, the cables below are only used for position switch axis 1.

Cable

Position switch cable, axis 1, 7 m




Art. no.

Connection point, robot

3HAC13175-1 R1.SW

3HAC13175-2 R1.SW

3HAC13175-3 R1.SW

3HAC13175-4 R1.SW

Connection point, cabinet

XS8

XS8

XS8

XS8

Cabling inside control cabinet

Additional cabling must be connected inside the control cabinet when installing position switches.

Cable Art. no.

Connection point 1 inside cabinet

Connection point 2 inside cabinet

Bracket in the cabinet wall (M2004) 3HAC020813-082 -

Harness position switch axis 1

(M2004)

3HAC021117-001 XS8

-

XT8.1 and

XT8.2



2.7.1. Commissioning (Foundry Prime)

2.7 Making robot ready for operation (Foundry Prime)

2.7.1. Commissioning (Foundry Prime)

General

The following should be taken in consideration when running a robot in a water jet application cell:

CAUTION!

Never switch off the overpressure in motors and serial measurement compartment during cooling down of robot after it has been switched off.

NOTE!

To reduce the risk for corrosion due to condensation in gearboxes, it is recommendable that the robot is running with high speed on each axes at least on one occasion each hour. This is to lubricate the gearbox cavities.

NOTE!

When turning off a cleaning cell we recommend that the humid air is ventilated out from the cell, to avoid that the humid air is sucked into gearboxes for example, due to the raised vacuum when cooled down.


3 Maintenance

3.1. Introduction

3 Maintenance


Structure of this chapter

This chapter details all maintenance activities recommended for the robot and any external units of the robot.

It is based on the maintenance schedule, located in the beginning of the chapter. The schedule contains information about required maintenance activities including intervals and refers to procedures for the activities.

Each procedure contains all information required to perform the activity, that is, required tools and materials.

The procedures are gathered in different sections and divided according to the maintenance activity.


Before any service work is commenced, it is extremely important that all safety information is observed!

There are general safety aspects that must be read through, as well as more specific safety information that describe danger and safety risks when performing the procedures. Read the chapter

Safety on page 13

before performing any service work.


3 Maintenance

3.2.1. Specification of maintenance intervals

3.2 Maintenance schedule and expected component life

3.2.1. Specification of maintenance intervals

Description

The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot:

• Calendar time: specified in months regardless of whether the robot system is run or not

•

Operating time: specified in operating hours. More frequent running of the robot means more frequent maintenance activities.


3 Maintenance

3.2.2. Maintenance schedule

3.2.2. Maintenance schedule

General

The robot must be maintained regularly to ensure proper function. The maintenance activities and intervals are specified in the table below.

Non-predictable situations also give rise to inspections of the robot. Any damages must be attended to immediately!

The inspection intervals do not specify the life of each component.

Values for these are specified in

Expected component life on page 83

.

Activities and intervals, standard equipment

The table below specifies the required maintenance activities and intervals.

Maintenance activity

Equipment

Cleaning

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Changing

Changing

Changing

Replacement


Interval Detailed in section

Robot

Axes 2 and 3 gears, oil level

12 mths

1)

Mechanical stop, axis 1

Dampers

Axis 1 gear oil:

Kyodo Yushi TMO

150

Axes 2 & 3 gear oil:

Kyodo Yushi TMO

150

First change: 6 000 h

Second change: 24 000 h

4)

Axis 6 gear oil:

Kyodo Yushi TMO

150

-

Axis 1 gear, oil level 12 mths

1)

Axis 6 gear, oil level 12 mths

1)

Balancing device

Cable harness

Information labels 12 mths

Axis 1 gearbox

12 mths

12 mths

12 mths

12 mths



4)



4)

As specified by SIS, or typically 96 mths.

Cleaning, robot on page

126

Inspection, oil level gearbox axis 1 on page

84

Inspection, oil level gearbox axes 2 - 3 on page 86

.

Oil change, gearbox axis 6 on page 118

.

Inspection, balancing device on page 90

Inspection, cable harness on page 94

Inspection, information labels on page 97

Inspection, mechanical stop, axis 1 on page 99

Inspection, dampers on page 102

.

Do not mix with other oils!



Oil change, gearbox axes 2-3 on page 115



Replacement of gearbox, axis 1 on page

225


81

3 Maintenance

3.2.2. Maintenance schedule

Continued


Equipment

Replacement

Replacement

Replacement

Replacement

Lubrication

Axes 2 and 3 gearboxes

Axis 6 gearbox

Cable harness

SMB battery pack 36 mths

Balancing device

Interval



See note below

2)

12 000 h

3)

Detailed in section

Replacement of gearbox, axes 2- 3 on page 232

.

Replacement of gearbox, axis 6 on page

236

.

Replacement of cable harness, lower end

(axes 1-3) on page 135

.

Replacement of cable harness, upper end

(incl. axis 6) on page

144

.

Replacement of SMB unit on page 205

.

Lubrication of bearing, balancing device on page 123

•

•

•

•

1)

If the robot is run at ambient temperatures higher than 50°C, the equipment may require maintenance more frequently.

2)

Replace when damage is detected or when approaching life limit as specified in

Expected component life on page 83

.

3)

The interval is the same as the interval for changing axis 2 gear oil because of the similarity of the type and degree of operation. Always lubricate the front eye bearing after refitting the balancing device shaft!

4)

"24000 h" = 6000 h + 18000 h

Activities and intervals, optional equipment

The table below specifies the required maintenance activities and intervals for common optional equipment. Maintenance of other external equipment for the robot is detailed in separate documentation.


Inspection

Inspection

Inspection

Equipment

Signal lamp

Interval Detailed in section

Inspection, signal lamp on page 106

Additional mechanical stop axis 1

Position switches, axis 1

12 mths

12 mths


3 Maintenance

3.2.3. Expected component life

3.2.3. Expected component life

General

The expected life of a component can vary greatly depending on how hard it is run.

Expected life

Component

Cabling for robot

Balancing device

Gearbox

Expected life

4,000,000 cycles axis 1 ±180º

2,000,000 cycles axis 1 ±220º

2,000,000 cycles

40,000h

Note

See note

1)

See note

2)

See note

3)

1)

The expected life can also be affected by assemblage of cabling other than standard options.

The given life is based on a test cycle that for every axis starts from the calibration position to minimum angle to maximum angle and back to the calibration position. Deviations from this cycle will result in differences in expected life! The life may also be affected by acid or alkaline environment.

See the note in the

Product specification

about warrenty, when running the robot in a cold environment (0°C to 5°C).

2)

The given life for the balancing device is based on a test cycle that starts from the initial position and goes to maximum extension, and back. Deviations from this cycle will result in differences in expected life!

3)

The robot is dimensioned for a life of 8 years (350,000 cycles per year) in a normal application. Depending on the actual application, the life of individual gearboxes may vary greatly from this specification. The Service Information System (SIS), integrated in the robot software, keeps track of the gearbox life in each individual case and will notify the user when a service is due.

The SIS for an M2004 system is described in the Operating manual - Service Information

System. Document number can be found in section


.


3 Maintenance

3.3.1. Inspection, oil level gearbox axis 1

3.3 Inspection activities

3.3.1. Inspection, oil level gearbox axis 1

Location of gearbox

The axis 1 gearbox is located between the frame and base. The oil plugs are shown in the figure below. xx0500002479

A

B

C

D

E

Oil plug, inspection

Gearbox, axis 1

Oil plug filling

Motor, axis 1

Drain hose (Behind cover)


Equipment

Lubricating oil

Standard toolkit


-

Art. no.

3HAC032140-001

Note

Kyodo Yushi TMO 150

Note! Do not mix with other oil types!



.


84



3 Maintenance


Continued

Inspection, oil level gearbox, axis 1

The procedure below details how to inspect the oil level in gearbox axis 1.

Note

1.

Action

2.

WARNING!

Handling gearbox oil involves several safety risks. Before proceeding, please observe the safety information in section

WARNING - Safety risks during work with gearbox oil on page 35

.

DANGER!


3. Open the oil plug, inspection.

Shown in the figure

Location of gearbox on page 84

.

4. Required oil level: max. 10 mm below the oil plug hole!

5. Add oil if required.

6. Refit the oil plug, inspection.



.

Further information about how to fill

the oil may be found in section

Filling oil, axis 1 on page 114

.



3 Maintenance

3.3.2. Inspection, oil level gearbox axes 2 - 3

3.3.2. Inspection, oil level gearbox axes 2 - 3

Location of gearbox, axes 2-3

The gearboxes axes 2-3 are located in the lower arm rotational center, underneath the motor attachment.

The figures below shows the position of gearbox axes 2 and 3.

xx0500002482

A

B

C

D

Gearbox, axis 2

Oil plug, draining

Oil plug, filling

Ventilation hole, gearbox axis 2

86 xx0500002483

A

B

C

D

Gearbox, axis 3

Oil plug, draining

Oil plug, filling




3 Maintenance

3.3.2. Inspection, oil level gearbox axes 2 - 3

Continued


Equipment etc.

Lubricating oil

Standard toolkit -

Art.no.

3HAC032140-001

Note

Kyodo Yushi TMO 150



section


.


Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below

Inspection, oil level gearbox 2 - 3

The procedure below details how to inspect the oil level in gearbox axis 2 - 3.

Note

1.

Action

2.

WARNING!


WARNING -

Safety risks during work with gearbox oil on page 35

.

DANGER!


3. Open the oil plug, filling Shown in

Location of gearbox, axes

2-3 on page 86

.

4. Measure the oil level at the oil plug, filling.

Required oil level: max. 5 mm below the oil plug hole.


Art.no. is specified in


.

Filling of oil is detailed further in

section


.

6. Refit the oil plug, filling.

Tightening torque: 24 Nm


3 Maintenance


3.3.3. Inspection, oil level gearbox axis 6


The axis 6 gearbox is located in the tilthouse unit as shown in the figure below.

xx0500002484

A

B

C

Gearbox, axis 6

Oil plug, filling

Oil plug, draining


Equipment Art. no. Note

Lubricating oil, IRB 660

Standard toolkit


-

3HAC032140-001 Kyodo Yushi TMO 150

Do not mix with other oil types!



.


88



3 Maintenance


Continued

Inspection, oil level gearbox 6

The procedure below details how to inspect the oil level in gearbox axis 6.

Note

1.

Action

2.

WARNING!



.

DANGER!


3. Open the oil plug, filling.


5. Refit the oil plug, filling.

Shown in the figure


.



.

Further information about how to fill the oil may be found in section

Filling, oil on page 119

.



3 Maintenance

3.3.4. Inspection, balancing device

3.3.4. Inspection, balancing device

Overview

The procedure below details how to inspect the bearings and piston rod of the balancing device.

Location of balancing device

The figure below shows the location of the balancing device.

xx0500002495

A

B

C

Balancing device

Piston rod

Guide ring (not visible in this figure)


Equipment

Balancing device

Grease

Locking liquid

Auxiliary shaft, upper

Auxiliary shaft, lower

Standard toolkit

Spare part no.

3HAC024779-001

3HAC024779-001

Art.no

3HAB3537-1

3HAC5276-1

-

3HAC5275-1

Note

White RAL 9003

Loctite 243


section


.

90



3 Maintenance


Continued

Equipment

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

Spare part no.

Art.no

Note


Inspection, bearings

The procedure below details how to inspect the bearings, balancing device.

Action

1. Move the axis 2 to calibration position.

2.

Note

DANGER!


3. Remove the locknuts (KM-8), sealing rings and the outer support washers.

xx0500002496

• A: Ear (adjustable needle bearing located inside)

• B: Support washer

• C: Lock nut (with sealing ring)

• D: Piston rod

• E: Guide ring (not visible in this view)

• F: Inner ring

4. Fit the auxiliary shafts on upper and lower axes of balancing device.

The shafts should be tightened to their bottom position.



.



91

3 Maintenance


Continued

Action

5. Remove the protection hood from the

M12 hole on top of the balancing device.

Note

92 xx0600002687

• A: Attachment (seen from above)

• B: Protection hood

6. Unload the bearings using a M12x50 screw, in the hole for the protective hood, at the cylinder top.

7. Pull out the cylinder a little, in order to be able to inspect the inner rings without removing the balancing cylinder.

Shown in the figure above in this procedure

Inspection, bearings on page 91

.

8. Wipe the inner rings clean and check that there are no pressure marks or other similar deformations.

NOTE!

It is quite normal for the bearing races to have a darker color than the surrounding material.

9. Inspect the bearings, support washers and sealing rings.

Shown in the figure above in this procedure

Inspection, bearings on page 91

.

10. If any of the parts looks abnormal, replace.

11. Lubricate the shafts, if needed.

Detailed in section

Replacement of balancing device on page 200

.

12. Push the cylinder back in. Make sure that the inner support washers and sealing rings get in the correct position.

13. Remove the auxiliary shafts.

14. Remove the M12x50 screw.

Put back the protection hood in the hole.

15. Apply locking liquid on the locknuts

(KM-8) and refit them.

NOTE!

Don´t forget to remove the screw!

If the screw isn´t removed it may damage the balancing device, when the robot starts operating.

Tightening torque on the locknuts:

• 120 Nm



3 Maintenance


Continued

Inspection, wear on the guide ring

The procedure below details how to inspect the piston rod for wear on the guide ring.

Action

1. Move axis 2 to a position where the balancing device is in a horizontal position.

2.

Note

DANGER!


3. Check the guide ring for wear.

Replace if necessary.

4.

NOTE!

If there is a risk of metallic contact between the piston rod and the end cover, the guide ring must be replaced!

xx0600002689

• A: Guide ring

• B: Circlip


3 Maintenance

3.3.5. Inspection, cable harness

3.3.5. Inspection, cable harness

Location of cable harness, axes 1-6

The robot cable harness, axes 1-6, is located as shown in the figure below.

xx0500002497

C

D

A

B

E

Cable harness robot, axes 1-6

Connectors at base

Motor cables

Cable guide, axis 2

Metal clamps


Equipment, etc.

Standard toolkit -

Art.no.

94

Note

Detailed in section


.



3 Maintenance


Continued

Equipment, etc.


Circuit diagram

Art.no.

Note


See chapter

Circuit diagram

.

Inspection cable harness, axes 1-6

The procedure below details how to inspect the cable harness of axes 1-6.

Note

1.

Action

DANGER!


2. Make an overall inspection of the cable harness, in order to detect wear and damage.

3. Check the connectors at the base.

4. Check the motor cables.

Shown in the figure

Location of cable harness, axes 1-6 on page 94

Shown in the figure


.

5. If the robot is equipped with forklift device, check that the velcro strap holding the motorcable, is properly attached to the adapter.

6. Check the cable guide axis 2.

Replace if damaged.

7. Check the metal clamps on the lower arm.

xx0600002691

• A: Velcro strap

Shown in the figure


.

Shown in the figure




95

3 Maintenance


Continued

Action

8. Check the metal clamps holding the cable harness inside the upper arm, as shown in the figure to the right.

Note

xx0500002498

• A: Metal clamp inside upper arm

9. Check the metal clamp holding the motorcable on axis 6.

Shown in the figure


.

10. Replace the cable harness if wear or damage is detected!

Detailed in section:

Replacement of cable harness, lower end (axes 1-3) on page 135

.

Replacement of cable harness, upper end (incl. axis 6) on page 144

.


3 Maintenance

3.3.6. Inspection, information labels

3.3.6. Inspection, information labels

Location of labels

The figures below show the location of the information labels to be inspected. xx0502499

J

K

A

B

D

G

-

Warning label “High teperature”, (located on motor cover), 29454489-16 (4 pcs)

Warning sign, symbol of flash (located on motor cover), 3HAC1589-1 (4 pcs)

Warning label “Brake release”, 3HAC024985-001

Warning label “Caught danger”, 3HAC4517-1

Warning label “Shut off power”, 3HAC17804-1

Warning label “Extended working range and pos switch” (option), 3HAC021761-

001

Information labels about what oil is filled, on gearboxes and at the robot base.



97

3 Maintenance

3.3.6. Inspection, information labels

Continued

xx0500002500

C

E

F

H

L

Instruction label “Safety instructions”, 3HAC4591-1

Instruction label “Lifting the robot”, 3HAC024629-001

Warning label “Robot can tip forward...”, 3HAC9191-1

Warning label “Stored energy”, 3HAC3981-1

Information label at base, Kyodo Yushi TMO 150 in gearboxes, 3HAC024977-002


Equipment

Labels and plate set

Label set, oil labels

Art. no.

3HAC022897-001

3HAC024977-001

Note

Includes all labels specified in the two previous figures! The labels are in english.

Includes only the oil labels at the gearboxes and at the robot base.

Are fitted to the robot if the gearboxes include Kyodo Yushi TMO 150.

Inspection, labels

Action

1.

Note

DANGER!


2. Check the labels, located as shown in the figures

Location of labels on page 97

.

3. Replace any missing or damaged labels. Art. no. is specified in


.


3 Maintenance

3.3.7. Inspection, mechanical stop, axis 1

3.3.7. Inspection, mechanical stop, axis 1

Location of mechanical stop

The mechanical stop axis 1 is located at the base as shown in the figure below.

xx0600002695

A

B

Mechanical stop pin

Fixed stop


Equipment, etc.

Mechanical stop ax 1

Standard toolkit

Art. no.

-

3HAC17358-1

Note

To be replaced when damaged.



.

Inspection, mechanical stop

The procedure below details how to inspect the mechanical stop axis 1.

Note

1.

Action

DANGER!


2. Inspect the mechanical stop, axis 1.

3. Make sure the mechanical stop can move in both directions.

Shown in the figure

Location of mechanical stop on page 99

.



99

3 Maintenance

3.3.7. Inspection, mechanical stop, axis 1

Continued

Action

4. If the stop pin is bent or damaged, it must be replaced!

Note



.

NOTE!

The expected life of gearboxes can be reduced as a result of collissions with the mechanical stop.


3 Maintenance

3.3.8. Inspection, additional mechanical stops

3.3.8. Inspection, additional mechanical stops

Location of mechanical stops

The figure below shows the location of the additional mechanical stops on axis 1. (The figure shows IRB 7600 but the location on axis 1 is the same on IRB 660.) Additional mechanical stops for axes 2-3 are not available for the IRB 660.


Equipment etc.

Standard toolkit -

Art. no. Note



.

Inspection, mechanical stops

The procedure below details how to inspect the additional mechanical stops on axes 1.

Note

1.

Action

DANGER!


2. Check the additional stops on axis 1 for damage. Shown in the figure

Location of mechanical stops on page 101

.

3. Make sure the stops are properly attached.

Correct tightening torque, mechanical stop axis 1:

120 Nm.

4. If any damage is detected, the mechanical stops must be replaced!

Correct attachment screws (lubricated with Molycote

1000):

• Axis 3: M6 x 16



.


3 Maintenance

3.3.9. Inspection, dampers

3.3.9. Inspection, dampers

Location of dampers

The figure below shows the location of the dampers.

xx0500002501

-

C

A

B

Damper, lower arm, upper (2 pcs)

Damper, lower arm, lower (1 pc)

Damper, axis 2 (2 pcs)

Damper, axis 3 (2 pcs) Not visible in this view,


Equipment

Damper axis 2, 3

Damper lower arm, upper

Damper lower arm, lower

Art.no

3HAC 12991-1

3HAC 022338-001

3HAC 022339-001

Note

To be replaced if damaged



102



Inspection, dampers

The procedure below details how to inspect the dampers.

1.

Action Note

3 Maintenance

3.3.9. Inspection, dampers

Continued

DANGER!


2. Check all dampers for damage, cracks or existing impressions larger than 1 mm.

Shown in the figure

Location of dampers on page 102

.

3. Check attachment screws for deformation.

4. If any damage is detected, the damper must be replaced with a new one.



.


3 Maintenance

3.3.10. Inspection, position switch axis 1

3.3.10. Inspection, position switch axis 1

Position switch, axes 1

The illustration below shows the position switch for axis 1.

xx0100000158

D

E

F

A

B

C


Cam

Set screw, cam

Protection sheet

Rail

Rail attachment


Equipment


Standard toolkit


Art.no

-

3HAC 024854-001

Note



.


104



3 Maintenance

3.3.10. Inspection, position switch axis 1

Continued

Inspection, position switch

The procedure below details how to inspect the position switch, axis 1.

Note

1.

Action

DANGER!


2. Check the position switch!

• Check that the rollers are easy to push in and that they roll freely.

3. Check the rail!

• Check that the rail is firmly attached with the attachment screws.

4. Check the cams!

• Check that the rollers have not caused any impressions on the cams.

• Check that the cams are clean. Wipe them if necessary!

• Check that the set screws holding the cams in position are firmly attached.

5. Check the protection sheets on axis 1!

• Check that the three sheets are in position and not damaged. Deformation can result in rubbing against the cams!

• Check that the area inside of the sheets is clean enough not to interfere with the function of the position switch.

6. If any damage is detected, the position switch must be replaced!


3 Maintenance

3.3.11. Inspection, signal lamp

3.3.11. Inspection, signal lamp

Location of signal lamp

The signal lamp is located as shown in the figure below.

xx0500002466

A

B

C

D

Signal lamp

Cable straps, outdoor

Cable

Connection point to cable gland


Equipment, etc. Art. no. Note

Kit for UL lamp

Standard toolkit


-

3HAC023750-001 To be replaced in case of detected damage.



.


Inspection, signal lamp

The procedure below details how to inspect the function of the signal lamp.

Action

1. Check that the signal lamp is lit, when the motors are put in operation ("MOTORS ON").

Note

106



3 Maintenance

3.3.11. Inspection, signal lamp

Continued

Note Action

2.

DANGER!


3. If the lamp is not lit, trace the fault by:

• Checking whether the signal lamp is broken.

If so, replace it.

• Checking the cable connections.



.

• Measuring the voltage in connectors motor axis 6 (=24V).

• Checking the cabling. Replace cabling if a fault is detected.


3 Maintenance

3.4.1. Type of oil in gearboxes

3.4 Replacement/changing activities

3.4.1. Type of oil in gearboxes

Location of gearboxes

The figure show the location of the gearboxes on the robot.

xx0500002467

A

B

C

D

Gearbox, axis 1

Gearbox, axis 2

Gearbox, axis 3

Gearbox, axis 6

Type of oil - historically used

The gearboxes of the robot have historically been filled with different types of oils. Today only the types of oil specified in the table is recommended.

NOTE!

When there is a change of oil types in the gearbox, it need to be rinsed. See

Rinsing gearbox on page 110

.

CAUTION!

When filling gearbox oil, do not mix different types of oil as this may cause severe damage to the gearbox! Always use the type of oil specified in the table!

If oils are mixed, the gearbox must be thoroughly rinsed! See


.

Type of oil - currently used

The table show which types of oil is used in gearboxes.

Gearbox

Axis 1

Axis 2

Axis 3

Axis 6

Type of oil

Kyodo Yushi TMO 150

Kyodo Yushi TMO 150

Kyodo Yushi TMO 150

Kyodo Yushi TMO 150

Art. no.

Amount

3HAC032140-001 8,000 ml

3HAC032140-001 5,000 ml

3HAC032140-001 5,000 ml

3HAC032140-001 250 ml

108



3 Maintenance


Continued

Labels next to oil plugs

Labels located next to oil plugs of each gearbox show which type of oil it contains. All gearboxes must have the correct label clearly visible.

xx0800000230

Labels located next to oil plugs Currently used types of oils xx0800000241

Historically used types of oil Need to be replaced, if currently used.

Labels at robot base

Label located at robot base show the types of oil in all gearboxes.

xx0500002477

Label at robot base. Currently used types of oil.



109

3 Maintenance


Continued

Mixed types of oil may cause may cause severe damage!

When refilling or replacing oil in a gearbox it is important to first check which type of oil is

recommended to use in the gearbox. See

Type of oil - currently used on page 108

. If the oil used is other than the one in the list of currently used types of oil, it is recommended to replace the oil.

As Kyodo Yushi TMO 150 (as well as Shell Tivela S 150) is not compatible with mineral oil, contamination with other types of oil in the gearboxes is not accepted! Equipment used in handling of Kyodo Yushi (as well as Shell Tivela S 150) must be carefully cleaned before use!

In case of changing the type of oil, the gearbox therefor must be thoroughly rinsed! See


.

NOTE!

When filling gearbox oil, do not mix different types of oil as this may cause severe damage to the gearbox! Always use the oil recommended by the manufacturer!

Rinsing gearbox

Depending on which types of oil are mixed and which type of oil shall be filled in the gearbox after rinsing, use the appropiate procedure.

The same applies if the type of oil shall be changed in the gearbox.

NOTE!

What is said about Kyodo Yushi TMO 150, also applies to Shell Tivela S 150.

What is said about Mobilgear 600 XP320, also applies to Mobil Gearlube X320.

Kyodo Yushi TMO 150 mixed with Optimol Optigear RMO 150/Optigear RO 150

Use this procedure to rinse the contaminated gearbox if the oil types Kyodo Yushi TMO 150 and Optimol Optigear RMO 150/Optigear RO 150 are mixed.

•

Flush the gearbox properly three times with the correct type of oil. Use a service program when flushing.

• Refill the gearbox with the correct type of oil.

Kyodo Yushi TMO 150 mixed with Mobilgear 600 XP320

Use this procedure to rinse the contaminated gearbox if the gearbox shall contain Kyodo

Yushi TMO 150 and it is mixed with Mobilgear 600 XP320.

• Flush the gearbox properly three times with Kyodo Yushi TMO 150. Use a service program when flushing.

•

Refill the gearbox with Kyodo Yushi TMO 150.

110



Equipment

3 Maintenance


Continued

Equipment

Label set

Oil change equipment

Art. no.

Note

See Spare Parts.

Includes small labels to each gearbox and the complete label to be fitted at the robot base.

NOTE!

The correct labels must be fitted to the robot in case of changing of oil types!

3HAC021745-001 Includes pump with outlet pipe.


3 Maintenance

3.4.2. Oil change, gearbox axis 1

3.4.2. Oil change, gearbox axis 1

Location of oil plugs

The axis 1 gearbox is located between the frame and base. The oil plugs for filling and inspection are shown in the figure below. The oil is drained through a hose, available in the rear of the robot base, not shown in the figure.

xx0500002479

A

B

C

D

E

Oil plug, inspection

Gearbox axis 1

Oil plug, filling

Motor, axis 1

Drain hose


Equipment, etc.

Lubricating oil

Oil collecting vessel

Oil exchange equipment

Standard toolkit

Art. no. Amount Note

-

3HAC032140-001 8,000 ml Kyodo Yushi TMO 150


-

3HAC021745-001

Capacity: 8,000 ml.


Special tools on page 259

.



.

112



3 Maintenance


Continued

Draining oil, axis 1

The procedure below details how to drain the oil in gearbox axis 1.

When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.

no. for the kit is specified in


.

Note

1.

Action

2.

DANGER!


WARNING!


WARNING -


.

3. Remove the rear cover on the base by unscrewing its attachment screws.

4. Pull the oil draining hose out of the rear of the base.

5. Place an oil vessel close to the hose end.

6. Remove the oil plug, filling, in order to drain the oil quicker!

Vessel capacity is specified in


.

Shown in the figure

Location of oil plugs on page 112

.

7. Open the hose end and drain the oil into the vessel. xx0200000237

The hose is located beneath the base, as shown in the figure with a view from below.

• A: Oil draining hose

NOTE!

The draining is time-consuming.

Elapsed time depends on the temperature of the oil.

8. Close the oil drain hose, and put it back inside the base.

9. Refit the rear cover by securing it with its attachment screws.



113

3 Maintenance


Continued

Filling oil, axis 1

The procedure below details how to fill the oil in gearbox axis 1.

Note

1.

Action

2.

DANGER!


WARNING!

Handling gearbox oil involves several safety risks.

Before proceeding, please observe the safety information in section


.

3. Open the oil plug, filling.

Shown in the figure

Location of oil plugs on page 112

.

4. Refill the gearbox with lubricating oil.

The amount of oil to be refilled depends on the amount previously being drained. The correct oil level

is detailed in section

Inspection, oil level gearbox axis

1 on page 84

.

Art. no. and the total amount are

specified in


.

5. Refit the oil plug, filling. Tightening torque: 24 Nm.


3 Maintenance

3.4.3. Oil change, gearbox axes 2-3

3.4.3. Oil change, gearbox axes 2-3

Location of oil plugs

The gearboxes axes 2-3 are located in the lower arm rotational center, underneath the motor attachment.

The figures below shows the position of gearbox axis 2 and 3. xx0500002482

A

B

C

D

Gearbox axis 2

Oil plug, draining

Oil plug, filling

Ventilation hole, gearbox axis 2 xx0500002483

A

B

C

D

Gearbox, axis 3

Oil plug, draining

Oil plug, filling




115

3 Maintenance


Continued


Equipment etc.

Lubricating oil



Standard toolkit -

Art.no

3HAC021745-001

Amount Note

3HAC032140-001 5,000 ml Kyodo Yushi TMO 150

Capacity: 6,000 ml


Special tools on page

259

.


section

Standard toolkit on page

258

.

Draining

The procedure below details how to drain the oil in gearbox axis 2-3.

Note

1.

Action

2.

DANGER!


WARNING!

Handling gearbox oil involves several safety risks. Before proceeding, please observe the

safety information in section

WARNING -


.

3. Remove the plug of the vent hole.

4. Remove the oil plug, draining, and drain the gearbox using a hose with a nipple and an oil collecting vessel.

5. Refit the oil plug.

Shown in

Location of oil plugs on page

115

.

Shown in


115

.



.

Draining is time-consuming.

Elapsed time varies depending on the temperature of the oil.


116



Filling

3 Maintenance


Continued

The procedure below details how to fill oil in the gearbox axes 2-3.

Note

1.

Action

2.

DANGER!


WARNING!


WARNING -


.

3. Refit the oil plug, draining.

Shown in


115

.


4.

NOTE!

Don´t mix Kyodo Yushi TMO 150 with other oil types!

5. Refill the gearbox with lubricating oil.

The amount of oil to be filled depends on the amount previously being drained.

6. Refit the oil plug, filling and the plug in the

ventilation hole.

Art.no. and total amount are specified

in


.

Shown in


115

.



3 Maintenance


3.4.4. Oil change, gearbox axis 6


The gearbox axis 6 is located in the center of the tilt house unit as shown in the figure below.


Equipment, etc. Art.no.

Lubrication oil 3HAC032140-001



Standard tollkit

3HAC021745-001

-

Amount Note

250 ml Kyodo Yushi TMO 150

Do not mix with other oil types!

Vessel capacity: 300 ml.



.

Draining, oil

xx0500002484

A

B

C

Gearbox, axis 6

Oil plug, filling

Oil plug, draining

The procedure below details how to drain oil from the gearbox axis 6.

When using the oil change equipment, follow the instructions enclosed with the kit.

Action

1. Put the tilt house in a suitable position.

Note

Location of oil plugs are shown in the figure


.

118



Filling, oil

3 Maintenance


Continued

Note

2.

Action

DANGER!


3. Drain the oil from the gearbox into a vessel by removing the oil plug draining.

Also remove the oil plug, filling.



.

4. Refit the oil plugs, draining and filling.

The procedure below details how to fill oil to the gearbox axis 6.

When using the oil change equipment, follow the instructions enclosed with the kit.

Note

1.

Action

DANGER!


2. Remove the oil plug, filling.

3. Refill the gearbox with lubricating oil.

The amount of oil to be refilled on the amount previously being drained. The correct oil level

is detailed in section

Inspection, oil level gearbox 6 on page 89

.

Shown in


.

Art.no. and the total amount are specified in


.

4. Refit the oil plug.



3 Maintenance

3.4.5. Replacement of SMB battery

3.4.5. Replacement of SMB battery

Location of SMB battery

The SMB battery (SMB = serial measurement board) is located on the left hand side of the frame as shown in the figure below.


Equipment, etc.

Battery pack

Standard toolkit

Circuit Diagram

-

-

Spare part no. Note

3HAC16831-1 Battery includes protection circuits. Replace it only with given spare part no. or an ABB approved equivalent.



.

See chapter

Circuit diagram

.

Removal, battery

xx0500002486

A

B

C

SMB battery cover

SMB battery pack

Battery cable

The procedure below details how to remove the SMB battery.

Action

1. Move the robot to its calibration position.

Note

This is done in order to facilitate the updating of the revolution counter.

120



Action

2.

3.

DANGER!


3 Maintenance


Continued

Note

esd

WARNING!

The unit is sensitive to ESD, before handling the unit please observe the safety information in

section

WARNING - The unit is sensitive to ESD! on page 34

4. Remove the SMB battery cover by unscrewing its attachment screws.

Shown in the figure

Location of SMB battery on page 120

.

5. Pull out the battery and disconnect the battery

cable.

Shown in the figure


.

6. Remove the SMB battery.

Battery includes protection circuits. Replace it only with the specified spare part or with an ABB approved equivalent.

Shown in the figure


.

Refitting, battery

The procedure below details how to refit the SMB battery.

Note

1.

Action

2.

DANGER!


esd

WARNING!

The unit is sensitive to ESD, before handling the unit please observe the safety information in section

WARNING - The unit is sensitive to

ESD! on page 34

3. Reconnect the battery cable to the SMB battery

pack and fit it to the frame.



.

Shown in the figure


.

4. Secure the SMB battery cover with its attachment screws.

Shown in the figure


.



121

3 Maintenance


Continued

Action

5. Update the revolution counter.

6.

DANGER!



.

Note

Detailed in chapter Calibration - section

Updating revolution counters on page 246

.


3 Maintenance

3.5.1. Lubrication of bearing, balancing device

3.5 Lubrication activities

3.5.1. Lubrication of bearing, balancing device

NOTE!

This section is not applicable to the robot variant IRB 6660-205/1.9

Overview

The procedure below details how to lubricate the bearings and piston rod of the balancing device.

Location of bearing and piston rod

The figure below shows the location of the bearings and piston rod.

Note! The balancing device must be fitted on the robot when lubricating the bearings!

xx0500002489

A

B

Ear (adjustable needle bearing located inside)

Support washer



123

3 Maintenance


Continued

C

D

E

Lock nut

Piston rod

Guide ring (not visible in this view)


Equipment

Lubrication tool

Bearing grease

Piston rod grease

Art.no.

3HAC 5222-1

3HAB 3537-1

Castrol Spheerol SX2

Shell SRS 4000

OK Super Grease L2

Statoil Uniway 2X2N

Locking liquid

Standard toolkit -

Note

Equivalent:

• Shell Alvania WR 2


Loctite 243



.


Lubrication, bearings

The procedure below details how to lubricate the bearings, balancing device.

Note Action

1. Move axis 2 to the calibration position.

2.

124

DANGER!


3. Remove the locknut.

Be careful not to loose the support washer in the process.

4. Fit the lubricating tool.

The lubricating tool should be tightened to the bottom, by hand only.

5. Grease through the nipple on the lubricating tool.

6. Continue filling grease until the clean grease exudes behind the inner sealing ring.

Repeat this procedure for the other ring!

7. Remove the lubricating tool and clean the threads on the shaft ends, free from grease.

Also clean from old grease on the inner side!



3 Maintenance


Continued

Action

8. Apply some grease on the support washers.

9. Apply locking liquid on the locknuts (KM-

8).

Note

Tightening torque on the locknuts:

• 120 Nm

NOTE!

Do not apply locking liquid on the shafts!

10. Check the play between support washer and bearingseat at both bearings.

Minimum play:

• 0.1 mm

Lubrication, piston rod

The procedure below details how to lubricate the piston rod, balancing device.

Action

1. Move axis 2 to a position where the balancing device is in the horizontal position and the piston rod extended as much as possible.

2.

Note

DANGER!


3. The piston rod must be lubricated.

4. Clean the piston rod before applying new grease.

5. Apply new grease, if necessary.

Type of grease is specified in


.


3 Maintenance

3.6.1. Cleaning, robot

3.6 Cleaning activities

3.6.1. Cleaning, robot

General

The protection class is IP 67, that is the robot is watertight.

Activities

This instruction specifies how to clean the robot.

Periodicity

The periodicity of cleaning the robot varies a great deal depending on the actual environment and function of the robot. Clean a contamined robot as required.

Special points

Special points to be observed are shown in the figure below:

126 xx0200000239

A

B

C

D

E

Spiral cables to motor 6

Inside of upper arm tube

Rear of upper arm tube

Inside of lower arm

Inside of base/axis 1



3 Maintenance


Continued

xx0600002624

C

D

A

B

Inside upper arm

Inside lower arm

Inside frame

Inside base


Equipment, etc.

Steam cleaner

High pressure water cleaner

Art. no. Note

-

-

• Water pressure at nozzle: max.

2,500 kN/m

2

(25 bar)

• Type of nozzle: fan jet, min. 45° spread

• Flow: max. 100 litres/min.

• Water temperature: max. 80° C

• Max. water pressure on enclosures:

50 kN/m

2

(0.5 bar)

• Fan jet nozzle should be used, min.

45° spread

• Flow: max. 100 litres/min.



127

3 Maintenance


Continued

Do's and don'ts!

The section below specifies some special considerations when cleaning the robot.

Always!

•

Always use cleaning equipment as specified above! Any other cleaning equipment may shorten the life of paintwork, rust inhibitors, signs, or labels!

• Always check that all protective covers are fitted to the robot before cleaning!

Never!

• Never point the water jet at bearing seals, contacts, and other seals!

•

Never spray from a distance closer than 0.4 m!

• Never remove any covers or other protective devices before cleaning the robot!

•

Never use any cleaning agents, for example compressed air or solvents, other than those specified above!

• Although the robot is watertight, avoid spraying connectors and similar items with a high pressure cleaner!


4 Repair

4.1. Introduction

4 Repair


Structure of this chapter

This chapter details all repair activities recommended for the robot and any external units of the robot.

It is made up of separate procedures, each detailing a specific repair activity. Each procedure contains all information required to perform the activity, e.g. spare parts numbers, required special tools and materials.

The procedures are gathered in sections, divided according to the component location on the robot.


All equipment required to perform a specific repair activity is listed together with the current procedure.

The equipment is also gathered in different lists in the

Product manual, reference information

.


Before any service work is commenced, it is extremely important that all safety information is observed!

There are general safety aspects that must be read through, as well as more specific safety information that describe danger and safety risks when performing specific steps in a

procedure. Make sure to read through the chapter

Safety on page 13

before commencing any service work.


4 Repair

4.2.1. Performing a leak-down test

4.2 General procedures

4.2.1. Performing a leak-down test

General

After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test.


Equipment, etc.

Leakdown tester

Leak detection spray

Art. no.

3HAC0207-1

-

Note

Procedure

Action Note

1. Finish the refitting procedure of the motor or gear in question.

2. Remove the topmost oil plug on the gear in question, and replace it with the leakdown tester.

Adapters may be required, which are included in the leakdown tester kit.



.

3. Apply compressed air, and raise the pressure with the knob until the correct value is shown on the manometer.

4. Disconnect the compressed air supply.

Recommended value:

0.2 - 0.25 bar (20 - 25 kPa)

5. Wait for approx. 8-10 minutes. No pressure loss must be detected.

If the compressed air is significantly colder or warmer than the gearbox to be tested, a slight pressure increase or decrease respectively may occur. This is quite normal.

6. Was any pressure drop evident?

Localize the leak as detailed below.

Remove the leakdown tester, and refit the oil plug.

The test is complete.

7. Spray suspected leak areas with leak detection spray.

Bubbles indicate a leak.

8. When the leak has been localized: take the necessary measures to correct the leak.


4 Repair

4.2.2. Mounting instructions for bearings

4.2.2. Mounting instructions for bearings

General

This section details how to mount and grease different types of bearings on the robot.

Equipment

Equipment, etc.

Grease

Art. no.

3HAB3537-1

Note

Used to grease the bearings, if not specified otherwise.

Assembly of all bearings

Follow the instructions below when mounting a bearing on the robot.

Action

1. To avoid contamination, let a new bearing remain in its wrapping until it is time for fitting.

2. Ensure that all parts included in the bearing fitting are free from burrs, grinding waste and other contamination. Cast components must be free from foundry sand.

3. Bearing rings, inner rings and roller elements must under no circumstances be subjected to direct impact. Furthermore, the roller elements must not be exposed to any stresses during the assembly work.

Note

Assembly of tapered bearings

Follow the previous instructions for assembly of all bearings, when mounting a tapered bearing on the robot.

In addition to those instructions, the procedure below must be carried out to enable the roller elements to adjust to the correct position against the race flange.

Action

1. Tension the bearing gradually until the recommended pre-tension is achieved.

Note

NOTE!

The roller elements must be rotated at a specified number of turns before pre-tensioning is carried out and also rotated during the pretensioning sequence.

2. Make sure the bearing is properly aligned, as this will directly affect the lifespan of the bearing.



131

4 Repair

4.2.2. Mounting instructions for bearings

Continued

Greasing of bearings

The bearings must be greased after assembly, according to instructions below:

• The bearings must not be completely filled with grease. However, if space is available beside the bearing fitting, the bearing may be totally filled with grease when mounted, as excessive grease will be pressed out from the bearing when the robot is started.

•

During operation, the bearing should be filled to 70-80% of the available volume.

• Ensure that grease is handled and stored properly, to avoid contamination.

Grease the different types of bearings as detailed below:

• Grooved ball bearings must be filled with grease from both sides.

•

Tapered roller bearings and axial needle bearings must be greased in the split condition.


4 Repair

4.2.3. Mounting instructions for seals

4.2.3. Mounting instructions for seals

General

This sections details how to mount different types of seals to the robot.

Equipment

Equipment, etc.

Grease

Art. no.

3HAB3537-1

Note

Used to lubricate the seals.

Rotating seals

The procedure below details how to fit rotating seals.

CAUTION!

Please observe the following before commencing any assembly of seals:

• Protect the sealing surfaces during transport and mounting.

•

Keep the seal in its original wrappings or protect it well before actual mounting.

• The fitting of seals and gears must be carried out on clean workbenches.

•

Use a protective sleeve for the sealing lip during mounting, when sliding over threads, keyways, etc.

Action Note

1. Check the seal to ensure that:

• the seal is of the correct type (provided with cutting edge).

• there is no damage to the sealing edge (feel with a fingernail).

2. Inspect the sealing surface before mounting. If scratches or damage are found, the seal must be replaced, as it may result in future leakage.

3. Lubricate the seal with grease just before fitting. (Not too early as there is a risk of dirt and foreign particles adhering to the seal.)

Fill the space between the dust tongue and sealing lip to 2/

3 with grease. The rubber coated external diameter must also be greased, unless otherwise specified.


Equipment on page 133

.

4. Mount the seal correctly with a mounting tool.

Never hammer directly on the seal as this may result in leakage.

Flange seals and static seals

The procedure below details how to fit flange seals and static seals.

Action

1. Check the flange surfaces. They must be even and free from pores.

It is easy to check flatness using a gauge on the fastened joint (without sealing compound).

If the flange surfaces are defective, the parts may not be used because leakage could occur.



133

4 Repair

4.2.3. Mounting instructions for seals

Continued

Action

2. Clean the surfaces properly and in accordance with ABB recommendations.

3. Distribute the sealing compound evenly over the surface, preferably with a brush.

4. Tighten the screws evenly when fastening the flange joint.

O-rings

The procedure below details how to fit o-rings.

Action Note

1. Ensure that the correct o-ring size is used.

2. Check the o-ring for surface defects, burrs, shape accuracy, etc.

Defective o-rings may not be used.

3. Check the o-ring grooves.

The grooves must be geometrically correct and free from pores and contamination.

4. Lubricate the o-ring with grease.

Defective o-rings may not be used.

5. Tighten the screws evenly when assembling.


4 Repair

4.3.1. Replacement of cable harness, lower end (axes 1-3)

4.3 Complete robot

4.3.1. Replacement of cable harness, lower end (axes 1-3)

Overview

The cable harness 1-6 is undivided.

Replacement of the cable harness is detailed in two steps - lower end (axes 1-3) and upper end (axes 4-6). The procedure below details replacement of lower end of the cable harness.

The procedure for replacing the upper end is detailed in section


.

Location of cable harness - lower end (axes 1-3)

The cable harness, lower end (axes 1-3) is located throughout the base, frame and lower arm as shown in the figure below.

xx0600002608

E

F

G

H

C

D

A

B

K

L

I

J

Cable harness, lower end

Cable harness, upper end

Connector R1.MP

Connector R1.SMB

Attachment point for earth lug

Cover plate

Rear cover plate

Cable gland, SMB

Cable guide, axis 2

Metal clamp, frame

Metal clamp, lower arm

Metal clamp, upper arm



135

4 Repair


Continued

M Metal clamp, tilthouse

136 xx0700000070

D

E

F

G

H

A

B

C

Cable guide, axis 2

Metal clamp

Connector at base

Cable guide, axis 1

Cable harness, axes 1-6

Cover plate

Rear cover plate




4 Repair


Continued

The motors axes 2-3 are located on either side of the robot as shown in the figure below.

xx0600002599

C

D

A

B

E

Motor, axis 2

Motor, axis 3

Motor attachment screws and washers

Cable gland cover (located on the lower side of the motor)

Motor cover


Equipment, etc.

Spare part no.

Cable harness 1-6 3HAC022544-001

Gasket

Standard toolkit

3HAC3537-1

-

Art.no.

Note


Circuit diagram

Motor axes 1-5


section


.


3HAC025690-001

3HAC025691-001

See chapter

Circuit diagram

.

Removal, cable harness - lower end (axes 1-3)

The procedure below details how to remove the cable harness, lower end (axes 1-3).

Action

1. Move the robot to the calibration position.

Note

This is done in order to facilitate updating of the revolution counter.



137

4 Repair


Continued

2.

Action Note

DANGER!


3. Remove the rear cover plate on the robot by removing its attachment screws.

4. Disconnect the earth cable.

Shown in

Location of cable harness - lower end (axes 1-3) on page 135

.

Shown in


.

5. Disconnect connectors R1.MP and R1.SMB.

Shown in


.

6. Remove the cable guide axis 2.

138

7. Unscrew the screws in the metal clamps holding the cable harness in the frame and lower arm.

8. Remove the motor cover, axis 1, 2, 3 by removing its attachment screws, in order to reach the connectors.

9. Disconnect all connectors at motor 1, 2 and 3.

xx0600002698

• A: Cable guide ax 2

Shown in




4 Repair


Continued

Action

10. Open the SMB cover carefully.

The cable (C) between the battery and the SMB unit may stay connected, in order to avoid an update of the revolution counter. Be careful not to let the weight of the cover strain the cable!

In order to remove the cover completely, the connector R1.G must be disconnected! This causes a necessary updating of the revolution counter!

Note

11. Disconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB4-6 from the SMB unit.

Disconnect X8, X9 and X10 from the brake release unit.

12. Remove the cable gland, SMB by removing its four attachment screws from inside the SMB recess.

Perform this removal with care, in order not to damage any of the components inside the SMB recess.

xx0600002700

• A: SMB battery cover

• B: SMB battery pack

• C: Battery cable xx0600002701

• A: Cable gland, SMB

• B: Attachment screws (4 pcs)



139

4 Repair


Continued

Action

13. Gently pull the cable harness out of base through the cable guide, axis 1 and the frame.

Note

14. Continue removal of the cable harness in the upper arm.

xx0600002699


• B: Metal clamp, frame

• C: Cable guide, axis 1

Detailed in


.

140



4 Repair


Continued

Refitting, cable harness - lower end (axes 1-3)

The procedure below details how to refit the cable harness, lower end (axes 1-3).

Action Note

1. Pull the cable and connectors down through the cable guide axis 1 in the center of the frame.

Make sure the cables are not twisted with each other or with eventual customer harness!

2. Pull out the cables and connectors to the SMB unit through the frame and refit the cable gland with its four attachment screws from inside the

SMB recess.

Perform this refitting with care, in order not to damage any of the components inside the SMB recess.

xx0600002699


• B: Metal clamp, frame

• C: Cable guide, axis 1 xx0600002701


• B: Attachment screws, (4 pcs)

3. Reconnect connectors R1.MP and R1.SMB at the robot base.

Attachment points are shown in the figure


.



141

4 Repair


Continued

Action

4. Reconnect the earth cable.

5. Refit the rear cover plate on the robot with its attachment screws.

Note

Attachment point is shown in the

figure


Shown in the figure


6. Reconnect all connectors at motor 1, 2 and 3.

7. Refit the motor cover, axis 1, 2, 3.

Make sure the cabling is placed correctly when refitting the cover and does not get jammed.

8. Reconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB4-6 to the SMB unit.

Reconnect X8, X9 and X10 to the brake release unit.

Reconnect R1.G if it has been disconnected.

9. Secure the SMB cover with its attachment screws.

10.

WARNING!

Before continuing any service work, please observe the safety information in section

WARNING - The brake release buttons may be jammed after service work on page 33

!

11. Refit the cable guide, axis 2.

142 xx0600002698

• A: Cable guide axis 2

12. Pull the cable harness through the lower arm.

13. Continue refitting of the cable harness in the upper arm.

14. Update the revolution counter!

Detailed in section


.

Detailed in section


.



4 Repair


Continued

Note

15.

Action

DANGER!



.


4 Repair

4.3.2. Replacement of cable harness, upper end (incl. axis 6)

4.3.2. Replacement of cable harness, upper end (incl. axis 6)

Overview

Replacement of the cable harness is detailed in two steps - lower end (axes 1-3) and upper end. The procedure below details replacement of the cable harness in the upper end (incl. axis

6). The procedure for replacing the lower end (axis 1-3) is detailed in section

Replacement of cable harness, lower end (axes 1-3) on page 135 .

Location of cable harness, upper arm

The cable harness, upper end is located as shown in the figure below.

144 xx0600002608

E

F

G

H

C

D

A

B

K

L

I

J

M

Cable harness, lower end

Cable harness, upper end

Connector R1.MP

Connector R1.SMB


Cover plate

Rear cover plate

Cable gland, SMB

Cable guide, axis 2

Metal clamp, frame

Metal clamp, lower arm

Metal clamp, upper arm

Metal clamp, tilthouse



4 Repair


Continued

The motor axis 6 is located as shown in the figure below.

xx0600002600

A

B

C

D

Motor, axis 6

Attachment screws and washers

Cable gland cover

Motor cover


Equipment, etc

Cable harness, 1-6

Standard toolkit

Spare part no.

3HAC 022544-001

-

Art.no.

Note

Detailed in section

Spare parts - cable harness on page 266

.



.


Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below.

Circuit diagram 3HAC 025690-001

3HAC 025691-001

See chapter

Circuit diagram

.

Removal, cable harness upper end (incl. axis 6)

The following procedure details how to remove the cable harness, upper arm (incl. axis 6).

Action Note


This is done in order to facilitate updating of the revolution counter.



145

4 Repair


Continued

2.

Action Note

DANGER!


3. If the complete cable harness is being replaced, start removal by removing the

cable harness, lower end.

4. Remove the motor cover axis 6 by removing its attachment screws, in order to reach the connectors.

Detailed in section

Replacement of cable harness, lower end (axes 1-3) on page

135

146

5. Disconnect connectors at motor axis 6.

6. Remove the cable gland on motor axis 6 by unscrewing the screw which is found after removing the motor cover.

xx0600002696

• A: Motor cover

• B: Attachment screws

• C: Cable gland xx0600002694

• A: Screw holding the cable gland



4 Repair


Continued

Action

7. Remove the metal clamp holding the cable at the tilt house, by removing its nuts.

Note

8. Carefully pull the cable harness out of motor axis 6.

9. Remove the cable clamps holding the harness inside the upper arm by removing its four nuts.

xx0600002702

• A: Metal clamp, axis 6

10. Carefully pull out the cable harness from the upper and lower arm.

xx0500002498

• A: Metal clamp, upper arm

Refitting, cable harness upper arm

The following procedure details how to refit the cable harness, upper arm. It also details how to refit the cable harness in axis 6.

Action Note

1. Start by fitting the cable harness, lower end if it has been removed.

Detailed in section

Replacement of cable harness, lower end (axes 1-3) on page

135

2. Push the cable harness through the lower and upper arm.



147

4 Repair


Continued

Action

3. Refit the cable harness inside the upper arm by refitting the cable clamps with its four nuts inside the upper arm.

Note

4. Refit the metal clamp at the tilthouse with its nuts.

xx0500002498

• A: Metal clamp, upper arm

5. Push the motor cables axis 6 carefully through the cable gland.

6. Refit the cable gland with the screw which is found under the motor cover.

xx0600002702

• A: Metal clamp, axis 6

148

7. Reconnect the connectors in motor axis 6.

Put the cables in a way that they are not twisted.

8. Refit the motor cover.

Make sure the cabling is placed correctly when refitting the cover and does not get jammed.

xx0600002694




4 Repair


Continued

Action


10.

Note

Detailed in section


.

DANGER!


DANGER -

First test run may cause injury or damage! on page 32

.


4 Repair

4.3.3. Replacement of complete arm system

4.3.3. Replacement of complete arm system

Location of arm system

The complete arm system is defined as the complete robot except for the base and gearbox axis 1. This is shown in the figure below.

A more detailed view of the component and its position may be found in chapter

Spare parts and exploded views on page 263

.

xx0600002612

D

E

F

G

H

A

B

C

Parallel rod

Linkage

Complete upper arm (incl. tilthouse)

Balancing device

Frame

Gearbox, axis 1

Base

Base attachment screws


Equipment, etc.

Lifting device, robot

Art. no.

3HAC15607-1

Note

Instruction 3HAC15971-2 is enclosed!

150



4 Repair


Continued

Equipment, etc.

Guide pins M12 x 130

Hoisting block

Standard toolkit


-

Art. no.

3HAC022637-001

-

Note

Used to guide the complete arm system when refitting.

Always use the guide pins in pairs!

In order to make the refitting easier, it is recommended to use two guide pins of different lengths. Notice that longer guide pins than 140 mm will not be possible to remove from the frame because lack of space after refitting!

Used to adjust the length of the lifting chain.



.


Removal, arm system

The procedure below details how to lift and remove the complete arm system.

Action

1. Make sure the robot is positioned as shown in figure to the right. If it is not, position it that way.

Note

Release the brakes if necessary, as detailed in section


.

xx0500002275

2.

DANGER!


3. Drain the oil from gearbox axis 1.

Detailed in section


.

4. Loosen the cable connectors from the base and pull up the cabling from the base, through the hole in the center of the frame.

Detailed in section

Replacement of cable harness, axes 1-6

.



151

4 Repair


Continued

Action

5. Remove the motor, axis 1.

Note

Detailed in section

Removal, motor on page

213

.

6. Run the overhead crane to a position above the robot.

7. Fit the lifting device and adjust it as detailed in the enclosed instructions.

8. Remove the block for calibrationand

calibration plate axis 1 from the bottom of the frame.



.

Make sure the lift is done completely level!

How to adjust the lift is described in the enclosed instruction to the lifting device!

Read the instructions before lifting!

152

9. Unfasten the arm system from the base by unscrewing its 24attachment screws.

10. Fit the two guide pins in two opposite screw holes.

11.

xx0600002734

• A: Block for calibration

• B: Calibration plate axis 1

Shown in the figure

Location of arm system on page 150

.



.

CAUTION!

The complete arm system weighs 1250 kg! All lifting equipment used must be sized accordingly!

12. Lift the arm system carefully and secure it in a safe area.

Always move the robot at very low speeds, making sure it does not tip.

Continue lifting even if the arm system turns out to be unbalanced despite earlier adjustments! The risk of damaging the interfaces is bigger if the load is lowered unbalanced!

Make sure all hooks and attachments stay in the correct position while lifting the arm system and that the lifting device does not wear against sharp edges.



4 Repair


Continued

Refitting, arm system

The procedure below details how to lift and refit the complete arm system.

Note

1.

Action

DANGER!


2. Fit the lifting device as detailed in enclosed instruction.

Also fit a hoisting block to the frontchain, used to adjust the balance of the arm system in order to lift it completely level!



.

Make sure the lift is done completely level! How to adjust the lift is described in the enclosed instruction to the lifting device! Follow the instructions before

lifting!

3.

CAUTION!

The complete arm system weighs 1250 kg!

All lifting equipment used must be sized accordingly!

4. Lift the complete arm system and move it at very low speed, making sure it does not tip!

Make sure the lift is done completely level.

Adjust the length of the chains as detailed in enclosed instruction or with a hoisting block.

Make sure all the hooks and attachments stay in the correct position while lifting the robot!

5. Fit the two guide pins to the frame attachment holes, as shown in the figure to the right.

3HAC025755-001 Revision: B x0600002632

The figure above shows the frame, view from below.

• A: Attachment holes for the guide pins, M12


153

4 Repair


Continued

Action Note

6. Look through the empty mounting hole of motor 1 to assist in aligning the assembly during refitting of the arm system.

Lower the arm system with guidance from the guide pins previously fitted to the frame.

This is a complex task to be performed with utmost care in order to avoid injury or damage!

NOTE!

The refitting must be made completely level!

Make sure the lifting device is adjusted prior to refitting of arm system.

7. Refit 22 of the 24 attachment screws before the arm system is completely lowered.

8. Remove the guide pins and secure the arm system to the base with its 24attachment

screws and washers.

Shown in the figure

Location of arm system on page 150

.

M12 x 70, tightening torque: 115 Nm.

Reused screws may be used, providing they are lubricated as detailed in section

Screw joints on page 254

before fitting.

9. Refit the block for calibrationandcalibration

plate axis 1 at the bottom of the frame.

154

10. Refit the motor axis 1. xx060002734

• A: Block for calibration

• B: Calibration plate axis 1

Detailed in section

Refitting, motor on page 215

.

11. Refit the cabling in the base.

12. Perform a leak-down test of the gearbox axis

1.

Detailed in section

Performing a leakdown test on page 130

.

13. Refill the gearbox axis 1 with lubricating oil.

Detailed in section


.



Action

14. Recalibrate the robot.

15.

DANGER!

Make sure all safety requirements are met when performing the first test run. These are

further detailed in section


.

4 Repair


Continued

Note




.


4 Repair

4.4.1. Replacement of turning disk

4.4 Upper and lower arm

4.4.1. Replacement of turning disk

Location of turning disk

The turning disk is located in the front of the wrist housing, as shown in the figure below.



.

xx0600002627

C

D

A

B

E

Turning disk

Attachment screws (6 pcs) turning disk

Tilthouse unit

Gearbox, axis 6

Attachment screws, axis 6


Equipment, etc.

Turning disk, diam. 200

O-ring

Grease

Standard toolkit

Spare part no. Art. no. Note

For robot version 180/3.15,

250/3.15

O-rings are not included!

3HAB3772-65

(1 pc)

21520431-20 (6 pcs)

For robot v. IRB 660 180/

3.15, 250/3.15

Must be replaced when replacing the turning disk!

-

3HAB3537-1 Used to lubricate the o-rings.



.

156



4 Repair


Continued

Equipment, etc.


Spare part no. Art. no.

Removal, turning disk

The procedure below details how to remove the turning disk.

Note

1.

Action

Note


DANGER!


2. Remove any equipment fitted to the turning disk.

3. Run the robot to a position where it is best to remove the turning disk.

4. Drain the oil from gearbox 6. Detailed in section

Draining, oil on page 118

.

5. Remove the turning disk by unscrewing its

attachment screws.

Shown in the figure

Location of turning disk on page 156

.



157

4 Repair


Continued

Refitting, turning disk

The procedure below details how to refit the turning disk.

Action

1. Lubricate the turning disk o-ring with grease.

Fit the o-ring to the rear of the turning disk.

Also fit the six o-rings, when refitting the attachment screws.

Note



.

158

2. Secure the turning disk with its attachment

screws. xx0200000218

• A: Sealing surface, o-ring

6 pcs M14 x 25, 12.9 quality.


Reused screws may be used, providing they are lubricated as detailed in

section


before fitting.

3. Perform a leak-down test of the gearbox axis 6. Detailed in section


.

4. Refill the gearbox 6 with oil.

Detailed in section

119

.

Filling, oil on page

5. Refit any equipment removed during disassembly, to the turning disk.

6.

DANGER!



.


4 Repair

4.4.2. Replacement of tilthouse unit

4.4.2. Replacement of tilthouse unit

Location of tilt house

The tilthouse unit is located as shown in the figure below.



.

xx0600002616

D

E

F

G

A

B

C

Tilthouse unit

Upper arm

Upper rod

Screw M6x10

Washer 6.4x12x1.6

Ballplug

Protection cap



159

4 Repair


Continued

Location of axes 2 and 3 sides of the robot

The figure below shows the location of the axes 2 and 3 sides of the robot. See markings on the lower arm (axis 2) and the parallel arm (axis 3).

xx0600002743

A

B

Axis 2 side of the robot

Axis 3 side of the robot

Cut away view of the assembly of the tilthouse unit

The figure below shows a cut away view of how the tilthouse unit is fitted to the upper arm.

The letters in the figure are being referred to in the step by step procedures below.

160 xx0600002742

A

B

Axis 2 side

Axis 3 side



K

L

M

N

O

P

I

J

G

H

E

F

C

D

4 Repair


Continued

VK cover, VK 19 x 6, 2 pcs

VK cover, VK 68 x 8, 2 pcs

Screw M6 x 10 Steel 8.8-A2F + Washers, 4 + 4 pcs (for filling bearing grease)

Retaining ring fore bores, 2 pcs

Rust protection, Dinitrol 490

Upper arm

Tilthouse

Bearing, 2 pcs (on the outside of the tilthouse)

Bearing, 2 pcs (on the inside of the tilthouse)

Ring

Shaft, 2 pcs

Radial seal with dustlip, 2 pcs

Lock nut, KM7 2 pcs

Screw M6x16 + washer (for locking the shafts), 2 + 2 pcs


Equipment, etc.

Press tool, premounting bearing

Press tool, mounting axis 6

Shims

Grease

Rust protection

Locking liquid

Standard toolkit

Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below.

Circuit diagram

Spare part no.

Art.no.

3HAC 023075-001

Note

-

3HAC 023080-001

3HAB 3537-1

Width = 3 mm

Dinitrol 490

Loctite 243


section


.


3HAC 025690-001

3HAC 025691-001

See chapter

Circuit diagram

.



161

4 Repair


Continued

Press tool premounting bearing

The press tool for premounting the bearing race, bearing complete, radial seal with dustlip and ring in the tilthouse, is assembled with the parts shown in the figure below.

Note! The parts cannot be ordered separatly, but are inluded when ordering the complete tool.

The article numbers are given only for identification.

xx0600002750

E

F

G

C

D

A

B

Hydraulic cylinder, 3HAC 11731-1

Mounting washer, 3HAC 023075-004

Bushing, 3HAC 023075-006

Screw M6x25, 2 pcs (MC6S)

Threaded washer, 3HAC 5507-1

Press washer, 3HAC 023075-002

Threaded bar, M16 L = 300 mm

162



4 Repair


Continued

Press tool mounting axis 6

The press tool for mounting the tilthouse on the upper arm, is assembled with the parts shown in the figure below.

Note! The parts cannot be ordered separatly, but are included when ordering the complete tool. The article numbers are given only for identification.

xx0600002751

D

E

F

G

H

A

B

C

Hydraulic cylinder, 3HAC 11731-1

Distance, 3HAC 023062-001

Press housing, 3HAC 023080-004

Support housing, 3HAC 023080-003

Screw M6x14, 2pcs (MC6S)

Flange lock nut, M16

Threaded bar, M16 L=435 mm

Nut M16

Removal, tilthouse

The procedure below details how to remove the tilthouse unit.

The item letters within paranthesis refer to the figure

Cut away view of the assembly of the tilthouse unit on page 160

.

Action

1. Move the robot to a position where the tilthouse rests on a table or similar.

Note



163

4 Repair


Continued

2.

Action Note

DANGER!


3. Secure the tilthouse with a roundsling in an overhead crane.

4. Remove the upper rod.

5. Remove one of the M6 screws and washer at the cover for filling grease.

This is done in order to prevent the tilthouse from falling down when the shafts are removed.

Detailed in section

Replacement of linkage - upper rod on page 177

164

6. Note! Do not remove the ball plug!

Be careful not to damage the ball plug!

xx0600002735

• A: Screw M6, grease filling hole

Shown in the figure

house on page 159

.

Location of tilt

7. Remove the motor cable axis 6.

Detailed in section


Put the motor cable in a way that is isn´t damaged.

8. Remove one shaft at a time by following the steps below.

9. Use compressed air in the M6 hole for filling grease (E), in order to remove the VK cover (D).

Note! Only a very low air pressure is needed!

Put a hand with some paper over the

VK cover in order to catch it.



Action

10. Remove the screw that locks the shaft.

4 Repair


Continued

Note

xx0600002703

• A: Screw M6x16

• B: Shaft

• C: Upper arm

11. Remove the small VK cover (C) from the inside with the help of a punch.

Shown in the figure


.

12. Remove the lock nut (O).

Shown in the figure


.

13. Remove the shaft (M) with the press tool,

mounting axis 6.

Note! A longer threaded bar M16 is needed when removing the shaft than the one specified when fitting.

Art.no is specified in


14. Check that the tilthouse is secured in a overhead crane or similar before proceeding with the next shaft.

15. Remove the other shaft in the same way.

16. Lift the tilthouse to a safe place.

17. Force away the sealing ring (N) with a screwdriver or similar.

18. If needed change the bearings.

Follow steps 9 through 13.

Check that the bearings are kept clean, if they are refitted.

The sealing must be replaced with a new one when refitting.

Premounting tilthouse bearings and other parts, axis 2 side

The procedure below details how to fit the bearings and other parts in the tilthouse on the axis

2 side, before fitting the tilthouse to the upper arm.

This work is best done on a workbench or similair.

Action

1. Lift the tilthouse to a workbench (or similair) with a roundsling in an overhead crane.

Note



165

4 Repair


Continued

Action Note

2. Apply some grease in the hole for the bearings

(J) and (K).



.

Shown in the figure


.

3. Fit two retaining rings for bores (F).

Shown in the figure


.

4. Fit the outer race of the bearing (J) facing the outside of the tilthouse. Use a plastic hammer or similair.

Shown in the figure


.

5. Thread the radial seal with dustlip (N) and the

inner bearing complete (K) on the presswasher

(F) of the pressing tool, premounting bearings.

Shown in the figure


.

Shown in the figure

Press tool premounting bearing on page 162

.



.

6. Thread the race of the outer bearing (J) on the

bushing (C) of the pressing tool, premounting

bearings.

Shown in the figure


.

Shown in the figure


.



.

7. Fit the pressing tool and press the parts together.

Premounting tilthouse bearings and other parts, axis 3 side

The procedure below details how to fit the bearings and other parts in the tilthouse on the axis

3 side, before fitting the tilthouse to the upper arm.

This work is best done on a workbench or similair.

Action Note

1. Apply some grease in the hole for the bearings

(J) and (K).



.

Shown in the figure


.

2. Fit the outer race of the bearing (J) facing the outside of the tilthouse. Use a plastic hammer or similiar.

Shown in the figure


.

3. Thread the radial seal with dustlip (N), the inner

bearing complete (K) and the ring (L) on the

press washer (F) of the pressing tool,

premounting bearings.

Shown in the figure


.

Shown in the figure


.

Art.no. specified in


.

166



4 Repair


Continued

Action Note

4. Thread the race of the outer bearing (J) on the

bushing (C) of the pressing tool, premounting

bearings.

Shown in the figure


.

Shown in the figure


.



.

5. Fit the pressing tool and press the parts together.

Refitting, tilt house

The procedure below details how to refit the tilthouse unit.

Before starting this procedure, prepare the tilthouse as detailed in the procedures

Premounting tilthouse bearings and other parts, axis 2 side on page 165

and

Premounting tilthouse bearings and other parts, axis 3 side on page 166

.

Action Note

1. Secure the tilthouse with a roundsling in an overhead crane and lift it to its mounting position on the upper arm.

2. Apply Dinitrol 490 (G) on the surfaces where the tilthouse faces the upper arm for rust protection.

7. Fit the rest of the press tool, mounting axis 6 from the outside of the tilthouse.Secure the parts with the flange locknut (F).

Shown in the figure


.

3. Apply some grease in the holes for the shafts

(M) in the upper arm.

4. Note! Fit the axis 2 side first.



.

Shown in the figure


.

Shown in the figure

Location of axes 2 and 3 sides of the robot on page 160

.

5. Push the axis 2 shaft (M) into its hole, from the inside.

Shown in the figure


.

6. Thread the race of the bearing (J) facing the outside of the tilthouse, on the press housing

(C) of the press tool, mounting axis 6 and fit it on the shaft (M).

Shown in the figure


.

Shown in the figure

Press tool mounting axis 6 on page 163

.



.



.

Shown in the figure

Press tool mounting axis 6 on page 163

.



167

4 Repair


Continued

Action Note

8. Insert the shims in the space between the tilthouse and the upper arm on the axis 2 side.



.

xx0600002748

• Shims, width = 3 mm

• A: 68 mm

9. Press the parts together.

10. Fit the axis 3 side in the same way, by following steps 4 through 6.

11. Insert the shims in the space between the tilthouse and the upper arm on the axis 3 side.

12. Press the parts together.

13. Apply locking liquid on the lock nut, KM7 axis 2 side and fit it with the flat surface facing inside.

Loctite 243.


14. Apply locking liquid on the lock nut, KM7 axis 3 side and fit it with the flat surface facing inside.

Loctite 243.


15. Apply locking liquid in the holes for the screws locking the shafts and fit screws and washers on both sides, locking the shafts.

168

16. Fit the inner VK cover (C) on both axes.

17. Fit the outer VK cover (D) on both axes.

18. Fill bearings with grease.

0600002703

• A: Screw M6x16

• B: Shaft

• C: Upper arm

Shown in the figure


.

Shown in the figure


.

Specified in


.



4 Repair


Continued

Action

19. Refit the motor cable, axis 6.

20. Refit the M6 screw and washer at the cover for filling grease.

Note

Detailed in section


21. Refit the upper rod.


23.

DANGER!



.

xx0600002735

• A: Screw M6, grease filling hole

Detailed in section





.


4 Repair

4.4.3. Replacement of upper arm

4.4.3. Replacement of upper arm

Location of upper arm

The upper arm is located as shown in the figure below.



.

xx0600002609

D

E

F

A

B

C

Upper arm

Motor axis 6

Balancing device

Lower arm

Parallel rod

Linkage

170



4 Repair


Continued

View of the assembly of the upper arm components

The figure below show a cut away view how the upper arm is fitted to the lower arm. (Seen from above) The letters in the figure are being referred to in the step by step procedures below.

xx0600002692

E

F

G

H

C

D

A

B

Shaft, axis 2

Shaft, axis 3

Set screw, cup point ( M10 x 20)

Lubricant paste (Molycote 1000)

Sealing ring (V-ring)

Sealing ring

Taper roller bearing

O-ring



171

4 Repair


Continued

K

L

I

J

Sealing ring

Sealing assembly

Lock nut (KM 12)

O-ring (Di = 54.2 mm, t = 5.7 mm)


Equipment, etc.

Spare part no.

Upper arm, axis 4 3HAC025525-001

3HAC026674-001

Adapter

Grease filling tool

Pressing tool, upper arm

KM12 socket

Standard toolkit

Art.no.

3HAC023916-001

-

3HAC023084-001

-

3HAC5347-1


Circuit diagram -

Note

White RAL 9003


section


.


See chapter

Circuit diagram

.

Removal, upper arm

The procedure below details how to remove the upper arm.

Action

1. Remove all equipment fitted to the turning disk.

2. Move the upper arm to a horizontal position.

3.

Note

172

DANGER!


4. Secure the upper arm with roundslings in an overhead crane.

5. Remove the cable harness in the upper arm.

6. Raise the lifting equipment to take the weight of the upper arm.

7. Remove the balancing device.

Detailed in section

Detailed in section




4 Repair


Continued

Action Note

8. Remove the linkage.

9. Remove the parallel rod.

Detailed in section


Detailed in section

Replacement of linkage - lower rod on page 180

Detailed in section

Replacement of linkage - link on page 183

Detailed in section

Replacement of parallel rod on page 188

10. Remove the lock nut (K) on the shaft, axis

3 (B).

Shown in the figure

View of the assembly of the upper arm components on page

171

.

11. Remove the set screw (C) holding the shaft. Shown in the figure


171

.

12. Put the adapter on the shaft.

13. Remove the shaft axis 3 (B).

14. Then remove the shaft, axis 2 (A) in the same order:

1. Remove the lock nut (K)

2. Remove the set screw (C) holding the shaft

3. Remove the shaft axis 2.



Shown in the figure


171

.

Perform the removal with care. Threads can otherwise be damaged!

Shown in the figure


171

.

NOTE!

The adapter is not needed on this shaft!

15. Put the shafts in a clean and safe place.

16. Remove the upper arm.

Preparations before refitting, upper arm

The procedure below details the preparations which must be done before refitting the upper arm.

Action Note

1. Put the shafts (A & B) on a workbench and fit the sealing rings (E).

Shown in the figure


171

.

2. Apply some grease on the shafts and

sealing rings.

NOTE!

Don´t apply grease on the threads and cones of the shafts!



173

4 Repair


Continued

Action Note

3. Fill the bearings (G) with bearing grease.

Use grease filling tool.

Art. no. is specified


Shown in the figure


171

.

4. Apply lubricant paste (D) on the threads and cones of the shafts.

Molycote 1000.

Shown in the figure


171

Refitting, upper arm

The procedure below details how to refit the upper arm.

Action

1. Secure the upper arm with roundslings in an overhead crane.

2.

Note

3.

CAUTION!

The complete upper arm with weighs 170 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel!

CAUTION!

The complete upper arm weighs 380 kg without any additional equipment fitted!

Use a suitable lifting device to avoid injury to personnel!

4. Lift the upper arm with an overhead crane and move it to its mounting position.

Make sure that the upper arm is placed in a horizontal position.

5.

NOTE!

Refit the axis 3 side first!

6. Carefully refit the shaft, axis 3 (B) by hand only.

Don´t use force since the threads can be damaged if fitting is not done in the correct way.

Shown in the figure


171

.

174



4 Repair


Continued

Action Note

7. Put the adapter on the shaft and fit it.

Secure the shaft.


8. Refit the sealing ring (F) on the shaft.



The adapter is used in order to be able to use the same tool on both axis 2 and 3

shaft when refitting.

The adapter is only used on the shaft axis

3.

Shown in the figure


171

.

9. Refit the bearing (G) on the shaft with the pressing tool, upper arm.

Shown in the figure


171

.

10. Fit an o-ring (H) on the sealing ring (I) and fit it on the shaft.

Shown in the figure


171

.

NOTE!

The o-ring shall be faced against the

bearing.

11. Fit the o-ring (L) on the sealing assembly (J) and refit the sealing assembly on the shaft.

Shown in the figure


171

.

12. Apply locking liquid on the lock nut (K) and refit it.

Shown in the figure


171

.

Loctite 243.

Tightening torque 90 Nm.

13. The refit the axis 2 side in the same order with the exception of the lock nut (K).

Follow the steps for refitting shaft axis 3 above.

Shown in the figure


171

.



175

4 Repair


Continued

Action Note

14. Apply locking liquid on the lock nut (K) and refit it.

NOTE!

The order of the tightening torques is very important!

Shown in the figure


171

.

Loctite 243.

Tightening torque the first time: 300 Nm

Tightening torque the second time: 90

Nm

176

NOTE!

The fitting of the lock nut on axis 2 is performed in three steps:

1. Fit the lock nut with a tightening torque of 300 Nm.

2. Unscrew the lock nut.

3. Fit the lock nut once again. This time with a tightening torque of 90 Nm.

15. Apply locking liquid in the holes for the set

screws (C) and fit the screws.

Shown in the figure


171

Loctite 243.


16. Wipe residual grease from the shafts.

17. Refit the parallel rod.

18. Refit the cable harness, upper end.

19. Refit the linkage.

20. (Not applicable to the robot variant IRB

6660 - 205/1.9! )

Refit the balancing device.


Detailed in section


Detailed in section

Detailed in section


Detailed in section


Detailed in section


Detailed in section



General calibration information is

included in section


.

22.

DANGER!


DANGER -


.


4 Repair

4.4.4. Replacement of linkage - upper rod

4.4.4. Replacement of linkage - upper rod

Overview

The link system consists of three basic parts - upper rod, lower rod and link. The procedures below details how to remove and refit the upper rod.



.

Location of upper rod

The upper rod is located as shown in the figure below.

xx0600002592

A

B

C

Lower rod

Upper rod

Link


Equipment

Upper rod

Needle bearing

Bearing grease

Locking liquid

Spare part no.

Art no.

3HAC023744-003

3HAC3311-1

3HAB3537-1

3HAB7116-1


Note

White RAL 9003

Replace if damaged.

Used to lubricate the bearings.

Loctite 243


177

4 Repair


Continued

Equipment

Standard toolkit


Spare part no.

-

Art no.

Note


section


.


Removal, upper rod

The procedure below details how to remove the upper rod of the linkage.

Action

1. Put the robot in a position where it is possible to reach all parts that shall be removed.

2.

Note

Check especially that it is possible to remove the lock nut at the link.

DANGER!


3. Let the tilthouse rest on something, (a table for example).

This is done in order to prevent the tilthouse from falling downwards when the upper rod is removed.

4. Remove the lock nuts holding the upper rod at each end.

5. Remove the support washers from the upper rod.

6. Remove the upper rod.

Note! The support washers on the inside of the rod can stick to the grease of the bearings when the rod is being removed.

Remove them from the rod!

7. Remove the support washers and the sealing rings.

8. Remove residual grease.

Refitting, upper rod

The procedure below details how to refit the upper rod of the linkage.

178

Action Note

1. If needed, replace the bearings in the rod.

Note! The bearings are sensitive for pushes. Make sure they are not damaged!

Spare part no. is specified in

equipment on page 177

.

Required

2. Lubricate the bearings properly with bearing

grease.

Specified in

Required equipment on page

177

.

3. Refit the sealing rings on the shaft ends of the link and tilthouse.



4 Repair


Continued

Action Note

4. Refit the support washers on the shaft ends.

5. Refit the upper rod to its place on the shafts. Check that the rod is pushed in completely.

6. Refit the support washers on the outside of the upper rod, on the shaft ends.

7. Refit the lock nuts on the link and tilthouse, using locking liquid.


8.

DANGER!



.


4 Repair

4.4.5. Replacement of linkage - lower rod

4.4.5. Replacement of linkage - lower rod

Overview

The linkage consists of three basic parts - upper rod, lower rod and link. The procedures below details how to remove and refit the lower rod.



.

Location of lower rod

The lower rod is located as shown in the figure below.

xx0600002592

A

B

C

Lower rod

Upper rod

Link


Equipment

Lower rod

Needle bearing

Bearing grease

Locking liquid

Spare part no.

3HAC023239-003

3HAC3311-1

Art no.

3HAB3537-1

3HAB7116-1

Note

White RAL 9003

Replace if damaged.

Loctite 243

180



4 Repair


Continued

Equipment

Standard toolkit


Spare part no.

Art no.

Note



.


Removal, lower rod

The procedure below details how to remove the lower rod of the linkage.

Note

1.

Action

DANGER!


2. If the upper rod is removed, secure the link with a roundsling in a crane. Use the hole in the middle of the link.

This is done in order to prevent the link from moving if both the upper and lower rod are removed.

3. Remove the lock nuts holding the lower rod at each end.

4. Remove the support washers.

These can stick to the grease and can easy be forgotten and lost when removing the lock nuts.

5. Remove the lower rod.

Note! The support washers on the inside of the rod can stick to the grease of the bearings when the rod is being removed.

Remove them from the rod!

6. Remove the support washers and the sealing rings and remove residual grease.

Refitting, lower rod

The procedure below details how to refit the lower rod of the linkage.

Action

1. If needed, replace the bearings.

Note! The bearings are sensitive for pushes.

Make sure they are not damaged!

2. Lubricate the bearings properly with bearing

grease.

3. Refit the sealing rings to the shaft ends on the link and frame.

4. Refit the support washers to the shaft ends.

Note

Spare part no. is specified in


.

Specified in


.

Tip! Putting some grease on the support washers will keep them in position.



181

4 Repair


Continued

Action Note

5. Refit the lower rod on the shaft ends of the link and frame.

6. Refit the support washers on the outside of the lower rod, on the link and frame shafts.

7. Refit the lock nuts on the shaft ends, using

locking liquid.

Check that the lower rod is pushed completely in.


Locking liquid is specified in


.

8.

DANGER!

Make sure all safety requirements are met when performing the first test run. These are further

detailed in section


.


4 Repair

4.4.6. Replacement of linkage - link

4.4.6. Replacement of linkage - link

Overview

The linkage consist of three basic parts - upper rod, lower rod and link. The procedures below details how to remove and refit the link.



.

Location of link

The link is located as shown in the figure below.

xx0600002592

A

B

C

Lower rod

Upper rod

Link


Equipment, etc.


Link

Auxiliary shaft

Pressing tool, link

Pressing tool, link

Note

White RAL 9003

3HAC 023081-004

3HAC 023081-001 Used to press the link on the shaft

3HAC 023079-001 Used to press the outer rings of the bearings in the link



183

4 Repair


Continued

Equipment, etc.


Lubrication tool

Sealing compound

Locking liquid

Grease

Standard toolkit

3HAC 5222-2

3HAB 3537-1


Removal, link

The procedure below details how to remove the link of the linkage.

Note

1.

Action

Note

Permatex No. 3

Loctite 243

The contents are defined in section Standard toolkit!


DANGER!


2. Secure the link with a roundsling in a crane.

Use the hole in the middle of the link.

This is done to prevent the link from moving when the upper and lower rods are removed.

3. Remove the upper and lower rods.

4. Fit the auxiliary shaft on the shaft.

Detailed in section


Detailed in section




184



Action

5. Remove screw and washer in the hole for filling grease.

Note

4 Repair


Continued

Refitting, link

xx0600002597

• A: Hole for filling grease

6. Use compressed air to remove the VK cover. Blow with a very low air pressure into the hole for filling grease.

Note! A very low air pressure is needed!

Put one hand with some paper on top of the VK cover in order to catch it when released.

7. Remove the lock nut.

8. Put the end of the link facing the upper rod, downwards in order to find room to knock on it from the inside as close to its center as possible.

Normally a not too hard knock is needed to loosen the link.

Note! Loosen the roundsling some before knocking! Otherwise the link may be locked by the lifting power.

9. Use a pair of levers, to bend the link loose.

10. Remove the link.

11. Remove the support ring with the radial seal.

12. Wipe off residual grease.

13. If needed, replace the bearings and radial seal.

The procedure below details how to refit the link of the linkage.

Action Note

1. Put the link on a bench. Place the outer rings of the bearings in the link.

2. Use the pressing tool, link and fit the outer rings.





185

4 Repair


Continued

Action Note

3. Secure the link with a roundsling in an overhead crand. Lift it to the mounting position.

4. Fit the auxiliary shaft on the shaft.



Permatex No. 3 5. Apply sealing compound on the support ring.

6. Fit the support ring with the radial seal fitted. Replace the radial seal if needed!

7. Fit the bearings and link, in the following order: bearing, link, bearing.

8. Use the pressing tool, link to fit the link.



9. Apply locking liquid on the lock nut.

10. Fit the lock nut first with a tightening torque of 300 Nm. Then unscrew the lock nut and fit it once again. This time with a tightening torque of 90 Nm.

Note the order of the two tightening torques!

Loctite 243

Tightening torque first time: 300 Nm

Tightening torque the second time: 90

Nm

11. Refit the VK cover.

12. Fill the link with grease. Use lubrication tool. Art.no. is specified in


186 xx0500002597

• A: Hole for filling grease

13. Refit the screw and washer in the hole for filling grease.

14. Refit the upper rod to the link.

15. Refit the lower rod to the link.

Detailed in section


Detailed in section




Action


17.

DANGER!



.

4 Repair


Continued

Note




.


4 Repair

4.4.7. Replacement of parallel rod

4.4.7. Replacement of parallel rod

Location of parallel rod

The parallel rod is located as shown in the figure below.



.

xx0600002610

A Parallel rod


Equipment, etc. Spare part no.

Parallel rod

Mounting/

Demounting tool

Locking liquid

Standard toolkit

3HAC021084-004

-

Art.no.

3HAC5021-1

Note

White RAL 9003

Loctite 243


section


.

188



4 Repair


Continued

Equipment, etc. Spare part no.


Art.no.

Note


Removal, parallel rod

The procedure below details how to remove the parallel rod. The procedure is the same in both ends of the parallel rod.

Note

1.

Action

DANGER!


2. Secure the upper arm with a roundsling in a crane.

3. Remove the upper lock screw and washer, locking the parallel rod in position.

xx0600002741

• A: Lock screw M6x16



189

4 Repair


Continued

Action

4. Remove the upper shaft (A) and cover

washer (B).

Note

8. Remove the parallel rod from the robot.

9. Replace the bearings (D), if necessary.

xx0700000065

Parts:

• A: Shaft

• B: Cover washer

• C: Parallel rod

• D: Sealed spherical bearing

• E: Bearing grease

• F: Thrust washer

5. Remove the thrust washer (F).

6. Remove the parallel rod (C) backwards from its upper connection point and let it rest against frame and base.

7. Continue by removing the lower end of the parallel rod in the same way as the upper end:

1. Remove the lower lock screw and washer

2. Remove the lower shaft (A )and

cover washer (B)

3. Remove the thrust washer (F)

See figure above!

See figure above and

Location of parallel rod on page 188

!

See figure above!

See figure above!

Refitting, parallel rod

The procedure below details how to refit the parallel rod. The procedure is the same in both ends of the parallel rod.

Action

1. Lift the parallel rod to the mounting position.

Note

190



Action

2. Put the thrust washer (F) on the axis 2 side of the parallel rod (C).

Note

4 Repair


Continued

xx0700000065

3. Put the cover washer (B) on the axis 3 side of the parallel rod.

See figure above!

4. Refit the shaft (A) by pushing it through the parallel bar.

Press the shaft in position.

See figure above!

Loctite 243 5. Apply locking liquid in the hole of the lock screw.

6. Refit the lock screw and plain washer.


8.

DANGER!



.

3HAC025755-001 Revision: B xx0600002741

• A: Lock screw M6x16



included in section


.

191

4 Repair

4.4.8. Replacement of complete lower arm

4.4.8. Replacement of complete lower arm

Location of lower arm

The complete lower arm is located as shown in the figure below.



.

xx0600002611

A

B

Lower arm

Parallel arm


Equipment, etc.

Lower arm

Crank

Lock screw M16x90

Lifting tool, lower arm complete

Standard toolkit

Spare part no.

Art.no.

3HAC021464-004

3HAC021464-004

-

3HAC023132-001

3HAC8446-1

-

Note

White RAL 9003


section


.

192



4 Repair


Continued

Equipment, etc.


Circuit diagram

Spare part no.

Art.no.

-

Note


See chapter

Circuit diagram

.

Removal, lower arm

The procedure below details how to remove the lower arm.

Note

1.

Action

DANGER!


2. Secure the lower arm with a lock screw in the hole as shown in the figure to the right.

3. Remove the linkage.

4. Remove the balancing device.

5. Remove the parallel rod.

3HAC025755-001 Revision: B xx0600002736

• A: Hole for lock screw,

M16x90

Detailed in section


Detailed in section


Detailed in section


Detailed in section


Detailed in section


.


193

4 Repair


Continued

Action

6. Remove the upper part of the cable harness.

Secure the cable harness in a way that it is protected from getting damaged and from oil spill.

7. Remove the complete upper arm.

8. Remove the motors axes 2-3.

9. Remove gearbox axes 2-3.

10.

Note

Detailed in section

Replacement of cable harness, upper end (incl. axis

6) on page 144

.

Detailed in section

Replacement of upper arm on page 170

.

Detailed in section

Replacement of motor, axes 2 and 3 on page 217

.

Detailed in section

Replacement of gearbox, axes 2- 3 on page 232 .

CAUTION!

The lower arm weighs 160 kg! All lifting equipment used must be sized accordingly!

11. Secure the complete lower arm (including the parallel arm) with the lifting tool, lower arm

complete in an overhead crane or similar.

12. Remove all M12 and M16 screws holding the lower arm, on both sides.

13. Push the lower arm and parallel arm together with the help of an iron bar or similar.



.

14. Remove the complete lower arm (including the parallel arm).

If the parts are not pushed together, it will be difficult to remove the complete lower arm.

How to replace the parallel arm is

detailed in section

Replacement of parallel arm on page 197

.

Refitting, lower arm

The procedure below details how to refit the lower arm.

Note

1.

Action

194

CAUTION!

The lower arm weighs 160 kg! All lifting equipment used must be sized accordingly!

2. Fit the lifting tool lower arm complete, to the lower arm complete and lift it up.

3. Fit the two guide sleeves for the sealings axes 2/

3, to the lower arm and put the sealings on them.



.

4. Put the lower arm in the mounting position.

Use a crank to find the correct hole pattern.

5.

NOTE!

Refit the axis 2 side first!



4 Repair


Continued

Action Note

6. Refit all screws (both M12 and M16) with washers on the axis 2 side that are possible to fit at this stage.

7. Push the parallel arm against the axis 2 side.

Tightening torque M16: 300 Nm


8. Refit all screws with washers on the axis 3 side that are possible to fit.


NOTE!

The axis 3 side has no M16 screws!

9. Change the position of the lower arm in order to reach the remaining attachment holes, and fit the remaining screws.

10. Secure the lower arm by fitting a lock screw.

11. Refit gearbox axis 2-3.

12. Refit motor axes 2-3.

13. Refit the complete upper arm.

14. Refit the cable harness.

15. Refit the parallel rod.

16. Refit the balancing device.

3HAC025755-001 Revision: B xx0600002736

• A: Hole for lock screw

M16x90

Detailed in section

Replacement of gearbox, axes 2- 3 on page 232

.

Detailed in section


.

Detailed in section

Replacement of upper arm on page 170

.

Detailed in section

Replacement of cable harness, upper end (incl. axis

6) on page 144

Detailed in section


Detailed in section

Replacement of balancing device on page 200 .


195

4 Repair


Continued

Action

17. Refit the linkage.

18. Remove the lock screw.


20.

DANGER!



.

Note

Detailed in section


Detailed in section


Detailed in section




included in section


.


4 Repair

4.4.9. Replacement of parallel arm

4.4.9. Replacement of parallel arm

Location of parallel arm

The parallel arm is located as shown in the figure below.



.

0600002611

A

B

Lower arm

Parallel arm


Equipment, etc.

Spare part no.

Art.no.

Parallel arm 3HAC023026-003

3HAC023026-003

Bearing grease

Pressing tool, lower arm

Lifting device, parallel arm

Lifting tool, lower arm complete

Level

3HAB 3537-1

-

3HAC023092-001

3HAC023098-001

3HAC8446-1

Note

White RAL 9003



197

4 Repair


Continued

Equipment, etc.

Standard toolkit

Spare part no.

Art.no.

-


Removal, parallel arm

The procedure below details how to remove the parallel arm.

Note

1.

Action

Note



.


DANGER!


2. Remove the complete lower arm.

Detailed in section

Replacement of complete lower arm on page

192

.

3. Put the complete lower arm on a workbench.

Removal of the parallel arm is best perfomed on a workbench.

4. Remove the two VK covers.

5. Fit the lifting device, parallel arm on the parallel arm. Art.no. is specified in


.

6. Disassemble the parallel arm from the lower arm by using the pressing tool, lower arm.



.

7.

CAUTION!

The parallel arm weighs 92 kg.

8. If necessary, change the bearings.

Refitting, parallel arm

The procedure below details how to refit the parallel arm.

Action

1. Refitting of the parallel arm is best performed on a workbench.

2. Apply some grease on the shafts on the parallel arm.

3. Refit a spacing sleeve on each shaft.

Note

198



4 Repair


Continued

Action

4. Refit a bearing on each shaft with pressing tool,

lower arm.

5. Refit the protection washer on the inner shaft.

6. Refit the lock ring on the inner shaft.

7. Lift the lower arm onto the workbench with lifting

tool, lower arm complete.

8. Adjust the lower arm in a way that both holes are parallel.

Use a level.

9. Apply some grease in the holes in the lower arm.

10. Fit the lifting device, parallel arm.

Note







.

11.

CAUTION!

The parallel arm weighs 92 kg.

12. Lift the parallel arm and put it in mounting position with the lower arm.

13. Carefully press the parallel arm onto the lower arm with the pressing tool, lower arm.



.

14. Refit the big and small VK covers.

15. Refit the complete lower arm.


Detailed in section

Replacement of complete lower arm on page

192

.




.

17.

DANGER!



.


4 Repair

4.5.1. Replacement of balancing device

4.5 Frame and base

4.5.1. Replacement of balancing device

Location, balancing device

The balancing device is located as shown in the figure below.



.

200 xx0600002604

C

D

A

B

Balancing device

Hole to neutralize the spring force. (M12)

Hole on lifting ear

Hole for lock screw



4 Repair


Continued


Equipment, etc.

Spare part no.

Art.no.

Balancing device 3HAC024779-001

3HAC024779-001

Auxiliary shaft

Auxiliary shaft, long

Auxiliary shaft, short

Lock screw

Screw

-

Note

White RAL 9003

3HAC5281-1 For fitting the inner rings of the bearings

3HAC5275-1

3HAC5276-1

M16 x 90

For securing the lower arm.

M12 x 50

For neutralizing the spring force of the balancing cylinder.

Lubrication tool

Standard toolkit -

3HAC5222-2



.



Removal

The procedure below details how to remove the balancing device.

Action Note

1. Move the robot to a position close enough to its calibration position, to allow the lock screw to be inserted into the hole for the lock screw.

The balancing device must be placed in a 90° angle from the floor, in order the be lifted in the most secure way.

Shown in section

Location, balancing device on page 200

.



201

4 Repair


Continued

Action

2. Lock the lower arm by inserting the lock screw into the hole.

Note

202 xx0600002736

• A: Hole for lock screw M16x90

3.

DANGER!


4. Remove the protection hood in the upper end of the balancing device.

5. Insert a long screw (M12x50) in the hole to neutralize the spring force.

6. Attach a roundsling to the balancing device.

7. Remove the lock nuts.

The length of the cylinder is now locked.

Use the hole in the lifting ear.

Note! Make sure that the shaft between the upper and lower arm does not rotate when unscrewing the lock nuts! The lock nut is locked with

Loctite 243.



8. Fit the auxiliary shafts on the upper and lower pivot shaft.

Fit the short auxiliary shaft on the upper shaft and the longer on the lower shaft.

9. Stretch the roundsling.

10.

CAUTION!

The balancing device weighs 70 kg! All lifting equipment used must be sized accordingly!

11. Carefully remove the balancing device from its upper and lower attachment.

12. Remove the balancing device and put it in a safe place.

13. Remove the inner rings of the bearings.



Refitting

4 Repair


Continued

Action

14. Remove the sealing rings and support washers.

Note

The procedure below details how to refit the balancing device.

Action Note

1. Apply sealing compound on the surface for the sealing ring.

2. Refit the inner sealing rings and support washers.

3. Refit the inner ring of the bearings on the upper and lower pivot shaft with the auxialiary shaft.

4. Fit the auxiliary shafts on the upper and lower shafts.

Fit the short auxiliary shaft on the upper shaft and the longer on the lower shaft.

5. Attach a roundsling to the balancing device and lift it on to the auxiliary shafts.

Art.no. is specified in section


6. Adjust the length between the upper and lower bearings by means of the M12 screw, used to neutralize the spring force.

This length should preferably be 0.5 mm too short than 0.1 mm too long. If the distance is too long the bearings may be damaged when erecting the balancing device.

7.

CAUTION!

The balancing device weighs 70 kg! All lifting equipment used must be sized accordingly!

8. Carefully refit the balancing device on the upper and lower shafts.

9. Fit the lubricating tool.

The tool should be tightened to the bottom position by hand power only.

10. Fill the bearings with grease through the nipple.

Continue until grease excudes behind the inner sealing.

Art.no. is specified in section


.

11. Remove the lubricating tool and wipe off protruding grease.

12. Remove the auxiliary shafts.

13. Apply locking liquid on the lock nuts.

14. Refit the lock nuts and support washers.

15. Check play (min. 0.1 mm) between support washers and bearing seat at both bearings.

16. Remove the M12x50 screw to restore the springforce.

Loctite 243




203

4 Repair


Continued

Action

17. Remove the M16x90 lock screw.

Note

18.

DANGER!



.

xx0600002736

• A: Hole for lock screw M16x90


4 Repair

4.5.2. Replacement of SMB unit

4.5.2. Replacement of SMB unit

Location of SMB unit

The SMB unit (SMB = serial measurement board) is located on the left hand side of the frame as shown in the figure below.

xx0600002621

C

D

A

B

E

SMB cover

SMB unit

Battery cable

SMB battery

SMB battery, cover


Equipment, etc. Spare part no. Art. no.

SMB unit

Battery pack

Standard toolkit

3HAC022286-001

3HAC16831-1

3HAC16831-1

-

Note

Circuit Diagram -

Removal, SMB unit

The procedure below details how to remove the SMB unit.

Action


Note



.

See chapter

Circuit diagram

.



205

4 Repair


Continued

Action

2.

3.

DANGER!


Note

esd

WARNING!



4. Remove the SMB cover by unscrewing its attachment screws.

5. Remove the connectors X8, X9 and X10 from the brake release board, if need of more space.

Shown in the figure

Location of

SMB unit on page 205

.

6. Remove the nuts and washers from the pins securing the board.

Shown in the figure

Location of


.

7. Gently disconnect the connectors from the SMB unit when pulling the board out.

Connectors R1.SMB1-3,

R1.SMB4-6 and R2.SMB

8. Disconnect the battery cable from the SMB unit. Shown in the figure

Location of


.

Refitting, SMB unit

The procedure below details how to refit the SMB unit.

Action

1.

Note

2.

DANGER!


esd

WARNING!

The unit is sensitive to ESD, before handling the unit please observe the safety information in

section


3. Connect the battery cable to the SMB unit. Shown in the figure

Location of SMB unit on page 205

.

206



4 Repair


Continued

Action Note

4. Connect all connectors to the SMB board and fit the SMB unit onto the pins.



.

Shown in the figure


.

R1.SMB1-3, R1.SMB4-6 and R2.SMB

5. Secure the SMB unit to the pins with the nuts and washers.

6. If disconnected, reconnect the connectors X8, X9 and X10 to the brake release board.

7. Secure the SMB cover with its attachment screws.


Shown in the figure


.

Detailed in chapter Calibration -

section


.

9.

DANGER!



.


4 Repair

4.5.3. Replacement of brake release unit

4.5.3. Replacement of brake release unit

Location of brake release unit

The brake release unit is located together with the SMB unit on the left hand side of the frame, right next to the gearbox, axis 2, as shown in figure below. xx0600002621

A

B

C

D

E

SMB cover

SMB unit

Battery cable

SMB battery

SMB battery, cover


Equipment, etc. Art. no. Note

Brake release unit with buttons 3HAC16035-1 Located together with the SMB-unit at the left hand side of the frame.

Standard toolkit The content is defined in section


.



208



4 Repair


Continued

Removal, brake release unit

The procedure below details how to remove the brake release unit.

Note

1.

Action

2.

DANGER!


esd

WARNING!



ESD! on page 34

3. Remove the push button guard from the SMB cover.

Shown in the figure


.

The guard must be removed to ensure a correct refitting of the brake release unit.

4. Open the SMB cover by unscrewing the attachment screws.

Let the battery stay connected, to avoid the need of synchronization of the robot!

Shown in the figure


.

5. Remove the complete brake release unit

(including brake release unit and bracket) from the SMB recess, by removing its two attachment screws.

6. Disconnect the connectors X8, X9 and X10 from the brake release unit.

3HAC025755-001 Revision: B xx0200000129

• A: Connector X8

• B: Connector X9

• C: Connector X10

• D: Push buttons

Location of brake release unit is shown

in the figure


.


209

4 Repair


Continued

Action

7. Remove the brake release unit from the bracket by removing the four attachment screws.

Note

Refitting, brake release unit

The procedure below details how to refit the brake release unit.

Note

1.

Action

2.

DANGER!


esd

WARNING!

The unit is sensitive to ESD, before handling the unit please observe the safety information

in section


ESD! on page 34

3. Fasten the brake release unit on the bracket with the attachment screws.

Make sure the unit is positioned as straight as possible on the bracket! The push buttons can otherwise get jammed when the SMB cover is refitted.

Shown in the figure


.



.

4. Connect the connectors X8, X9 and X10 to the brake release unit.

210

5. Refit the complete brake release unit

(including brake release unit and bracket) to the SMB recess with the two attachment screws.

xx0200000129

• A: Connector X8

• B: Connector X9

• C: Connector X10

• D: Push buttons



4 Repair


Continued

Action Note

6. Refit the SMB cover with its attachment screws.

The push button guard must not be mounted on the cover before the check described below is made!

Shown in the figure


.

7.

WARNING!

Before continuing any service work, please observe the safety information in section

WARNING - The brake release buttons may be jammed after service work on page 33

!

8. Refit the push button guard to the SMB cover. Shown in the figure


.

9. If the battery has been disconnected the revolution counter must be updated.

Detailed in the Calibration chapter -

section


.

10.

DANGER!



.


4 Repair

4.6.1. Replacement of motor, axis 1

4.6 Motors

4.6.1. Replacement of motor, axis 1

Location of motor

The motor axis 1 is located on the left hand side of the robot as shown in the figure below.

xx0600002598

C

D

A

B

Motor axis 1



Motor cover


Equipment, etc Spare part no.

Motor axis 1 3HAC024775-001

3HAC028861-001

Art.no.

Grease

Power supply

Standard toolkit -

-

3HAB3537-1

Note

Includes:

• motor

• pinion

• o-ring (Old o-ring must be replaced when replacing the motor)

Used to lubricate the o-ring

24 VDC, max. 1,5 A

For releasing the brakes.



.

212



Equipment, etc Spare part no.


Circuit diagram -

Art.no.

4 Repair


Continued

Note


See chapter

Circuit diagram

.

Removal, motor

The procedure below details how to remove motor, axis 1.

Note

1.

Action

DANGER!


2. Remove the motor cover in order to get access to the connectors on top of the motor by unscrewing its four attachment screws.

Shown in the figure

Location of motor on page 212

.

xx0600002696

• A: Motor cover


• C: Cable gland



213

4 Repair


Continued

Action Note

3. Remove the cable gland cover at the cable exit by unscrewing its attachment screw which is found after removing the motor cover.

Shown in the figure


.

Make sure the gasket is not damaged!

xx0600002694


4. Disconnect all connectors beneath the motor cover.

5. In order to release the brake, connect the 24

VDC power supply.

6. Remove the motor by unscrewing its four

attachment screws and plain washers.

7. If required, press the motor out of position by fitting two screws in the holes on the motor for pressing out the motor.

8.

Connect to connector R2.MP1

• + : pin 2

• - : pin 5

Shown in the figure


.

Always use the removal screws in pairs!

CAUTION!

The motor weighs 29 kg! All lifting equipment used must be sized accordingly!

9. Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.

10. Remove the motor by gently lifting it straight up.

11. Check the pinion. If there is any damage, the pinion must be replaced.

NOTE!

If the gearbox is replaced, the motor pinion must also be replaced!

214



4 Repair


Continued

Refitting, motor

The procedure below details how to refit motor, axis 1.

Action

1. Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the o-ring with grease.

Note

NOTE!

The o-ring must be replaced when replacing the motor.

2.

CAUTION!



VDC power supply.

4. Fit the motor, making sure the motor pinion is properly mated to the gearbox of axis 1.

5. Secure the motor with its four attachment

screws and plain washers.


• + : pin 2

• - : pin 5

Make sure the motor is turned the right way, that is connections on the left hand side.

Make sure the motor pinion does not get damaged!

M10 x 40

Shown in the figure


.


6. Disconnect the brake release voltage.

7. Reconnect all connectors beneath the motor cover.

8. Refit the cable gland cover at the cable exit with its attachment screw.

Make sure the cover is tightly sealed!

Replace the gasket.

3HAC025755-001 Revision: B xx0600002694

• Screw holding the cable gland


215

4 Repair


Continued

Action

9. Refit the motor cover with its four attachment screws.

Note



11.

DANGER!




.

xx0600002696

• A: Motor cover


• C: Cable gland



included in section


.


4 Repair

4.6.2. Replacement of motor, axes 2 and 3

4.6.2. Replacement of motor, axes 2 and 3

Location of motors, axes 2 and 3

The motors axes 2 and 3 are located on either side of the robot as shown in the figure below.

The procedure is the same for both motors.

xx0600002599

C

D

A

B

E

F

Motor, axis 2

Motor, axis 3



Motor cover

Hole for lock screw


Equipment, etc.

Spare part no.

Art. no.

Motor axis 2-3 3HAC024776-001

3HAC021030-001

Grease

Guide pins M10 x

150

Lifting tool, motor axes 2-3

Power supply

Rotation tool

3HAB3537-1

3HAC13120-2

-

3HAC14586-1

Note

Includes

• motor

• pinion

• o-ring (The o-ring must be replaced when the motor is replaced)

For lubricating the o-ring.

For guiding the motor.

Guide pins are to be used in pairs!


24 VDC, 1.5 A


Used to rotate the motor pinion when mating it to the gear, when brakes are released with 24 VDC power supply.


217

4 Repair


Continued

Equipment, etc.

Spare part no.

Art. no.

Standard toolkit


Circuit diagram -

Note


section


.


See chapter

Circuit diagram

.

Removal, motor

218

The procedure below details how to remove motors, axes 2 and 3.

Action Note

1. Run the robot to a position close enough to its calibration position, to allow the lock screw to be inserted into the hole for lock screw.

2. Secure the upper arm with roundslings in an overhead crane.

This is done in order to secure axis 3 from collapsing when gearbox axis 3 is being removed.

3.

DANGER!


4. Lock the lower arm by inserting the lock screw into the hole.

Shown in the figure

Location of motors, axes 2 and 3 on page 217

.

5. Drain the oil from gearbox, axes 2- 3.

Detailed in

Oil change, gearbox axes

2-3 on page 115 .

6. Remove the motor cover by unscrewing its four attachment screws.

Shown in the figure


.

7. Remove the cable gland cover at the cable exit by unscrewing its two attachment screws.

Shown in the figure


.


8. Disconnect all connectors beneath the motor cover.


VDC power supply.


• + : pin 2

• - : pin 5

10. Remove the motor by unscrewing its four

attachment screws and plain washers.

11. Fit the two guide pins in two of the motor attachment holes.

Shown in the figure




.

.

12. If required, press the motor out of position by fitting two screws in the motor attachment holes diagonal to each other.

Always use the removal tools in pairs!



4 Repair


Continued

Action

13. Remove the two screws and fit the lifting toll,

motor axes 2-3 to the motor.

14.

Note



.

CAUTION!


15. Lift the motor to get the pinion away from the gear.

16. Remove the motor by gently lifting it straight out and place it on a secure surface.

Disconnect the brake release voltage!

17. Check the pinion. If there is any damage, the motor pinion must be replaced.

Note! If the gearbox is replaced, the motor pinion must also be replaced!

Make sure the pinion does not get damaged!


The procedure below details how to refit motors, axes 2 and 3.

Action Note

1. Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the o-ring with grease.


VDC power supply.


• + : pin 2

• - : pin 5

3. Fit the lifting tool, motor axes 2-3 to the motor.



.

4. Fit the two guide pins in the two lower motor attachment holes.

5.



.

CAUTION!


6. Lift the motor and guide it on to the guide pins, as close to the correct position as possible without pushing the motor pinion into the gear.

Make sure the motor is turned the right way, that is connections for the cables facing downwards.

7. Remove the lifting tool and allow the motor to rest on the guide pins.



219

4 Repair


Continued

Action

8. Use the rotation tool in order to rotate the motor pinion when mating it to the gear (see figure beside). Fit the motor, making sure the motor pinion is properly mated to the gear of gearbox axis 2-3 and that it doesn´t get damaged.

Note

220 xx0200000165

The rotation tool is used beneath the motor cover, directly on the motor shaft as shown in figure above.

- A: Rotation tool

9. Remove the guide pins.

10. Secure the motor with its four attachment

screws and plain washers.

Shown in the figure


.

M10 x 40, tightening torque: 50 Nm.

Reused screws may be used, providing they are lubricated as

detailed in section


before fitting.


12. Reconnect all connectors beneath the motor cover.

Connect in accordance with markings on connectors.

13. Refit the cable gland cover at the cable exit with its two attachment screws.

Shown in the figure


.

Replace the gasket.


14. Refit the motor cover with its four attachment screws and washers.

15. Remove the lock screw from the hole for lock

screw.

Shown in the figure


.

16. Perform a leak-down test of the axis 2 (or 3) gearbox.

17. Refill the gearbox with oil.


Detailed in

Oil change, gearbox axes

2-3 on page 115

.



included in section


.

19.

DANGER!




.


4 Repair


4.6.3. Replacement of motor, axis 6

Location of motor axis 6

The motor axis 6 is located in the center of the tilthouse as shown in the figure below.

xx0600002595

C

D

A

B

Motor, axis 6


Cable gland cover

Motor cover


Equipment, etc.

Spare part no.

Motor axis 6 3HAC 024777-001

Art.no.

Power supply

Grease

Standard toolkit


Circuit diagram

-

-

3HAB 3537-1

Note

Includes

• motor

• pinion

• o-ring (the o-ring must be replaced when the motor is replaced)

24 VDC, 1.5 A





.



3HAC 025690-001

3HAC 025691-001

See chapter

Circuit diagram

.


221

4 Repair


Continued

Removal, motor

The procedure below details how to remove motor, axis 6.

Action

1. Run the robot to a position where it is easiest to remove the motor axis 6 when standing in front of the robot.

2.

Note

The motor axis 6 can be replaced without draining the gear oil.

DANGER!


3. Remove the motor cover, axis 6.

Shown in the figure

Location of motor axis

6 on page 221

.

4. Remove the cable gland cover at the cable exit by unscrewing its attachment screw.


222

5. Disconnect all connectors beneath the cover, motor axis 6.

Note! The connection to the UL lamp, if the robot is equipped with it, must also be disconnected.

xx0600002694

• A: Screw holding the cable gland xx0500002466

• A: Signal lamp

• B: Cable straps, outdoor

• C: Cable

• D: Connection point to the cable gland


VDC power supply.


• + : pin 2

• - : pin 5

7. Remove the motor by unscrewing its four attachment screws and washers.

8. If required, press the motor out of position by fitting two screws in the motor attachment holes diagonal to each other

Always use the screws for removal in pairs!



4 Repair


Continued

Action Note

9. Lift the motor carefully to get the pinion away from the gear.

Disconnect the brake release voltage.


10. Remove the motor by gently lifting it straight up and place it on a secure surface.



The procedure below details how to refit motor axis 6.

Action Note

1. Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the o-ring with grease.

Note! The o-ring must be replaced when the motor is replaced.


VDC power supply.

3. Fit the two guide pins in two of the motor attachment holes.


• + : pin 2

• - : pin 5



.

4. Lift the motor and carefully and refit it, with guidance from the pins.

Make sure the motor pinion is properly mated to the gearbox, axis 6.

Make sure the motor is turned the right way, i.e. connections for the cables facing downwards.

5. Remove the guide pins.

6. Secure the motor with its four attachment screws and washers.

M10 x 40




before fitting.


8. Reconnect all connectors in motor axis 6.

9. Refit the connections to the UL lamp, if the robot is equipped with one.

Connect in accordance with markings on connectors.



223

4 Repair


Continued

Action

10. Refit the cable gland with its attachment screw.

Note

11. Refit the cover, motor axis 6 with its four attachment screws and washers.

xx0600002694



Replace if damaged.

224


13.

DANGER!




.

xx0600002696

• A: Motor cover


• C: Cable gland





.


4 Repair

4.7.1. Replacement of gearbox, axis 1

4.7 Gearboxes

4.7.1. Replacement of gearbox, axis 1


The axis 1 gearbox is located between the frame and base as shown in the figure below.



.

xx0600002631

A

B

C

Gearbox, axis 1

Frame

Base



Gearbox 3HAC022279-001

3HAC10828-1

O-ring

O-ring

Sealing ring

Grease

Support, base

Lifting device, base

Lifting tool (chain)

Standard toolkit


3HAB3772-54

3HAB3772-55

3HAC11581-4

3HAC3537-1

3HAC15535-1

3HAC15560-1

3HAC15556-1

-

Note

Includes:

• gearbox

• all o-rings and sealing rings

Replace only when damaged!



For lubricating the o-rings.


section


.


225

4 Repair


Continued



Removal, gearbox axis 1

The procedure below details how to remove gearbox, axis 1.

Action

1. Move the robot to its most stable position, shown in the figure to the right.

Note

Note


226 xx0500002275

2.

DANGER!


3. Drain the oil from gearbox 1.

Detailed in section


.

4. Disconnect all cabling in the rear of the robot base and remove the cable support plate inside of the base.

5. Pull the disconnected cabling up through the center of gearbox 1.

6. Remove the complete arm system.

7. Remove the robot's attachment screws to unfasten the base from the foundation.

8. Attach the lifting device, base and gear 1 and the lifting tool (chain), to the gearbox.

Detailed in section

Removal, arm system on page 151

.



.



4 Repair


Continued

Note

9.

Action

CAUTION!

The base and gearbox weighs 423 kg together! All lifting equipment must be used accordingly!

10. Lift the robot base to allow fitting the

support, base and gear 1 on each sides of the base.



.

11. Fit the support, base.

Make sure the base remains in a stable position before performing any work underneath the base!

12. Remove the bottom plate from underneath the base in order to get access to the attachment screws. It may be necessary to also remove the rear connector plate.

13. Unscrew the 18 attachment screws and remove the 3 washers, shown in the figure to the right. xx0300000612

• A: Bottom plate

• B: Rear connector plate

• C: Attachment screw

• D: Groove

3HAC025755-001 Revision: B xx0200000227

A view from below:

• A: Oil drain hose

• B: Attachment screws, gearbox axis 1, 18 pcs

• C: Washers, 3 pcs


227

4 Repair


Continued

Action

14. Remove the cable guide in the center of gearbox 1 by unscrewing its attachment screws.

Note

xx0200000256

• A: Location for attachment screws, cable guide (cable guide removed in the figure)

15.

CAUTION!

The gearbox weighs 160 kg! All lifting equipment used must be sized accordingly!

16. Lift the gearbox away with the already mounted lifting tools.

Refitting, gearbox axis 1

The procedure below details how to refit gearbox, axis 1.

Action Note

1. If the base is not supported with support, base

and gear 1, this should be done first.

Mounting of the support, base and gear

1 is detailed in section

Removal, gearbox axis 1 on page 226

.

2. Make sure the two o-rings (C, D) on the circumference of the gearbox are seated properly in their grooves respectively.

Lubricate them with grease .

Make sure the small o-ring around the oil hole is fitted properly!

Art no. is specified in


.

228 xx0200000055

• A: Guide pin

• C: O-ring 3HAB 3772-54

• D: O-ring 3HAB 3772-55

• E: Sealing ring 3HAC 11581-4



4 Repair


Continued

Action

3. Refit the cable guide in the center of gearbox

1 with its attachment screws.

Note

4. Fit the lifting device, base and the lifting tool

(chain) to the gearbox.

5.

xx0200000256

• A: Location for attachment screws, cable guide (cable guide removed in figure)

Art no. is specified in


.

CAUTION!


6. Lift the gearbox to its mounting position in the center of the base.

7. Make sure the guide pin in the bottom face of the gearbox is properly aligned with the base.

Shown in the figure xx0200000055 above!

8. Secure the gearbox and the three washers with the 18 attachment screws, gearbox axis

1.

18 pcs, M16 x 70, 12.9 quality

UNBRAKO, tightening torque: 300 Nm.



before fitting.

3HAC025755-001 Revision: B xx0200000227

A view from below:

• A: Oil drain hose

• B: Attachment screws, gearbox axis 1, 18 pcs

• C: Washers, 3 pcs


229

4 Repair


Continued

Action Note

9. Refit the bottom plate underneath the robot base by pushing it into the groove and fitting the attachment screw.

If removed, also refit the rear connector plate.

1 screw: M6 x 8.

NOTE!

Direct the bends on the bottom plate downwards!

xx0300000612

• A: Bottom plate

• B: Rear connector plate

• C: Attachment screw

• D: Groove

10.

CAUTION!

The base and gearbox weighs 423 kg together! All lifting equipment must be used accordingly!

11. Lift the robot base and gearbox 1 to allow removing the support, base and gear.

12. Secure the base to the mounting site.

13. Refit the complete arm system.

Detailed in section

Orienting and securing the robot on page 61

.

Detailed in section

Refitting, arm system on page 153

.

This is a complex task to be performed with utmost care in order to avoid injury or damage!

14. Refit the cable support plate inside of the base and reconnect the cabling in the rear of the robot base.

15. Perform a leak-down test.


Detailed in section


.

Detailed in section


.

17. Recalibrate the robot. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.


included in section


.

230



18.

Action

DANGER!




.

4 Repair


Continued

Note


4 Repair

4.7.2. Replacement of gearbox, axes 2- 3

4.7.2. Replacement of gearbox, axes 2- 3

Location of gearbox, axes 2-3

The axes 2-3 gearbox is located on either side of the frame as shown in the figure below.

xx0500002467

C

D

A

B

Gearbox, axis 1

Gearbox, axis 2

Gearbox, axis 3

Gearbox, axis 6


Equipment, etc.

Spare part no.

Art.no

Gearbox, axes 2-3 3HAC022644-001

3HAC022644-001

Sealing axes 2-3 3HAC022379-001

3HAC022379-001

Lock screw M16x90

Guide pins

Lifting tool gearbox axes 2-3

Standard toolkit

-

-

3HAC023240-001


Note

Use guide pins in pairs.


section


.


232



4 Repair


Continued

Removal, gearbox axes 2-3

The procedure below details how to remove gearbox axes 2-3.

Action

1. Put the robot close to its calibration position.

2. Fit the lock screw (M16x90) in the lower arm.

Note

xx0600002736

• A: Hole for lock screw, M16x90

3.

DANGER!


4. Drain the gearbox axis 2-3 from oil.

Detailed in section


.

5. Remove the motor cables of motor axes 2-

3, and protect the cables from getting damaged and from oil spill.

6. Remove one gearbox at a time!

7.

NOTE!

Time-consuming activity!

DANGER!

Secure the weight of the lower arm properly before releasing the brakes of motor, axis 2!

When releasing the holding brakes of the motor, the lower arm will be movable and may fall down!

8. Secure the upper arm with a roundsling in an overhead crane.



233

4 Repair


Continued

Action Note

9. Remove motor axis 2-3.

10. Remove the gearbox cover by removing its attachment screws.

11. Remove two of the attachment screws holding the gearbox axis 2-3 and replace them with two guide pins.

12. Remove the remaining attachment screws.

13. Fit the lifting tool, gearbox axes 2-3.



.

14.

Detailed in section


CAUTION!


15. If required, apply two M12 screws to the holes in the gearbox, in order to press it free.

16. Remove the gearbox axis 2-3 using an overhead crane or similar, with guidance from the fitted guide pins.

17. Remove the sealing from the lower arm and clean it.

Refitting, gearbox axes 2-3

The procedure below details how to refit gearbox axes 2-3.

Action

1. Make sure that the o-ring is fitted to the gearbox axis 2-3. Lightly lubricate it with grease.

2. Fit the guide pins, axes 2-3 in the frame.

Use two of the attachment holes for the screws holding the gearbox.

3.

Note

CAUTION!


4. Fit the lifting tool, gearbox axes 2-3 to the gearbox. Use an overhead crane and put the gearbox onto the guide pins.

5. Slide the gearbox axis 2 on the guide pins, through the attachment screw holes.



.

234



4 Repair


Continued

Action Note

6. Refit the gearbox axis 2 with its attachment screws and washers.

Remove the guide pins and replace them with the remaining attachment screws.


7. Refit the gearbox axis 3 in the same way.


8. Clean the gearboxes of residual grease.

9. Apply locking liquid in the attachment holes of the cover in the frame.

Loctite 243.

10. Refit the cover with its attachment screws and washers.


11. Refit the motors axes 2-3.

Detailed in section


12. Perform a leakdown test.

13. Refill the gearbox axes 2-3 with oil.

Detailed in section


14. Remove the locking screw, lower arm.



General calibration information is included

in section

Calibration information on page

241

.

16.

DANGER!


DANGER -


.


4 Repair


4.7.3. Replacement of gearbox, axis 6


The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. xx0600002627

C

D

A

B

E

Turning disk

Attachment screws (6 pcs) turning disk

Tilthouse unit

Gearbox, axis 6

Attachment screws and washers, gearbox axis 6

236 xx0200000219

C

D

A

B

Gearbox, axis 6 (IRB 6620 Foundry Plus)


Oil plug, draining

Oil plug, filling



4 Repair


Continued



Gearbox

Turning disk, dia.

200

Washers

3HAC 9744-6

O-ring

Grease

Standard toolkit

Calibration

Pendulum toolkit


Note

Includes o-ring 3HAB3772-

58.

3HAA1001-172 Not included in gearbox!


3HAB3772-58

3HAB3772-64

3HAB3772-61

Must be replaced when reassembling gearbox!

3HAB3537-1

-




.

3HAC15716-1 Complete kit that also includes operating manual.


Removal, gearbox

The procedure below details how to remove gearbox, axis 6.

Action

1.

Note

DANGER!


2. Drain the oil from gearbox, axis 6.

3. Remove the turning disk.

4. Remove the gearbox by unscrewing its 8 attachment screws.

Detailed in section

Draining, oil on page

118

.

Detailed in section

Removal, turning disk on page 157

.

Shown in the figure


.



237

4 Repair


Continued

Action

5. If required, apply M8 screws to the holes shown in the figure beside to press the gearbox out.

Note

6. Remove the gearbox axis 6 by lifting it out carefully.

7. Check the pinion. A damaged pinion must be replaced!

xx0200000220

• A: M8 holes for pressing out the gearbox

Be careful not to damage the motor pinion!

Refitting, gearbox

The procedure below details how to refit gearbox, axis 6.

Note

1.

Action

DANGER!


238



4 Repair


Continued

Action Note

2. Make sure the o-ring is fitted to the rear of the gearbox. Lubricate the o-ring with

grease.



. xx0100000132

• A: O-ring, gearbox axis 6

3. Release the holding brake of motor axis 6. Detailed in section


.

4. Insert the gearbox, axis 6 into the wrist unit. Art. no. is specified in


.

Shown in the figure


.

Make sure the gears of the gearbox mate with the gears of the motor!

5. Secure the gearbox with the attachment

screws and washers.

Shown in the figure


.

8 pcs : M8 x 40, 12.9 quality UNBRAKO,




before fitting.

6. Refit the turning disk.

7. Perform a leak-down test.

Detailed in section

Refitting, turning disk on page 158

.

Detailed in section

Performing a leak-down test on page 130

.



Detailed in section

Filling, oil on page 119

.


General calibration information is included

in section

Calibration information on page

241

.



239

4 Repair


Continued

Action

10.

DANGER!

Make sure all safety requirements are met when performing the first test run. These

are further detailed in section

DANGER -


.

Note


5 Calibration information

5.1. Introduction



General

This chapter includes general information about different calibration methods and also details procedures that do not require specific calibration equipment.

When the robot system must be recalibrated, it is done according to documentation enclosed with the calibration tools.

When to calibrate

The system must be calibrated if any of the below occurs.

The resolver values are changed

If resolver values are changed, the robot must be recalibrated using the calibration methods supplied from ABB. Calibrate the robot carefully with standard calibration. The different

methods are briefly described in section

Calibration methods on page 242

, and further

detailed in separate Calibration manuals.

If the robot has Absolute Accuracy calibration, it is also recommended but not always needed to be calibrated for new Absolute Accuracy.

The resolver values will change when parts affecting the calibration position are replaced on the robot, for example motors, or parts of transmission.

Contents of the revolution counter memory are lost

If the contents of the revolution counter memory are lost, the counters must be updated as detailed in section


. This will occur when:

• the battery is discharged

• a resolver error occurs

• the signal between a resolver and measurement board is interrupted

• a robot axis is moved with the control system disconnected

The revolution counters must also be updated after the robot and controller are connected at the first installation.

The robot is rebuilt

If the robot is rebuilt, for example after a crash or when the robot is changed for other reachability, it needs to be recalibrated for new resolver values.

If the robot has Abslolute Accuracy calibration, it needs to be calibrated for new Absolute

Accuracy.



5.2. Calibration methods

5.2. Calibration methods

Overview

This section specifies the different types of calibration and the calibration methods that are supplied from ABB.

Types of calibration

Type of calibration

Description Calibration method

Standard calibration

Absolute Accuracy calibration

(optional)

The calibrated robot is positioned at home position, that is the axes positions (angles) are set to 0º.

Standard calibration data is found in the file calib.cfg, supplied with the robot at delivery.

The file identifies the correct resolver/motor position corresponding to the robot home position.

From deliveries together with RobotWare 5.0.5 and higher, the data will instead be found on the SMB (serial measurement board) in the robot, and not in a separate file.

Calibration Pendulum

(standard method)

Based on standard calibration, and besides positioning the robot at home position, the

Absolute Accuracy calibration also compensates for:

• mechanical tolerances in the robot structure

• deflection due to load.

Absolute Accuracy calibration focuses on positioning accuracy in the Cartesian coordinate system for the robot.

Absolute Accuracy data is found in the file absacc.cfg, supplied with the robot at delivery.

The file replaces the calib.cfg file and identifies motor positions as well as absacc-compensation parameters.

From deliveries together with RobotWare 5.0.6 and higher, the data will instead be found on the SMB (serial measurement board) in the robot, and not in a separate file.

A robot calibrated with AbsAcc has a sticker next to the identification plate of the robot.

To regain 100% Absolute Accuracy performance, the robot must be recalibrated for

Absolute Accuracy!

CalibWare xx0400001197

242




5.2. Calibration methods

Continued

Calibration methods

Each calibration method is detailed in a separate manual. Below is a brief description of the methods available.

Calibration Pendulum - standard method

Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB

6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the standard type of calibration. It is the recommended method in order to achieve proper performance.

Two different routines are available for the Calibration Pendulum method:

• Calibration Pendulum II

•

Reference Calibration.

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the operating manual for Calibration Pendulum, which describes the method and the different routines further.

CalibWare - Absolute Accuracy calibration

In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy is used as a TCP calibration. The tool CalibWare guides through the calibration process and calculates new compensation parameters. This is further detailed in the application manual

Absolute Accuracy Calibware 2.0.

If a service operation is done to a robot with Absolute Accuracy, a new absolute accuracy calibration is required in order to establish full performance. For most cases after motor and transmission replacements that do not include taking apart the robot structure, standard calibration is sufficient. Standard calibration also supports wrist exchange.

References

Article numbers for the calibration tools are listed in section

Special tools on page 259

.

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including Operating manual - Calibration Pendulum, which describes the method and the different routines further.



5.3. Calibration scales and correct axis position

5.3. Calibration scales and correct axis position

Introduction

This section specifies the calibration scale positions and/or correct axis position for all robot models.

Calibration scales/marks, IRB 660

The illustration below shows the positions of the calibration marks on the robot.

xx0500002487

A

B

C

D

E

Calibration plate, axis 1

Calibration tab on robot

Calibration mark, axis 2

Calibration mark, axis 3

Calibration plate and marking, axis 6

Calibration marks at axes 2 and 3

The calibration marks at axes 2, 3 and 6 shown in the figure above, consist of two single marks that should be positioned opposite to one another when the robot is standing in its calibration position. One of the marks is more narrow than the other and should be positioned within the limits of the wider mark.



5.4. Calibration movement directions for all axes

5.4. Calibration movement directions for all axes

Overview

When calibrating, the axis must consistently be run towards the calibration position in the same direction, in order to avoid position errors caused by backlash in gears etc. Positive directions are shown in the figure below.

This is normally handled by the robot calibration software.

Calibration movement directions, 4 axes

Note! The figure shows an IRB 260, but the positive direction is the same for all 4-axis robots xx0500001927



5.5. Updating revolution counters

5.5. Updating revolution counters

General

This section details how to perform a rough calibration of each robot axis, that is updating the revolution counter value for each axis, using the pendant.

Step 1 - Manually running the robot to the calibration position

This procedure details the first step when updating the revolution counter; manually running the robot to the calibration position.

Action Note

1. Select axis-by-axis motion mode.

3. When all axes are positioned, store the revolution counter settings.

2. Jog the robot to place the calibration marks within the tolerance zone.

Shown in section

Calibration scales and correct axis position on page 244

.

Detailed in section:

Step 2 - Storing the revolution counter setting with the FlexPendant on page 246

(RobotWare 5.0).

Step 2 - Storing the revolution counter setting with the FlexPendant

This procedure details the second step when updating the revolution counter; storing the revolution counter setting with the FlexPendant (RobotWare 5.0).

Action

1. On the ABB menu, tap Calibration.

All mechanical units connected to the system are shown along with their calibration status.

246



Action

2. Tap the mechanical unit in question.

A screen is displayed: tap Rev. Counters.


5.5. Updating revolution counters

Continued

en0400000771

3. Tap Update Revolution Counters....

A dialog box is displayed, warning that updating the revolution counters may change programmed robot positions:

• Tap Yes to update the revolution counters.

• Tap No to cancel updating the revolution counters.

Tapping Yes displays the axis selection window.

4. Select the axis to have its revolution counter updated by:

• Ticking in the box to the left

• Tapping Select all to update all axes.

Then tap Update.

5. A dialog box is displayed, warning that the updating operation cannot be undone:

• Tap Update to proceed with updating the revolution counters.

• Tap Cancel to cancel updating the revolution counters.

Tapping Update updates the ticked revolution counters and removes the tick from the list of axes.

6.

CAUTION!

If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury!

Check the calibration position very carefully after each update.

See section

Checking the calibration position on page 248

.



5.6. Checking the calibration position

5.6. Checking the calibration position

General

Check the calibration position before beginning any programming of the robot system. This may be done:

• Using a MoveAbsJ instruction with argument zero on all axes.

•

Using the Jogging window on the teach pendant.

Using a MoveAbsJ instruction on the FlexPendant, IRC5

This section describes how to create a program, which runs all the robot axes to their zero position.

Action Note

1. On ABB menu tap Program Editor.

2. Create a new program.

3. Use MoveAbsJ in the Motion&Proc menu.

4. Create the following program: MoveAbsJ

[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,

9E9]]\NoEOffs, v1000, z50, Tool0

5. Run the program in manual mode.

6. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!

The calibration marks are shown in

section


.

How to update the revolution counters is detailed in section


.

Using the Jogging window on the FlexPendant, IRC5

This section describes how to jog the robot to all axes zero position.

Action Note

1. Tap Jogging in the ABB menu.

2. Tap Motion mode to choose group of axes to jog.

3. Tap axis 1-3 to jog axis 1, 2, or 3.

4. Manually run the robots axes to a position where the axis position value read on the

FlexPendant, is equal to zero.

5. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!

The calibration marks are shown in section


.

How to update the counters is detailed in section


.


Overview

Overview

About this manual

This manual contains reference information for all procedures described in the Product

manual, procedures .

Usage

This manual should be used during

•

installation

• maintenance work

•

repair work.

Who should read this manual?

This manual is intended for:

• installation personnel

•

maintenance personnel

• repair personnel.

Prerequisites

A maintenance/repair/ installation craftsman working with an ABB Robot must:

• be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work.

Organization of chapters

The manual is organized in the following chapters:

Chapter Contents

Reference information Useful information when performing installation, maintenance or repair work (lists of necessary tools, reference documents, safety standards).

Part list Complete list of manipulator parts, shown in the exploded views or foldouts.

Exploded views / Foldouts Detailed illustrations of the manipulator with reference numbers to the part list.

Circuit Diagram Circuit Diagram of the manipulator.

Revisions

-

Revision Description

First edition.


Overview


6 Reference information

6.1. Introduction



General

This chapter includes general information, complementing the more specific information in the different procedures in the manual.



6.2. Applicable Safety Standards

6.2. Applicable Safety Standards

Standards, general

The robot is designed in accordance with the requirements of:

• EN ISO 10218-1: 2006 Robots for industrial environments - Safety requirements -

Part 1 Robot.

•

EN 292-1 - Basic terminology.

• EN 292-2 - Technical principles.

•

EN 418 - Emergency stop.

• EN 563 - Temperatures of surfaces.

•

EN 954-1 - Safety related parts of control systems.

• EN ISO 60204-1: 2005 Safety of machinery - Electrical equipment of machines - Part

1 General requirements.

•

EN 1050 - Principles for risk assessment.

• ANSI/RIA 15.06-1999 - Industrial robots, safety requirements.

•

DIN 19258 - Interbus-S, International Standard

Standards, robot cell

The following standards are applicable when the robot is part of a robot cell:

•

EN 953 - Fixed and moveable guards

• EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.

•

EN 349 - Minimum gaps to avoid crushing of parts of the human body.

• EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.

•

EN 1088 - Interlocking devices

• EN 999 - The positioning of protective equipment in respect of approach speeds of the human body.

•

ISO 11 161 - Industrial automation systems - Safety of intergrated manufacturing systems.



6.3. Unit conversion

6.3. Unit conversion

Converter table

Use the table below to convert units used in this manual.

Quantity

Length

Weight

Pressure

Force

Moment

Volume

Units

1 m

1 kg

1 bar

1 N

1 Nm

1 L

3.28 ft

2.21 lb

100 kPa

0.738 lbf

0.738 lbf-tn

0.264 US gal

39.37 in

14.5 psi



6.4. Screw joints

6.4. Screw joints

General

This section details how to tighten the various types of screw joints on the robot.

The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.

UNBRAKO screws

UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue.

Whenever used, this is specified in the instructions, and in such cases, no other type of

replacement screw is allowed! Using other types of screws will void any warranty and may potentially cause serious damage or injury!

Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.

Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this the screw must be discarded and replaced with a new one.

When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used.

Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the repair, maintenance or installation procedure descriptions.

In such cases, proceed as follows:

1. Apply lubricant to the screw thread.

2. Apply lubricant between the plain washer and screw head.

3. Tighten to the torque specified in section

Tightening torque on page 255

below. Screw

dimensions of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.

Lubricant Art. no.

Molycote 1000 (molybdenum disulphide grease) 11712016-618

254




6.4. Screw joints

Continued

Tightening torque

Before tightening any screw, note the following:

• Determine whether a standard tightening torque or special torque is to be applied.

The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure descriptions. Any

special torque specified overrides the standard torque!

•

Use the correct tightening torque for each type of screw joint.

• Only use correctly calibrated torque keys.

•

Always tighten the joint by hand, and never use pneumatical tools.

• Use the correct tightening technique, that is do not jerk. Tighten the screw in a slow, flowing motion.

•

Maximum allowed total deviation from the specified value is 10%!

The table below specifies the recommended standard tightening torque for oil-lubricated

screws with slotted or cross-recess head screws.

Dimension

Tightening torque (Nm)

Class 4.8, oil-lubricated

M2.5

M3

M4

M5

M6

0.25

0.5

1.2

2.5

5.0

The table below specifies the recommended standard tightening torque for oil-lubricated

screws with Allen head screws.

Dimension


(Nm)


M5

M6

M8

M10

M12

M16

M24

6

10

24

47

82

200

725


(Nm)



(Nm)


-

-

34

67

115

290

960

-

-

40

80

140

340

1150

The table below specifies the recommended standard tightening torque for Molycote-

lubricated screws with Allen head screws.

Dimension


Class 10.9, Molycote-lubricated



M8

M10

M12

28

55

96

35

70

120



255


6.4. Screw joints

Continued

Dimension





M16

M24

235

790

280

950

The table below specifies the recommended standard tightening torque for water and air

connectors when one or both connectors are made of brass.

Dimension


Nm - Nominal

1/8

1/4

3/8

1/2

3/4

12

15

20

40

70


Nm - Min.

8

10

15

30

55


Nm - Max.

15

20

25

50

90



6.5. Weight specifications

6.5. Weight specifications

Definition

In installation, repair and maintenance procedures, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.

To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each manipulator model.

Example

Below is an example of how a weight specification is presented, inside a procedure table:

Action Note

CAUTION!




6.6. Standard toolkit

6.6. Standard toolkit

General

All service (repairs, maintenance and installation) procedures contain lists of tools required to perform the specified activity.

All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the Standard toolkit and defined in the table below.

This way, the tools required are the sum of the Standard Toolkit and any tools listed in the instruction.

Contents, standard toolkit

Qty Tool

1

1

1

1

1

1

1

1

1

2

1

1

Ring-open-end spanner 8-19 mm

Socket head cap 5-17 mm

Torx socket no: 20-60

Box spanner set

Torque wrench 10-100 Nm

Torque wrench 75-400 Nm

Ratchet head for torque wrench 1/2

Hexagon-headed screw M10x100

Socket head cap no: 14, socket 40 mm bit L 100 mm




Rem.

To be shortened to 12 mm



6.7. Special tools

6.7. Special tools

General

All service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in section


,

and of special tools, listed directly in the instructions and also gathered in this section.

Calibration equipment, Calibration Pendulum

The table below specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method.

Description Art. no.

Note

Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating manual.

Oil exchange equipment

The table below specifies the recommended equipment for oil exhange.

Description Art. no.

Oil exchange equipment 3HAC021745-001

Note

Includes

• vacuum pump with regulator, hose and coupling

• couplings and adapters

• pump (manual) with hose and coupling

• graduated measuring glass

• oil gun

• user instructions.

Basic tools

The table below specifies the tools in the basic toolkit that are used for the current robot model. This toolkit is necessary primarly when removing and refitting the motors.

The tools are also listed directly in the instructions.

Description



Lifting tool, motor ax 1

Lifting tool, motor ax 2, 3

Removal tool, motor M12x

Rotation tool

Standard toolkit (content described in

section


)

1

1

Qty

2

2

1

1

Art. no.

3HAC15521-1

3HAC15521-2

3HAC14459-1

3HAC15534-1

Fits motors axes 1, 2 and 3.

-

3HAC17105-1



259


6.7. Special tools

Continued

Lifting tools

The table below specifies the lifting tools required during several of the service procedures.

The tools may be ordered separately and are also specified directly in concerned instructions in the

Product manual, procedures

.

Qty Description

Lifting tool, tilt house

Lifting tool, motor

Lifting tool, gear ax.2

Lifting tool, frame

Lifting tool, complete robot

Lifting tool, parallel arm

Lifting tool, turning device gearbox ax.1

Lifting tool, base

Guide pin, (short)

Guide pin, (long)

Article no.

3HAC023154-001

3HAC14586-1

3HAC023240-001

3HAC023308-001

3HAC15607-1

3HAC023098-001

3HAC14406-1

3HAC14868-1

3HAC7601-086

3HAC7601-087

Special tools

The table below specifies the special tools required during several of the service procedures.

The tools may be ordered separately and are also specified directly in concerned instructions.

Qty Description

Lower arm fixture

Pressing, link

Pressing, outer ring on link

Pressing, innerring (nållager)

KM-socket for link

Pinion crank

Pressing, lower arm/balancing weight

Pressing, upper arm

Pressing, tie rod

Pressing, tilt house

Pressing, outer ring, tilt house

Auxiliary shaft, long

Auxiliary shaft, short

Support shaft/bearing race

Axis 1 pinion

Tool for lubrication

Adapter for shaft axis 3

Article no.

3HAC7035-1

3HAC023081-001

3HAC023079-001

3HAC023112-008

3HAC5347-1

3HAC023132-001

3HAC023092-001

3HAC023084-001

3HAC5021-1

3HAC023080-001

3HAC023075-001

3HAC5275-1

3HAC5276-1

3HAC5281-1

3HAC022436-001

3HAC5222-1

3HAC023916-001



6.8. Lifting equipment and lifting instructions

6.8. Lifting equipment and lifting instructions

General

Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure.

The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment.

This implies that the instructions delivered with the lifting equipment should be stored for later reference.



6.8. Lifting equipment and lifting instructions


7 Spare parts and exploded views

7.1. Introduction



Definitions

This chapter specifies all spare parts and replacement articles of the robot.



7.2. Spare parts - frame to base

7.2. Spare parts - frame to base

Parts list

Pos Article no.

112

113

114

115

108

109

110

111

116

117

118

119

101

102

103

104

105

106

107

3HAC 17224-4

3HAC 021659-003

3HAC 022279-001

3HAB 7700-73

3HAA 1001-134

3HAC 11732-2

3HAB 7700-5

3HAC 14453-1

3HAC 11529-1

9ADA 618-56

3HAC 4428-2

3HAC 14453-2

3HAC 12252-1

3HAC 14131-1

9ADA 618-58

3HAC 11769-1

9ADA 618-56

3HAB 3537-1

9ADA 618-53

Description

Base, machining

Frame, machining

RV 400C-224.26

Screw M12x70

Washer 13x19x1.5

Washer T = 3

Screw M16x70

Hose with flange

Rubber lined clip D = 28

Screw M6x16

Hose clip

Plug

Bottom plate

Connection plate, base

Screw M6x25

Cable guide, ax. 1

Screw M6x16

Bearing grease

Screw M6x8

Qty

1

2

1

1

1

1

1

1

24

24

3

18

1

1

1

1

2

10 g

1

264



Exploded view


7.2. Spare parts - frame to base

Continued

xx0500002567



7.3. Spare parts - cable harness

7.3. Spare parts - cable harness

Parts list

Item

90.19

90.20

90.21

90.22

90.24

90.26

90.29

90.30

90.1

90.2

90.3

90.4

90.5

90.7

90.8

90.31

90.36

90.37

Article no.

3HAC022544-001

3HAC022539-001

3HAC 13416-1

3HAC 11774-3

3HAC 5172-1

3HAC 022967-001

3HAC 022968-001

3HAC 12129-1

9ADA 267-6

9ADA 618-57

9ADA 183-24

9ADA 618-56

9ADA 183-37

9ADA 629-56

9ADA 183-25

3HAB7116-1

3HAC14222-1

9ADA 618-57

Description

Cable harness, man ax.1-6

Metal clamp, manip.

Protection cover

Adapter, complete

Cable guide, ax.2

Bracket for cables

Distance

Cover plate

Nut M6

Screw M6x20

Screw M6x16

Screw M6x16

Screw M8x25

Screw M6x16

Screw M6x20

Locking liquid

Plate

Screw M6x20

Qty

6

4

4

3

2

1

2

12

1

3

1

1

1

1

1

1 ml

1

4

266



Exploded view


7.3. Spare parts - cable harness

Continued

xx0500002568



7.4. Spare parts - customer harness

7.4. Spare parts - customer harness

Parts list

Pos

1.1

1.2

1.3

1.4

1.5

1.7

1.8

1.9

1.10

1.12

1.15

1.16

Article no.

3HAC022545-001

3HAC023407-001

3HAC 13416-1

3HAC 11774-3

9ADA 183-24

9ADA 618-57

3HAC 12625-1

9ADA 183-15

9ADA 267-6

9ADA 183-34

3HAC022969-001

3HAC023100-001

Description

Cable harness, customer

Attachment plate

Protection cover

Adapter, complete

Screw M6x16

Screw M6x20

Strap, Velco M5x300

Screw M5x20

Nut

Screw M8x12

Bracket

Cover plate

Qty

4

1

1

4

1

1

1

2

1

6

10

1

268



Exploded view


7.4. Spare parts - customer harness

Continued

xx0500002569



7.5. Spare parts - lower arm system

7.5. Spare parts - lower arm system

Parts list

304

305

306

310

311

312

313

314

315

316

317

318

Pos

301

302

303

Article no.

3HAC021464-004

3HAC023026-003

3HAA 2166-18

3HAB 3537-1

3HAC 4435-1

3HAB 4169-1

3HAA 2166-23

3HAC022338-001

9ADA 183-37

9ADA 312-7

3HAB7116-1

3HAC 12991-1

9ADA 618-57

3HAC 4836-8

3HAC022339-001

Description Qty

Lower arm (White RAL 9003) 1

Parallel arm (White RAL 9003)

VK-Cover, VK 35x8

(Not visible in this figure.)

1

1

Bearing grease Shell Alvania WR2 10 g

Spacing sleeve

Sealed spherical bearing

VK-cover, VK 120x12

Damper

Screw M8x25

Plain washer 8,4x16x1,6

Locking liquid

Damper ax.2

Screw M6x20

Protection plug

Damper

3

1

1

1

2

2

2

4

4

1 ml

3

270



Exploded view


7.5. Spare parts - lower arm system

Continued

xx0500002570



7.6. Spare parts - parallel rod

7.6. Spare parts - parallel rod

Parts list

Pos

201

202

203

204

205

206

Article no.

3HAC021084-004

3HAB 3537-1

3HAC 4331-1

3HAC 3715-1

3HAC 4332-1

3HAC 4330-1

Description

Parallel rod (White RAL 9003)

Bearing grease Shell Alvania WR2

Thrust washer

Sealed spherical bearing

Cover washer

Shaft

Qty

2

2

2

1

4 g

2

272



Exploded view


7.6. Spare parts - parallel rod

Continued

xx05000002571



7.7. Spare parts - Balancing device

7.7. Spare parts - Balancing device

Parts list

Pos Article no.

62

63

64

58

59

60

61

4 3HAC024779-001

4.6

3HAC 3476-1

4.10

3HAC 3530-1

1236 0012-202

3HAC 7343-1

3HAC 7253-1

3HAC 3311-1

3HAB 3537-1

3HAC 7349-1

3HAB7116-1

Description

Balancing device (White RAL 9003)

Guiding ring

Circlip

Sealing compound

Sealing ring

Support washer

Adjust. Needle bearing

Bearing grease Shell Alvania RW2

Lock nut

Locking liquid

Qty

1

1

1

4

2

4 ml

2

10 g

2

1 ml

274



Exploded view


7.7. Spare parts - Balancing device

Continued

xx0500002572



7.8. Spare parts - frame to lower arm

7.8. Spare parts - frame to lower arm

Parts list

Pos Article no.

38

39

40

41

42

34

35

36

37

30

31

32

33

26

27

28

29

22

23

24

25

18

19

20

21

14

15

16

17

11

12

13

3HAC022379-001

3HAA 1001-134

3HAB 7700-71

3HAC022644-001

3HAB 3772-84

9ADA 312-7

9ADA 183-39

3HAC021663-003

3HAB 4233-1

3HAB 3409-50

3HAC024776-001

3HAC022379-001

3HAC022644-001

3HAB 7700-71

3HAA 1001-134

3HAC021663-003

9ADA 183-39

9ADA 312-7

3HAB 3772-84

3HAC024776-001

3HAB 3409-50

3HAB 4233-1

3HAB 3409-86

3HAA 1001-186

3HAB 7700-69

3HAA 1001-134

3HAB 7700-69

3HAA 1001-134

3HAC032140-001

3HAC 16721-1

3HAC 16721-1

3HAC032140-001

Description Qty.

Sealing ax.2/3

Washer 13x19x1,5

Screw M12x60

RV-450E

O-ring


Screw M8x35

Cover, machined

Washer

Screw M10x40

Motor incl pinion ax.2 (White RAL 9003)

Sealing ax.2/3

RV-450E ax.3

Screw M12x60

Washer 13x19x1,5

Cover, machined

Screw M8x35


O-ring

Motor inc. Pinion ax.3 (White RAL 9003) 1

Screw M10x40 4

Washer

Screw M16x60

4

6

1

16

16

1

Washer 17x25x3

Screw M12x50

Washer 13x19x1,5

Screw M12x50

Washer 13x19x1,5

Lubricating oil Kyodo Yushi TMO 150

Magnetic plug

Magnetic plug


6

21

21

21

3

3

21

5000 ml

5000 ml

1

1

24

24

4

1

1

4

1

1

16

16

1

24

24

276



Exploded view


7.8. Spare parts - frame to lower arm

Continued

xx0500002573



7.9. Spare parts - shafts

7.9. Spare parts - shafts

Parts list

Pos

52

53

54

55

48

49

50

51

56

57

44

45

46

47

501

502

43

Article no.

3HAC 021113-003

3HAA 1001-124

3HAC 4545-1

3HAC 022446-001

1171 2016-618

3HAB 3772-29

2216 264-16

3HAC 022581-001

3HAB 3537-1

2213 3802-8

3HAC 7817-1

3HAC 6627-1

3HAA 1001-658

3HAB 7116-1

2126 2851-112

9ADA 205-75

3HAB 7116-1

Description Qty

Upper arm machining

Support ring

Shaft

Shaft

Lubricant, paste

O-ring

Sealing ring

Sealing ring 2

Bearing grease Shell Alvania RW2 10 g


Nilos ring

2

2

Spacer

O-ring

Locking liquid, Loctite 243

Lock nut

Screw M10x20

Locking liquid, Loctite 243

2

2

4 ml

2

2

4 ml

2

2

1

5

1

2

1

278



Exploded view


7.9. Spare parts - shafts

Continued

xx0500002574



7.10. Spare parts - tilthouse

7.10. Spare parts - tilthouse

Parts list

Pos Article no.

508

508.1

508.2

508.3

508.4

508.5

508.6

3HAC022764-003

3HAC022740-003

3HAC023533-001

3HAC 10828-10

3HAB 7700-55

3HAA 1001-172

3HAC 9744-5

508.7

508.8

3HAC022977-001

9ADA 618-32

508.9

2121 2518-577

508.10

2522 122-1

508.11

9ADA 624-69

508.12

3HAC 14263-1

508.13

9ADA 183-37

508.14

9ADA 312-7

508.15

3HAB7116-1

508.16

2152 0431-20

508.17

3HAC032160-001

508.18

3HAB 3772-65

508.19

2152 0441-1

Description

Tilthouse complete (White RAL 9003)

Tilthouse, machining

Motor incl pinion

RV 40E-81

Screw M8x40

Washer 8,4x13x1,5

Turning disc

Sync.plate

Screw M4x8

Screw M14x25

Magnetic plug

Screw M8x20

Protection Cover

Screw M8x25


Locking liquid

O-ring 15,5x1,5


O-ring 131x2

Washer

Qty

4

4

2

1

6

2

1

2

8

1

1

8

1

1

1

1 ml

6

250 ml

1

2

280



Exploded view


7.10. Spare parts - tilthouse

Continued

xx0500002575



7.11. Spare parts - upper arm front

7.11. Spare parts - upper arm front

Parts list

Pos

513

514

515

516

509

510

511

512

517

518

519

520

501

503

504

505

506

507

508

Article no.

3HAC025525-001

9ADA 629-56

9ADA 327-4

3HAB7116-1

3HAC022673-001

3HAC023027-001

3HAC022764-001

3HAA 2166-21

2126 2851-107

3HAC021158-001

3HAA 2166-17

2213 3802-11

3HAB 3537-1

3HAC022645-001

3HAB 3701-35

9ADA 183-22

3HAC020537-001

3HAC 8286-1

9ABA 137-28

Description Qty

Upper arm machining (White RAL 9003) 1

Screw M6x16

Plain washer 6,4x17x3

2

2

Locking liquid

Ball plug

Protection cap

Tilt house

1

1

1 ml

1

VK-Cover, VK 68x8

Lock nut

Shaft upper arm

VK-Cover, VK 19x6



Ring

Radial seal w. dustlip 50x68x8

Screw M6x10

Washer 6,4x12x1,6

Dinitrol 490

Retaining ring, bore

4

4

30 ml

2

2

2

2

2

1

2

4

130 g

282



Exploded view


7.11. Spare parts - upper arm front

Continued

xx0500002576



7.12. Spare parts - Linkage

7.12. Spare parts - Linkage

Parts list

Pos

703

704

705

706

608

609

701

702

601

602

603

604

605

606

607

707

708

709

Article no.

3HAC023744-003

3HAC023239-003

12360012-202

3HAC7343-1

3HAC7253-1

3HAC3311-1

3HAB3537-1

3HAC7349-1

3HAB7116-1

3HAC021088-003

3HAA 2103-13

3HAB 3537-1

1236 0012-202

3HAB 3702-31

3HAC022521-001

2126 2851-108

3HAB7116-1

3HAA 2166-13

Description

Upper rod (White RAL 9003)

Lower rod (White RAL 9003)

Sealing compound

Ring

Support washer

Adjust. needel bearing

Bearing grease

Lock nut

Locking liquid

Link, machining



Sealing compound Permatex No 3

Radial seal 85x100x9

Support Ring

Lock nut

Locking liquid

VK-Cover

Qty.

1

2

4

2

1

1

35 g

2 ml

4

8

4

10

1

1

2

1

1 ml

1

284



Exploded view


7.12. Spare parts - Linkage

Continued

xx0500002577



7.13. Spare parts - motor axis1

7.13. Spare parts - motor axis1

Parts list

Pos

76

77

78

72

73

74

75

68

69

70

71

65

66

67

Article no.

3HAC024775-001

3HAB 3409-50

3HAB 4233-1

2522 122-1

3HAC 16721-1

3HAC021469-001

3HAC 12671-6

3HAC 14024-1

9ADA 618-57

3HAC021287-001

9ADA 618-56

3HAC 17358-1

3HAC 18306-1

3HAB 7700-89

Description

Motor inc. pinion ax.1 (White RAL 9003)

Screw M10x40

Washer

Magnetic plug

Magnetic plug

Lubricating oil

Block for calibration

Protection screw

Screw M6x20

Sync.plate

Screw M6x16

Mech.stop

Cover sheet

Screw M16x90

Qty

1

1

1

1

2

1

3

1

4

4

1

1

8000 ml

1

286



Exploded view


7.13. Spare parts - motor axis1

Continued

xx0500002578



7.14. Spare parts - SMB

7.14. Spare parts - SMB

Parts list

Pos

90.16

90.17

90.18

90.20

90.23

90.25

90.27

90.28

90.35

90.9

90.10

90.11

90.12

90.13

90.14

90.15

Article no.

3HAC 11526-1

3HAC022204-001

3HAC 2744-1

3HAC 4813-1

3HAC 16035-1

3HAC 14791-3

3HAC 13151-1

3HAC 15619-1

3HAC022286-001

3HAC 16831-1

9ADA 267-6

9ADA 183-25

9ADA 183-13

9ADA 312-6

3HAC 021349-003

9ADA 618-45

Description

Stud screw

Bracket

Push button guard

Cover, push button guard

BU w.buttons DSQC 563

Cover battery box

Cable battery/SMB

Cable, FB7-SMB 1.7

Serial measurement unit

Battery pack

Nut M6

Screw M6x20

Screw M5x12

Plain washer 6.4x12x1.6

Cover SMB

Screw M5x16

Qty

2

1

10

6

6

1

3

1

1

1

1

1

1

2

1

1

288



Exploded view



Continued

xx0500002579





8 Circuit diagram


Overview

This chapter includes the circuit diagram for the robot.


8.1. Introduction



8.1. Introduction


Latest revision:

Prepared by, date: Approved by, date:

The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.

Except as may be expressly stated anywhere in this document, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

In no event shall ABB be liable for incidental or consequential damages arising from use of this document.

This document and parts thereof must not be reproduced or copied without ABB's written permission, and contents therof must not be imparted to a third party nor be used for any unauthorized purpose.

Contravention will be prosecuted.

Additional copies of this document may be obtained from ABB at its then current charge.

© Copyright 2004 ABB ALL right reserved.

ABB Automation Technologies AB

Robotics


Sweden

Lab/Office:

COPYRIGHT PAGE

Title page/cover sheet

Status:

2000-03-03

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC025690-001

=

+

+

IRB660, CC

Manipulator

Rev. Ind

01

Page

Next

Total

1

2

7

Customer

Robot serial number(s)

Drawing number

Drawing version

Manufacture

Type

Type of installation

Control cabinet

Mains voltage

Supply

Control voltage

Year of construction

Project start

Project manager

Last revision

Designed by

Designed date

Number of pages

:

:

:

:

3HAC025690-001

:

:

:

:

:

:

:

: 2008-03-03

:

:

:

:

:

:

:

2005-08-30 sethsta

2008-03-03

7

Latest revision:


Lab/Office:

TITLE PAGE

Title page/cover sheet

Status:

2000-03-03

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC025690-001

=

+

+

IRB660, CC

Manipulator

Rev. Ind

01

Page

Next

Total

2

3

7

Table of contents

Plant Location

IRB660, CC Manipulator





IRB660, CC CP/CS

IRB660, CC CBUS

Page Page description

1 COPYRIGHT PAGE

2 TITLE PAGE

3 Table of contents: (1 - 22)

4 Revision information

11 Connection point location

21 Customer power/Customer signal

22 Customer bus

Page supplementary field

Approved

Approved

Approved

Approved

Approved

Approved

Approved

Date

ABB_table_of_contents

Editor

2008-03-03 sethsta

2008-03-03 sethsta

2008-03-03 sethsta

2008-03-03 sethsta

2008-03-03 sethsta

2008-03-03 sethsta

2008-03-03 sethsta

Latest revision:


Lab/Office:

Table of contents: (1 - 22)

Table of contents

Status:

Approved

Document no.

Plant:

Location:

Sublocation:

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=

+

+

IRB660, CC

Manipulator

Rev. Ind

01

Page

Next

Total

3

4

7

1 2 3

Revision 01

Sheet 3 new table of contents.

Sheet 4 new, revision information

Sheet 21 One of the parallel earth wire was removed, coordinate column 3,4 and 5

Sheet 21 Two twisted symbol removed at coordinate column 4.

Sheet 21 Shield symbol changed, the shield include wire D1,D3, D4 and D6.

4 5 6 7 8

Latest revision:

Prepared by, date:

EM 080303

Approved by, date:

ER 080303

Lab/Office:

Revision information

Status:

2008-03-03

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC025690-001

=

+

+

IRB660, CC

Manipulator

Rev. Ind

01

Page 4

Next 11

Total 7

1 2 3 4

R2.CP/CS

5 6 7 8

Latest revision:

Prepared by, date:

EM 080303

Approved by, date:

ER 080303

Lab/Office:

Connection point location

R1.CP/CS

Status:

2008-03-03

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC025690-001

=

+

+

IRB660, CC

Manipulator

Rev. Ind

01

Page 11

Next 21

Total 7

1 2

Latest revision:

Prepared by, date:

EM 080303

Approved by, date:

ER 080303

-R1.CP/CS

D1

D6

D3

D4

B13

B14

B15

B16

B9

B10

B11

B12

B5

B6

B7

B8

B1

B2

B3

B4

C16

C17

C18

C19

B18

B19

B20

B21

C20

C21

3 7 8 4

4

5

6

7

GN/YE

WH/GN

GN

WH/BU

BU

WH/VT

VT

WH/GY

GY

WH/BK

BK

WH/OG

OG

WH/BN

BN

WH/RD

RD

WH/BK

BK

WH/BN

BN

WH/RD

RD

WH/OG

OG

WH/YE

YE

5 6

-R2.CP/CS

C4

C5

24V

0V

C6

C7

24V

0V

PE

B18

B19

B20

B21

B22

B23

B24

B25

B16

B17

B1

B2

B3

B4

B5

B6

B7

B8

B9

B10

B11

B12

B13

B14

B15

C8

CS1

CS2

CS3

CS4

CS5

CS6

CS7/KSR

CS8/KSR

CS9

CS10

CS11

CS12

CS13

CS14

CS15

CS16

CS17

CS18

CS19

CS20

CS25

CS26

CS27

CS28

CS29

CS30

Lab/Office:

Customer power/Customer signal

Status:

2008-03-03

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC025690-001

=

+

+

IRB660, CC

CP/CS

Rev. Ind

01

Page 21

Next 22

Total 7

1 2 3

-R1.CP/CS

B22

B23

A5

A6

A9

A10

B24

B25

A3

A4

A11

A12

4

5 YE

6 YE

7 VT

8 VT

1 GN

2 GN

3 GN

4 GN

WH/BK

BK

WH/BN

2

5

-R2.CP/CS

A1

A2

A9

A10

A5

A6

A3

A4

A7

A8

A11

A12

6 7 8

Latest revision:

Prepared by, date:

EM 080303

Approved by, date:

ER 080303

Lab/Office:

Customer bus

Status:

2008-03-03

Approved

Document no.

Plant:

Location:

Sublocation:

3HAC025690-001

=

+

+

IRB660, CC

CBUS

Rev. Ind

01

Page 22

Next

Total 7

1 2 3 4 5 6 7 8

The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.

Except as may be expressly stated anywhere in this document, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

In no event shall ABB be liable for incidental or consequential damages arising from use of this document.

This document and parts thereof must not be reproduced or copied without ABB's written permission, and contents therof must not be imparted to a third party nor be used for any unauthorized purpose.

Contravention will be prosecuted.

Additional copies of this document may be obtained from ABB at its then current charge.

© Copyright 2004 ABB ALL right reserved.

ABB Automation Technologies AB

Robotics


Sweden

Latest revision:

Prepared by, date:

EM 2008-06-02

Approved by, date:

JM 080603

Lab/Office:

COPYRIGHT PAGE

Status:

2008-06-03

Approved

Document no.

Plant:

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+

IRB660

Location:

Sublocation:

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Manipulator

3HAC025691-001

Rev. Ind

02

Page

Next

1

2

Total 12

1 2 3 4 5 6 7 8

Customer

Robot serial number(s) :

:

Drawing number

Drawing version :

:

Manipulator

Manufacture

Type

Type of installation

Control cabinet

Mains voltage

Supply

Control voltage

Year of construction

:

:

:

:

:

:

:

:

2008-06-04

RMM

Project start

Project manager

Last revision

Designed by

Designed date

Number of pages :

:

:

:

:

:

:

2005-08-31 seermes

2008-06-04

12

Latest revision:

Prepared by, date:

EM 2008-06-02

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JM 080603

Lab/Office:

TITLE PAGE

Status:

2008-06-03

Approved

Document no.

Plant:

=

+

IRB660

Location:

Sublocation:

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Manipulator

3HAC025691-001

Rev. Ind

02

Page

Next

2

3

Total 12

1 2 3

Table of contents

Plant

IRB660

Location

Manipulator

Page Page description

1 COPYRIGHT PAGE

IRB660

IRB660

IRB660

IRB660

IRB660

IRB660

IRB660

IRB660

IRB660

IRB660

IRB660

Manipulator

Manipulator

2 TITLE PAGE

3 Table of contents:

Manipulator 4 Revision information

Manipulator 11 Connection point location

BU

SMB

21 Brake Release Unit

22 Serial Measuring Board

Axis 1

Axis 2

Axis 3

Axis 6

Switches

23

24

25

Axis 1

Axis 2

Axis 3

26 Axis 6

27 Switches axis 1

4 5 6 7 8

Page supplementary field

Approved

Approved

Approved

Approved

Approved

Approved

Approved

Approved

Approved

Approved

Approved

Approved

ABB_table_of_contents

Date Editor

2008-06-04 seermes

2008-06-04 seermes

2008-02-27 sethsta

2008-06-04 seermes

2008-06-04 seermes

2008-06-04 seermes

2008-06-04 seermes

2008-06-04 seermes

2008-06-04 seermes

2008-06-04 seermes

2008-06-04 seermes

2008-06-03 seermes

Latest revision:

Prepared by, date:

EM 2008-06-02

Approved by, date:

JM 080603

Lab/Office:

Table of contents:

Status:

2008-06-03

Approved

Document no.

Plant:

=

+

IRB660

Location:

Sublocation:

+

Manipulator

3HAC025691-001

Rev. Ind

02

Page

Next

3

4

Total 12

1 2

080228 rev.01

Sh.3 New sheet, Table of contents.

Sh.4 New sheet . Revision information.

Sh.11 R1.SW1 add.

Sh.27 New sheet, Switches axis 1

080602 rev.02

Sh.23 The page description has been changed.

3 4 5 6 7 8

Latest revision:

Prepared by, date:

EM 2008-06-02

Approved by, date:

JM 080603

Lab/Office:

Revision information

Status:

2008-06-03

Approved

Document no.

Plant:

=

+

IRB660

Location:

Sublocation:

+

Manipulator

3HAC025691-001

Rev. Ind

02

Page

Next

4

11

Total 12

1 2

R2.MP6

R2.FB6

R2.H1

R2.H2

3

R3.H1

R3.H2

4 5 6 7 8

Latest revision:

Prepared by, date:

EM 2008-06-02

Approved by, date:

JM 080603

R2.MP2

R2.FB2

R1.G

R2.SMB

R1.SMB1-3

R1.SMB6

X8

X9

X10

R2.MP1

R2.FB1

Lab/Office:

Connection point location

R2.MP3

R2.FB3

R1.MP

R1.SMB

R1.SW1

Status:

2008-06-03

Approved

Document no.

Plant:

=

+

IRB660

Location:

Sublocation:

+

Manipulator

3HAC025691-001

Rev. Ind

02

Page

Next

11

+BU/21

Total 12

1

-R1.MP

13

11

12

2

Brake Release 2

Brake PB

0V

1

4

=+-BU 0V M1

/ +Axis 1/23.2

=+-BU 0V M2

/ +Axis 2/24.2

=+-BU 0V M3

/ +Axis 3/25.2

3

5

3

1

-X8

4

-BU Brake Release (Simplified)

-X8

1

2

5

3

4

5

=+-BU 0V M6

/ +Axis 6/26.2

6 7 8

A K

1

-X10

-X10

1

Brake Bleed Circuit

2

A K

3

Brake Bleed Circuit

4

A K

5

3

5

Brake Bleed Circuit

6

A

Key Pin

K

4

-X9

9

5

6

7

R1.MP

R1.MP

R1.MP

Brake Bleed Circuit

5

A K

8

Brake Bleed Circuit

9

A K

10

Brake Bleed Circuit

11

Key Pin

1

-X9

10

10

R1.MP

=+-BU M1

/ +Axis 1/23.2

=+-BU M2

=+-BU M3

=+-BU M6

/ +Axis 2/24.2

/ +Axis 3/25.2

/ +Axis 6/26.2

Latest revision:

2

Prepared by, date:

EM 2008-06-02

Approved by, date:

JM 080603

Lab/Office:

Brake Release Unit

Status:

2008-06-03

Approved

Document no.

Plant:

=

+

IRB660

Location:

Sublocation:

+

BU

Rev. Ind

3HAC025691-001

02

Page 21

Next +SMB/22

Total 12

1 2 3 4 5

-SMB

6 7 8

+Axis 6/26.3

+Axis 6/26.3

-R1.SMB

A

B

E

F

C

D

L

M

SDI

SDI-N

SDO

SDO-N

0V

24V

24V EXT.LAMP

0V EXT.LAMP

BK

WHBK

BN

WHBN

RD

WHRD

OG

WHOG

3

7

8

4

-R2.SMB

9

5

-R2.SMB

9

5

3

7

8

4

G

+ + + -

0V

+

-R1.G(X3)

2

1

-R1.G(X3)

2

1

Latest revision:

Prepared by, date:

EM 2008-06-02

Approved by, date:

JM 080603

Lab/Office:

Serial Measuring Board

Status:

2008-06-03

Approved

Document no.

Plant:

=

+

IRB660

Location:

Sublocation:

+

SMB

Rev. Ind

3HAC025691-001

02

Page 22

Next +Axis 1/23

Total 12

1 2

-R1.MP

17

25

19

24

18

26

+Axis 2/24.2

/

+-PTC M2

+BU/21.7

/

=+-BU M1

+BU/21.2

/

=+-BU 0V M1

27

3

M1R

M1R

M1S

M1S

M1T

M1T

PE

PE

PTC M

PTC M2

BU M1

BU 0V M1

9

10

7

8

3

4

1

2

5

6

GNYE

GNYE

4 5 6

10

9

12

3

7

4

6

-R2.MP1

1

-MU1

-R2.MP1

1

10

9

12

3

7

4

6

8

11

8

11

7

RD

RD

WH

WH

BK

BK

GNYE

GNYE

R (U)

S (V)

PE

M

3~

T (W)

-PTC

BU

BK

2

5

2

5

BU +

BU -

Brake

8

-SMB

6

18

3

15

-R1.SMB1-3

2

14

-R1.SMB1-3

2

14

6

18

3

15

Latest revision:

Prepared by, date:

EM 2008-06-02

Approved by, date:

JM 080603

BK

WHBK

BN

WHBN

RD

WHRD

X1

0V X1

Y1

0V Y1

0V EXC1

EXC1

Lab/Office:

Axis 1

7

2

8

3

-R2.FB1

6

1

-FB1

-R2.FB1

6

RD

1

BK

2

7

BU

YE

8

WHBK (WHYE)

3

WHRD

Resolver

Status:

2008-06-03

Approved

Document no.

Plant:

=

+

IRB660

Location:

Sublocation:

+

Axis 1

Rev. Ind

3HAC025691-001

02

Page 23

Next +Axis 2/24

Total 12

1

+Axis 1/23.2

/

+-PTC M2

+Axis 3/25.2

/

+-PTC M3

+BU/21.7

/

=+-BU M2

+BU/21.2

/

=+-BU 0V M2

2

-R1.MP

23

31

21

32

22

30

3

M2T

M2T

PE

PE

M2R

M2R

M2S

M2S

PTC M2

PTC M3

BU M2

BU 0V M2

9

10

7

8

3

4

1

2

5

6

GNYE

GNYE

4 5 6

10

9

12

3

7

4

6

-R2.MP2

1

-MU2

-R2.MP2

1

10

9

12

3

7

4

6

8

11

8

11

7

RD

RD

WH

WH

BK

BK

GNYE

GNYE

R (U)

S (V)

PE

M

3~

T (W)

+Axis 1-PTC

BU

BK

2

5

2

5

BU +

BU -

Brake

8

-SMB

-R1.SMB1-3

4

16

-R1.SMB1-3

4

16

7

19

5

17

7

19

5

17

Latest revision:

Prepared by, date:

EM 2008-06-02

Approved by, date:

JM 080603

BK

WHBK

BN

WHBN

RD

WHRD

X2

0V X2

Y2

0V Y2

0V EXC1

EXC1

Lab/Office:

Axis 2

7

2

8

3

-R2.FB2

6

1

-FB2

-R2.FB2

6

RD

1

BK

7

BU

2

YE

8

WHBK (WHYE)

3

WHRD

Resolver

Status:

2008-06-03

Approved

Document no.

Plant:

=

+

IRB660

Location:

Sublocation:

+

Axis 2

Rev. Ind

3HAC025691-001

02

Page 24

Next +Axis 3/25

Total 12

1

+Axis 2/24.2

/

+-PTC M3

+Axis 6/26.2

/

+-PTC M6

+BU/21.7

/

=+-BU M3

+BU/21.2

/

=+-BU 0V M3

2

-R1.MP

3

6

7

4

5

14

3

M3T

M3T

PE

PE

M3R

M3R

M3S

M3S

PTC M3

PTC M6

BU M3

BU 0V M3

9

10

7

8

3

4

1

2

5

6

GNYE

GNYE

4 5 6

-R2.MP3

1

-MU3

-R2.MP3

1

10

9

12

3

7

4

6

10

9

12

3

7

4

6

8

11

8

11

7

RD

RD

WH

WH

BK

BK

GNYE

GNYE

R (U)

S (V)

PE

M

3~

T (W)

+Axis 1-PTC

BU

BK

2

5

2

5

BU +

BU -

Brake

8

-SMB

-R1.SMB1-3

21

-R1.SMB1-3

9

21

8

20

10

22

8

20

10

22

Latest revision:

Prepared by, date:

EM 2008-06-02

Approved by, date:

JM 080603

BK

WHBK

BN

WHBN

RD

WHRD

X3

0V X3

Y3

0V Y3

0V EXC1

EXC1

Lab/Office:

Axis 3

7

2

8

3

-R2.FB3

6

1

-FB3

-R2.FB3

6

RD

1

BK

7

BU

2

YE

8

WHBK (WHYE)

3

WHRD

Resolver

Status:

2008-06-03

Approved

Document no.

Plant:

=

+

IRB660

Location:

Sublocation:

+

Axis 3

Rev. Ind

3HAC025691-001

02

Page 25

Next +Axis 6/26

Total 12

6

-R2.MP6

1

-MU6

-R2.MP6

1

RD

7

3

3

WH

R (U)

S (V)

PE

M

3~

T (W)

7

9

7

BK

9

GNYE

+Axis 1-PTC

8

11

2

5

8

11

BU

BK

2

5

BU +

BU -

Brake

8

-SIGNAL LAMP (OPTIONAL)

R3.H

A K

1

2

7

2

8

3

-R2.FB6

6

1

-FB6

-R2.FB6

6

RD

1

BK

7

BU

2

YE

8

WHBK (WHYE)

3

WHRD

Resolver

Status:

2008-06-03

Approved

Document no.

Plant:

=

+

IRB660

Location:

Sublocation:

+

Axis 6

Rev. Ind

3HAC025691-001

02

Page 26

Next +Switches/27

Total 12

1 2

-R1.SW

B

D

A

C

POWER 1.1.2 2

SIGNAL 1.1.2 4

POWER 1.1.1 1

SIGNAL 1.1.1 3

E

G

F

H

POWER 1.2.2 6

SIGNAL 1.2.2 8

POWER 1.2.1 5

SIGNAL 1.2.1 7

K

M

J

L

POWER 1.3.2 10

SIGNAL 1.3.2 12

POWER 1.3.1 9

SIGNAL 1.3.1 11

P

S

N

R

POWER 1.4.2 14

SIGNAL 1.4.2 16

POWER 1.4.1 13

SIGNAL 1.4.1 15

T

V

U

W

POWER 1.5.2 18

SIGNAL 1.5.2 20

POWER 1.5.1 17

SIGNAL 1.5.1 19

Y a

X

Z

POWER 1.6.2 22

SIGNAL 1.6.2 24

POWER 1.6.1 21

SIGNAL 1.6.1 23

3

-SW1.1

13 14

21 22

-SW1.2

13 14

21 22

-SW1.3

13 14

21 22

-SW1.4

13 14

21 22

-SW1.5

13 14

21 22

-SW1.6

13 14

21 22

4

SWITCHES AXIS 1

BRYTARE AXEL 1

5

Latest revision:

Prepared by, date:

EM 2008-06-02

Approved by, date:

JM 080603

Lab/Office:

Switches axis 1

6 7

LOCATION OF SWITCHES

PLACERING AV BRYTARE

8

SW1.6

SW1.5

SW1.4

SW1.3

SW1.2

SW1.1

Status:

2008-06-03

Approved

Document no.

Plant:

=

+

IRB660

Location:

Sublocation:

+

Switches

3HAC025691-001

Rev. Ind

02

Page

Next

27

Total 12

Index

A

Absolute Accuracy, calibration

243

B

brake release unit, replacement

208

brakes testing function

24

C

cabling between robot and controller

76

cabling, robot

76

calibrating roughly

246

calibration

Absolute Accuracy type

242

marks/scales

244

rough

246

standard type

242

when to calibrate

241

calibration manuals

243

calibration position

246

checking

248

jogging to, FlexPendant

248

scales

244

calibration, Absolute Accuracy

243

CalibWare

242

complete arm system, replacement

150

connecting the robot and controller, cabling

76

Connection of external safety devices

14

D

direction of axes

245

E

enabling device

26

ESD damage elimination

34

sensitive equipment

34

wrist strap connection point

34

explanation, safety symbols

29

F

FlexPendant jogging to calibration position

248

MoveAbsJ instruction

248

updating revolution counters

246

fork lift

45

foundation loads

40

requirements

41

G

gearbox axis 1, replacement

225

gearbox axis 6, replacement

236

H

hold-to-run

26

I

installation mechanical stop axis 1

69


L

lifting equipment

257

lifting of robot with lifting slings

52

lifting robot with fork lift

45

lifting slings, robot

52

linkage replacing lower rod

180

replacing upper rod

177

loads on foundation

40

M

mechanical stop axis 1

69

MoveAbsJ instruction

FlexPendant

248

N

negative directions, axes

245

O

oil change safety risks

35

operating conditions, robot

41

P

position, robot

244

positive directions, axes

245

protection classes

41

R

replacement brake release unit

208

complete arm system

150

gearbox axis 1

225

gearbox axis 6

236

turning disk

156

replacing lower rod, linkage

180

upper rod, linkage

177

requirements on foundation

41

restricting working range axis 1

69

revolution counters storing on FlexPendant

246

updating

246

risk of tipping

44

robot operating conditions

41

protection class

41

storage conditions

41

weight

40

robot position

244

S

safety equipment mechanical stop

69

signal lamp

106

Safety, service

14

safety, symbols

29

293

Index

scales on robot

244

securing the robot to foundation, attachment screws

61

securing, base plate

57

securing, robot

61

serial measurement board unit, replacement

205

special tools

259

stability

44

storage conditions, robot

41

symbols, safety

29

sync marks

244

T

testing, brakes

24

tightening torque mechanical stop axis 1

70

tools

Calibration Pendulum equipment

259

for service

259

oil exchange equipment

259

turning disk replacement

156

U

updating revolution counters

246

V

Validity and responsibility

14

W

weight base plate

56

,

60

complete arm system

152

,

153

gearbox

228

,

229

,

234

lower arm

194

motor

214

,

215

robot

51

,

53

upper arm

174

weight, robot

40

working range

42

restricting axis 1

69


ABB AB

Robotics Products

S-721 68 VÄSTERÅS

SWEDEN

Telephone: +46 (0) 21 344000

Telefax: +46 (0) 21 132592