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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
© Copyright 2006-2008 ABB. All rights reserved.
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.
© Copyright 2006-2008 ABB All rights reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
© Copyright 2006-2008 ABB. All rights reserved.
Additional copies of this manual may be obtained from ABB at its then current charge.
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
© Copyright 2006-2008 ABB. All rights reserved.
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
Table of Contents
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.2 Oil change, gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.3 Oil change, gearbox axes 2-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.4 Oil change, gearbox axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4.5 Replacement of SMB battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
108
112
115
118
120
3.5 Lubrication activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.5.1 Lubrication of bearing, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
3.6 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.2 Replacement of tilthouse unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.3 Replacement of upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.4 Replacement of linkage - upper rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.5 Replacement of linkage - lower rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.6 Replacement of linkage - link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.7 Replacement of parallel rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4.8 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
156
159
170
177
180
183
188
192
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
3.6.1 Cleaning, robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Table of Contents
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
© Copyright 2006-2008 ABB. All rights reserved.
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
3HAC025755-001 Revision: B
293
5
© Copyright 2006-2008 ABB. All rights reserved.
Table of Contents
6
3HAC025755-001 Revision: B
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
© Copyright 2006-2008 ABB. All rights reserved.
The manual is organized in the following chapters:
Chapter
Contents
Safety
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.
Installation and commissioning
Required information about lifting and installation of the robot.
Maintenance
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.
Repair
Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Calibration Information
Procedures that does not require specific calibration equipment.
Decommissioning
Environmental information about the robot and its components.
Continues on next page
3HAC025755-001 Revision: B
7
Overview
Continued
References
Document name
Document ID
Product specification - IRB 660
3HAC023932-001
Product manual - IRC5
3HAC021313-001
Operating manual - IRC5 with FlexPendant
3HAC16590-1
Operating manual - Calibration Pendulum
3HAC16578-1
Operating manual - Service Information System
3HAC025709-001
Application manual - Additional axes and stand alone controller
3HAC021395-001
Technical reference manual - System parameters
3HAC17076-1
Revisions
Description
-
First edition
A
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.
B
Changes made in:
• Prerequisites in section Overview
• Oil change in section Maintenance
© Copyright 2006-2008 ABB. All rights reserved.
Revision
8
3HAC025755-001 Revision: B
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
© Copyright 2006-2008 ABB. All rights reserved.
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
Continues on next page
3HAC025755-001 Revision: B
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
© Copyright 2006-2008 ABB. All rights reserved.
•
10
3HAC025755-001 Revision: B
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.
8.
Action
Note/Illustration
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.
© Copyright 2006-2008 ABB. All rights reserved.
The table below shows an example of a reference to a list of required equipment, from a step
in a procedure.
3.
Action
Note/Illustration
Fit a new sealing, axis 2 to the gearbox.
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.
3HAC025755-001 Revision: B
11
© Copyright 2006-2008 ABB. All rights reserved.
How to read the product manual
12
3HAC025755-001 Revision: B
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.
© Copyright 2006-2008 ABB. All rights reserved.
•
3HAC025755-001 Revision: B
13
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
Related information
14
Type of information
Detailed in document
Section
Installation of safety
devices
Product manual for the robot
Installation and commissioning
Changing operating
modes
Operating manual - IRC5 with
FlexPendant
(RobotWare 5.0)
Operating modes
Restricting the working
space
Product manual for the robot
Installation and commissioning
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
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.
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.
© Copyright 2006-2008 ABB. All rights reserved.
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.
Continues on next page
3HAC025755-001 Revision: B
15
1 Safety
1.2.2.1. Safety risks during installation and service work on robot
Continued
Complete robot
Safety risk
Description
Hot components!
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!
Removed parts may result in
collapse of robot!
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
Description
Cable packs are sensitive to
mechanical damage!
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
Description
Gears may be damaged if
excessive force is used!
CAUTION!
Whenever parting/mating motor and gearbox, the gears
may be damaged if excessive force is used!
16
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
Safety risk
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!
© Copyright 2006-2008 ABB. All rights reserved.
Ensure that a gripper is prevented from dropping a workpiece, if such is used.
3HAC025755-001 Revision: B
17
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.
•
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.
© Copyright 2006-2008 ABB. All rights reserved.
Safe design
18
3HAC025755-001 Revision: B
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.
•
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.
Qualified personnel
Extraordinary risks
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC025755-001 Revision: B
19
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
•
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.
20
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
A danger of high voltage is associated with, for example, the following parts:
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).
© Copyright 2006-2008 ABB. All rights reserved.
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the robot.
3HAC025755-001 Revision: B
21
1 Safety
1.2.3.2. Fire extinguishing
1.2.3.2. Fire extinguishing
NOTE!
© Copyright 2006-2008 ABB. All rights reserved.
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot system (robot
or controller)!
22
3HAC025755-001 Revision: B
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
© Copyright 2006-2008 ABB. All rights reserved.
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!
3HAC025755-001 Revision: B
23
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.
© Copyright 2006-2008 ABB. All rights reserved.
If the robot does not change position as the motors are switched off, then the brake
function is adequate.
24
3HAC025755-001 Revision: B
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!
© Copyright 2006-2008 ABB. All rights reserved.
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".
3HAC025755-001 Revision: B
25
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
How to operate the hold-to-run function is detailed in Operating manual - IRC5 with
FlexPendant.
26
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
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.
1 Safety
1.2.3.7. Work inside the robot's working range
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.
© Copyright 2006-2008 ABB. All rights reserved.
•
3HAC025755-001 Revision: B
27
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
© Copyright 2006-2008 ABB. All rights reserved.
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.
xx0500002517
A
28
Free space for adding a fourth language
3HAC025755-001 Revision: B
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
Designation
Signification
DANGER
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.
WARNING
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.
ELECTRICAL
SHOCK
The electrocution or electrical shock symbol
indicates electrical hazards which could result in
severe personal injury or death.
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.
© Copyright 2006-2008 ABB. All rights reserved.
danger
warning
Electrical shock
caution
Continues on next page
3HAC025755-001 Revision: B
29
1 Safety
1.3.1. Safety signals, general
Continued
Symbol
Designation
Signification
ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates
DISCHARGE (ESD) electrostatic hazards which could result in severe
damage to the product.
Electrostatic discharge
(ESD)
NOTE
Note symbols alert you to important facts and
conditions.
TIP
Tip symbols direct you to specific instructions, where
to find additional information or how to perform a
certain operation in an easier way.
Note
© Copyright 2006-2008 ABB. All rights reserved.
Tip
30
3HAC025755-001 Revision: B
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.
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 FlexPendant.
© Copyright 2006-2008 ABB. All rights reserved.
3. Make sure no personnel are present within
the working range of the robot before
pressing the start button.
3HAC025755-001 Revision: B
31
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!
© Copyright 2006-2008 ABB. All rights reserved.
4. Pay special attention to the function of the part previously serviced!
32
3HAC025755-001 Revision: B
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.
© Copyright 2006-2008 ABB. All rights reserved.
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!
3HAC025755-001 Revision: B
33
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
© Copyright 2006-2008 ABB. All rights reserved.
The wrist strap button is located in the right corner as shown in the illustration below.
xx0500002171
A
34
Wrist strap button
3HAC025755-001 Revision: B
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
Make sure that protective gear
gearbox oil may require
like goggles and gloves are
handling hot oil of up to 90 °C! always worn during this activity.
-
Hot oil!
When opening the oil plug,
Open oil plug carefully and keep
there may be pressure present away from the opening. Do not
in the gearbox, causing oil to overfill the gearbox when filling.
spray from the opening!
-
Possible pressure build
up in gearbox!
-
© Copyright 2006-2008 ABB. All rights reserved.
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.
Make sure not to overfill the
gearbox when filling with oil!
After filling, check the correct oil
level.
Mixing types of oil may cause
severe damage to the
gearbox!
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!
Warm oil drains quicker than
cold oil.
When changing gearbox oil, first
run the robot for a time to heat
up the oil.
-
Do not mix types of oil!
-
Heat up the oil!
-
Specified amount
depends on drained
volume!
3HAC025755-001 Revision: B
The specified amount of oil is After refilling, check the oil level.
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.
35
1 Safety
© Copyright 2006-2008 ABB. All rights reserved.
1.3.6. WARNING - Safety risks during work with gearbox oil
36
3HAC025755-001 Revision: B
2 Installation and commissioning
2.1. Introduction
2 Installation and commissioning
2.1. Introduction
General
This chapter contains information for installing the robot to the working site.
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC025755-001 Revision: B
37
2 Installation and commissioning
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.
© Copyright 2006-2008 ABB. All rights reserved.
Securing the robot
xx0800000062
Action
Note
1. Mount the transport support lower end to the Do not tightening the screw.
robot using the recommended screw joint, (A) See attachment point for the specific
in figure.
robot in section Transport position with
a mounted tool.
Continues on next page
38
3HAC025755-001 Revision: B
2 Installation and commissioning
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 Transport position with a mounted
CAUTION!
tool.
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 See attachment point for the specific
final resting position on the transport support, robot in section Transport position with
see section Manually releasing the brakes on a mounted tool
page 54.
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.
© Copyright 2006-2008 ABB. All rights reserved.
5. Use the brake release for axis 5 and 6 to
reach the final resting position for the tool, see
section Manually releasing the brakes on
page 54
3HAC025755-001 Revision: B
39
2 Installation and commissioning
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.
The table below shows the weights of the different models:
Robot model
Weight
IRB 660 - 180/3.15
1750 kg
IRB 660 - 250/3.15
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!
Force
Endurance load (operation)
Max. load (emergency stop)
Force xy
± 8.0 kN
± 15.9 kN
Force z
17.0 ±3.3 kN
17.0 ±10.6 kN
Torque xy
± 23.2 kNm
± 40.6 kNm
Continues on next page
40
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
Weight, robot
2 Installation and commissioning
2.3.1. Pre-installation procedure
Continued
Force
Endurance load (operation)
Max. load (emergency stop)
Torque z
± 10.1 kNm
± 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
Min. levelity
0.5 mm
Max. tilt
5°
Min. resonance frequency
22 Hz
Note
The limit for the maximum load on the robot
is reduced if the robot is tilted.
Contact ABB for further information about
acceptable loads.
Storage conditions, robot
The table below shows the allowed storage conditions for the robot:
Parameter
Value
Min. ambient temperature
-25° C
Max. ambient temperature
+55° C
Max. ambient temperature (less than 24 hrs)
+70° C
Max. ambient humidity
Max. 95% at constant temperature
Operating conditions, robot
© Copyright 2006-2008 ABB. All rights reserved.
The table below shows the allowed operating conditions for the robot:
Parameter
Value
Min. ambient temperature
0° C 1)
Max. ambient temperature
+50° C
Max. ambient humidity
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
3HAC025755-001 Revision: B
41
2 Installation and commissioning
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.
H
Mechanical stop
J
Max working range
Position x (mm) Position z (mm)
Angle axis 2
(degrees)
Angle axis 3
(degrees)
A
1910
1833
0
0
B
972
1966
-42
-20
C
895
870
-42
28
D
866
207
50
120
E
1160
-505
85
120
F
3139
315
85
15
G
2809
1837
50
-20
The table below specifies the types and ranges of the robot motion in every axis.
Axis Type of motion
Range of motion
1
-180° to +180°
Rotation motion
Continues on next page
42
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
xx0500002274
2 Installation and commissioning
2.3.2. Working range and type of motion
Continued
Range of motion
2
Arm motion
-42° to +85°
3
Arm motion
-20° to +120°
2-3
Arm motion
20° to 160°
6
Turn motion
-300° to +300°
© Copyright 2006-2008 ABB. All rights reserved.
Axis Type of motion
3HAC025755-001 Revision: B
43
2 Installation and commissioning
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
The robot is likely to be mechanically unstable while not secured to the foundation!
44
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
WARNING!
2 Installation and commissioning
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.
© Copyright 2006-2008 ABB. All rights reserved.
xx0500002276
A
Attachment points on adapter and horizontal attachment screws
B
Attachment points, horizontal attachment screws
C
Attachment points, vertical attachment screws
Required equipment
Equipment, etc.
Art. no.
Note
Fork lift set, incl. all required 3HAC023044-001 See the figure Fork lift set, 3HAC023044hardware
3HAC023044-001 001 on page 46.
Standard toolkit
-
The content is defined in section Standard
toolkit on page 258.
Continues on next page
3HAC025755-001 Revision: B
45
2 Installation and commissioning
2.4.1. Lifting robot with fork lift
Continued
Fork lift set, 3HAC023044-001
xx0500002277
A
Fork lift pocket (2 pcs, one long & one short)
B
Adapter (1 + 1 pcs)
C
Horizontal attachment screws (4 pcs/fork lift pocket)
D
Attachment screws for adapter (1 pc/adapter)
E
Vertical attachment screws (2 pcs)
Continues on next page
46
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
The fork lift set 3HAC023044-001, is fitted to the robot as shown in the figure below.
2 Installation and commissioning
2.4.1. Lifting robot with fork lift
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 Release the brakes if required as
right!
detailed in section Manually releasing
the brakes on page 54.
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.
© Copyright 2006-2008 ABB. All rights reserved.
3. Strap up the axis 2 motor cable on the adapter.
xx0500002278
•
A: Strap, velcro
Continues on next page
3HAC025755-001 Revision: B
47
2 Installation and commissioning
2.4.1. Lifting robot with fork lift
Continued
Action
Note
4.
CAUTION!
The fork lift pocket weighs 60 kg!
5. Secure the longer fork lift pocket to the adapter Make sure the original screws are
and frame with four of the horizontal
always used (or replacements of
attachment screws and washers.
equivalent quality: M16, quality 12.9)!
Attachment points on the robot are
shown in the figure Attachment points
on page 45.
NOTE!
The vertically and the horizontally attached
screws are identical, but tightened with
different torques!
xx0500002279
•
•
A: Horizontal attachment
screws, 4 pcs, M16 x 60.
Tightening torque: 60 Nm.
B: Adapter
xx0700000655
•
A: Securing screw must be
removed!
Continues on next page
48
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
6. Make sure the securing screw is removed from
the fork lift pocket! It is only used for robot
model IRB 6650S.
2 Installation and commissioning
2.4.1. Lifting robot with fork lift
Continued
Action
Note
7. Secure the fork lift pocket to the robot with the
two vertical attachment screws and washers.
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.
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 Attachment points
on page 45.
8.
CAUTION!
The fork lift pocket weighs 22 kg!
© Copyright 2006-2008 ABB. All rights reserved.
9. Secure the shorter fork lift pocket on the other 4 pcs, M16x60.
side of the robot with the four remaining
Tightening torque: 60 Nm.
horizontal attachment screws.
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 Attachment points
on page 45.
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!
3HAC025755-001 Revision: B
49
2 Installation and commissioning
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
© Copyright 2006-2008 ABB. All rights reserved.
The figure below shows how to attach the roundslings to the robot.
xx0500002285
A
Chain sling with shortener
Continues on next page
50
3HAC025755-001 Revision: B
2 Installation and commissioning
2.4.2. Lifting robot with roundslings
Continued
B
Roundsling, robot
C
Roundsling, upper arm. Used to secure against rotation.
D
Note! No sharp edges!
E
Shackle
Sling specification
Sling type
Qty
Lifting capacity
Length / Note
Chain sling with shortener
4 pcs
4 250 kg
0.605 m
0.8 m
1.0 m (2 pcs)
Roundsling, robot
4 pcs
2 000 kg
2m
Roundsling, upper arm
1 pc
2 000 kg
1m
2m
Secures against
rotation.
Lifting with roundslings
Action
Note
1. Attach the roundslings to the robot according to
the figure Attachment points on page 50.
NOTE!
For Cleanroom robots it is important to
apply the roundslings:
• between robot harness and
lower arm
• behind the side bracket,
balancing cylinder.
© Copyright 2006-2008 ABB. All rights reserved.
2.
CAUTION!
The robot weighs 1750 kg! All lifting equipment
used must be sized accordingly!
3.
WARNING!
Personnel must not, under any circumstances,
be present under the suspended load!
3HAC025755-001 Revision: B
51
2 Installation and commissioning
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
© Copyright 2006-2008 ABB. All rights reserved.
The figure below shows how to lift the complete robot with lifting slings.
xx0500002460
A
Lifting device´s eye
B
Swivelling lifting eyes, 3 pcs
C
Chain
D
Lifting sling, short. Secures against rotation.
E
Lifting slings, long
F
Hook
Required equipment
Equipment
Art. no.
Note
Lifting device, robot
3HAC15607-1
Includes
• user instructions (3HAC15971-2).
Continues on next page
52
3HAC025755-001 Revision: B
2 Installation and commissioning
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 Release the brakes if required as
the figure on the right. If it is not, position it that detailed in section Manually releasing
way
the brakes on page 54.
xx0500002275
3.
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!
Art. no. is specified in Required
equipment on page 52.
© Copyright 2006-2008 ABB. All rights reserved.
5.
CAUTION!
The robot weighs 1750 kg! All lifting
equipment used must be sized accordingly!
6.
WARNING!
Personnel must not, under any circumstances, be present under the suspended
load!
7. Raise the overhead crane to lift the robot.
3HAC025755-001 Revision: B
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.
53
2 Installation and commissioning
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
The procedure below details how to release the holding brakes when the robot is equipped
with an internal brake release unit.
Action
Note
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.
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.
Continues on next page
54
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
Releasing the brakes
2 Installation and commissioning
2.4.4. Manually releasing the brakes
Continued
Action
Note
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.
Action
Note
1.
DANGER!
Incorrect connections, such as supplying
power to the wrong pin, may cause all
brakes to be released simultaneously!
© Copyright 2006-2008 ABB. All rights reserved.
2. Supply 0V on pin 12 and 24V on pin 11.
xx0300000565
3HAC025755-001 Revision: B
55
2 Installation and commissioning
2.4.5. Lifting the base plate
2.4.5. Lifting the base plate
Required equipment
Equipment
Art. no.
Note
Lifting eye, M16
3HAC14457-4
3 pcs
Lifting slings
3 pcs
Length: approx. 2 m
Hole configuration
xx0200000096
Attachment holes for lifting eyes (x3)
Lifting, base plate
Action
Note
1.
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.
Shown in the figure Hole configuration on page 56.
3. Fit the lifting slings to the eyes and to the lifting device.
56
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
A
2 Installation and commissioning
2.4.6. Securing the base plate
2.4.6. Securing the base plate
General
This section details how to secure the base plate.
© Copyright 2006-2008 ABB. All rights reserved.
Base plate, dimensions
xx0100000105
Continues on next page
3HAC025755-001 Revision: B
57
2 Installation and commissioning
2.4.6. Securing the base plate
© Copyright 2006-2008 ABB. All rights reserved.
Continued
xx0400000715
A
Four holes for alternative clamping, 4x Ø18
Continues on next page
58
3HAC025755-001 Revision: B
2 Installation and commissioning
2.4.6. Securing the base plate
Continued
Base plate, grooves and holes
The illustration below shows the orienting grooves and guide sleeve holes in the base plate.
© Copyright 2006-2008 ABB. All rights reserved.
xx0300000045
A
Guide sleeve holes (2 pcs)
B
Orienting grooves (3 pcs)
C
Levelling bolts, attachment holes (4 pcs)
Required equipment
Equipment
Art. no.
Note
Base plate
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!
Standard toolkit
-
The content is defined in section
Standard toolkit on page 258.
Other tools and procedures may
be required. See references to
these procedures in the step-bystep instructions below.
These procedures include references
to the tools required.
Continues on next page
3HAC025755-001 Revision: B
59
2 Installation and commissioning
2.4.6. Securing the base plate
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
Note
1. Make sure the foundation is level.
2.
CAUTION!
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 If possible, observe the recommendaattachment holes as required by the selected tions specified in section Recommendabolt dimension.
tions, 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 Shown in the figure Base plate, grooves
level the base plate.
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
Maximum allowed deviation: 0.5 mm
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.
60
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
The base plate weighs 353 kg! All lifting
equipment used must be sized accordingly!
2 Installation and commissioning
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.
© Copyright 2006-2008 ABB. All rights reserved.
xx0300000566
A
Robot attachment bolts and washers, 8 pcs (M24 x 140)
B
Orienting grooves in the robot base and in the base plate
C
Levelling screws
D
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:
Quality 8.8
Suitable washer:
Thickness: 4 mm
Outer diameter: 44 mm
Inner diameter: 25 mm
Tightening torque:
725 Nm
Continues on next page
3HAC025755-001 Revision: B
61
2 Installation and commissioning
2.4.7. Orienting and securing the robot
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
1. Lift the robot.
Note
Detailed in section Lifting robot with
lifting slings on page 52.
Detailed in section Lifting robot with
roundslings on page 50.
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.
NOTE!
One of the guide sleeve holes is
elongated!
4. Guide the robot gently using two M24 screws
while lowering it into its mounting position.
Make sure the robot base is correctly
fitted onto the guide sleeves!
5. Fit the bolts and washers in the base
attachment holes.
Specified inAttachment screws on
page 61.
Shown in the figure Illustration, robot
fitted to base plate on page 61.
NOTE!
Lightly lubricate the screws before
assembly!
© Copyright 2006-2008 ABB. All rights reserved.
6. Tighten the bolts in a criss-cross pattern to
ensure that the base is not distorted.
Continues on next page
62
3HAC025755-001 Revision: B
2 Installation and commissioning
2.4.7. Orienting and securing the robot
Continued
Hole configuration, base
The illustration below shows the hole configuration used when securing the robot.
xx0600002628
Cross section, guide sleeve hole
© Copyright 2006-2008 ABB. All rights reserved.
The illustration below shows the cross section of the guide sleeve holes.
xx0600002629
3HAC025755-001 Revision: B
63
2 Installation and commissioning
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.
© Copyright 2006-2008 ABB. All rights reserved.
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
Fitting holes, M10 (2 pcs)
B
Fitting holes, M10 (2 pcs)
C
Fitting holes, M10 (2 pcs)
Continues on next page
64
3HAC025755-001 Revision: B
2 Installation and commissioning
2.4.8. Fitting equipment on robot
Continued
Illustration, fitting of extra equipment on frame
The illustration below shows the mounting holes available for fitting extra equipment on the
frame.
© Copyright 2006-2008 ABB. All rights reserved.
xx0500002505
Continues on next page
3HAC025755-001 Revision: B
65
2 Installation and commissioning
2.4.8. Fitting equipment on robot
Continued
Illustration, fitting on 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.
66
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
The illustration below shows the mounting holes available for fitting equipment on the
turning disk.
2 Installation and commissioning
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
© Copyright 2006-2008 ABB. All rights reserved.
Robot motor brake performance depends on any loads attached. For further information about
brake performance, please contact ABB.
3HAC025755-001 Revision: B
67
2 Installation and commissioning
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.
© Copyright 2006-2008 ABB. All rights reserved.
Notice that adjustments must also be made in the software. References to software manuals
are given in the following installation procedures.
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3HAC025755-001 Revision: B
2 Installation and commissioning
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
© Copyright 2006-2008 ABB. All rights reserved.
The illustration below shows the mounting position of the stop pin and one of the additional
mechanical stops available for axis 1.
xx0300000049
A
Additional mechanical stop
B
Stop pin
Required equipment
Equipment, etc.
Art. no.
Note
Mechanical stop for axis 1, 7.5°
3HAC11076-1
Includes attachment screws
and an assembly drawing.
Mechanical stop for axis 1, 15°
3HAC11076-2
Includes attachment screws
and an assembly drawing.
Standard toolkit
-
The content is defined in
section Standard toolkit on
page 258.
Technical reference manual - System parameters (RobotWare 5.0)
Art. no. is specified in section
References on page 8.
Continues on next page
3HAC025755-001 Revision: B
69
2 Installation and commissioning
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.
Action
Note
1.
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.
Tightening torque: 120 Nm.
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 NOTE!
To utilize the option 561-1 "Extended working System parameters.
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.
4.
WARNING!
© Copyright 2006-2008 ABB. All rights reserved.
If the mechanical stop is deformed after a
hard collision, it must be replaced!
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3HAC025755-001 Revision: B
2 Installation and commissioning
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.
Required equipment
Description
Art.no.
Note
Position switch, axis 1
3HAC 15715-1
Includes position switch and
plate for customer connections.
Connector kit R1.SW1
3HAC 17252-1
Plate for customer
connections
3HAC 025778-001
Additional cabling to and
inside the controller
-
An additional connection
plate must be fitted to the
robot base, if not already
installed.
Axis 1
© Copyright 2006-2008 ABB. All rights reserved.
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
Position switch, axis 1
B
Cam
Continues on next page
3HAC025755-001 Revision: B
71
2 Installation and commissioning
2.5.3. Installation of position switch, axis 1 (option)
Continued
C
Set screw, cam (cam stop)
D
Protection sheet
E
Rail
F
Rail attachment
Specifications
Maximum voltage/current for the position switches:
Parameter
Value
Voltage
Max. 50 VDC
Current
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 Required equipment on page 71.
Further information about cables and connection points, see section Robot cabling and
connection points on page 76.
© Copyright 2006-2008 ABB. All rights reserved.
Plate customer connections, at base
xx0500002301
A
Plate for customer connections
B
Attachment screws, 3 pcs, M6x16
Continues on next page
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2 Installation and commissioning
2.5.3. Installation of position switch, axis 1 (option)
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.
Action
Note
1. Move the robot to its calibration position.
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Remove the rear cover (A) from the robot
base.
xx0500002306
4. Fit the position switch to the frame of the
robot.
© Copyright 2006-2008 ABB. All rights reserved.
5. Run the cabling through the notch in the base
of the robot next to the rear cover.
xx0600002625
•
A: Notch for pos.switch cable
Continues on next page
3HAC025755-001 Revision: B
73
2 Installation and commissioning
2.5.3. Installation of position switch, axis 1 (option)
Continued
Action
Note
6. Connect the connector R1.SW1 to the
position switch of axis 1 (D).
xx0600002626
•
•
•
•
7. Connect the connector R1.SW1 to the base
of the robot (B).
A: Cable, pos.switch axis 1
B: Connection point R1.SW1
C: Notch for cable
D: Position switch, axis 1
See figure above!
8. Refit the rear cover to the robot base.
9. Recalibrate the robot!
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.
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
Note
1. Cut the cam to a suitable length.
Use a sharp knife and rubber hammer
or similair.
2. Cut the edge of the cam edge to max 30°!
Shown in the figure Illustration, cutting
the cam on page 75.
If the angle is larger, this may damage
the position switch!
Continues on next page
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3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
DANGER!
2 Installation and commissioning
2.5.3. Installation of position switch, axis 1 (option)
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 Shown in the figure Illustration, adjust
the M5 screw to secure the cam.
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.
© Copyright 2006-2008 ABB. All rights reserved.
xx0100000113
A
Cam stop, M5 nut and M5 x 6 set screw
B
Adjustable cam
C
Profile
Illustration, cutting the cam
The illustration below shows how to cut the position switch cam.
xx010000114
A
3HAC025755-001 Revision: B
Remove the gray section
75
2 Installation and commissioning
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
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.
Position switch cables
(option)
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)
Art. no. is specified in section References on page 8.
Robot cables
These cables are included in the standard delivery. They are completely pre-manufactured
and ready to plug in.
Cable sub-category Description
Connection
Connection
point, cabinet point, robot
Robot cable, power
Transfers drive power from the
drive units in the control cabinet
to the robot motors.
XS1
R1.MP
Robot cable, signals
Transfers resolver data from
and power supply to the serial
measurement board.
XS2
R1.SMB
Robot cable, power
Cable
Art. no.
Robot cable, power, 7 m
3HAC11818-1
Robot cable, power, 15 m
3HAC11818-2
Continues on next page
76
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
The cable categories are divided into sub-categories, specified below:
2 Installation and commissioning
2.6.1. Robot cabling and connection points
Continued
Cable
Art. no.
Robot cable, power, 22 m
3HAC11818-3
Robot cable, power, 30 m
3HAC11818-4
Cable
Art. no.
Robot cable, signal, shielded, 7 m
3HAC7998-1
Robot cable, signal, shielded, 15 m
3HAC7998-2
Robot cable, signal, shielded, 22 m
3HAC7998-3
Robot cable, signal, shielded, 30 m
3HAC7998-4
Robot cable, signals
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
© Copyright 2006-2008 ABB. All rights reserved.
In a M2004 robot system, the cables below are only used for position switch axis 1.
Cable
Art. no.
Connection point,
robot
Connection
point,
cabinet
Position switch cable, axis 1, 7 m
3HAC13175-1
R1.SW
XS8
Position switch cable, axis 1, 15 m
3HAC13175-2
R1.SW
XS8
Position switch cable, axis 1, 22 m
3HAC13175-3
R1.SW
XS8
Position switch cable, axis 1, 30 m
3HAC13175-4
R1.SW
XS8
Cabling inside control cabinet
Additional cabling must be connected inside the control cabinet when installing position
switches.
Cable
Art. no.
Connection
Connection
point 1 inside point 2 inside
cabinet
cabinet
Bracket in the cabinet wall (M2004) 3HAC020813-082
-
-
Harness position switch axis 1
(M2004)
XS8
XT8.1 and
XT8.2
3HAC025755-001 Revision: B
3HAC021117-001
77
2 Installation and commissioning
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!
© Copyright 2006-2008 ABB. All rights reserved.
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.
78
3HAC025755-001 Revision: B
3 Maintenance
3.1. Introduction
3 Maintenance
3.1. Introduction
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.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC025755-001 Revision: B
79
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.
© Copyright 2006-2008 ABB. All rights reserved.
•
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3HAC025755-001 Revision: B
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
© Copyright 2006-2008 ABB. All rights reserved.
The table below specifies the required maintenance activities and intervals.
Maintenance
activity
Equipment
Interval
Detailed in section
Cleaning
Robot
-
Cleaning, robot on page
126
Inspection
Axis 1 gear, oil level 12 mths 1)
Inspection, oil level
gearbox axis 1 on page
84
Inspection
Axes 2 and 3 gears, 12 mths 1)
oil level
Inspection, oil level
gearbox axes 2 - 3 on
page 86.
Inspection
Axis 6 gear, oil level 12 mths 1)
Oil change, gearbox
axis 6 on page 118.
Inspection
Balancing device
12 mths
Inspection, balancing
device on page 90
Inspection
Cable harness
12 mths
Inspection, cable
harness on page 94
Inspection
Information labels
12 mths
Inspection, information
labels on page 97
Inspection
Mechanical stop,
axis 1
12 mths
Inspection, mechanical
stop, axis 1 on page 99
Inspection
Dampers
12 mths
Inspection, dampers on
page 102.
Changing
Axis 1 gear oil:
Kyodo Yushi TMO
150
First change: 6 000 h
Second change: 24 000 h
Do not mix with other
oils!
Oil change, gearbox
axis 1 on page 112
4)
Changing
Axes 2 & 3 gear oil: First change: 6 000 h
Kyodo Yushi TMO
Second change: 24 000 h
4)
150
Do not mix with other
oils!
Oil change, gearbox
axes 2-3 on page 115
Changing
Axis 6 gear oil:
Kyodo Yushi TMO
150
First change: 6 000 h
Second change: 24 000 h
Do not mix with other
oils!
Oil change, gearbox
axis 6 on page 118
Axis 1 gearbox
As specified by SIS, or
typically 96 mths.
Replacement
4)
Replacement of
gearbox, axis 1 on page
225
Continues on next page
3HAC025755-001 Revision: B
81
3 Maintenance
3.2.2. Maintenance schedule
Continued
Maintenance
activity
Equipment
Interval
Detailed in section
Replacement
Axes 2 and 3
gearboxes
As specified by SIS, or
typically 96 mths.
Replacement of
gearbox, axes 2- 3 on
page 232.
Replacement
Axis 6 gearbox
As specified by SIS, or
typically 96 mths.
Replacement of
gearbox, axis 6 on page
236.
Replacement
Cable harness
See note below 2)
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
SMB battery pack
36 mths
Replacement of SMB
unit on page 205.
Lubrication
Balancing device
12 000 h 3)
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)
•
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)
Replace when damage is detected or when approaching life limit as specified in
Expected component life on page 83.
"24000 h" = 6000 h + 18000 h
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.
82
Maintenance
activity
Equipment
Inspection
Signal lamp
Inspection
Additional mechanical stop
axis 1
12 mths
Inspection
Position switches, axis 1
12 mths
Interval
Detailed in section
Inspection, signal lamp on
page 106
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
Activities and intervals, optional equipment
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
Expected life
Note
Cabling for robot
4,000,000 cycles axis 1 ±180º
2,000,000 cycles axis 1 ±220º
See note 1)
Balancing device
2,000,000 cycles
See note 2)
Gearbox
40,000h
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)
© Copyright 2006-2008 ABB. All rights reserved.
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 References on page 8.
3HAC025755-001 Revision: B
83
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.
A
Oil plug, inspection
B
Gearbox, axis 1
C
Oil plug filling
D
Motor, axis 1
E
Drain hose (Behind cover)
Required equipment
Equipment
Art. no.
Note
Lubricating oil
3HAC032140-001
Kyodo Yushi TMO 150
Note! Do not mix with other oil
types!
Standard toolkit
-
The content is defined in section
Standard toolkit on page 258.
Other tools and procedures may
be required. See references to
these procedures in the step-bystep instructions below.
These procedures include
references to the tools required.
Continues on next page
84
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
xx0500002479
3 Maintenance
3.3.1. Inspection, oil level gearbox axis 1
Continued
Inspection, oil level gearbox, axis 1
The procedure below details how to inspect the oil level in gearbox axis 1.
Action
Note
1.
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.
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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!
Art. no. is specified in Required
equipment on page 84.
Further information about how to fill
the oil may be found in section Filling
oil, axis 1 on page 114.
6. Refit the oil plug, inspection.
Tightening torque: 24 Nm.
© Copyright 2006-2008 ABB. All rights reserved.
5. Add oil if required.
3HAC025755-001 Revision: B
85
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
Gearbox, axis 2
B
Oil plug, draining
C
Oil plug, filling
D
Ventilation hole, gearbox axis 2
© Copyright 2006-2008 ABB. All rights reserved.
A
xx0500002483
A
Gearbox, axis 3
B
Oil plug, draining
C
Oil plug, filling
D
Ventilation hole, gearbox axis 3
Continues on next page
86
3HAC025755-001 Revision: B
3 Maintenance
3.3.2. Inspection, oil level gearbox axes 2 - 3
Continued
Required equipment
Equipment etc.
Art.no.
Note
Lubricating oil
3HAC032140-001
Kyodo Yushi TMO 150
Note! Do not mix with other oil
types!
Standard toolkit
-
The content is defined in
section Standard toolkit on
page 258.
Other tools and procedures
may be required. See
references to these
procedures in the step-bystep instructions below
These procedures include
references to the tools
required.
Inspection, oil level gearbox 2 - 3
The procedure below details how to inspect the oil level in gearbox axis 2 - 3.
Action
Note
1.
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.
2.
© Copyright 2006-2008 ABB. All rights reserved.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.
5. Add oil if required.
Art.no. is specified in Required
equipment on page 87.
Filling of oil is detailed further in
section Oil change, gearbox axes 2-3
on page 115.
6. Refit the oil plug, filling.
Tightening torque: 24 Nm
3HAC025755-001 Revision: B
87
3 Maintenance
3.3.3. Inspection, oil level gearbox axis 6
3.3.3. Inspection, oil level gearbox axis 6
Location of gearbox
The axis 6 gearbox is located in the tilthouse unit as shown in the figure below.
xx0500002484
A
Gearbox, axis 6
B
Oil plug, filling
C
Oil plug, draining
Equipment
Art. no.
Note
Lubricating oil, IRB 660
3HAC032140-001
Kyodo Yushi TMO 150
Do not mix with other oil types!
Standard toolkit
-
The content is defined in section
Standard toolkit on page 258.
Other tools and procedures may
be required. See references to
these procedures in the step-bystep instructions below.
These procedures include
references to the tools required.
Continues on next page
88
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
Required equipment
3 Maintenance
3.3.3. Inspection, oil level gearbox axis 6
Continued
Inspection, oil level gearbox 6
The procedure below details how to inspect the oil level in gearbox axis 6.
Action
Note
1.
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.
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Shown in the figure Location of
gearbox on page 88.
4. Add oil if required.
Art. no. is specified in Required
equipment on page 88.
Further information about how to fill
the oil may be found in section Filling,
oil on page 119.
5. Refit the oil plug, filling.
Tightening torque: 24 Nm.
© Copyright 2006-2008 ABB. All rights reserved.
3. Open the oil plug, filling.
3HAC025755-001 Revision: B
89
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.
A
Balancing device
B
Piston rod
C
Guide ring (not visible in this figure)
Required equipment
Equipment
Spare part no.
Balancing device
3HAC024779-001
3HAC024779-001
Grease
Art.no
Note
White RAL 9003
3HAB3537-1
Locking liquid
Loctite 243
Auxiliary shaft,
upper
3HAC5276-1
Auxiliary shaft, lower
3HAC5275-1
Standard toolkit
-
The content is defined in
section Standard toolkit on
page 258.
Continues on next page
90
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
xx0500002495
3 Maintenance
3.3.4. Inspection, balancing device
Continued
Equipment
Spare part no.
Art.no
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step instructions below.
Note
These procedures include
references to the tools
required.
Inspection, bearings
The procedure below details how to inspect the bearings, balancing device.
Action
Note
1. Move the axis 2 to calibration position.
2.
DANGER!
Turn off all electric power, hydraulic
and pneumatic pressure supplies to
the robot!
© Copyright 2006-2008 ABB. All rights reserved.
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
Art.no. is specified in Required equipment on
lower axes of balancing device.
page 90.
The shafts should be tightened to their
bottom position.
Continues on next page
3HAC025755-001 Revision: B
91
3 Maintenance
3.3.4. Inspection, balancing device
Continued
Action
Note
5. Remove the protection hood from the
M12 hole on top of the balancing
device.
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 Shown in the figure above in this procedure
be able to inspect the inner rings
Inspection, bearings on page 91.
without removing the balancing
cylinder.
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 Shown in the figure above in this procedure
and sealing rings.
Inspection, bearings on page 91.
Detailed in section Replacement of balancing
device on page 200.
11. Lubricate the shafts, if needed.
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.
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.
15. Apply locking liquid on the locknuts
(KM-8) and refit them.
Tightening torque on the locknuts:
• 120 Nm
Continues on next page
92
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
10. If any of the parts looks abnormal,
replace.
3 Maintenance
3.3.4. Inspection, balancing device
Continued
Inspection, wear on the guide ring
The procedure below details how to inspect the piston rod for wear on the guide ring.
Action
Note
1. Move axis 2 to a position where the
balancing device is in a horizontal
position.
2.
DANGER!
Turn off all electric power, hydraulic
and pneumatic pressure supplies to
the robot!
3. Check the guide ring for wear.
Replace if necessary.
© Copyright 2006-2008 ABB. All rights reserved.
xx0600002689
•
•
A: Guide ring
B: Circlip
4.
NOTE!
If there is a risk of metallic contact
between the piston rod and the end
cover, the guide ring must be
replaced!
3HAC025755-001 Revision: B
93
3 Maintenance
3.3.5. Inspection, cable harness
3.3.5. Inspection, cable harness
Location of cable harness, axes 1-6
© Copyright 2006-2008 ABB. All rights reserved.
The robot cable harness, axes 1-6, is located as shown in the figure below.
xx0500002497
A
Cable harness robot, axes 1-6
B
Connectors at base
C
Motor cables
D
Cable guide, axis 2
E
Metal clamps
Required equipment
Equipment, etc.
Art.no.
Note
Standard toolkit
-
Detailed in section Standard
toolkit on page 258.
Continues on next page
94
3HAC025755-001 Revision: B
3 Maintenance
3.3.5. Inspection, cable harness
Continued
Equipment, etc.
Art.no.
Note
Other tools and procedures
may be required. See
references to these
procedures in the step-bystep instructions below.
These procedures include
references to the tools required.
Circuit diagram
See chapter Circuit diagram.
Inspection cable harness, axes 1-6
The procedure below details how to inspect the cable harness of axes 1-6.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Make an overall inspection of the cable
harness, in order to detect wear and damage.
3. Check the connectors at the base.
Shown in the figure Location of cable
harness, axes 1-6 on page 94
4. Check the motor cables.
Shown in the figure Location of cable
harness, axes 1-6 on page 94.
© Copyright 2006-2008 ABB. All rights reserved.
5. If the robot is equipped with forklift device,
check that the velcro strap holding the
motorcable, is properly attached to the
adapter.
xx0600002691
•
A: Velcro strap
6. Check the cable guide axis 2.
Replace if damaged.
Shown in the figure Location of cable
harness, axes 1-6 on page 94.
7. Check the metal clamps on the lower arm.
Shown in the figure Location of cable
harness, axes 1-6 on page 94
Continues on next page
3HAC025755-001 Revision: B
95
3 Maintenance
3.3.5. Inspection, cable harness
Continued
Action
Note
8. Check the metal clamps holding the cable
harness inside the upper arm, as shown in the
figure to the right.
xx0500002498
•
A: Metal clamp inside upper arm
9. Check the metal clamp holding the motorcable Shown in the figure Location of cable
on axis 6.
harness, axes 1-6 on page 94.
© Copyright 2006-2008 ABB. All rights reserved.
10. Replace the cable harness if wear or damage Detailed in section:
is detected!
Replacement of cable harness, lower
end (axes 1-3) on page 135.
Replacement of cable harness, upper
end (incl. axis 6) on page 144.
96
3HAC025755-001 Revision: B
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.
© Copyright 2006-2008 ABB. All rights reserved.
xx0502499
A
Warning label “High teperature”, (located on motor cover), 29454489-16 (4 pcs)
B
Warning sign, symbol of flash (located on motor cover), 3HAC1589-1 (4 pcs)
D
Warning label “Brake release”, 3HAC024985-001
G
Warning label “Caught danger”, 3HAC4517-1
J
Warning label “Shut off power”, 3HAC17804-1
K
Warning label “Extended working range and pos switch” (option), 3HAC021761001
-
Information labels about what oil is filled, on gearboxes and at the robot base.
Continues on next page
3HAC025755-001 Revision: B
97
3 Maintenance
3.3.6. Inspection, information labels
Continued
xx0500002500
C
Instruction label “Safety instructions”, 3HAC4591-1
E
Instruction label “Lifting the robot”, 3HAC024629-001
F
Warning label “Robot can tip forward...”, 3HAC9191-1
H
Warning label “Stored energy”, 3HAC3981-1
L
Information label at base, Kyodo Yushi TMO 150 in gearboxes, 3HAC024977-002
Equipment
Art. no.
Note
Labels and plate set
3HAC022897-001
Includes all labels specified in the two
previous figures! The labels are in english.
Label set, oil labels
3HAC024977-001
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
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Check the labels, located as shown in the figures
Location of labels on page 97.
3. Replace any missing or damaged labels.
98
Art. no. is specified in Required
equipment on page 98.
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
Required equipment
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
Mechanical stop pin
B
Fixed stop
Required equipment
Equipment, etc.
Art. no.
Note
Mechanical stop ax 1
3HAC17358-1
To be replaced when damaged.
Standard toolkit
-
The content is defined in section Standard
toolkit on page 258.
Inspection, mechanical stop
© Copyright 2006-2008 ABB. All rights reserved.
The procedure below details how to inspect the mechanical stop axis 1.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Inspect the mechanical stop, axis 1.
Shown in the figure Location of
mechanical stop on page 99.
3. Make sure the mechanical stop can move in both
directions.
Continues on next page
3HAC025755-001 Revision: B
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
Art. no. is specified in Required
equipment on page 99.
NOTE!
© Copyright 2006-2008 ABB. All rights reserved.
The expected life of gearboxes can be reduced
as a result of collissions with the mechanical stop.
100
3HAC025755-001 Revision: B
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.
Required equipment
Equipment etc.
Art. no.
Note
Standard toolkit
-
The content is defined in section Standard
toolkit on page 258.
Inspection, mechanical stops
The procedure below details how to inspect the additional mechanical stops on axes 1.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Check the additional stops on axis 1 for damage.
Shown in the figure Location of
mechanical stops on page 101.
© Copyright 2006-2008 ABB. All rights reserved.
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
Art. no. is specified in Required
must be replaced!
equipment on page 101.
Correct attachment screws (lubricated with Molycote
1000):
• Axis 3: M6 x 16
3HAC025755-001 Revision: B
101
3 Maintenance
3.3.9. Inspection, dampers
3.3.9. Inspection, dampers
Location of dampers
xx0500002501
A
Damper, lower arm, upper (2 pcs)
B
Damper, lower arm, lower (1 pc)
C
Damper, axis 2 (2 pcs)
-
Damper, axis 3 (2 pcs) Not visible in this view,
Required equipment
Equipment
Art.no
Note
Damper axis 2, 3
3HAC 12991-1
To be replaced if damaged
Damper lower arm,
upper
3HAC 022338-001
To be replaced if damaged
Damper lower arm,
lower
3HAC 022339-001
To be replaced if damaged
Continues on next page
102
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
The figure below shows the location of the dampers.
3 Maintenance
3.3.9. Inspection, dampers
Continued
Inspection, dampers
The procedure below details how to inspect the dampers.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.
© Copyright 2006-2008 ABB. All rights reserved.
4. If any damage is detected, the damper must be Art.no. is specified in Required
replaced with a new one.
equipment on page 102.
3HAC025755-001 Revision: B
103
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.
A
Position switch, axis 1
B
Cam
C
Set screw, cam
D
Protection sheet
E
Rail
F
Rail attachment
Required equipment
Equipment
Art.no
Position switch, axis 1
3HAC 024854-001
Standard toolkit
-
Other tools and procedures may
be required. See references to
these procedures in the step-bystep instructions below.
Note
The content is defined in section
Standard toolkit on page 258.
These procedures include
references to the tools required.
Continues on next page
104
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
xx0100000158
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.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.
© Copyright 2006-2008 ABB. All rights reserved.
6. If any damage is detected, the position switch
must be replaced!
3HAC025755-001 Revision: B
105
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
Signal lamp
B
Cable straps, outdoor
C
Cable
D
Connection point to cable gland
Equipment, etc.
Art. no.
Note
Kit for UL lamp
3HAC023750-001
To be replaced in case of detected
damage.
Standard toolkit
-
The content is defined in section
Standard toolkit on page 258.
Other tools and procedures may
be required. See references to
these procedures in the step-bystep instructions below.
These procedures include
references to the tools required.
Inspection, signal lamp
The procedure below details how to inspect the function of the signal lamp.
Action
Note
1. Check that the signal lamp is lit, when the motors are
put in operation ("MOTORS ON").
Continues on next page
106
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
Required equipment
3 Maintenance
3.3.11. Inspection, signal lamp
Continued
Action
Note
2.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
© Copyright 2006-2008 ABB. All rights reserved.
3. If the lamp is not lit, trace the fault by:
Art. no. is specified in Required
• Checking whether the signal lamp is broken. equipment on page 106.
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.
3HAC025755-001 Revision: B
107
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
Gearbox, axis 1
B
Gearbox, axis 2
C
Gearbox, axis 3
D
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.
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 Rinsing gearbox on page 110.
Type of oil - currently used
The table show which types of oil is used in gearboxes.
Gearbox
Type of oil
Art. no.
Amount
Axis 1
Kyodo Yushi TMO 150
3HAC032140-001
8,000 ml
Axis 2
Kyodo Yushi TMO 150
3HAC032140-001
5,000 ml
Axis 3
Kyodo Yushi TMO 150
3HAC032140-001
5,000 ml
Axis 6
Kyodo Yushi TMO 150
3HAC032140-001
250 ml
Continues on next page
108
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
NOTE!
3 Maintenance
3.4.1. Type of oil in gearboxes
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
© Copyright 2006-2008 ABB. All rights reserved.
Label located at robot base show the types of oil in all gearboxes.
xx0500002477
-
Label at robot base. Currently used types of oil.
Continues on next page
3HAC025755-001 Revision: B
109
3 Maintenance
3.4.1. Type of oil in gearboxes
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
Rinsing gearbox on page 110.
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
•
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.
Continues on next page
110
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
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.
3 Maintenance
3.4.1. Type of oil in gearboxes
Continued
Equipment
Art. no.
Note
Label set
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!
Oil change equipment
3HAC021745-001
Includes pump with outlet pipe.
© Copyright 2006-2008 ABB. All rights reserved.
Equipment
3HAC025755-001 Revision: B
111
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.
A
Oil plug, inspection
B
Gearbox axis 1
C
Oil plug, filling
D
Motor, axis 1
E
Drain hose
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil
3HAC032140-001
8,000 ml
Kyodo Yushi TMO 150
Note! Do not mix with other oil
types!
Oil collecting vessel
-
Capacity: 8,000 ml.
Oil exchange
equipment
3HAC021745-001
The content is defined in section
Special tools on page 259.
Standard toolkit
-
The content is defined in section
Standard toolkit on page 258.
Continues on next page
112
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
xx0500002479
3 Maintenance
3.4.2. Oil change, gearbox axis 1
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 Required equipment on page 112.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.
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.
© Copyright 2006-2008 ABB. All rights reserved.
xx0200000237
The hose is located beneath the base,
as shown in the figure with a view from
below.
• A: Oil draining hose
5. Place an oil vessel close to the hose end.
Vessel capacity is specified in
Required equipment on page 112.
6. Remove the oil plug, filling, in order to drain the Shown in the figure Location of oil
oil quicker!
plugs on page 112.
7. Open the hose end and drain the oil into the
vessel.
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.
Continues on next page
3HAC025755-001 Revision: B
113
3 Maintenance
3.4.2. Oil change, gearbox axis 1
Continued
Filling oil, axis 1
The procedure below details how to fill the oil in gearbox axis 1.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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.
3. Open the oil plug, filling.
Shown in the figure Location of
oil plugs on page 112.
4. Refill the gearbox with lubricating oil.
Art. no. and the total amount are
specified in Required equipment
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil level on page 112.
is detailed in section Inspection, oil level gearbox axis
1 on page 84.
Tightening torque: 24 Nm.
© Copyright 2006-2008 ABB. All rights reserved.
5. Refit the oil plug, filling.
114
3HAC025755-001 Revision: B
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
Gearbox axis 2
B
Oil plug, draining
C
Oil plug, filling
D
Ventilation hole, gearbox axis 2
© Copyright 2006-2008 ABB. All rights reserved.
A
xx0500002483
A
Gearbox, axis 3
B
Oil plug, draining
C
Oil plug, filling
D
Ventilation hole, gearbox axis 3
Continues on next page
3HAC025755-001 Revision: B
115
3 Maintenance
3.4.3. Oil change, gearbox axes 2-3
Continued
Required equipment
Equipment etc.
Art.no
Amount
Note
Lubricating oil
3HAC032140-001
5,000 ml
Kyodo Yushi TMO 150
Oil collecting vessel
Capacity: 6,000 ml
Oil exchange
equipment
3HAC021745-001
The content is defined in
section Special tools on page
259.
Standard toolkit
-
The content is defined in
section Standard toolkit on page
258.
Draining
The procedure below details how to drain the oil in gearbox axis 2-3.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
WARNING!
3. Remove the plug of the vent hole.
Shown in Location of oil plugs on page
115.
4. Remove the oil plug, draining, and drain the
gearbox using a hose with a nipple and an oil
collecting vessel.
Shown in Location of oil plugs on page
115.
Vessel capacity is specified in
Required equipment on page 116.
Draining is time-consuming.
Elapsed time varies depending on the
temperature of the oil.
5. Refit the oil plug.
Tightening torque: 24 Nm.
Continues on next page
116
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
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.
3 Maintenance
3.4.3. Oil change, gearbox axes 2-3
Continued
Filling
The procedure below details how to fill oil in the gearbox axes 2-3.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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.
3. Refit the oil plug, draining.
Shown in Location of oil plugs on page
115.
Tightening torque: 24 Nm.
4.
NOTE!
Don´t mix Kyodo Yushi TMO 150 with other oil
types!
Art.no. and total amount are specified
in Required equipment on page 116.
6. Refit the oil plug, filling and the plug in the
ventilation hole.
Shown in Location of oil plugs on page
115.
Tightening torque: 24 Nm.
© Copyright 2006-2008 ABB. All rights reserved.
5. Refill the gearbox with lubricating oil.
The amount of oil to be filled depends on the
amount previously being drained.
3HAC025755-001 Revision: B
117
3 Maintenance
3.4.4. Oil change, gearbox axis 6
3.4.4. Oil change, gearbox axis 6
Location of gearbox
The gearbox axis 6 is located in the center of the tilt house unit as shown in the figure below.
xx0500002484
A
Gearbox, axis 6
B
Oil plug, filling
C
Oil plug, draining
Equipment, etc. Art.no.
Amount
Note
Lubrication oil
3HAC032140-001
250 ml
Kyodo Yushi TMO 150
Do not mix with other oil types!
Oil exchange
equipment
3HAC021745-001
Oil collecting
vessel
Standard tollkit
Vessel capacity: 300 ml.
-
The content is defined in section
Standard toolkit on page 258.
Draining, oil
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 Location of gearbox on
page 118.
Continues on next page
118
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
Required equipment
3 Maintenance
3.4.4. Oil change, gearbox axis 6
Continued
Action
Note
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Drain the oil from the gearbox into a vessel by Vessel capacity is specified in
removing the oil plug draining.
Required equipment on page 118.
Also remove the oil plug, filling.
4. Refit the oil plugs, draining and filling.
Filling, oil
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.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Remove the oil plug, filling.
Shown in Location of gearbox on
page 118.
3. Refill the gearbox with lubricating oil.
Art.no. and the total amount are
The amount of oil to be refilled on the amount specified in Required equipment
previously being drained. The correct oil level on page 118.
is detailed in section Inspection, oil level
gearbox 6 on page 89.
Tightening torque: 24 Nm.
© Copyright 2006-2008 ABB. All rights reserved.
4. Refit the oil plug.
3HAC025755-001 Revision: B
119
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.
xx0500002486
A
SMB battery cover
B
SMB battery pack
C
Battery cable
Equipment, etc.
Spare part no.
Note
Battery pack
3HAC16831-1
Battery includes protection circuits. Replace it
only with given spare part no. or an ABB
approved equivalent.
Standard toolkit
-
The content is defined in section Standard
toolkit on page 258.
Circuit Diagram
-
See chapter Circuit diagram.
Removal, battery
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.
Continues on next page
120
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
Required equipment
3 Maintenance
3.4.5. Replacement of SMB battery
Continued
Action
Note
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.
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 Shown in the figure Location of SMB
attachment screws.
battery on page 120.
5. Pull out the battery and disconnect the battery
cable.
Shown in the figure Location of SMB
battery on page 120.
6. Remove the SMB battery.
Shown in the figure Location of SMB
battery on page 120.
Battery includes protection circuits. Replace it
only with the specified spare part or with an ABB
approved equivalent.
Refitting, battery
The procedure below details how to refit the SMB battery.
Action
Note
© Copyright 2006-2008 ABB. All rights reserved.
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
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 Art. no. is specified in Required
pack and fit it to the frame.
equipment on page 120.
Shown in the figure Location of SMB
battery on page 120.
4. Secure the SMB battery cover with its
attachment screws.
Shown in the figure Location of SMB
battery on page 120.
Continues on next page
3HAC025755-001 Revision: B
121
3 Maintenance
3.4.5. Replacement of SMB battery
Continued
Action
5. Update the revolution counter.
Note
Detailed in chapter Calibration section Updating revolution counters
on page 246.
6.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
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.
122
3HAC025755-001 Revision: B
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.
© Copyright 2006-2008 ABB. All rights reserved.
Note! The balancing device must be fitted on the robot when lubricating the bearings!
xx0500002489
A
Ear (adjustable needle bearing located inside)
B
Support washer
Continues on next page
3HAC025755-001 Revision: B
123
3 Maintenance
3.5.1. Lubrication of bearing, balancing device
Continued
C
Lock nut
D
Piston rod
E
Guide ring (not visible in this view)
Required equipment
Equipment
Art.no.
Note
Lubrication tool
3HAC 5222-1
Bearing grease
3HAB 3537-1
Piston rod grease
Castrol Spheerol SX2
Shell SRS 4000
OK Super Grease L2
Statoil Uniway 2X2N
Equivalent:
• Shell Alvania WR 2
Locking liquid
Standard toolkit
Loctite 243
-
The content is defined in
section Standard toolkit on
page 258.
Other tools and procedures
may be required. See
references to these
procedures in the step-bystep instructions below.
These procedures include
references to the tools
required.
Lubrication, bearings
The procedure below details how to lubricate the bearings, balancing device.
Action
Note
1. Move axis 2 to the calibration position.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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 Also clean from old grease on the inner
threads on the shaft ends, free from
side!
grease.
Continues on next page
124
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
2.
3 Maintenance
3.5.1. Lubrication of bearing, balancing device
Continued
Action
Note
8. Apply some grease on the support
washers.
9. Apply locking liquid on the locknuts (KM8).
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
Note
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.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. The piston rod must be lubricated.
Type of grease is specified in
Required equipment on page 124.
4. Clean the piston rod before applying new
grease.
© Copyright 2006-2008 ABB. All rights reserved.
5. Apply new grease, if necessary.
3HAC025755-001 Revision: B
125
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
© Copyright 2006-2008 ABB. All rights reserved.
Special points to be observed are shown in the figure below:
xx0200000239
A
Spiral cables to motor 6
B
Inside of upper arm tube
C
Rear of upper arm tube
D
Inside of lower arm
E
Inside of base/axis 1
Continues on next page
126
3HAC025755-001 Revision: B
3 Maintenance
3.6.1. Cleaning, robot
Continued
© Copyright 2006-2008 ABB. All rights reserved.
xx0600002624
A
Inside upper arm
B
Inside lower arm
C
Inside frame
D
Inside base
Required equipment
Equipment, etc.
Art. no.
Steam cleaner
-
Note
•
•
•
•
High pressure water cleaner
-
•
•
•
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.
Continues on next page
3HAC025755-001 Revision: B
127
3 Maintenance
3.6.1. Cleaning, robot
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!
© Copyright 2006-2008 ABB. All rights reserved.
•
128
3HAC025755-001 Revision: B
4 Repair
4.1. Introduction
4 Repair
4.1. Introduction
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.
Required equipment
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.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC025755-001 Revision: B
129
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.
Required equipment
Equipment, etc.
Art. no.
Leakdown tester
3HAC0207-1
Leak detection spray
-
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, Art. no. is specified in Required
and replace it with the leakdown tester.
equipment on page 130.
Adapters may be required, which are included in the
leakdown tester kit.
3. Apply compressed air, and raise the pressure with the Recommended value:
knob until the correct value is shown on the
0.2 - 0.25 bar (20 - 25 kPa)
manometer.
5. Wait for approx. 8-10 minutes. No pressure loss must If the compressed air is signifibe detected.
cantly 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.
130
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
4. Disconnect the compressed air supply.
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.
Art. no.
Note
Grease
3HAB3537-1
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
Note
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.
Assembly of tapered bearings
© Copyright 2006-2008 ABB. All rights reserved.
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
Note
1. Tension the bearing gradually until the recommended pre-tension
is achieved.
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.
Continues on next page
3HAC025755-001 Revision: B
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.
© Copyright 2006-2008 ABB. All rights reserved.
•
132
3HAC025755-001 Revision: B
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.
Art. no.
Note
Grease
3HAB3537-1
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).
© Copyright 2006-2008 ABB. All rights reserved.
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
Art. no. is specified in
early as there is a risk of dirt and foreign particles adhering Equipment on page 133.
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.
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.
Continues on next page
3HAC025755-001 Revision: B
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.
Defective o-rings may not be used.
The grooves must be geometrically correct and
free from pores and contamination.
4. Lubricate the o-ring with grease.
© Copyright 2006-2008 ABB. All rights reserved.
5. Tighten the screws evenly when assembling.
134
3HAC025755-001 Revision: B
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 Replacement of cable
harness, upper end.
Location of cable harness - lower end (axes 1-3)
© Copyright 2006-2008 ABB. All rights reserved.
The cable harness, lower end (axes 1-3) is located throughout the base, frame and lower arm
as shown in the figure below.
xx0600002608
A
Cable harness, lower end
B
Cable harness, upper end
C
Connector R1.MP
D
Connector R1.SMB
E
Attachment point for earth lug
F
Cover plate
G
Rear cover plate
H
Cable gland, SMB
I
Cable guide, axis 2
J
Metal clamp, frame
K
Metal clamp, lower arm
L
Metal clamp, upper arm
Continues on next page
3HAC025755-001 Revision: B
135
4 Repair
4.3.1. Replacement of cable harness, lower end (axes 1-3)
Continued
M
Metal clamp, tilthouse
A
Cable guide, axis 2
B
Metal clamp
C
Connector at base
D
Cable guide, axis 1
E
Cable harness, axes 1-6
F
Cover plate
G
Rear cover plate
H
Attachment point for earth lug
© Copyright 2006-2008 ABB. All rights reserved.
xx0700000070
Continues on next page
136
3HAC025755-001 Revision: B
4 Repair
4.3.1. Replacement of cable harness, lower end (axes 1-3)
Continued
The motors axes 2-3 are located on either side of the robot as shown in the figure below.
xx0600002599
A
Motor, axis 2
B
Motor, axis 3
C
Motor attachment screws and washers
D
Cable gland cover (located on the lower side of the motor)
E
Motor cover
Required equipment
Equipment, etc.
Spare part no.
Cable harness 1-6
3HAC022544-001
Gasket
3HAC3537-1
© Copyright 2006-2008 ABB. All rights reserved.
Standard toolkit
Art.no.
Note
Motor axes 1-5
-
The content is defined in
section Standard toolkit
on page 258.
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.
Circuit diagram
These procedures include
references to the tools
required.
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.
Continues on next page
3HAC025755-001 Revision: B
137
4 Repair
4.3.1. Replacement of cable harness, lower end (axes 1-3)
Continued
Action
Note
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Remove the rear cover plate on the robot by
removing its attachment screws.
Shown in Location of cable harness lower end (axes 1-3) on page 135.
4. Disconnect the earth cable.
Shown in Location of cable harness lower end (axes 1-3) on page 135.
5. Disconnect connectors R1.MP and R1.SMB.
Shown in Location of cable harness lower end (axes 1-3) on page 135.
6. Remove the cable guide axis 2.
•
7. Unscrew the screws in the metal clamps
holding the cable harness in the frame and
lower arm.
A: Cable guide ax 2
Shown in Location of cable harness lower end (axes 1-3) on page 135
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.
Continues on next page
138
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
xx0600002698
4 Repair
4.3.1. Replacement of cable harness, lower end (axes 1-3)
Continued
Action
Note
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!
xx0600002700
•
•
•
A: SMB battery cover
B: SMB battery pack
C: Battery cable
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.
© Copyright 2006-2008 ABB. All rights reserved.
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.
xx0600002701
•
•
A: Cable gland, SMB
B: Attachment screws (4 pcs)
Continues on next page
3HAC025755-001 Revision: B
139
4 Repair
4.3.1. Replacement of cable harness, lower end (axes 1-3)
Continued
Action
Note
13. Gently pull the cable harness out of base
through the cable guide, axis 1 and the frame.
xx0600002699
•
•
•
Detailed in Replacement of cable
harness, upper end.
© Copyright 2006-2008 ABB. All rights reserved.
14. Continue removal of the cable harness in the
upper arm.
A: Cable gland, SMB
B: Metal clamp, frame
C: Cable guide, axis 1
Continues on next page
140
3HAC025755-001 Revision: B
4 Repair
4.3.1. Replacement of cable harness, lower end (axes 1-3)
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 Make sure the cables are not twisted
cable guide axis 1 in the center of the frame.
with each other or with eventual
customer harness!
xx0600002699
© Copyright 2006-2008 ABB. All rights reserved.
•
•
•
A: Cable gland, SMB
B: Metal clamp, frame
C: Cable guide, axis 1
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.
xx0600002701
•
•
3. Reconnect connectors R1.MP and R1.SMB at
the robot base.
A: Cable gland, SMB
B: Attachment screws, (4 pcs)
Attachment points are shown in the
figure Location of cable harness lower end (axes 1-3) on page 135.
Continues on next page
3HAC025755-001 Revision: B
141
4 Repair
4.3.1. Replacement of cable harness, lower end (axes 1-3)
Continued
Action
Note
4. Reconnect the earth cable.
Attachment point is shown in the
figure Location of cable harness lower end (axes 1-3) on page 135
5. Refit the rear cover plate on the robot with its
attachment screws.
Shown in the figure Location of cable
harness - lower end (axes 1-3) on
page 135
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!
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.
Detailed in section Replacement of
cable harness, upper end.
14. Update the revolution counter!
Detailed in section Updating
revolution counters on page 246.
Continues on next page
142
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
11. Refit the cable guide, axis 2.
4 Repair
4.3.1. Replacement of cable harness, lower end (axes 1-3)
Continued
Action
Note
15.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC025755-001 Revision: B
143
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.
A
Cable harness, lower end
B
Cable harness, upper end
C
Connector R1.MP
D
Connector R1.SMB
E
Attachment point for earth lug
F
Cover plate
G
Rear cover plate
H
Cable gland, SMB
I
Cable guide, axis 2
J
Metal clamp, frame
K
Metal clamp, lower arm
L
Metal clamp, upper arm
M
Metal clamp, tilthouse
© Copyright 2006-2008 ABB. All rights reserved.
xx0600002608
Continues on next page
144
3HAC025755-001 Revision: B
4 Repair
4.3.2. Replacement of cable harness, upper end (incl. axis 6)
Continued
The motor axis 6 is located as shown in the figure below.
xx0600002600
A
Motor, axis 6
B
Attachment screws and washers
C
Cable gland cover
D
Motor cover
Required equipment
Equipment, etc
Spare part no.
Cable harness, 1-6
3HAC 022544-001
© Copyright 2006-2008 ABB. All rights reserved.
Standard toolkit
Art.no.
Detailed in section
Spare parts - cable
harness on page 266.
-
The content is
defined in section
Standard toolkit on
page 258.
Other tools and
procedures may be
required. See
references to these
procedures in the stepby-step instructions
below.
Circuit diagram
Note
These procedures
include references to
the tools required.
3HAC 025690-001 See chapter Circuit
3HAC 025691-001 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
1. Move the robot to the calibration position.
Note
This is done in order to facilitate updating
of the revolution counter.
Continues on next page
3HAC025755-001 Revision: B
145
4 Repair
4.3.2. Replacement of cable harness, upper end (incl. axis 6)
Continued
Action
Note
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. If the complete cable harness is being
replaced, start removal by removing the
cable harness, lower end.
Detailed in section Replacement of cable
harness, lower end (axes 1-3) on page
135
4. Remove the motor cover axis 6 by removing
its attachment screws, in order to reach the
connectors.
xx0600002696
•
•
•
A: Motor cover
B: Attachment screws
C: Cable gland
5. Disconnect connectors at motor axis 6.
xx0600002694
•
A: Screw holding the cable gland
Continues on next page
146
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
6. Remove the cable gland on motor axis 6 by
unscrewing the screw which is found after
removing the motor cover.
4 Repair
4.3.2. Replacement of cable harness, upper end (incl. axis 6)
Continued
Action
Note
7. Remove the metal clamp holding the cable
at the tilt house, by removing its nuts.
xx0600002702
•
A: Metal clamp, axis 6
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.
xx0500002498
© Copyright 2006-2008 ABB. All rights reserved.
•
A: Metal clamp, upper arm
10. Carefully pull out the cable harness from the
upper and lower 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 Detailed in section Replacement of cable
if it has been removed.
harness, lower end (axes 1-3) on page
135
2. Push the cable harness through the lower
and upper arm.
Continues on next page
3HAC025755-001 Revision: B
147
4 Repair
4.3.2. Replacement of cable harness, upper end (incl. axis 6)
Continued
Action
Note
3. Refit the cable harness inside the upper arm
by refitting the cable clamps with its four
nuts inside the upper arm.
xx0500002498
•
A: Metal clamp, upper arm
4. Refit the metal clamp at the tilthouse with its
nuts.
xx0600002702
•
A: Metal clamp, axis 6
6. Refit the cable gland with the screw which is
found under the motor cover.
xx0600002694
•
A: Screw holding the cable gland
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.
Continues on next page
148
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
5. Push the motor cables axis 6 carefully
through the cable gland.
4 Repair
4.3.2. Replacement of cable harness, upper end (incl. axis 6)
Continued
Action
9. Update the revolution counter!
Note
Detailed in section Updating revolution
counters on page 246.
10.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC025755-001 Revision: B
149
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 .
A
Parallel rod
B
Linkage
C
Complete upper arm (incl. tilthouse)
D
Balancing device
E
Frame
F
Gearbox, axis 1
G
Base
H
Base attachment screws
Required equipment
Equipment, etc.
Art. no.
Note
Lifting device, robot
3HAC15607-1
Instruction 3HAC15971-2 is enclosed!
Continues on next page
150
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
xx0600002612
4 Repair
4.3.3. Replacement of complete arm system
Continued
Equipment, etc.
Art. no.
Note
Guide pins M12 x 130
3HAC022637-001
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!
Hoisting block
-
Used to adjust the length of the lifting
chain.
Standard toolkit
-
The content is defined in section
Standard toolkit on page 258.
Other tools and procedures
may be required. See
references to these
procedures in the step-bystep instructions below.
These procedures include references to
the tools required.
Removal, arm system
The procedure below details how to lift and remove the complete arm system.
Action
© Copyright 2006-2008 ABB. All rights reserved.
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 Manually releasing the brakes on
page 54.
xx0500002275
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Drain the oil from gearbox axis 1.
Detailed in section Oil change, gearbox axis 1
on page 112.
4. Loosen the cable connectors from the
Detailed in section Replacement of cable
base and pull up the cabling from the
harness, axes 1-6.
base, through the hole in the center of the
frame.
Continues on next page
3HAC025755-001 Revision: B
151
4 Repair
4.3.3. Replacement of complete arm system
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.
Art. no. is specified in Required equipment on
page 150.
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!
8. Remove the block for calibrationand
calibration plate axis 1 from the bottom of
the frame.
xx0600002734
A: Block for calibration
B: Calibration plate axis 1
9. Unfasten the arm system from the base
by unscrewing its 24attachment screws.
Shown in the figure Location of arm system
on page 150.
10. Fit the two guide pins in two opposite
screw holes.
Art. no. is specified in section Required
equipment on page 150.
11.
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.
Continues on next page
152
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
•
•
4 Repair
4.3.3. Replacement of complete arm system
Continued
Refitting, arm system
The procedure below details how to lift and refit the complete arm system.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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!
Art. no. is specified in Required
equipment on page 150.
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 Make sure all the hooks and attachments
very low speed, making sure it does not tip! stay in the correct position while lifting the
Make sure the lift is done completely level. robot!
Adjust the length of the chains as detailed in
enclosed instruction or with a hoisting block.
© Copyright 2006-2008 ABB. All rights reserved.
5. Fit the two guide pins to the frame
attachment holes, as shown in the figure to
the right.
x0600002632
The figure above shows the frame, view
from below.
• A: Attachment holes for the guide
pins, M12
Continues on next page
3HAC025755-001 Revision: B
153
4 Repair
4.3.3. Replacement of complete arm system
Continued
Action
Note
6. Look through the empty mounting hole of
This is a complex task to be performed
motor 1 to assist in aligning the assembly
with utmost care in order to avoid injury or
during refitting of the arm system.
damage!
Lower the arm system with guidance from
the guide pins previously fitted to the frame.
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 Shown in the figure Location of arm
system to the base with its 24attachment
system on page 150.
screws and washers.
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.
xx060002734
•
•
10. Refit the motor axis 1.
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 Detailed in section Performing a leak1.
down test on page 130.
13. Refill the gearbox axis 1 with lubricating oil. Detailed in section Oil change, gearbox
axis 1 on page 112.
Continues on next page
154
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
9. Refit the block for calibrationandcalibration
plate axis 1 at the bottom of the frame.
4 Repair
4.3.3. Replacement of complete arm system
Continued
Action
14. Recalibrate the robot.
Note
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.
15.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC025755-001 Revision: B
155
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.
A more detailed view of the component and its position may be found in chapter Spare parts
and exploded views on page 263 .
A
Turning disk
B
Attachment screws (6 pcs) turning disk
C
Tilthouse unit
D
Gearbox, axis 6
E
Attachment screws, axis 6
Required equipment
Equipment, etc.
Spare part no. Art. no.
Turning disk, diam. 200
Note
For robot version 180/3.15,
250/3.15
O-rings are not included!
O-ring
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!
Grease
3HAB3537-1
Used to lubricate the o-rings.
Standard toolkit
-
The content is defined in
section Standard toolkit on
page 258.
Continues on next page
156
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
xx0600002627
4 Repair
4.4.1. Replacement of turning disk
Continued
Equipment, etc.
Spare part no. Art. no.
Note
Other tools and
procedures may be
required. See references
to these procedures in
the step-by-step instructions below.
These procedures include
references to the tools
required.
Removal, turning disk
The procedure below details how to remove the turning disk.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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.
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.
© Copyright 2006-2008 ABB. All rights reserved.
4. Drain the oil from gearbox 6.
Continues on next page
3HAC025755-001 Revision: B
157
4 Repair
4.4.1. Replacement of turning disk
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
Art. no. is specified in Required
equipment on page 156.
xx0200000218
2. Secure the turning disk with its attachment
screws.
A: Sealing surface, o-ring
6 pcs M14 x 25, 12.9 quality.
Tightening torque: 175 Nm
Reused screws may be used, providing
they are lubricated as detailed in
section Screw joints on page 254
before fitting.
3. Perform a leak-down test of the gearbox axis 6. Detailed in section Performing a leakdown test on page 130.
4. Refill the gearbox 6 with oil.
Detailed in section Filling, oil on page
119.
5. Refit any equipment removed during disassembly, to the turning disk.
6.
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.
158
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
•
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.
A more detailed view of the component and its position may be found in chapter Spare parts
and exploded views on page 263 .
© Copyright 2006-2008 ABB. All rights reserved.
xx0600002616
A
Tilthouse unit
B
Upper arm
C
Upper rod
D
Screw M6x10
E
Washer 6.4x12x1.6
F
Ballplug
G
Protection cap
Continues on next page
3HAC025755-001 Revision: B
159
4 Repair
4.4.2. Replacement of tilthouse unit
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
Axis 2 side of the robot
B
Axis 3 side of the robot
Cut away view of the assembly of the tilthouse unit
© Copyright 2006-2008 ABB. All rights reserved.
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.
xx0600002742
A
Axis 2 side
B
Axis 3 side
Continues on next page
160
3HAC025755-001 Revision: B
4 Repair
4.4.2. Replacement of tilthouse unit
Continued
C
VK cover, VK 19 x 6, 2 pcs
D
VK cover, VK 68 x 8, 2 pcs
E
Screw M6 x 10 Steel 8.8-A2F + Washers, 4 + 4 pcs (for filling bearing grease)
F
Retaining ring fore bores, 2 pcs
G
Rust protection, Dinitrol 490
H
Upper arm
I
Tilthouse
J
Bearing, 2 pcs (on the outside of the tilthouse)
K
Bearing, 2 pcs (on the inside of the tilthouse)
L
Ring
M
Shaft, 2 pcs
N
Radial seal with dustlip, 2 pcs
O
Lock nut, KM7 2 pcs
P
Screw M6x16 + washer (for locking the shafts), 2 + 2 pcs
Required equipment
Equipment, etc.
Spare part no.
Art.no.
Press tool,
premounting bearing
3HAC 023075-001
Press tool, mounting
axis 6
3HAC 023080-001
Shims
Grease
Width = 3 mm
3HAB 3537-1
Rust protection
Dinitrol 490
Locking liquid
Loctite 243
Standard toolkit
© Copyright 2006-2008 ABB. All rights reserved.
Note
Other tools and
procedures may be
required. See
references to these
procedures in the stepby-step instructions
below.
Circuit diagram
-
The content is defined in
section Standard toolkit on
page 258.
These procedures include
references to the tools
required.
3HAC 025690-001 See chapter Circuit
3HAC 025691-001 diagram.
Continues on next page
3HAC025755-001 Revision: B
161
4 Repair
4.4.2. Replacement of tilthouse unit
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
Hydraulic cylinder, 3HAC 11731-1
B
Mounting washer, 3HAC 023075-004
C
Bushing, 3HAC 023075-006
D
Screw M6x25, 2 pcs (MC6S)
E
Threaded washer, 3HAC 5507-1
F
Press washer, 3HAC 023075-002
G
Threaded bar, M16 L = 300 mm
© Copyright 2006-2008 ABB. All rights reserved.
A
Continues on next page
162
3HAC025755-001 Revision: B
4 Repair
4.4.2. Replacement of tilthouse unit
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.
© Copyright 2006-2008 ABB. All rights reserved.
xx0600002751
A
Hydraulic cylinder, 3HAC 11731-1
B
Distance, 3HAC 023062-001
C
Press housing, 3HAC 023080-004
D
Support housing, 3HAC 023080-003
E
Screw M6x14, 2pcs (MC6S)
F
Flange lock nut, M16
G
Threaded bar, M16 L=435 mm
H
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
Note
1. Move the robot to a position where the tilthouse
rests on a table or similar.
Continues on next page
3HAC025755-001 Revision: B
163
4 Repair
4.4.2. Replacement of tilthouse unit
Continued
Action
Note
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Secure the tilthouse with a roundsling in an
overhead crane.
This is done in order to prevent the
tilthouse from falling down when the
shafts are removed.
4. Remove the upper rod.
Detailed in section Replacement of
linkage - upper rod on page 177
5. Remove one of the M6 screws and washer at
the cover for filling grease.
xx0600002735
A: Screw M6, grease filling
hole
6. Note! Do not remove the ball plug!
Be careful not to damage the ball plug!
Shown in the figure Location of tilt
house on page 159.
7. Remove the motor cable axis 6.
Detailed in section Replacement of
cable harness, upper end (incl. axis 6)
on page 144
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
Put a hand with some paper over the
grease (E), in order to remove the VK cover (D). VK cover in order to catch it.
Note! Only a very low air pressure is needed!
Continues on next page
164
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
•
4 Repair
4.4.2. Replacement of tilthouse unit
Continued
Action
Note
10. Remove the screw that locks the shaft.
xx0600002703
•
•
•
A: Screw M6x16
B: Shaft
C: Upper arm
11. Remove the small VK cover (C) from the inside Shown in the figure Cut away view of
with the help of a punch.
the assembly of the tilthouse unit on
page 160.
12. Remove the lock nut (O).
Shown in the figure Cut away view of
the assembly of the tilthouse unit on
page 160.
13. Remove the shaft (M) with the press tool,
Art.no is specified in Required
mounting axis 6.
equipment on page 161
Note! A longer threaded bar M16 is needed
when removing the shaft than the one specified
when fitting.
© Copyright 2006-2008 ABB. All rights reserved.
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.
Follow steps 9 through 13.
16. Lift the tilthouse to a safe place.
Check that the bearings are kept
clean, if they are refitted.
17. Force away the sealing ring (N) with a
screwdriver or similar.
The sealing must be replaced with a
new one when refitting.
18. If needed change the bearings.
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
Note
1. Lift the tilthouse to a workbench (or similair) with
a roundsling in an overhead crane.
Continues on next page
3HAC025755-001 Revision: B
165
4 Repair
4.4.2. Replacement of tilthouse unit
Continued
Action
Note
2. Apply some grease in the hole for the bearings Art.no. is specified in Required
(J) and (K).
equipment on page 161.
Shown in the figure Cut away view of
the assembly of the tilthouse unit on
page 160.
3. Fit two retaining rings for bores (F).
Shown in the figure Cut away view of
the assembly of the tilthouse unit on
page 160.
4. Fit the outer race of the bearing (J) facing the Shown in the figure Cut away view of
outside of the tilthouse. Use a plastic hammer or the assembly of the tilthouse unit on
similair.
page 160.
5. Thread the radial seal with dustlip (N) and the Shown in the figure Cut away view of
inner bearing complete (K) on the presswasher the assembly of the tilthouse unit on
(F) of the pressing tool, premounting bearings. page 160.
Shown in the figure Press tool
premounting bearing on page 162.
Art.no. is specified in Required
equipment on page 161.
6. Thread the race of the outer bearing (J) on the Shown in the figure Cut away view of
bushing (C) of the pressing tool, premounting the assembly of the tilthouse unit on
bearings.
page 160.
Shown in the figure Press tool
premounting bearing on page 162.
Art.no. is specified in Required
equipment on page 161.
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.
Action
Note
1. Apply some grease in the hole for the bearings Art.no. is specified in Required
(J) and (K).
equipment on page 161.
Shown in the figure Cut away view of
the assembly of the tilthouse unit on
page 160.
2. Fit the outer race of the bearing (J) facing the Shown in the figure Cut away view of
outside of the tilthouse. Use a plastic hammer or the assembly of the tilthouse unit on
similiar.
page 160.
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 Cut away view of
the assembly of the tilthouse unit on
page 160.
Shown in the figure Press tool
premounting bearing on page 162.
Art.no. specified in Required
equipment on page 161.
Continues on next page
166
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
This work is best done on a workbench or similair.
4 Repair
4.4.2. Replacement of tilthouse unit
Continued
Action
Note
4. Thread the race of the outer bearing (J) on the Shown in the figure Cut away view of
bushing (C) of the pressing tool, premounting the assembly of the tilthouse unit on
bearings.
page 160.
Shown in the figure Press tool
premounting bearing on page 162.
Art.no. is specified in Required
equipment on page 161.
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
© Copyright 2006-2008 ABB. All rights reserved.
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.
Shown in the figure Cut away view of
the assembly of the tilthouse unit on
page 160.
3. Apply some grease in the holes for the shafts
(M) in the upper arm.
Art. no. is specified in Required
equipment on page 161.
Shown in the figure Cut away view of
the assembly of the tilthouse unit on
page 160.
4. Note! Fit the axis 2 side first.
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 Shown in the figure Cut away view of
inside.
the assembly of the tilthouse unit on
page 160.
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 Cut away view of
the assembly of the tilthouse unit on
page 160.
Shown in the figure Press tool
mounting axis 6 on page 163.
Art. no. is specified in Required
equipment on page 161.
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).
Art. no. is specified in Required
equipment on page 161.
Shown in the figure Press tool
mounting axis 6 on page 163.
Continues on next page
3HAC025755-001 Revision: B
167
4 Repair
4.4.2. Replacement of tilthouse unit
Continued
Action
Note
8. Insert the shims in the space between the
Art. no. is specified in Required
tilthouse and the upper arm on the axis 2 side. equipment on page 161.
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 Loctite 243.
side and fit it with the flat surface facing inside. Tightening torque: 90 Nm
14. Apply locking liquid on the lock nut, KM7 axis 3 Loctite 243.
side and fit it with the flat surface facing inside. Tightening torque: 90 Nm
0600002703
•
•
•
A: Screw M6x16
B: Shaft
C: Upper arm
16. Fit the inner VK cover (C) on both axes.
Shown in the figure Cut away view of
the assembly of the tilthouse unit on
page 160.
17. Fit the outer VK cover (D) on both axes.
Shown in the figure Cut away view of
the assembly of the tilthouse unit on
page 160.
18. Fill bearings with grease.
Specified in Required equipment on
page 161.
Continues on next page
168
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
15. Apply locking liquid in the holes for the screws
locking the shafts and fit screws and washers
on both sides, locking the shafts.
4 Repair
4.4.2. Replacement of tilthouse unit
Continued
Action
19. Refit the motor cable, axis 6.
Note
Detailed in section Replacement of
cable harness, upper end (incl. axis 6)
on page 144
20. Refit the M6 screw and washer at the cover for
filling grease.
xx0600002735
•
A: Screw M6, grease filling
hole
21. Refit the upper rod.
Detailed in section Replacement of
linkage - upper rod on page 177
22. Recalibrate the robot.
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.
© Copyright 2006-2008 ABB. All rights reserved.
23.
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.
3HAC025755-001 Revision: B
169
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.
A more detailed view of the component and its position may be found in chapter Spare parts
and exploded views on page 263 .
A
Upper arm
B
Motor axis 6
C
Balancing device
D
Lower arm
E
Parallel rod
F
Linkage
© Copyright 2006-2008 ABB. All rights reserved.
xx0600002609
Continues on next page
170
3HAC025755-001 Revision: B
4 Repair
4.4.3. Replacement of upper arm
Continued
View of the assembly of the upper arm components
© Copyright 2006-2008 ABB. All rights reserved.
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
A
Shaft, axis 2
B
Shaft, axis 3
C
Set screw, cup point ( M10 x 20)
D
Lubricant paste (Molycote 1000)
E
Sealing ring (V-ring)
F
Sealing ring
G
Taper roller bearing
H
O-ring
Continues on next page
3HAC025755-001 Revision: B
171
4 Repair
4.4.3. Replacement of upper arm
Continued
I
Sealing ring
J
Sealing assembly
K
Lock nut (KM 12)
L
O-ring (Di = 54.2 mm, t = 5.7 mm)
Required equipment
Equipment, etc.
Spare part no.
Upper arm, axis 4
3HAC025525-001
3HAC026674-001
Art.no.
Note
White RAL 9003
Adapter
3HAC023916-001
Grease filling tool
-
Pressing tool, upper
arm
3HAC023084-001
KM12 socket
3HAC5347-1
Standard toolkit
-
The content is defined in
section Standard toolkit on
page 258.
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.
Circuit diagram
These procedures include
references to the tools
required.
-
See chapter Circuit
diagram.
Removal, upper arm
The procedure below details how to remove the upper arm.
Note
1. Remove all equipment fitted to the turning
disk.
2. Move the upper arm to a horizontal position.
3.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
4. Secure the upper arm with roundslings in
an overhead crane.
5. Remove the cable harness in the upper
arm.
Detailed in section
6. Raise the lifting equipment to take the
weight of the upper arm.
7. Remove the balancing device.
Detailed in section Replacement of
balancing device on page 200
Continues on next page
172
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
Action
4 Repair
4.4.3. Replacement of upper arm
Continued
Action
Note
8. Remove the linkage.
Detailed in section Replacement of
linkage - upper rod on page 177
Detailed in section Replacement of
linkage - lower rod on page 180
Detailed in section Replacement of
linkage - link on page 183
9. Remove the parallel rod.
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 View of the assembly
of the upper arm components on page
171.
12. Put the adapter on the shaft.
Art.no. is specified in Required equipment
on page 172
13. Remove the shaft axis 3 (B).
Shown in the figure View of the assembly
of the upper arm components on page
171.
Perform the removal with care. Threads
can otherwise be damaged!
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 View of the assembly
of the upper arm components on page
171.
NOTE!
The adapter is not needed on this shaft!
15. Put the shafts in a clean and safe place.
© Copyright 2006-2008 ABB. All rights reserved.
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
1. Put the shafts (A & B) on a workbench and
fit the sealing rings (E).
Note
Shown in the figure View of the assembly
of the upper arm components on page
171.
2. Apply some grease on the shafts and
sealing rings.
NOTE!
Don´t apply grease on the threads and
cones of the shafts!
Continues on next page
3HAC025755-001 Revision: B
173
4 Repair
4.4.3. Replacement of upper arm
Continued
Action
3. Fill the bearings (G) with bearing grease.
Use grease filling tool.
Note
Art. no. is specified Required equipment
on page 172
Shown in the figure View of the assembly
of the upper arm components on page
171.
4. Apply lubricant paste (D) on the threads and Molycote 1000.
cones of the shafts.
Shown in the figure View of the assembly
of the upper arm components on page
171
Refitting, upper arm
The procedure below details how to refit the upper arm.
Action
Note
1. Secure the upper arm with roundslings in
an overhead crane.
2.
CAUTION!
The complete upper arm with weighs 170 kg
without any additional equipment fitted! Use
a suitable lifting device to avoid injury to
personnel!
3.
CAUTION!
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 Shown in the figure View of the assembly
only.
of the upper arm components on page
171.
Don´t use force since the threads can be
damaged if fitting is not done in the correct
way.
Continues on next page
174
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
The complete upper arm weighs 380 kg
without any additional equipment fitted!
Use a suitable lifting device to avoid injury to
personnel!
4 Repair
4.4.3. Replacement of upper arm
Continued
Action
Note
7. Put the adapter on the shaft and fit it.
Secure the shaft.
Tightening torque: 400 Nm.
Art.no. is specified in Required equipment
on page 172
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.
8. Refit the sealing ring (F) on the shaft.
Shown in the figure View of the assembly
of the upper arm components on page
171.
9. Refit the bearing (G) on the shaft with the
pressing tool, upper arm.
Shown in the figure View of the assembly
of the upper arm components on page
171.
10. Fit an o-ring (H) on the sealing ring (I) and fit Shown in the figure View of the assembly
it on the shaft.
of the upper arm components on page
171.
NOTE!
The o-ring shall be faced against the
bearing.
11. Fit the o-ring (L) on the sealing assembly (J) Shown in the figure View of the assembly
and refit the sealing assembly on the shaft. of the upper arm components on page
171.
12. Apply locking liquid on the lock nut (K) and Shown in the figure View of the assembly
refit it.
of the upper arm components on page
171.
Loctite 243.
Tightening torque 90 Nm.
© Copyright 2006-2008 ABB. All rights reserved.
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 View of the assembly
of the upper arm components on page
171.
Continues on next page
3HAC025755-001 Revision: B
175
4 Repair
4.4.3. Replacement of upper arm
Continued
Action
14. Apply locking liquid on the lock nut (K) and
refit it.
NOTE!
The order of the tightening torques is very
important!
Note
Shown in the figure View of the assembly
of the upper arm components on page
171.
Loctite 243.
Tightening torque the first time: 300 Nm
Tightening torque the second time: 90
Nm
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 View of the assembly
of the upper arm components on page
171
Loctite 243.
Tightening torque: 35 Nm.
17. Refit the parallel rod.
Detailed in section Replacement of
parallel rod on page 188
18. Refit the cable harness, upper end.
Detailed in section
19. Refit the linkage.
Detailed in section Replacement of
linkage - upper rod on page 177
Detailed in section Replacement of
linkage - lower rod on page 180
Detailed in section Replacement of
linkage - link on page 183
20. (Not applicable to the robot variant IRB
6660 - 205/1.9! )
Refit the balancing device.
Detailed in section Replacement of
balancing device on page 200
21. Recalibrate the robot.
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.
22.
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.
176
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
16. Wipe residual grease from the shafts.
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.
A more detailed view of the component and its position may be found in chapter Spare parts
and exploded views on page 263 .
Location of upper rod
© Copyright 2006-2008 ABB. All rights reserved.
The upper rod is located as shown in the figure below.
xx0600002592
A
Lower rod
B
Upper rod
C
Link
Required equipment
Equipment
Spare part no.
Upper rod
3HAC023744-003
Needle bearing
3HAC3311-1
Art no.
Note
White RAL 9003
Replace if damaged.
Bearing grease
3HAB3537-1
Used to lubricate the
bearings.
Locking liquid
3HAB7116-1
Loctite 243
Continues on next page
3HAC025755-001 Revision: B
177
4 Repair
4.4.4. Replacement of linkage - upper rod
Continued
Equipment
Spare part no.
Standard toolkit
Art no.
Note
-
The content is defined in
section Standard toolkit on
page 258.
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step instructions below.
These procedures include
references to the tools
required.
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.
Note
Check especially that it is possible to
remove the lock nut at the link.
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Let the tilthouse rest on something, (a table This is done in order to prevent the
for example).
tilthouse from falling downwards when the
upper rod is removed.
4. Remove the lock nuts holding the upper rod
at each end.
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.
Action
1. If needed, replace the bearings in the rod.
Note! The bearings are sensitive for
pushes. Make sure they are not damaged!
Note
Spare part no. is specified in Required
equipment on page 177.
2. Lubricate the bearings properly with bearing Specified in Required equipment on page
grease.
177.
3. Refit the sealing rings on the shaft ends of
the link and tilthouse.
Continues on next page
178
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
5. Remove the support washers from the
upper rod.
4 Repair
4.4.4. Replacement of linkage - upper rod
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, Tightening torque: 120 Nm.
using locking liquid.
8.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC025755-001 Revision: B
179
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.
A more detailed view of the component and its position may be found in chapter Spare parts
and exploded views on page 263 .
Location of lower rod
xx0600002592
A
Lower rod
B
Upper rod
C
Link
Required equipment
Equipment
Spare part no.
Art no.
Lower rod
3HAC023239-003
White RAL 9003
Needle bearing
3HAC3311-1
Replace if damaged.
Bearing grease
3HAB3537-1
Locking liquid
3HAB7116-1
Note
Loctite 243
Continues on next page
180
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
The lower rod is located as shown in the figure below.
4 Repair
4.4.5. Replacement of linkage - lower rod
Continued
Equipment
Spare part no.
Art no.
Note
Standard toolkit
The content is defined in
section Standard toolkit
on page 258.
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step instructions below.
These procedures
include references to the
tools required.
Removal, lower rod
The procedure below details how to remove the lower rod of the linkage.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. If the upper rod is removed, secure the link This is done in order to prevent the link
with a roundsling in a crane. Use the hole in from moving if both the upper and lower
the middle of the link.
rod are removed.
© Copyright 2006-2008 ABB. All rights reserved.
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
Note
1. If needed, replace the bearings.
Note! The bearings are sensitive for pushes.
Make sure they are not damaged!
Spare part no. is specified in
Required equipment on page 180.
2. Lubricate the bearings properly with bearing
grease.
Specified in Required equipment on
page 180.
3. Refit the sealing rings to the shaft ends on the
link and frame.
4. Refit the support washers to the shaft ends.
Tip! Putting some grease on the
support washers will keep them in
position.
Continues on next page
3HAC025755-001 Revision: B
181
4 Repair
4.4.5. Replacement of linkage - lower rod
Continued
Action
5. Refit the lower rod on the shaft ends of the link
and frame.
Note
Check that the lower rod is pushed
completely in.
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.
Tightening torque: 120 Nm.
Locking liquid is specified in
Required equipment on page 180.
8.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
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.
182
3HAC025755-001 Revision: B
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.
A more detailed view of the component and its position may be found in chapter Spare parts
and exploded views on page 263 .
Location of link
© Copyright 2006-2008 ABB. All rights reserved.
The link is located as shown in the figure below.
xx0600002592
A
Lower rod
B
Upper rod
C
Link
Required equipment
Equipment, etc.
Spare part no. Art. no.
Link
Note
White RAL 9003
Auxiliary shaft
3HAC 023081-004
Pressing tool, link
3HAC 023081-001 Used to press the link on the
shaft
Pressing tool, link
3HAC 023079-001 Used to press the outer rings
of the bearings in the link
Continues on next page
3HAC025755-001 Revision: B
183
4 Repair
4.4.6. Replacement of linkage - link
Continued
Equipment, etc.
Spare part no. Art. no.
Lubrication tool
Note
3HAC 5222-2
Sealing compound
Permatex No. 3
Locking liquid
Loctite 243
Grease
3HAB 3537-1
Standard toolkit
The contents are defined in
section Standard toolkit!
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.
These procedures include
references to the tools
required.
Removal, link
The procedure below details how to remove the link of the linkage.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Remove the upper and lower rods.
Detailed in section Replacement of
linkage - upper rod on page 177
Detailed in section Replacement of
linkage - lower rod on page 180
4. Fit the auxiliary shaft on the shaft.
Art.no. is specified in Required equipment
on page 183
Continues on next page
184
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
2. Secure the link with a roundsling in a crane. This is done to prevent the link from
moving when the upper and lower rods
Use the hole in the middle of the link.
are removed.
4 Repair
4.4.6. Replacement of linkage - link
Continued
Action
Note
5. Remove screw and washer in the hole for
filling grease.
xx0600002597
•
A: Hole for filling grease
6. Use compressed air to remove the VK
Put one hand with some paper on top of
cover. Blow with a very low air pressure into the VK cover in order to catch it when
the hole for filling grease.
released.
Note! A very low air pressure is needed!
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.
© Copyright 2006-2008 ABB. All rights reserved.
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.
Refitting, link
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.
Art.no. is specified in Required equipment
on page 183
Continues on next page
3HAC025755-001 Revision: B
185
4 Repair
4.4.6. Replacement of linkage - link
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.
Art.no. is specified in Required equipment
on page 183
5. Apply sealing compound on the support
ring.
Permatex No. 3
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.
Art.no. is specified in Required equipment
on page 183
9. Apply locking liquid on the lock nut.
Loctite 243
10. Fit the lock nut first with a tightening torque Tightening torque first time: 300 Nm
of 300 Nm. Then unscrew the lock nut and Tightening torque the second time: 90
fit it once again. This time with a tightening Nm
torque of 90 Nm.
Note the order of the two tightening torques!
11. Refit the VK cover.
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.
Detailed in section Replacement of
linkage - upper rod on page 177
15. Refit the lower rod to the link.
Detailed in section Replacement of
linkage - lower rod on page 180
Continues on next page
186
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
12. Fill the link with grease. Use lubrication tool. Art.no. is specified in Required equipment
on page 183
4 Repair
4.4.6. Replacement of linkage - link
Continued
Action
16. Recalibrate the robot!
Note
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.
17.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC025755-001 Revision: B
187
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
Required equipment
Equipment, etc. Spare part no.
Parallel rod
Mounting/
Demounting tool
Art.no.
3HAC021084-004
White RAL 9003
3HAC5021-1
Locking liquid
Standard toolkit
Note
Loctite 243
-
The content is defined in
section Standard toolkit
on page 258.
Continues on next page
188
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
A more detailed view of the component and its position may be found in chapter Spare parts
and exploded views on page 263 .
4 Repair
4.4.7. Replacement of parallel rod
Continued
Equipment, etc. Spare part no.
Art.no.
Note
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.
These procedures
include references to the
tools required.
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.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Secure the upper arm with a roundsling in a
crane.
© Copyright 2006-2008 ABB. All rights reserved.
3. Remove the upper lock screw and washer,
locking the parallel rod in position.
xx0600002741
•
A: Lock screw M6x16
Continues on next page
3HAC025755-001 Revision: B
189
4 Repair
4.4.7. Replacement of parallel rod
Continued
Action
Note
4. Remove the upper shaft (A) and cover
washer (B).
xx0700000065
Parts:
•
•
•
•
•
•
5. Remove the thrust washer (F).
A: Shaft
B: Cover washer
C: Parallel rod
D: Sealed spherical bearing
E: Bearing grease
F: Thrust washer
See figure above!
6. Remove the parallel rod (C) backwards
See figure above and Location of parallel
from its upper connection point and let it rest rod on page 188!
against frame and base.
See figure above!
8. Remove the parallel rod from the robot.
9. Replace the bearings (D), if necessary.
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
Note
1. Lift the parallel rod to the mounting position.
Continues on next page
190
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
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)
4 Repair
4.4.7. Replacement of parallel rod
Continued
Action
Note
2. Put the thrust washer (F) on the axis 2 side
of the parallel rod (C).
xx0700000065
3. Put the cover washer (B) on the axis 3 side See figure above!
of the parallel rod.
4. Refit the shaft (A) by pushing it through the See figure above!
parallel bar.
Press the shaft in position.
5. Apply locking liquid in the hole of the lock
screw.
Loctite 243
© Copyright 2006-2008 ABB. All rights reserved.
6. Refit the lock screw and plain washer.
xx0600002741
•
7. Recalibrate the robot.
A: Lock screw M6x16
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.
8.
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.
3HAC025755-001 Revision: B
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.
A more detailed view of the component and its position may be found in chapter Spare parts
and exploded views on page 263 .
A
Lower arm
B
Parallel arm
Required equipment
Equipment, etc.
Spare part no.
Lower arm
3HAC021464-004
3HAC021464-004
Art.no.
Note
White RAL 9003
Crank
3HAC023132-001
Lock screw M16x90
-
Lifting tool, lower arm
complete
3HAC8446-1
Standard toolkit
-
The content is defined in
section Standard toolkit on
page 258.
Continues on next page
192
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
xx0600002611
4 Repair
4.4.8. Replacement of complete lower arm
Continued
Equipment, etc.
Spare part no.
Art.no.
Note
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step instructions below.
Circuit diagram
These procedures include
references to the tools
required.
-
See chapter Circuit
diagram.
Removal, lower arm
The procedure below details how to remove the lower arm.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
© Copyright 2006-2008 ABB. All rights reserved.
2. Secure the lower arm with a lock screw in the
hole as shown in the figure to the right.
xx0600002736
•
A: Hole for lock screw,
M16x90
3. Remove the linkage.
Detailed in section Replacement of
linkage - upper rod on page 177
Detailed in section Replacement of
linkage - lower rod on page 180
Detailed in section Replacement of
linkage - link on page 183
4. Remove the balancing device.
Detailed in section Replacement of
balancing device on page 200
5. Remove the parallel rod.
Detailed in sectionReplacement of
parallel rod on page 188 .
Continues on next page
3HAC025755-001 Revision: B
193
4 Repair
4.4.8. Replacement of complete lower arm
Continued
Action
Note
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.
Detailed in section Replacement of
cable harness, upper end (incl. axis
6) on page 144.
7. Remove the complete upper arm.
Detailed in section Replacement of
upper arm on page 170.
8. Remove the motors axes 2-3.
Detailed in section Replacement of
motor, axes 2 and 3 on page 217.
9. Remove gearbox axes 2-3.
Detailed in section Replacement of
gearbox, axes 2- 3 on page 232.
10.
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.
Art. no. is specified in Required
equipment on page 192.
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.
If the parts are not pushed together, it
will be difficult to remove the
complete lower arm.
14. Remove the complete lower arm (including the
parallel arm).
How to replace the parallel arm is
detailed in section Replacement of
parallel arm on page 197.
Refitting, lower arm
Action
Note
1.
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.
Art. no. is specified in Required
equipment on page 192.
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!
Continues on next page
194
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
The procedure below details how to refit the lower arm.
4 Repair
4.4.8. Replacement of complete lower arm
Continued
Action
Note
6. Refit all screws (both M12 and M16) with
Tightening torque M16: 300 Nm
washers on the axis 2 side that are possible to fit Tightening torque M12: 120 Nm
at this stage.
7. Push the parallel arm against the axis 2 side.
8. Refit all screws with washers on the axis 3 side
that are possible to fit.
Tightening torque M12: 120 Nm
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.
xx0600002736
© Copyright 2006-2008 ABB. All rights reserved.
•
A: Hole for lock screw
M16x90
11. Refit gearbox axis 2-3.
Detailed in section Replacement of
gearbox, axes 2- 3 on page 232.
12. Refit motor axes 2-3.
Detailed in section Replacement of
motor, axes 2 and 3 on page 217.
13. Refit the complete upper arm.
Detailed in section Replacement of
upper arm on page 170.
14. Refit the cable harness.
Detailed in section Replacement of
cable harness, upper end (incl. axis
6) on page 144
15. Refit the parallel rod.
Detailed in section Replacement of
parallel rod on page 188
16. Refit the balancing device.
Detailed in section Replacement of
balancing device on page 200.
Continues on next page
3HAC025755-001 Revision: B
195
4 Repair
4.4.8. Replacement of complete lower arm
Continued
Action
17. Refit the linkage.
Note
Detailed in section Replacement of
linkage - link on page 183
Detailed in section Replacement of
linkage - lower rod on page 180
Detailed in section Replacement of
linkage - upper rod on page 177
18. Remove the lock screw.
19. Recalibrate the robot.
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.
20.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
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.
196
3HAC025755-001 Revision: B
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.
A more detailed view of the component and its position may be found in chapter Spare parts
and exploded views on page 263 .
© Copyright 2006-2008 ABB. All rights reserved.
0600002611
A
Lower arm
B
Parallel arm
Required equipment
Equipment, etc.
Spare part no.
Parallel arm
3HAC023026-003
3HAC023026-003
Bearing grease
3HAB 3537-1
Art.no.
Note
White RAL 9003
Pressing tool, lower
arm
3HAC023092-001
Lifting device, parallel
arm
3HAC023098-001
Lifting tool, lower arm
complete
3HAC8446-1
Level
-
Continues on next page
3HAC025755-001 Revision: B
197
4 Repair
4.4.9. Replacement of parallel arm
Continued
Equipment, etc.
Spare part no.
Standard toolkit
Art.no.
Note
-
The content is defined in
section Standard toolkit
on page 258.
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step instructions below.
These procedures
include references to
the tools required.
Removal, parallel arm
The procedure below details how to remove the parallel arm.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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 Required
equipment on page 197.
© Copyright 2006-2008 ABB. All rights reserved.
6. Disassemble the parallel arm from the lower arm by Art.no. is specified in Required
using the pressing tool, lower arm.
equipment on page 197.
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
Note
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.
Continues on next page
198
3HAC025755-001 Revision: B
4 Repair
4.4.9. Replacement of parallel arm
Continued
Action
4. Refit a bearing on each shaft with pressing tool,
lower arm.
Note
Art. no. is specified in Required
equipment on page 197
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.
Art. no. is specified in Required
equipment on page 197
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.
Art. no. is specified in Required
equipment on page 197.
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 Art. no. is specified in Required
with the pressing tool, lower arm.
equipment on page 197.
© Copyright 2006-2008 ABB. All rights reserved.
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.
16. Recalibrate the robot.
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.
17.
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.
3HAC025755-001 Revision: B
199
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.
© Copyright 2006-2008 ABB. All rights reserved.
A more detailed view of the component and its position may be found in chapter Spare parts
and exploded views on page 263 .
xx0600002604
A
Balancing device
B
Hole to neutralize the spring force. (M12)
C
Hole on lifting ear
D
Hole for lock screw
Continues on next page
200
3HAC025755-001 Revision: B
4 Repair
4.5.1. Replacement of balancing device
Continued
Required equipment
Equipment, etc. Spare part no.
Balancing device
Art.no.
Note
3HAC024779-001
3HAC024779-001
White RAL 9003
Auxiliary shaft
3HAC5281-1
Auxiliary shaft, long
3HAC5275-1
Auxiliary shaft,
short
3HAC5276-1
Lock screw
-
M16 x 90
For securing the lower arm.
Screw
M12 x 50
For neutralizing the spring force
of the balancing cylinder.
Lubrication tool
3HAC5222-2
Standard toolkit
-
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.
For fitting the inner rings of the
bearings
The content is defined in section
Standard toolkit on page 258.
These procedures include
references to the tools required.
Removal
The procedure below details how to remove the balancing device.
© Copyright 2006-2008 ABB. All rights reserved.
Action
Note
1. Move the robot to a position close enough to its The balancing device must be placed
calibration position, to allow the lock screw to in a 90° angle from the floor, in order
be inserted into the hole for the lock screw.
the be lifted in the most secure way.
Shown in section Location, balancing
device on page 200.
Continues on next page
3HAC025755-001 Revision: B
201
4 Repair
4.5.1. Replacement of balancing device
Continued
Action
Note
2. Lock the lower arm by inserting the lock screw
into the hole.
xx0600002736
•
A: Hole for lock screw M16x90
3.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
5. Insert a long screw (M12x50) in the hole to
neutralize the spring force.
The length of the cylinder is now
locked.
6. Attach a roundsling to the balancing device.
Use the hole in the lifting ear.
7. Remove the lock nuts.
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.
Art.no. is specified in Required
equipment on page 201
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.
Continues on next page
202
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
4. Remove the protection hood in the upper end of
the balancing device.
4 Repair
4.5.1. Replacement of balancing device
Continued
Action
Note
14. Remove the sealing rings and support washers.
Refitting
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.
Art.no. is specified in section Required
equipment on page 201
5. Attach a roundsling to the balancing device and
lift it on to the auxiliary shafts.
6. Adjust the length between the upper and lower This length should preferably be 0.5
bearings by means of the M12 screw, used to mm too short than 0.1 mm too long. If
neutralize the spring force.
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!
© Copyright 2006-2008 ABB. All rights reserved.
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.
Art.no. is specified in section Required
equipment on page 201.
10. Fill the bearings with grease through the nipple.
Continue until grease excudes behind the inner
sealing.
11. Remove the lubricating tool and wipe off
protruding grease.
12. Remove the auxiliary shafts.
13. Apply locking liquid on the lock nuts.
Loctite 243
14. Refit the lock nuts and support washers.
Tightening torque: 120 Nm
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.
Continues on next page
3HAC025755-001 Revision: B
203
4 Repair
4.5.1. Replacement of balancing device
Continued
Action
Note
17. Remove the M16x90 lock screw.
xx0600002736
•
A: Hole for lock screw M16x90
18.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
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.
204
3HAC025755-001 Revision: B
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
A
SMB cover
B
SMB unit
C
Battery cable
D
SMB battery
E
SMB battery, cover
© Copyright 2006-2008 ABB. All rights reserved.
Required equipment
Equipment, etc. Spare part no.
Art. no.
Note
Standard toolkit
-
The content is defined in
section Standard toolkit on
page 258.
Circuit Diagram
-
See chapter Circuit diagram.
SMB unit
3HAC022286-001
Battery pack
3HAC16831-1
3HAC16831-1
Removal, SMB unit
The procedure below details how to remove the SMB unit.
Action
Note
1. Move the robot to the calibration position.
Continues on next page
3HAC025755-001 Revision: B
205
4 Repair
4.5.2. Replacement of SMB unit
Continued
Action
Note
2.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
3.
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 cover by unscrewing its
attachment screws.
Shown in the figure Location of
SMB unit on page 205.
5. Remove the connectors X8, X9 and X10 from the
brake release board, if need of more space.
6. Remove the nuts and washers from the pins securing Shown in the figure Location of
the board.
SMB unit on page 205.
7. Gently disconnect the connectors from the SMB unit Connectors R1.SMB1-3,
when pulling the board out.
R1.SMB4-6 and R2.SMB
8. Disconnect the battery cable from the SMB unit.
Shown in the figure Location of
SMB unit on page 205.
Refitting, SMB unit
The procedure below details how to refit the SMB unit.
Action
Note
© Copyright 2006-2008 ABB. All rights reserved.
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
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. Connect the battery cable to the SMB unit.
Shown in the figure Location of SMB
unit on page 205.
Continues on next page
206
3HAC025755-001 Revision: B
4 Repair
4.5.2. Replacement of SMB unit
Continued
Action
Note
4. Connect all connectors to the SMB board and fit Art. no. is specified in Required
the SMB unit onto the pins.
equipment on page 205.
Shown in the figure Location of SMB
unit on page 205.
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 Location of SMB
unit on page 205.
8. Update the revolution counter!
Detailed in chapter Calibration section Updating revolution counters
on page 246.
9.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC025755-001 Revision: B
207
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
SMB cover
B
SMB unit
C
Battery cable
D
SMB battery
E
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
Standard toolkit on page 258.
Other tools and procedures may
be required. See references to
these procedures in the step-bystep instructions below.
These procedures include references
to the tools required.
Continues on next page
208
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
Required equipment
4 Repair
4.5.3. Replacement of brake release unit
Continued
Removal, brake release unit
The procedure below details how to remove the brake release unit.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
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. Remove the push button guard from the SMB Shown in the figure Location of brake
cover.
release unit on page 208.
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 Location of brake
release unit on page 208.
5. Remove the complete brake release unit
(including brake release unit and bracket)
from the SMB recess, by removing its two
attachment screws.
© Copyright 2006-2008 ABB. All rights reserved.
6. Disconnect the connectors X8, X9 and X10
from the brake release unit.
xx0200000129
• A: Connector X8
• B: Connector X9
• C: Connector X10
• D: Push buttons
Location of brake release unit is shown
in the figure Location of brake release
unit on page 208.
Continues on next page
3HAC025755-001 Revision: B
209
4 Repair
4.5.3. Replacement of brake release unit
Continued
Action
Note
7. Remove the brake release unit from the
bracket by removing the four attachment
screws.
Refitting, brake release unit
The procedure below details how to refit the brake release unit.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
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. 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 Location of brake
release unit on page 208.
Art. no. is specified in Required
equipment on page 208.
xx0200000129
•
•
•
•
A: Connector X8
B: Connector X9
C: Connector X10
D: Push buttons
5. Refit the complete brake release unit
(including brake release unit and bracket) to
the SMB recess with the two attachment
screws.
Continues on next page
210
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
4. Connect the connectors X8, X9 and X10 to the
brake release unit.
4 Repair
4.5.3. Replacement of brake release unit
Continued
Action
Note
6. Refit the SMB cover with its attachment
Shown in the figure Location of brake
screws.
release unit on page 208.
The push button guard must not be mounted
on the cover before the check described below
is made!
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 Location of brake
release unit on page 208.
9. If the battery has been disconnected the
revolution counter must be updated.
Detailed in the Calibration chapter section Updating revolution counters on
page 246.
10.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC025755-001 Revision: B
211
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.
A
Motor axis 1
B
Motor attachment screws and washers
C
Cable gland cover (located on the lower side of the motor)
D
Motor cover
Required equipment
Equipment, etc
Spare part no.
Motor axis 1
3HAC024775-001
3HAC028861-001
Art.no.
Note
Includes:
• motor
• pinion
• o-ring (Old o-ring
must be replaced
when replacing the
motor)
Grease
3HAB3537-1
Used to lubricate the o-ring
Power supply
-
24 VDC, max. 1,5 A
For releasing the brakes.
Standard toolkit
-
The content is defined in
section Standard toolkit on
page 258.
Continues on next page
212
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
xx0600002598
4 Repair
4.6.1. Replacement of motor, axis 1
Continued
Equipment, etc
Spare part no.
Art.no.
Note
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.
Circuit diagram
These procedures include
references to the tools
required.
-
See chapter Circuit
diagram.
Removal, motor
The procedure below details how to remove motor, axis 1.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
© Copyright 2006-2008 ABB. All rights reserved.
2. Remove the motor cover in order to get access Shown in the figure Location of motor
to the connectors on top of the motor by
on page 212.
unscrewing its four attachment screws.
xx0600002696
•
•
•
A: Motor cover
B: Attachment screws
C: Cable gland
Continues on next page
3HAC025755-001 Revision: B
213
4 Repair
4.6.1. Replacement of motor, axis 1
Continued
Action
Note
3. Remove the cable gland cover at the cable exit Shown in the figure Location of motor
by unscrewing its attachment screw which is
on page 212.
found after removing the motor cover.
Make sure the gasket is not damaged!
xx0600002694
•
A: Screw holding the cable
gland
4. Disconnect all connectors beneath the motor
cover.
5. In order to release the brake, connect the 24
VDC power supply.
Connect to connector R2.MP1
• + : pin 2
• - : pin 5
6. Remove the motor by unscrewing its four
attachment screws and plain washers.
Shown in the figure Location of motor
on page 212.
7. If required, press the motor out of position by
fitting two screws in the holes on the motor for
pressing out the motor.
Always use the removal screws in
pairs!
8.
CAUTION!
The motor weighs 29 kg! All lifting equipment
used must be sized accordingly!
© Copyright 2006-2008 ABB. All rights reserved.
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!
Continues on next page
214
3HAC025755-001 Revision: B
4 Repair
4.6.1. Replacement of motor, axis 1
Continued
Refitting, motor
The procedure below details how to refit motor, axis 1.
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
replacing the motor.
2.
CAUTION!
The motor weighs 29 kg! All lifting equipment
used must be sized accordingly!
3. In order to release the brake, connect the 24
VDC power supply.
Connect to connector R2.MP1
• + : pin 2
• - : pin 5
4. Fit the motor, making sure the motor pinion is
properly mated to the gearbox of axis 1.
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!
5. Secure the motor with its four attachment
screws and plain washers.
M10 x 40
Shown in the figure Location of motor
on page 212.
Tightening torque: 50 Nm.
6. Disconnect the brake release voltage.
© Copyright 2006-2008 ABB. All rights reserved.
7. Reconnect all connectors beneath the motor
cover.
8. Refit the cable gland cover at the cable exit with Make sure the cover is tightly sealed!
its attachment screw.
Replace the gasket.
xx0600002694
•
Screw holding the cable gland
Continues on next page
3HAC025755-001 Revision: B
215
4 Repair
4.6.1. Replacement of motor, axis 1
Continued
Action
9. Refit the motor cover with its four attachment
screws.
Note
Make sure the cover is tightly sealed!
xx0600002696
•
•
•
10. Recalibrate the robot!
A: Motor cover
B: Attachment screws
C: Cable gland
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.
11.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
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.
216
3HAC025755-001 Revision: B
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
A
Motor, axis 2
B
Motor, axis 3
C
Motor attachment screws and washers
D
Cable gland cover (located on the lower side of the motor)
E
Motor cover
F
Hole for lock screw
© Copyright 2006-2008 ABB. All rights reserved.
Required equipment
Equipment, etc.
Spare part no.
Motor axis 2-3
3HAC024776-001
3HAC021030-001
Art. no.
Note
Includes
• motor
• pinion
• o-ring (The o-ring
must be replaced
when the motor is
replaced)
Grease
3HAB3537-1
For lubricating the o-ring.
Guide pins M10 x
150
3HAC13120-2
For guiding the motor.
Guide pins are to be used
in pairs!
Lifting tool, motor
axes 2-3
3HAC14586-1
Power supply
-
Rotation tool
24 VDC, 1.5 A
For releasing the brakes.
Used to rotate the motor
pinion when mating it to the
gear, when brakes are
released with 24 VDC
power supply.
Continues on next page
3HAC025755-001 Revision: B
217
4 Repair
4.6.2. Replacement of motor, axes 2 and 3
Continued
Equipment, etc.
Spare part no.
Art. no.
Note
Standard toolkit
The content is defined in
section Standard toolkit on
page 258.
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step instructions below.
These procedures include
references to the tools
required.
Circuit diagram
-
See chapter Circuit
diagram.
Removal, motor
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!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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 Shown in the figure Location of
attachment screws.
motors, axes 2 and 3 on page 217.
7. Remove the cable gland cover at the cable exit Shown in the figure Location of
by unscrewing its two attachment screws.
motors, axes 2 and 3 on page 217.
Make sure the gasket is not damaged!
8. Disconnect all connectors beneath the motor
cover.
9. In order to release the brake, connect the 24
VDC power supply.
Connect to connector R2.MP2
• + : pin 2
• - : pin 5
10. Remove the motor by unscrewing its four
attachment screws and plain washers.
Shown in the figure Location of
motors, axes 2 and 3 on page 217.
11. Fit the two guide pins in two of the motor
attachment holes.
Art. no. is specified in Required
equipment on page 217.
12. If required, press the motor out of position by
Always use the removal tools in pairs!
fitting two screws in the motor attachment holes
diagonal to each other.
Continues on next page
218
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
4. Lock the lower arm by inserting the lock screw Shown in the figure Location of
into the hole.
motors, axes 2 and 3 on page 217.
4 Repair
4.6.2. Replacement of motor, axes 2 and 3
Continued
Action
13. Remove the two screws and fit the lifting toll,
motor axes 2-3 to the motor.
Note
Art. no. is specified in Required
equipment on page 217.
14.
CAUTION!
The motor weighs 32 kg! All lifting equipment
used must be sized accordingly!
15. Lift the motor to get the pinion away from the
gear.
Make sure the pinion does not get
damaged!
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!
Refitting, motor
The procedure below details how to refit motors, axes 2 and 3.
Action
Note
© Copyright 2006-2008 ABB. All rights reserved.
1. Make sure the o-ring on the circumference of
the motor is seated properly. Lightly lubricate
the o-ring with grease.
2. In order to release the brake, connect the 24
VDC power supply.
Connect to connector R2.MP1
• + : pin 2
• - : pin 5
3. Fit the lifting tool, motor axes 2-3 to the motor.
Art. no. is specified in Required
equipment on page 217.
4. Fit the two guide pins in the two lower motor
attachment holes.
Art. no. is specified in Required
equipment on page 217.
5.
CAUTION!
The motor weighs 32 kg! All lifting equipment
used must be sized accordingly!
6. Lift the motor and guide it on to the guide pins, Make sure the motor is turned the right
as close to the correct position as possible
way, that is connections for the cables
without pushing the motor pinion into the gear. facing downwards.
7. Remove the lifting tool and allow the motor to
rest on the guide pins.
Continues on next page
3HAC025755-001 Revision: B
219
4 Repair
4.6.2. Replacement of motor, axes 2 and 3
Continued
Action
Note
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.
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 Location of
motors, axes 2 and 3 on page 217.
M10 x 40, tightening torque: 50 Nm.
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints on
page 254 before fitting.
11. Disconnect the brake release voltage.
12. Reconnect all connectors beneath the motor
cover.
Connect in accordance with markings
on connectors.
14. Refit the motor cover with its four attachment
screws and washers.
Make sure the cover is tightly sealed!
15. Remove the lock screw from the hole for lock
screw.
Shown in the figure Location of
motors, axes 2 and 3 on page 217.
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.
18. Recalibrate the robot!
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.
19.
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.
220
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
13. Refit the cable gland cover at the cable exit with Shown in the figure Location of
its two attachment screws.
motors, axes 2 and 3 on page 217.
Replace the gasket.
4 Repair
4.6.3. Replacement of motor, axis 6
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
A
Motor, axis 6
B
Attachment screws and washers
C
Cable gland cover
D
Motor cover
© Copyright 2006-2008 ABB. All rights reserved.
Required equipment
Equipment, etc.
Spare part no.
Motor axis 6
3HAC 024777-001
Art.no.
Note
Includes
• motor
• pinion
• o-ring (the o-ring
must be replaced
when the motor is
replaced)
Power supply
-
24 VDC, 1.5 A
For releasing the brakes.
Grease
3HAB 3537-1
For lubricating the o-ring.
Standard toolkit
-
The content is defined in
section Standard toolkit
on page 258.
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step instructions below.
Circuit diagram
These procedures
include references to the
tools required.
3HAC 025690-001
3HAC 025691-001
See chapter Circuit
diagram.
Continues on next page
3HAC025755-001 Revision: B
221
4 Repair
4.6.3. Replacement of motor, axis 6
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.
Note
The motor axis 6 can be replaced without
draining the gear oil.
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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 Make sure the gasket is not damaged!
exit by unscrewing its attachment screw.
xx0600002694
•
A: Screw holding the cable gland
xx0500002466
•
•
•
•
A: Signal lamp
B: Cable straps, outdoor
C: Cable
D: Connection point to the cable
gland
6. In order to release the brake, connect the 24 Connect to connector R2.MP6
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!
Continues on next page
222
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
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.
4 Repair
4.6.3. Replacement of motor, axis 6
Continued
Action
9. Lift the motor carefully to get the pinion
away from the gear.
Disconnect the brake release voltage.
Note
Make sure the pinion does not get
damaged!
10. Remove the motor by gently lifting it straight Make sure the pinion does not get
up and place it on a secure surface.
damaged!
Refitting, motor
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.
2. In order to release the brake, connect the 24
VDC power supply.
Connect to connector R2.MP6
• + : pin 2
• - : pin 5
3. Fit the two guide pins in two of the motor
attachment holes.
Art. no. is specified in Required
equipment on page 221.
4. Lift the motor and carefully and refit it, with
Make sure the motor is turned the
guidance from the pins.
right way, i.e. connections for the
Make sure the motor pinion is properly mated to cables facing downwards.
the gearbox, axis 6.
5. Remove the guide pins.
6. Secure the motor with its four attachment
screws and washers.
M10 x 40
Tightening torque: 50 Nm.
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints on
page 254 before fitting.
© Copyright 2006-2008 ABB. All rights reserved.
7. Disconnect the brake release voltage.
8. Reconnect all connectors in motor axis 6.
Connect in accordance with markings
on connectors.
9. Refit the connections to the UL lamp, if the robot
is equipped with one.
Continues on next page
3HAC025755-001 Revision: B
223
4 Repair
4.6.3. Replacement of motor, axis 6
Continued
Action
Note
10. Refit the cable gland with its attachment screw.
xx0600002694
•
A: Screw holding the cable
gland
Make sure the gasket is not damaged!
Replace if damaged.
11. Refit the cover, motor axis 6 with its four
attachment screws and washers.
• A: Motor cover
• B: Attachment screws
• C: Cable gland
Make sure the cover is tightly sealed!
12. Recalibrate the robot!
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.
13.
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.
224
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
xx0600002696
4 Repair
4.7.1. Replacement of gearbox, axis 1
4.7 Gearboxes
4.7.1. Replacement of gearbox, axis 1
Location of gearbox
The axis 1 gearbox is located between the frame and base as 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 .
xx0600002631
A
Gearbox, axis 1
B
Frame
C
Base
© Copyright 2006-2008 ABB. All rights reserved.
Required equipment
Equipment, etc.
Spare part no.
Gearbox
3HAC022279-001
3HAC10828-1
Art. no.
Note
Includes:
• gearbox
• all o-rings and
sealing rings
O-ring
3HAB3772-54
Replace only when
damaged!
O-ring
3HAB3772-55
Replace only when
damaged!
Sealing ring
3HAC11581-4
Replace only when
damaged!
Grease
3HAC3537-1
For lubricating the o-rings.
Support, base
3HAC15535-1
Lifting device, base
3HAC15560-1
Lifting tool (chain)
3HAC15556-1
Standard toolkit
-
The content is defined in
section Standard toolkit on
page 258.
Continues on next page
3HAC025755-001 Revision: B
225
4 Repair
4.7.1. Replacement of gearbox, axis 1
Continued
Equipment, etc.
Spare part no.
Art. no.
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step instructions below.
Note
These procedures include
references to the tools
required.
Removal, gearbox axis 1
The procedure below details how to remove gearbox, axis 1.
Action
Note
1. Move the robot to its most stable position,
shown in the figure to the right.
xx0500002275
2.
DANGER!
3. Drain the oil from gearbox 1.
Detailed in section Oil change, gearbox
axis 1 on page 112.
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.
Detailed in section Removal, arm system
on page 151.
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.
Art. no. is specified in Required
equipment on page 225.
Continues on next page
226
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
4 Repair
4.7.1. Replacement of gearbox, axis 1
Continued
Action
Note
9.
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
Art. no. is specified in Required
support, base and gear 1 on each sides of equipment on page 225.
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.
xx0300000612
© Copyright 2006-2008 ABB. All rights reserved.
•
•
•
•
A: Bottom plate
B: Rear connector plate
C: Attachment screw
D: Groove
13. Unscrew the 18 attachment screws and
remove the 3 washers, shown in the figure
to the right.
xx0200000227
A view from below:
• A: Oil drain hose
• B: Attachment screws, gearbox
axis 1, 18 pcs
• C: Washers, 3 pcs
Continues on next page
3HAC025755-001 Revision: B
227
4 Repair
4.7.1. Replacement of gearbox, axis 1
Continued
Action
Note
14. Remove the cable guide in the center of
gearbox 1 by unscrewing its attachment
screws.
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
2. Make sure the two o-rings (C, D) on the cirArt no. is specified in Required
cumference of the gearbox are seated
equipment on page 225.
properly in their grooves respectively.
Lubricate them with grease .
Make sure the small o-ring around the oil hole
is fitted properly!
xx0200000055
•
•
•
•
A: Guide pin
C: O-ring 3HAB 3772-54
D: O-ring 3HAB 3772-55
E: Sealing ring 3HAC 11581-4
Continues on next page
228
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
1. If the base is not supported with support, base Mounting of the support, base and gear
and gear 1, this should be done first.
1 is detailed in section Removal,
gearbox axis 1 on page 226.
4 Repair
4.7.1. Replacement of gearbox, axis 1
Continued
Action
Note
3. Refit the cable guide in the center of gearbox
1 with its attachment screws.
xx0200000256
•
4. Fit the lifting device, base and the lifting tool
(chain) to the gearbox.
A: Location for attachment
screws, cable guide (cable
guide removed in figure)
Art no. is specified in Required
equipment on page 225.
5.
CAUTION!
The gearbox weighs 160 kg! All lifting
equipment used must be sized accordingly!
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 Shown in the figure xx0200000055
the gearbox is properly aligned with the base. above!
© Copyright 2006-2008 ABB. All rights reserved.
8. Secure the gearbox and the three washers
18 pcs, M16 x 70, 12.9 quality
with the 18 attachment screws, gearbox axis UNBRAKO, tightening torque: 300 Nm.
1.
Reused screws may be used, providing
they are lubricated as detailed in
section Screw joints on page 254
before fitting.
xx0200000227
A view from below:
• A: Oil drain hose
• B: Attachment screws, gearbox
axis 1, 18 pcs
• C: Washers, 3 pcs
Continues on next page
3HAC025755-001 Revision: B
229
4 Repair
4.7.1. Replacement of gearbox, axis 1
Continued
Action
Note
9. Refit the bottom plate underneath the robot
1 screw: M6 x 8.
base by pushing it into the groove and fitting
the attachment screw.
If removed, also refit the rear connector plate.
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!
12. Secure the base to the mounting site.
Detailed in section Orienting and
securing the robot on page 61.
13. Refit the complete arm system.
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 Performing a leakdown test on page 130.
16. Refill the gearbox with oil.
Detailed in section Oil change, gearbox
axis 1 on page 112.
17. Recalibrate the robot.
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.
Continues on next page
230
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
11. Lift the robot base and gearbox 1 to allow
removing the support, base and gear.
4 Repair
4.7.1. Replacement of gearbox, axis 1
Continued
Action
Note
18.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC025755-001 Revision: B
231
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
A
Gearbox, axis 1
B
Gearbox, axis 2
C
Gearbox, axis 3
D
Gearbox, axis 6
Required equipment
Spare part no.
Gearbox, axes 2-3
3HAC022644-001
3HAC022644-001
Sealing axes 2-3
3HAC022379-001
3HAC022379-001
Art.no
Note
Lock screw M16x90
-
Guide pins
-
Lifting tool gearbox
axes 2-3
3HAC023240-001
Use guide pins in pairs.
Standard toolkit
The content is defined in
section Standard toolkit on
page 258.
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step instructions below.
These procedures include
references to the tools
required.
Continues on next page
232
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
Equipment, etc.
4 Repair
4.7.2. Replacement of gearbox, axes 2- 3
Continued
Removal, gearbox axes 2-3
The procedure below details how to remove gearbox axes 2-3.
Action
Note
1. Put the robot close to its calibration
position.
2. Fit the lock screw (M16x90) in the lower
arm.
xx0600002736
•
A: Hole for lock screw, M16x90
3.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
© Copyright 2006-2008 ABB. All rights reserved.
4. Drain the gearbox axis 2-3 from oil.
Detailed in section Oil change, gearbox
axes 2-3 on page 115.
NOTE!
Time-consuming activity!
5. Remove the motor cables of motor axes 23, and protect the cables from getting
damaged and from oil spill.
6. Remove one gearbox at a time!
7.
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.
Continues on next page
3HAC025755-001 Revision: B
233
4 Repair
4.7.2. Replacement of gearbox, axes 2- 3
Continued
Action
9. Remove motor axis 2-3.
Note
Detailed in section Replacement of motor,
axes 2 and 3 on page 217
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.
Art. no. is specified in Required equipment
on page 232.
14.
CAUTION!
The gearbox weighs 69 kg! All lifting
equipment used must be sized accordingly!
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.
Note
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.
CAUTION!
The gearbox weighs 69 kg! All lifting
equipment used must be sized accordingly!
4. Fit the lifting tool, gearbox axes 2-3 to the
gearbox. Use an overhead crane and put
the gearbox onto the guide pins.
Art. no. is specified in Required equipment
on page 232.
5. Slide the gearbox axis 2 on the guide pins,
through the attachment screw holes.
Continues on next page
234
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
Action
4 Repair
4.7.2. Replacement of gearbox, axes 2- 3
Continued
Action
Note
6. Refit the gearbox axis 2 with its attachment Tightening torque: 120 Nm.
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.
Tightening torque: 120 Nm
8. Clean the gearboxes of residual grease.
9. Apply locking liquid in the attachment holes Loctite 243.
of the cover in the frame.
10. Refit the cover with its attachment screws
and washers.
Tightening torque: 24 Nm
11. Refit the motors axes 2-3.
Detailed in section Replacement of motor,
axes 2 and 3 on page 217
12. Perform a leakdown test.
13. Refill the gearbox axes 2-3 with oil.
Detailed in section Oil change, gearbox
axes 2-3 on page 115
14. Remove the locking screw, lower arm.
15. Recalibrate the robot.
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.
16.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC025755-001 Revision: B
235
4 Repair
4.7.3. Replacement of gearbox, axis 6
4.7.3. Replacement of gearbox, axis 6
Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
xx0600002627
Turning disk
B
Attachment screws (6 pcs) turning disk
C
Tilthouse unit
D
Gearbox, axis 6
E
Attachment screws and washers, gearbox axis 6
© Copyright 2006-2008 ABB. All rights reserved.
A
xx0200000219
A
Gearbox, axis 6 (IRB 6620 Foundry Plus)
B
Attachment screws and washers
C
Oil plug, draining
D
Oil plug, filling
Continues on next page
236
3HAC025755-001 Revision: B
4 Repair
4.7.3. Replacement of gearbox, axis 6
Continued
Required equipment
Equipment, etc. Spare part no.
Art. no.
Note
Gearbox
Turning disk, dia.
200
Includes o-ring 3HAB377258.
3HAC 9744-6
Washers
3HAA1001-172
Not included in gearbox!
Replace only when damaged!
O-ring
3HAB3772-58
3HAB3772-64
3HAB3772-61
Must be replaced when reassembling gearbox!
Grease
3HAB3537-1
For lubricating the o-ring.
Standard toolkit
-
The content is defined in
section Standard toolkit on
page 258.
Calibration
Pendulum toolkit
3HAC15716-1
Complete kit that also
includes operating manual.
Other tools and
procedures may be
required. See
references to these
procedures in the
step-by-step
instructions below.
These procedures include
references to the tools
required.
Removal, gearbox
The procedure below details how to remove gearbox, axis 6.
Action
Note
© Copyright 2006-2008 ABB. All rights reserved.
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Drain the oil from gearbox, axis 6.
Detailed in section Draining, oil on page
118.
3. Remove the turning disk.
Detailed in section Removal, turning
disk on page 157.
4. Remove the gearbox by unscrewing its 8
attachment screws.
Shown in the figure Location of gearbox
on page 236.
Continues on next page
3HAC025755-001 Revision: B
237
4 Repair
4.7.3. Replacement of gearbox, axis 6
Continued
Action
Note
5. If required, apply M8 screws to the holes
shown in the figure beside to press the gearbox
out.
xx0200000220
•
6. Remove the gearbox axis 6 by lifting it out
carefully.
A: M8 holes for pressing out the
gearbox
Be careful not to damage the motor
pinion!
7. Check the pinion. A damaged pinion must be
replaced!
Refitting, gearbox
The procedure below details how to refit gearbox, axis 6.
Action
Note
1.
© Copyright 2006-2008 ABB. All rights reserved.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Continues on next page
238
3HAC025755-001 Revision: B
4 Repair
4.7.3. Replacement of gearbox, axis 6
Continued
Action
Note
2. Make sure the o-ring is fitted to the rear of Art. no. is specified in Required equipment
the gearbox. Lubricate the o-ring with
on page 237.
grease.
xx0100000132
•
A: O-ring, gearbox axis 6
3. Release the holding brake of motor axis 6. Detailed in section Manually releasing the
brakes on page 54.
© Copyright 2006-2008 ABB. All rights reserved.
4. Insert the gearbox, axis 6 into the wrist unit. Art. no. is specified in Required equipment
on page 237.
Shown in the figure Location of gearbox on
page 236.
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 Location of gearbox on
page 236.
8 pcs : M8 x 40, 12.9 quality UNBRAKO,
Tightening torque: 30 Nm.
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints on page 254 before fitting.
6. Refit the turning disk.
Detailed in section Refitting, turning disk on
page 158.
7. Perform a leak-down test.
Detailed in section Performing a leak-down
test on page 130.
8. Refill the gearbox with oil.
Detailed in section Filling, oil on page 119.
9. Recalibrate the robot.
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.
Continues on next page
3HAC025755-001 Revision: B
239
4 Repair
4.7.3. Replacement of gearbox, axis 6
Continued
Action
Note
10.
DANGER!
© Copyright 2006-2008 ABB. All rights reserved.
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.
240
3HAC025755-001 Revision: B
5 Calibration information
5.1. Introduction
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
© Copyright 2006-2008 ABB. All rights reserved.
If the contents of the revolution counter memory are lost, the counters must be updated as
detailed in section Updating revolution counters on page 246. 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.
3HAC025755-001 Revision: B
241
5 Calibration information
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
Description
Calibration method
Standard
calibration
The calibrated robot is positioned at home
Calibration Pendulum
position, that is the axes positions (angles) are (standard method)
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.
Absolute Accuracy
calibration
(optional)
Based on standard calibration, and besides
CalibWare
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!
xx0400001197
Continues on next page
242
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
Type of calibration
5 Calibration information
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
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC025755-001 Revision: B
243
5 Calibration information
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
© Copyright 2006-2008 ABB. All rights reserved.
The illustration below shows the positions of the calibration marks on the robot.
xx0500002487
A
Calibration plate, axis 1
B
Calibration tab on robot
C
Calibration mark, axis 2
D
Calibration mark, axis 3
E
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.
244
3HAC025755-001 Revision: B
5 Calibration information
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
© Copyright 2006-2008 ABB. All rights reserved.
Note! The figure shows an IRB 260, but the positive direction is the same for all 4-axis robots
xx0500001927
3HAC025755-001 Revision: B
245
5 Calibration information
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.
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.
3. When all axes are positioned, store the
revolution counter settings.
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
© Copyright 2006-2008 ABB. All rights reserved.
1. On the ABB menu, tap Calibration.
All mechanical units connected to the system are shown along with their calibration
status.
Continues on next page
246
3HAC025755-001 Revision: B
5 Calibration information
5.5. Updating revolution counters
Continued
Action
2. Tap the mechanical unit in question.
A screen is displayed: tap Rev. Counters.
en0400000771
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC025755-001 Revision: B
247
5 Calibration information
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 The calibration marks are shown in
correctly. If they do not, update the revolution
section Calibration scales and
counters!
correct axis position on page 244.
How to update the revolution
counters is detailed in section
Updating revolution counters on
page 246.
Using the Jogging window on the FlexPendant, IRC5
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
The calibration marks are shown in section
axes align correctly. If they do not, update Calibration scales and correct axis position
the revolution counters!
on page 244.
How to update the counters is detailed in
section Updating revolution counters on
page 246.
248
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
This section describes how to jog the robot to all axes zero position.
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
© Copyright 2006-2008 ABB. All rights reserved.
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.
3HAC025755-001 Revision: B
249
© Copyright 2006-2008 ABB. All rights reserved.
Overview
250
3HAC025755-001 Revision: B
6 Reference information
6.1. Introduction
6 Reference information
6.1. Introduction
General
© Copyright 2006-2008 ABB. All rights reserved.
This chapter includes general information, complementing the more specific information in
the different procedures in the manual.
3HAC025755-001 Revision: B
251
6 Reference information
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
252
•
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.
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
The following standards are applicable when the robot is part of a robot cell:
6 Reference information
6.3. Unit conversion
6.3. Unit conversion
Converter table
Use the table below to convert units used in this manual.
Units
Length
1m
3.28 ft
Weight
1 kg
2.21 lb
Pressure
1 bar
100 kPa
Force
1N
0.738 lbf
Moment
1 Nm
0.738 lbf-tn
Volume
1L
0.264 US gal
39.37 in
14.5 psi
© Copyright 2006-2008 ABB. All rights reserved.
Quantity
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253
6 Reference information
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.
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
Continues on next page
254
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
2. Apply lubricant between the plain washer and screw head.
6 Reference information
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
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
© Copyright 2006-2008 ABB. All rights reserved.
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.
Dimension
Tightening torque
(Nm)
Class 8.8, oil-lubricated
Tightening torque
(Nm)
Class 10.9, oil-lubricated
Tightening torque
(Nm)
Class 12.9, oil-lubricated
M5
6
-
-
M6
10
-
-
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
M24
725
960
1150
The table below specifies the recommended standard tightening torque for Molycotelubricated screws with Allen head screws.
Dimension
Tightening torque (Nm)
Tightening torque (Nm)
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8
28
35
M10
55
70
M12
96
120
Continues on next page
3HAC025755-001 Revision: B
255
6 Reference information
6.4. Screw joints
Continued
Dimension
Tightening torque (Nm)
Tightening torque (Nm)
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M16
235
280
M24
790
950
The table below specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of brass.
Tightening torque
Nm - Nominal
Tightening torque
Nm - Min.
Tightening torque
Nm - Max.
1/8
12
8
15
1/4
15
10
20
3/8
20
15
25
1/2
40
30
50
3/4
70
55
90
© Copyright 2006-2008 ABB. All rights reserved.
Dimension
256
3HAC025755-001 Revision: B
6 Reference information
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!
© Copyright 2006-2008 ABB. All rights reserved.
The motor weighs 32 kg! All lifting equipment used
must be sized accordingly!
3HAC025755-001 Revision: B
257
6 Reference information
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
Rem.
1
Ring-open-end spanner 8-19 mm
1
Socket head cap 5-17 mm
1
Torx socket no: 20-60
1
Box spanner set
1
Torque wrench 10-100 Nm
1
Torque wrench 75-400 Nm
1
Ratchet head for torque wrench 1/2
2
Hexagon-headed screw M10x100
1
Socket head cap no: 14, socket 40 mm bit L 100 mm
1
Socket head cap no: 14, socket 40 mm bit L 20 mm
1
Socket head cap no: 6, socket 40 mm bit L 145 mm
1
Socket head cap no: 6, socket 40 mm bit L 220 mm
© Copyright 2006-2008 ABB. All rights reserved.
To be shortened to 12 mm
258
3HAC025755-001 Revision: B
6 Reference information
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 Standard toolkit on page 258,
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.
Note
Oil exchange equipment
3HAC021745-001
Includes
• vacuum pump with
regulator, hose and coupling
• couplings and adapters
• pump (manual) with hose
and coupling
• graduated measuring glass
• oil gun
• user instructions.
© Copyright 2006-2008 ABB. All rights reserved.
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
Qty
Art. no.
Guide pins M10 x 100
2
3HAC15521-1
Guide pins M10 x 150
2
3HAC15521-2
Lifting tool, motor ax 1
1
3HAC14459-1
Lifting tool, motor ax 2, 3
1
3HAC15534-1
Removal tool, motor M12x
Fits motors axes 1, 2 and 3.
Rotation tool
1
3HAC17105-1
Standard toolkit (content described in
section Standard toolkit on page 258)
1
-
Continues on next page
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259
6 Reference information
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.
Description
Qty
Article no.
Lifting tool, tilt house
3HAC023154-001
Lifting tool, motor
3HAC14586-1
Lifting tool, gear ax.2
3HAC023240-001
Lifting tool, frame
3HAC023308-001
Lifting tool, complete robot
3HAC15607-1
Lifting tool, parallel arm
3HAC023098-001
Lifting tool, turning device gearbox ax.1
3HAC14406-1
Lifting tool, base
3HAC14868-1
Guide pin, (short)
3HAC7601-086
Guide pin, (long)
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.
260
Qty
Article no.
Lower arm fixture
3HAC7035-1
Pressing, link
3HAC023081-001
Pressing, outer ring on link
3HAC023079-001
Pressing, innerring (nållager)
3HAC023112-008
KM-socket for link
3HAC5347-1
Pinion crank
3HAC023132-001
Pressing, lower arm/balancing weight
3HAC023092-001
Pressing, upper arm
3HAC023084-001
Pressing, tie rod
3HAC5021-1
Pressing, tilt house
3HAC023080-001
Pressing, outer ring, tilt house
3HAC023075-001
Auxiliary shaft, long
3HAC5275-1
Auxiliary shaft, short
3HAC5276-1
Support shaft/bearing race
3HAC5281-1
Axis 1 pinion
3HAC022436-001
Tool for lubrication
3HAC5222-1
Adapter for shaft axis 3
3HAC023916-001
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
Description
6 Reference information
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.
© Copyright 2006-2008 ABB. All rights reserved.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
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261
6 Reference information
© Copyright 2006-2008 ABB. All rights reserved.
6.8. Lifting equipment and lifting instructions
262
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7 Spare parts and exploded views
7.1. Introduction
7 Spare parts and exploded views
7.1. Introduction
Definitions
© Copyright 2006-2008 ABB. All rights reserved.
This chapter specifies all spare parts and replacement articles of the robot.
3HAC025755-001 Revision: B
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7 Spare parts and exploded views
7.2. Spare parts - frame to base
7.2. Spare parts - frame to base
Parts list
Article no.
Description
Qty
101
3HAC 17224-4
Base, machining
1
102
3HAC 021659-003
Frame, machining
1
103
3HAC 022279-001
RV 400C-224.26
1
104
3HAB 7700-73
Screw M12x70
24
105
3HAA 1001-134
Washer 13x19x1.5
24
106
3HAC 11732-2
Washer T = 3
3
107
3HAB 7700-5
Screw M16x70
18
108
3HAC 14453-1
Hose with flange
1
109
3HAC 11529-1
Rubber lined clip D = 28
1
110
9ADA 618-56
Screw M6x16
1
111
3HAC 4428-2
Hose clip
1
112
3HAC 14453-2
Plug
1
113
3HAC 12252-1
Bottom plate
1
114
3HAC 14131-1
Connection plate, base
1
115
9ADA 618-58
Screw M6x25
2
116
3HAC 11769-1
Cable guide, ax. 1
1
117
9ADA 618-56
Screw M6x16
2
118
3HAB 3537-1
Bearing grease
10 g
119
9ADA 618-53
Screw M6x8
1
© Copyright 2006-2008 ABB. All rights reserved.
Pos
Continues on next page
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7 Spare parts and exploded views
7.2. Spare parts - frame to base
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Exploded view
xx0500002567
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7 Spare parts and exploded views
7.3. Spare parts - cable harness
7.3. Spare parts - cable harness
Parts list
Article no.
Description
Qty
90.1
3HAC022544-001
Cable harness, man ax.1-6
1
90.2
3HAC022539-001
Metal clamp, manip.
1
90.3
3HAC 13416-1
Protection cover
1
90.4
3HAC 11774-3
Adapter, complete
1
90.5
3HAC 5172-1
Cable guide, ax.2
1
90.7
3HAC 022967-001
Bracket for cables
1
90.8
3HAC 022968-001
Distance
3
90.19
3HAC 12129-1
Cover plate
2
90.20
9ADA 267-6
Nut M6
1
90.21
9ADA 618-57
Screw M6x20
2
90.22
9ADA 183-24
Screw M6x16
12
90.24
9ADA 618-56
Screw M6x16
4
90.26
9ADA 183-37
Screw M8x25
3
90.29
9ADA 629-56
Screw M6x16
6
90.30
9ADA 183-25
Screw M6x20
4
90.31
3HAB7116-1
Locking liquid
1 ml
90.36
3HAC14222-1
Plate
1
90.37
9ADA 618-57
Screw M6x20
4
© Copyright 2006-2008 ABB. All rights reserved.
Item
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7 Spare parts and exploded views
7.3. Spare parts - cable harness
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Exploded view
xx0500002568
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267
7 Spare parts and exploded views
7.4. Spare parts - customer harness
7.4. Spare parts - customer harness
Parts list
Article no.
Description
Qty
1.1
3HAC022545-001
Cable harness, customer
1
1.2
3HAC023407-001
Attachment plate
1
1.3
3HAC 13416-1
Protection cover
1
1.4
3HAC 11774-3
Adapter, complete
1
1.5
9ADA 183-24
Screw M6x16
4
1.7
9ADA 618-57
Screw M6x20
4
1.8
3HAC 12625-1
Strap, Velco M5x300
1
1.9
9ADA 183-15
Screw M5x20
6
1.10
9ADA 267-6
Nut
10
1.12
9ADA 183-34
Screw M8x12
2
1.15
3HAC022969-001
Bracket
1
1.16
3HAC023100-001
Cover plate
1
© Copyright 2006-2008 ABB. All rights reserved.
Pos
Continues on next page
268
3HAC025755-001 Revision: B
7 Spare parts and exploded views
7.4. Spare parts - customer harness
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Exploded view
xx0500002569
3HAC025755-001 Revision: B
269
7 Spare parts and exploded views
7.5. Spare parts - lower arm system
7.5. Spare parts - lower arm system
Parts list
Article no.
Description
Qty
301
3HAC021464-004
Lower arm (White RAL 9003)
1
302
3HAC023026-003
Parallel arm (White RAL 9003)
1
303
3HAA 2166-18
VK-Cover, VK 35x8
(Not visible in this figure.)
1
304
3HAB 3537-1
Bearing grease Shell Alvania WR2 10 g
305
3HAC 4435-1
Spacing sleeve
2
306
3HAB 4169-1
Sealed spherical bearing
2
310
3HAA 2166-23
VK-cover, VK 120x12
1
311
3HAC022338-001
Damper
2
312
9ADA 183-37
Screw M8x25
4
313
9ADA 312-7
Plain washer 8,4x16x1,6
4
314
3HAB7116-1
Locking liquid
1 ml
315
3HAC 12991-1
Damper ax.2
3
316
9ADA 618-57
Screw M6x20
3
317
3HAC 4836-8
Protection plug
1
318
3HAC022339-001
Damper
1
© Copyright 2006-2008 ABB. All rights reserved.
Pos
Continues on next page
270
3HAC025755-001 Revision: B
7 Spare parts and exploded views
7.5. Spare parts - lower arm system
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Exploded view
xx0500002570
3HAC025755-001 Revision: B
271
7 Spare parts and exploded views
7.6. Spare parts - parallel rod
7.6. Spare parts - parallel rod
Parts list
Article no.
Description
Qty
201
3HAC021084-004
Parallel rod (White RAL 9003)
1
202
3HAB 3537-1
Bearing grease Shell Alvania WR2
4g
203
3HAC 4331-1
Thrust washer
2
204
3HAC 3715-1
Sealed spherical bearing
2
205
3HAC 4332-1
Cover washer
2
206
3HAC 4330-1
Shaft
2
© Copyright 2006-2008 ABB. All rights reserved.
Pos
Continues on next page
272
3HAC025755-001 Revision: B
7 Spare parts and exploded views
7.6. Spare parts - parallel rod
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Exploded view
xx05000002571
3HAC025755-001 Revision: B
273
7 Spare parts and exploded views
7.7. Spare parts - Balancing device
7.7. Spare parts - Balancing device
Parts list
Article no.
Description
Qty
4
3HAC024779-001
Balancing device (White RAL 9003)
1
4.6
3HAC 3476-1
Guiding ring
1
4.10
3HAC 3530-1
Circlip
1
58
1236 0012-202
Sealing compound
4 ml
59
3HAC 7343-1
Sealing ring
2
60
3HAC 7253-1
Support washer
4
61
3HAC 3311-1
Adjust. Needle bearing
2
62
3HAB 3537-1
Bearing grease Shell Alvania RW2
10 g
63
3HAC 7349-1
Lock nut
2
64
3HAB7116-1
Locking liquid
1 ml
© Copyright 2006-2008 ABB. All rights reserved.
Pos
Continues on next page
274
3HAC025755-001 Revision: B
7 Spare parts and exploded views
7.7. Spare parts - Balancing device
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Exploded view
xx0500002572
3HAC025755-001 Revision: B
275
7 Spare parts and exploded views
7.8. Spare parts - frame to lower arm
7.8. Spare parts - frame to lower arm
Pos
Article no.
Description
Qty.
11
3HAC022379-001
Sealing ax.2/3
1
12
3HAA 1001-134
Washer 13x19x1,5
24
13
3HAB 7700-71
Screw M12x60
24
14
3HAC022644-001
RV-450E
1
15
3HAB 3772-84
O-ring
1
16
9ADA 312-7
Plain washer 8,4x16x1,6
16
17
9ADA 183-39
Screw M8x35
16
18
3HAC021663-003
Cover, machined
1
19
3HAB 4233-1
Washer
4
20
3HAB 3409-50
Screw M10x40
4
21
3HAC024776-001
Motor incl pinion ax.2 (White RAL 9003)
1
22
3HAC022379-001
Sealing ax.2/3
1
23
3HAC022644-001
RV-450E ax.3
1
24
3HAB 7700-71
Screw M12x60
24
25
3HAA 1001-134
Washer 13x19x1,5
24
26
3HAC021663-003
Cover, machined
1
27
9ADA 183-39
Screw M8x35
16
28
9ADA 312-7
Plain washer 8,4x16x1,6
16
29
3HAB 3772-84
O-ring
1
30
3HAC024776-001
Motor inc. Pinion ax.3 (White RAL 9003)
1
31
3HAB 3409-50
Screw M10x40
4
32
3HAB 4233-1
Washer
4
33
3HAB 3409-86
Screw M16x60
6
34
3HAA 1001-186
Washer 17x25x3
6
35
3HAB 7700-69
Screw M12x50
21
36
3HAA 1001-134
Washer 13x19x1,5
21
37
3HAB 7700-69
Screw M12x50
21
38
3HAA 1001-134
Washer 13x19x1,5
21
39
3HAC032140-001
Lubricating oil Kyodo Yushi TMO 150
5000 ml
40
3HAC 16721-1
Magnetic plug
3
41
3HAC 16721-1
Magnetic plug
3
42
3HAC032140-001
Lubricating oil Kyodo Yushi TMO 150
5000 ml
Continues on next page
276
3HAC025755-001 Revision: B
© Copyright 2006-2008 ABB. All rights reserved.
Parts list
7 Spare parts and exploded views
7.8. Spare parts - frame to lower arm
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Exploded view
xx0500002573
3HAC025755-001 Revision: B
277
7 Spare parts and exploded views
7.9. Spare parts - shafts
7.9. Spare parts - shafts
Parts list
Article no.
Description
Qty
501
3HAC 021113-003
Upper arm machining
1
502
3HAA 1001-124
Support ring
2
43
3HAC 4545-1
Shaft
1
44
3HAC 022446-001
Shaft
1
45
1171 2016-618
Lubricant, paste
5
46
3HAB 3772-29
O-ring
2
47
2216 264-16
Sealing ring
2
48
3HAC 022581-001
Sealing ring
2
49
3HAB 3537-1
Bearing grease Shell Alvania RW2 10 g
50
2213 3802-8
Taper roller bearing
2
51
3HAC 7817-1
Nilos ring
2
52
3HAC 6627-1
Spacer
2
53
3HAA 1001-658
O-ring
2
54
3HAB 7116-1
Locking liquid, Loctite 243
4 ml
55
2126 2851-112
Lock nut
2
56
9ADA 205-75
Screw M10x20
2
57
3HAB 7116-1
Locking liquid, Loctite 243
4 ml
© Copyright 2006-2008 ABB. All rights reserved.
Pos
Continues on next page
278
3HAC025755-001 Revision: B
7 Spare parts and exploded views
7.9. Spare parts - shafts
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Exploded view
xx0500002574
3HAC025755-001 Revision: B
279
7 Spare parts and exploded views
7.10. Spare parts - tilthouse
7.10. Spare parts - tilthouse
Parts list
Article no.
Description
Qty
508
3HAC022764-003
Tilthouse complete (White RAL 9003)
1
508.1
3HAC022740-003
Tilthouse, machining
1
508.2
3HAC023533-001
Motor incl pinion
1
508.3
3HAC 10828-10
RV 40E-81
1
508.4
3HAB 7700-55
Screw M8x40
8
508.5
3HAA 1001-172
Washer 8,4x13x1,5
8
508.6
3HAC 9744-5
Turning disc
1
508.7
3HAC022977-001
Sync.plate
1
508.8
9ADA 618-32
Screw M4x8
2
508.9
2121 2518-577
Screw M14x25
6
508.10
2522 122-1
Magnetic plug
2
508.11
9ADA 624-69
Screw M8x20
2
508.12
3HAC 14263-1
Protection Cover
1
508.13
9ADA 183-37
Screw M8x25
4
508.14
9ADA 312-7
Plain washer 8,4x16x1,6
4
508.15
3HAB7116-1
Locking liquid
1 ml
508.16
2152 0431-20
O-ring 15,5x1,5
6
508.17
3HAC032160-001
Lubricating oil Kyodo Yushi TMO 150
250 ml
508.18
3HAB 3772-65
O-ring 131x2
1
508.19
2152 0441-1
Washer
2
© Copyright 2006-2008 ABB. All rights reserved.
Pos
Continues on next page
280
3HAC025755-001 Revision: B
7 Spare parts and exploded views
7.10. Spare parts - tilthouse
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Exploded view
xx0500002575
3HAC025755-001 Revision: B
281
7 Spare parts and exploded views
7.11. Spare parts - upper arm front
7.11. Spare parts - upper arm front
Parts list
Article no.
Description
Qty
501
3HAC025525-001
Upper arm machining (White RAL 9003)
1
503
9ADA 629-56
Screw M6x16
2
504
9ADA 327-4
Plain washer 6,4x17x3
2
505
3HAB7116-1
Locking liquid
1 ml
506
3HAC022673-001
Ball plug
1
507
3HAC023027-001
Protection cap
1
508
3HAC022764-001
Tilt house
1
509
3HAA 2166-21
VK-Cover, VK 68x8
2
510
2126 2851-107
Lock nut
2
511
3HAC021158-001
Shaft upper arm
2
512
3HAA 2166-17
VK-Cover, VK 19x6
2
513
2213 3802-11
Taper roller bearing
4
514
3HAB 3537-1
Bearing grease Shell Alvania RW2
130 g
515
3HAC022645-001
Ring
1
516
3HAB 3701-35
Radial seal w. dustlip 50x68x8
2
517
9ADA 183-22
Screw M6x10
4
518
3HAC020537-001
Washer 6,4x12x1,6
4
519
3HAC 8286-1
Dinitrol 490
30 ml
520
9ABA 137-28
Retaining ring, bore
2
© Copyright 2006-2008 ABB. All rights reserved.
Pos
Continues on next page
282
3HAC025755-001 Revision: B
7 Spare parts and exploded views
7.11. Spare parts - upper arm front
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Exploded view
xx0500002576
3HAC025755-001 Revision: B
283
7 Spare parts and exploded views
7.12. Spare parts - Linkage
7.12. Spare parts - Linkage
Parts list
Article no.
Description
Qty.
601
3HAC023744-003
Upper rod (White RAL 9003)
1
602
3HAC023239-003
Lower rod (White RAL 9003)
1
603
12360012-202
Sealing compound
2
604
3HAC7343-1
Ring
4
605
3HAC7253-1
Support washer
8
606
3HAC3311-1
Adjust. needel bearing
4
607
3HAB3537-1
Bearing grease
10
608
3HAC7349-1
Lock nut
4
609
3HAB7116-1
Locking liquid
2
701
3HAC021088-003
Link, machining
1
702
3HAA 2103-13
Taper roller bearing
2
703
3HAB 3537-1
Bearing grease Shell Alvania RW2
35 g
704
1236 0012-202
Sealing compound Permatex No 3
2 ml
705
3HAB 3702-31
Radial seal 85x100x9
1
706
3HAC022521-001
Support Ring
1
707
2126 2851-108
Lock nut
1
708
3HAB7116-1
Locking liquid
1 ml
709
3HAA 2166-13
VK-Cover
1
© Copyright 2006-2008 ABB. All rights reserved.
Pos
Continues on next page
284
3HAC025755-001 Revision: B
7 Spare parts and exploded views
7.12. Spare parts - Linkage
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Exploded view
xx0500002577
3HAC025755-001 Revision: B
285
7 Spare parts and exploded views
7.13. Spare parts - motor axis1
7.13. Spare parts - motor axis1
Parts list
Article no.
Description
Qty
65
3HAC024775-001
Motor inc. pinion ax.1 (White RAL 9003)
1
66
3HAB 3409-50
Screw M10x40
4
67
3HAB 4233-1
Washer
4
68
2522 122-1
Magnetic plug
1
69
3HAC 16721-1
Magnetic plug
1
70
3HAC021469-001
Lubricating oil
8000 ml
71
3HAC 12671-6
Block for calibration
1
72
3HAC 14024-1
Protection screw
1
73
9ADA 618-57
Screw M6x20
3
74
3HAC021287-001
Sync.plate
1
75
9ADA 618-56
Screw M6x16
2
76
3HAC 17358-1
Mech.stop
1
77
3HAC 18306-1
Cover sheet
1
78
3HAB 7700-89
Screw M16x90
1
© Copyright 2006-2008 ABB. All rights reserved.
Pos
Continues on next page
286
3HAC025755-001 Revision: B
7 Spare parts and exploded views
7.13. Spare parts - motor axis1
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Exploded view
xx0500002578
3HAC025755-001 Revision: B
287
7 Spare parts and exploded views
7.14. Spare parts - SMB
7.14. Spare parts - SMB
Parts list
Article no.
Description
Qty
90.9
3HAC 11526-1
Stud screw
2
90.10
3HAC022204-001
Bracket
1
90.11
3HAC 2744-1
Push button guard
1
90.12
3HAC 4813-1
Cover, push button guard
1
90.13
3HAC 16035-1
BU w.buttons DSQC 563
1
90.14
3HAC 14791-3
Cover battery box
1
90.15
3HAC 13151-1
Cable battery/SMB
1
90.16
3HAC 15619-1
Cable, FB7-SMB 1.7
1
90.17
3HAC022286-001
Serial measurement unit
1
90.18
3HAC 16831-1
Battery pack
1
90.20
9ADA 267-6
Nut M6
3
90.23
9ADA 183-25
Screw M6x20
10
90.25
9ADA 183-13
Screw M5x12
6
90.27
9ADA 312-6
Plain washer 6.4x12x1.6
2
90.28
3HAC 021349-003
Cover SMB
1
90.35
9ADA 618-45
Screw M5x16
6
© Copyright 2006-2008 ABB. All rights reserved.
Pos
Continues on next page
288
3HAC025755-001 Revision: B
7 Spare parts and exploded views
7.14. Spare parts - SMB
Continued
© Copyright 2006-2008 ABB. All rights reserved.
Exploded view
xx0500002579
3HAC025755-001 Revision: B
289
7 Spare parts and exploded views
© Copyright 2006-2008 ABB. All rights reserved.
7.14. Spare parts - SMB
290
3HAC025755-001 Revision: B
8 Circuit diagram
8.1. Introduction
8 Circuit diagram
8.1. Introduction
Overview
© Copyright 2006-2008 ABB. All rights reserved.
This chapter includes the circuit diagram for the robot.
3HAC025755-001 Revision: B
291
8 Circuit diagram
© Copyright 2006-2008 ABB. All rights reserved.
8.1. Introduction
292
3HAC025755-001 Revision: B
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.
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
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
SE-721 68 Västerås
Sweden
Lab/Office:
Latest revision:
Status:
2000-03-03
Approved
Prepared by, date:
Approved by, date:
COPYRIGHT PAGE
Title page/cover sheet
Document no.
= IRB660, CC
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 1
Next 2
Total 7
3HAC025690-001
01
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Customer
:
Robot serial number(s)
:
Drawing number
: 3HAC025690-001
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
:
sethsta
Designed date
:
2008-03-03
Number of pages
:
7
2008-03-03
2005-08-30
:
Lab/Office:
Latest revision:
Status:
2000-03-03
Approved
Prepared by, date:
Approved by, date:
TITLE PAGE
Title page/cover sheet
Document no.
= IRB660, CC
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 2
Next 3
Total 7
3HAC025690-001
01
Table of contents
ABB_table_of_contents
Location
Page
Page description
IRB660, CC
Manipulator
1 COPYRIGHT PAGE
IRB660, CC
Manipulator
IRB660, CC
Page supplementary field
Date
Editor
Approved
2008-03-03
sethsta
2 TITLE PAGE
Approved
2008-03-03
sethsta
Manipulator
3 Table of contents: (1 - 22)
Approved
2008-03-03
sethsta
IRB660, CC
Manipulator
4 Revision information
Approved
2008-03-03
sethsta
IRB660, CC
Manipulator
11 Connection point location
Approved
2008-03-03
sethsta
IRB660, CC
CP/CS
21 Customer power/Customer signal
Approved
2008-03-03
sethsta
IRB660, CC
CBUS
22 Customer bus
Approved
2008-03-03
sethsta
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Plant
Lab/Office:
Latest revision:
Status:
Approved
Prepared by, date:
Approved by, date:
Table of contents: (1 - 22)
Table of contents
Document no.
= IRB660, CC
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 3
Next 4
Total 7
3HAC025690-001
01
1
2
3
4
5
6
7
8
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
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.
Lab/Office:
Latest revision:
Status:
Revision information
2008-03-03
Approved
Document no.
Prepared by, date:
EM 080303
Approved by, date:
ER 080303
= IRB660, CC
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 4
Next 11
Total 7
3HAC025690-001
01
1
2
3
4
5
6
7
8
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
R2.CP/CS
R1.CP/CS
Lab/Office:
Latest revision:
Status:
Connection point location
2008-03-03
Approved
Document no.
Prepared by, date:
EM 080303
Approved by, date:
ER 080303
= IRB660, CC
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 11
Next 21
Total 7
3HAC025690-001
01
1
2
3
4
5
-R1.CP/CS
6
5
D6
C4
C5
6
D3
7
D4
C6
C7
24V
0V
24V
0V
PE
GN/YE
WH/BK
B1
B2
B3
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
B15
B16
B18
B19
B20
B21
C16
C17
C18
C19
C20
BK
WH/BN
BN
WH/RD
RD
WH/OG
OG
WH/YE
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
C21
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:
Latest revision:
8
-R2.CP/CS
4
D1
7
Status:
Customer power/Customer signal
2008-03-03
Approved
Document no.
Prepared by, date:
EM 080303
Approved by, date:
ER 080303
= IRB660, CC
Plant:
+ CP/CS
Location:
Sublocation: +
Rev. Ind Page 21
Next 22
Total 7
3HAC025690-001
01
1
2
3
4
5
-R1.CP/CS
6
7
8
-R2.CP/CS
WH/BK
B22
BK
B23
A1
A2
WH/BN
B24
2
B25
A3
A4
5 YE
A3
6 YE
A4
A7
A8
7 VT
A5
8 VT
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A6
A9
A10
1 GN
A9
2 GN
A10
A5
A6
3 GN
A11
4 GN
A12
A11
A12
Lab/Office:
Latest revision:
Status:
Customer bus
2008-03-03
Approved
Document no.
Prepared by, date:
EM 080303
Approved by, date:
ER 080303
= IRB660, CC
Plant:
+ CBUS
Location:
Sublocation: +
Rev. Ind Page 22
Next
Total 7
3HAC025690-001
01
1
2
3
4
5
6
7
8
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
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
SE-721 68 Västerås
Sweden
Lab/Office:
Latest revision:
Status:
COPYRIGHT PAGE
Prepared by, date:
EM 2008-06-02
Approved by, date:
JM 080603
2008-06-03
Approved
Document no.
= IRB660
Plant:
Location: + Manipulator
Sublocation:+
Rev. Ind Page 1
Next 2
Total 12
3HAC025691-001 02
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
1
2
3
4
5
6
7
8
Customer
:
Robot serial number(s) :
Drawing number
: Manipulator
Drawing version
:
Manufacture
Type
Type of installation
Control cabinet
Mains voltage
Supply
Control voltage
Year of construction
: 2008-06-04
Project start
Project manager
Last revision
Designed by
Designed date
Number of pages
:
:
:
:
:
:
:
:
:
:
:
:
:
: RMM
2005-08-31
seermes
2008-06-04
12
Lab/Office:
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Status:
TITLE PAGE
Prepared by, date:
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Approved
Document no.
= IRB660
Plant:
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Sublocation:+
Rev. Ind Page 2
Next 3
Total 12
3HAC025691-001 02
1
2
3
4
5
6
7
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
Table of contents
Plant
IRB660
IRB660
IRB660
IRB660
IRB660
IRB660
IRB660
IRB660
IRB660
IRB660
IRB660
IRB660
Location
Manipulator
Manipulator
Manipulator
Manipulator
Manipulator
BU
SMB
Axis 1
Axis 2
Axis 3
Axis 6
Switches
Page
1
2
3
4
11
21
22
23
24
25
26
27
ABB_table_of_contents
Page description
COPYRIGHT PAGE
TITLE PAGE
Table of contents:
Revision information
Connection point location
Brake Release Unit
Serial Measuring Board
Axis 1
Axis 2
Axis 3
Axis 6
Switches axis 1
Page supplementary field Date
Editor
2008-06-04 seermes
Approved
2008-06-04 seermes
Approved
2008-02-27 sethsta
Approved
2008-06-04 seermes
Approved
2008-06-04 seermes
Approved
2008-06-04 seermes
Approved
2008-06-04 seermes
Approved
2008-06-04 seermes
Approved
2008-06-04 seermes
Approved
2008-06-04 seermes
Approved
2008-06-04 seermes
Approved
2008-06-03 seermes
Approved
Lab/Office:
Latest revision:
Status:
Table of contents:
Prepared by, date:
EM 2008-06-02
8
Approved by, date:
JM 080603
2008-06-03
Approved
Document no.
= IRB660
Plant:
Location: + Manipulator
Sublocation:+
Rev. Ind Page 3
Next 4
Total 12
3HAC025691-001 02
1
2
3
4
5
6
7
8
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
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080602 rev.02
Sh.23 The page description has been changed.
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Rev. Ind Page 4
Next 11
Total 12
3HAC025691-001 02
1
2
3
4
5
6
7
8
R3.H1
R3.H2
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
R2.MP6
R2.FB6
R2.H1
R2.H2
R2.MP3
R2.FB3
R2.MP2
R2.FB2
R1.G
R2.SMB
R1.SMB1-3
R1.SMB6
X8
X9
X10
R1.MP
R1.SMB
R1.SW1
R2.MP1
R2.FB1
Lab/Office:
Latest revision:
Status:
Connection point location
Prepared by, date:
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Approved
Document no.
= IRB660
Plant:
Location: + Manipulator
Sublocation:+
Rev. Ind Page 11
Next +BU/21
Total 12
3HAC025691-001 02
1
2
3
4
5
6
7
8
-BU Brake Release (Simplified)
-R1.MP
13
Brake Release
2
-X8
1
-X8
1
2
A
11
Brake PB
1
5
5
12
0V
4
3
3
=+-BU 0V M1 /
+Axis 1/23.2
Brake Bleed Circuit
+Axis 2/24.2
=+-BU 0V M3 /
+Axis 3/25.2
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
K
Brake Bleed Circuit
A
=+-BU 0V M6 /
K
Brake Bleed Circuit
A
K
Brake Bleed Circuit
A
K
Brake Bleed Circuit
A
K
Brake Bleed Circuit
3
5
R1.MP
3
6
R1.MP
5
7
R1.MP
10
R1.MP
=+-BU M1 /
+Axis 1/23.2
=+-BU M2 /
+Axis 2/24.2
=+-BU M3 /
+Axis 3/25.2
=+-BU M6 /
+Axis 6/26.2
4
5
6
Lab/Office:
-X9
5
8
9
JM 080603
-X9
10
10
11
1
Status:
Brake Release Unit
Approved by, date:
9
4
Key Pin
EM 2008-06-02
1
2
Key Pin
Prepared by, date:
-X10
+Axis 6/26.2
Latest revision:
2
-X10
1
4
A
=+-BU 0V M2 /
K
2008-06-03
Approved
Document no.
= IRB660
Plant:
Location: + BU
Sublocation:+
Rev. Ind Page 21
Next +SMB/22
Total 12
3HAC025691-001 02
1
2
3
4
5
6
7
8
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-SMB
-R1.SMB
-R2.SMB
-R2.SMB
A
SDI
BK
9
9
B
SDI-N
WHBK
5
5
C
SDO
BN
8
8
D
SDO-N
WHBN
4
4
E
0V
RD
3
3
F
24V
WHRD
7
7
L
24V EXT.LAMP
OG
0V EXT.LAMP
WHOG
M
+Axis 6/26.3 /=-0V
EXT.LAMP
+Axis 6/26.3 /=-24V
EXT.LAMP
G
-R1.G(X3)
+
-+
-+
-
-R1.G(X3)
0V
2
2
+
1
1
Lab/Office:
Latest revision:
Status:
Serial Measuring Board
Prepared by, date:
EM 2008-06-02
Approved by, date:
JM 080603
2008-06-03
Approved
Document no.
= IRB660
Plant:
Location: + SMB
Sublocation:+
Rev. Ind Page 22
Next +Axis 1/2
Total 12
3HAC025691-001 02
1
2
3
4
5
-R1.MP
17
M1R
1
24
M1R
2
18
M1S
25
6
7
-R2.MP1
-MU1
-R2.MP1
1
RD
4
4
RD
3
6
6
WH
M1S
4
3
3
WH
19
M1T
5
7
7
BK
26
M1T
6
10
10
BK
PE
GNYE
9
9
GNYE
PE
GNYE
12
12
GNYE
PTC M
7
8
8
BU
1
8
R (U)
PE
M
3~
T (W)
S (V)
-PTC
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27
+Axis 2/24.2 / +-PTC
M2
PTC M2
8
11
11
BK
+BU/21.7 / =+-BU
M1
BU M1
9
2
2
BU +
BU 0V M1
10
5
5
BU -
Brake
+BU/21.2 / =+-BU
0V M1
-SMB
-FB1
-R1.SMB1-3
-R1.SMB1-3
2
2
BK
X1
14
14
WHBK
0V X1
-R2.FB1
6
-R2.FB1
1
6
RD
1
BK
Resolver
3
3
BN
Y1
7
15
15
WHBN
0V Y1
2
6
6
RD
0V EXC1
8
8
WHBK (WHYE)
18
18
WHRD
EXC1
3
3
WHRD
Lab/Office:
Latest revision:
EM 2008-06-02
Approved by, date:
JM 080603
BU
YE
2
Status:
Axis 1
Prepared by, date:
7
2008-06-03
Approved
Document no.
= IRB660
Plant:
Location: + Axis 1
Sublocation:+
Rev. Ind Page 23
Next +Axis 2/2
Total 12
3HAC025691-001 02
1
2
3
4
5
-R1.MP
23
M2R
1
32
M2R
2
22
M2S
31
6
7
-R2.MP2
-MU2
-R2.MP2
1
RD
4
4
RD
3
6
6
WH
M2S
4
3
3
WH
21
M2T
5
7
7
BK
30
M2T
6
10
10
BK
PE
GNYE
9
9
GNYE
PE
GNYE
12
12
GNYE
1
8
R (U)
PE
M
3~
T (W)
S (V)
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
+Axis 1-PTC
+Axis 1/23.2 / +-PTC
M2
PTC M2
7
8
8
BU
+Axis 3/25.2 / +-PTC
M3
PTC M3
8
11
11
BK
+BU/21.7 / =+-BU
M2
BU M2
9
2
2
BU +
BU 0V M2
10
5
5
BU -
Brake
+BU/21.2 / =+-BU
0V M2
-SMB
-FB2
-R1.SMB1-3
-R1.SMB1-3
4
4
BK
X2
16
16
WHBK
0V X2
-R2.FB2
6
1
-R2.FB2
6
RD
1
BK
Resolver
5
5
BN
Y2
7
7
BU
17
17
WHBN
0V Y2
2
2
YE
7
7
RD
0V EXC1
8
8
WHBK (WHYE)
19
19
WHRD
EXC1
3
3
WHRD
Lab/Office:
Latest revision:
Status:
Axis 2
Prepared by, date:
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Approved by, date:
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2008-06-03
Approved
Document no.
= IRB660
Plant:
Location: + Axis 2
Sublocation:+
Rev. Ind Page 24
Next +Axis 3/2
Total 12
3HAC025691-001 02
1
2
3
4
5
-R1.MP
3
M3R
1
4
M3R
2
5
M3S
6
6
7
-R2.MP3
-MU3
-R2.MP3
1
RD
4
4
RD
3
6
6
WH
M3S
4
3
3
WH
7
M3T
5
7
7
BK
14
M3T
6
10
10
BK
PE
GNYE
9
9
GNYE
PE
GNYE
12
12
GNYE
1
8
R (U)
PE
M
3~
T (W)
S (V)
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
+Axis 1-PTC
+Axis 2/24.2 / +-PTC
M3
PTC M3
7
8
8
BU
+Axis 6/26.2 / +-PTC
M6
PTC M6
8
11
11
BK
+BU/21.7 / =+-BU
M3
BU M3
9
2
2
BU +
BU 0V M3
10
5
5
BU -
Brake
+BU/21.2 / =+-BU
0V M3
-SMB
-FB3
-R1.SMB1-3
21
-R1.SMB1-3
9
BK
X3
21
WHBK
0V X3
-R2.FB3
6
1
-R2.FB3
6
RD
1
BK
Resolver
10
10
BN
Y3
7
7
BU
22
22
WHBN
0V Y3
2
2
YE
8
8
RD
0V EXC1
8
8
WHBK (WHYE)
20
20
WHRD
EXC1
3
3
WHRD
Lab/Office:
Latest revision:
Status:
Axis 3
Prepared by, date:
EM 2008-06-02
Approved by, date:
JM 080603
2008-06-03
Approved
Document no.
= IRB660
Plant:
Location: + Axis 3
Sublocation:+
Rev. Ind Page 25
Next +Axis 6/2
Total 12
3HAC025691-001 02
1
2
3
4
5
-R1.MP
M6R
9
6
7
-R2.MP6
1
1
-MU6
-R2.MP6
8
RD
1
R (U)
PE
M
3~
8
M6S
2
3
3
WH
16
M6T
3
7
7
BK
PE
GNYE
9
9
GNYE
PTC M6
4
8
8
BU
PTC 0v
5
11
11
BK
BU M6
6
2
2
BU +
BU 0V M6
7
5
5
BU -
T (W)
S (V)
+Axis 1-PTC
+Axis 3/25.2 / +-PTC
M6
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
15
+BU/21.7 / =+-BU
M6
Brake
+BU/21.2 / =+-BU
0V M6
-SIGNAL LAMP (OPTIONAL)
R3.H
+SMB/22.2 =+SMB-24V
/
EXT.LAMP
OG
R2.H1
A
R2.H1
K
1
+SMB/22.2 =+SMB-0V
/
EXT.LAMP
R2.H2
R2.H2
2
-SMB
-FB6
-R1.SMB6
-R1.SMB6
9
9
BK
X6
21
21
WHBK
0V X6
-R2.FB6
6
1
-R2.FB6
6
RD
1
BK
Resolver
10
10
BN
Y6
7
7
BU
22
22
WHBN
0V Y6
2
2
YE
8
8
RD
0V EXC2
8
8
WHBK (WHYE)
20
20
WHRD
EXC2
3
3
WHRD
Lab/Office:
Latest revision:
Status:
Axis 6
Prepared by, date:
EM 2008-06-02
Approved by, date:
JM 080603
2008-06-03
Approved
Document no.
= IRB660
Plant:
Location: + Axis 6
Sublocation:+
Rev. Ind Page 26
Next +Switche
Total 12
3HAC025691-001 02
1
2
3
4
5
6
7
8
LOCATION OF SWITCHES
PLACERING AV BRYTARE
-SW1.1
-R1.SW
B
D
A
C
POWER
SIGNAL
POWER
SIGNAL
1.1.2
1.1.2
1.1.1
1.1.1
2
4
1
3
13
14
21
22
SW1.6
SW1.5
-SW1.2
F
H
E
G
POWER 1.2.2
SIGNAL 1.2.2
POWER 1.2.1
SIGNAL 1.2.1
6
8
5
7
SW1.4
13
14
SW1.3
21
22
SW1.2
SW1.1
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disclosure to third parties without express authority is strictly forbidden. © Copyright 2003 ABB
-SW1.3
K
M
J
L
POWER 1.3.2
SIGNAL 1.3.2
POWER 1.3.1
SIGNAL 1.3.1
10
12
9
11
13
14
21
22
SWITCHES AXIS 1
BRYTARE AXEL 1
-SW1.4
P
S
N
R
POWER
SIGNAL
POWER
SIGNAL
1.4.2
1.4.2
1.4.1
1.4.1
14
16
13
15
13
14
21
22
-SW1.5
U
W
T
V
POWER
SIGNAL
POWER
SIGNAL
1.5.2
1.5.2
1.5.1
1.5.1
18
20
17
19
13
14
21
22
-SW1.6
Y
a
X
Z
POWER
SIGNAL
POWER
SIGNAL
1.6.2
1.6.2
1.6.1
1.6.1
22
24
21
23
13
14
21
22
Lab/Office:
Latest revision:
Status:
Switches axis 1
Prepared by, date:
EM 2008-06-02
Approved by, date:
JM 080603
2008-06-03
Approved
Document no.
= IRB660
Plant:
Location: + Switches
Sublocation:+
Rev. Ind Page 27
Next
Total 12
3HAC025691-001 02
Index
A
L
Absolute Accuracy, calibration 243
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
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
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
gearbox axis 1, replacement 225
gearbox axis 6, replacement 236
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
H
S
hold-to-run 26
safety equipment
mechanical stop 69
signal lamp 106
Safety, service 14
safety, symbols 29
E
© Copyright 2006-2008 ABB. All rights reserved.
M
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
I
installation
mechanical stop axis 1 69
3HAC025755-001 Revision: B
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
© Copyright 2006-2008 ABB. All rights reserved.
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
294
3HAC025755-001 Revision: B
3HAC025755-001, Revision B, en
ABB AB
Robotics Products
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax:
+46 (0) 21 132592
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