ABB IRB 7600 Series, IRC5 Compact, M2000, M2000A Product Manual

ROBOTICS

Product manual

IRB 7600

Trace back information:

Workspace R18-1 version a12

Checked in 2018-03-27

Skribenta version 5.2.025

Product manual

IRB 7600 - 500/2.55

IRB 7600 - 500/2.3

IRB 7600 - 400/2.55

IRB 7600 - 340/2.8

IRB 7600 - 325/3.1

IRB 7600 - 150/3.5

M2000, M2000A, IRC5

Document ID: 3HAC022033-001

Revision: V

© Copyright 2007 - 2018 ABB. All rights reserved.

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.

Keep for future reference.

Additional copies of this manual may be obtained from ABB.

Original instructions.


ABB AB, Robotics

Robotics and Motion

Se-721 68 Västerås

Sweden

Table of contents


Overview of this manual ...................................................................................................................

Product documentation, M2000/M2000A .........................................................................................

Product documentation, IRC5 ..........................................................................................................

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

9

16

17

19

1 Safety

1.1

General safety information ..................................................................................

1.1.1

Limitation of liability .................................................................................

1.1.2

Protective stop and emergency stop ...........................................................

1.2

Safety actions ...................................................................................................

1.2.1

Fire extinguishing ....................................................................................

1.2.2

Emergency release of the robot axes ..........................................................

1.2.3

Make sure that the main power has been switched off ....................................

1.3

Safety risks ......................................................................................................

1.3.1

Safety risks during installation and service work on robots ..............................

1.3.2

Moving robots are potentially lethal ............................................................

1.3.3

First test run may cause injury or damage ....................................................

1.3.4

Work inside the working range of the robot ..................................................

1.3.5

Enabling device and hold-to-run functionality ...............................................

1.3.6

Risks associated with live electric parts .......................................................

1.3.7

The unit is sensitive to ESD .......................................................................

1.3.8

Hot parts may cause burns .......................................................................

1.3.9

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

1.3.10 Brake testing ..........................................................................................

1.3.11 Safety risks during handling of batteries ......................................................

1.3.12 Safety risks during work with gearbox lubricants (oil or grease) .......................

1.4

Safety signals and symbols .................................................................................

1.4.1

Safety signals in the manual ......................................................................

1.4.2

Safety symbols on product labels ...............................................................

21

33

34

36

37

28

30

31

32

25

26

27

28

21

21

24

25

38

39

40

41

43

43

45

2 Installation and commissioning 51

2.1

Introduction ......................................................................................................

2.2

Robot transportation precautions .........................................................................

2.3

Securing the robot with a transport support ...........................................................

2.4

Unpacking .......................................................................................................

2.4.1

Pre-installation procedure .........................................................................

2.4.2

Working range, IRB 7600 - 150/3.5 ..............................................................

2.4.3


2.4.4

Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55 ................................

2.4.5


2.4.6

Risk of tipping/stability .............................................................................

2.5

On-site installation ............................................................................................

2.5.1

Lifting robot with fork lift ...........................................................................

2.5.2

Lifting robot with lifting slings ....................................................................

2.5.3

Lifting robot with roundslings ....................................................................

2.5.4

Manually releasing the brakes ...................................................................

2.5.5

Lifting the base plate ................................................................................

2.5.6

Securing the base plate ............................................................................

2.5.7

Orienting and securing the robot ................................................................

2.5.8

Fitting equipment on robot .......................................................................

2.5.9

Installation of base spacers (option) ...........................................................

2.5.10 Extended working range, axis 1 (option 561-1) .............................................

2.5.11 Installation of cooling fan for motors (option) ................................................

2.5.12 Installation of Foundry Plus Cable guard (option no. 908-1) .............................

2.5.13 Loads fitted to the robot, stopping time and braking distances .........................

2.5.14 Signal lamp (option) .................................................................................

73

75

77

79

65

66

67

67

58

62

63

64

51

52

56

58

95

96

102

103

104

80

85

88

93

Product manual - IRB 7600

3HAC022033-001 Revision: V

5



2.6

Restricting the working range ..............................................................................

2.6.1

Axes with restricted working range .............................................................

2.6.2

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

2.6.3


2.6.4


2.6.5

Installation of position switches (option) ......................................................

2.7

Electrical connections ........................................................................................

2.7.1

Robot cabling and connection points ..........................................................

2.8

Start of robot in cold environments ......................................................................

105

105

106

108

110

113

125

125

130

3 Maintenance 131

3.1

Introduction ......................................................................................................

3.2

Maintenance schedule and expected life ...............................................................

3.2.1

Specification of maintenance intervals ........................................................

3.2.2

Maintenance schedule .............................................................................

3.2.3

Expected component life .........................................................................

3.3

Inspection activities ...........................................................................................

3.3.1

Inspecting the motor seal .........................................................................

3.3.2

Inspecting the oil level in axis-1 gearbox .....................................................

3.3.3


3.3.4


3.3.5


3.3.6


3.3.7


3.3.8

Inspecting the balancing device .................................................................

3.3.9

Inspecting the cable harness .....................................................................

3.3.10 Inspecting the axis-1 mechanical stop pin ...................................................

3.3.11 Inspecting the mechanical stops on axes 1, 2, and 3 ......................................

3.3.12 Inspecting the damper on axes 2 to 5 ..........................................................

3.3.13 Inspecting the position switch on axes 1, 2, and 3 .........................................

3.3.14 Inspecting the information labels ................................................................

3.3.15 Inspecting the UL lamp .............................................................................

3.4

Changing/replacement activities ..........................................................................

3.4.1

Type of lubrication in gearboxes ................................................................

3.4.2

Changing oil, axis-1 gearbox .....................................................................

3.4.3


3.4.4


3.4.5


3.4.6


3.4.7


3.4.8

Replacing the SMB battery ........................................................................

3.5

Lubrication activities ..........................................................................................

3.5.1

Lubrication of spherical roller bearing, balancing device .................................

3.6

Cleaning activities .............................................................................................

3.6.1

Flushing a contaminated gearbox ...............................................................

3.6.2

Cleaning the IRB 7600 ..............................................................................

3.7

Service Information System, M2000 ......................................................................

3.7.1

Using the SIS system ...............................................................................

3.7.2

Description of Service Information System (SIS) ...........................................

3.7.3

SIS system parameters ............................................................................

3.7.4

Setting the SIS parameters .......................................................................

3.7.5

Reading the SIS output logs ......................................................................

3.7.6

Exporting the SIS data .............................................................................

183

187

190

193

197

201

204

209

167

169

171

173

177

179

181

181

140

143

146

149

152

155

158

164

131

132

132

133

137

138

138

209

212

212

214

217

217

218

221

222

223

224

4 Repair 225

4.1

Introduction ......................................................................................................

4.2

General procedures ...........................................................................................

4.2.1

Performing a leak-down test ......................................................................

4.2.2

Mounting instructions for bearings .............................................................

225

226

226

227

6 Product manual - IRB 7600




4.2.3

Mounting instructions for seals ..................................................................

4.2.4

Cut the paint or surface on the robot before replacing parts ............................

4.2.5

The brake release buttons may be jammed after service work .........................

4.3

Complete robot .................................................................................................

4.3.1

Replacement of cable harness, axes 1-4 .....................................................

4.3.2

Replacement of cable harness, axes 5-6 ......................................................

4.3.3

Replacement of complete arm system .........................................................

4.4

Upper and lower arm .........................................................................................

4.4.1

Replacing turning disk ..............................................................................

4.4.2

Replacement of complete wrist unit ............................................................

4.4.3

Replacement of complete upper arm ...........................................................

4.4.4

Replacement of complete lower arm ...........................................................

4.4.5

Replacement of lower arm shaft .................................................................

4.5

Frame and base ................................................................................................

4.5.1

Replacing the SMB unit ............................................................................

4.5.2

Replacement of brake release board ...........................................................

4.5.3

Replacement of spherical roller bearing, balancing device ..............................

4.5.4

Replacement of balancing device ...............................................................

4.5.4.1 Replacing the balancing device ......................................................

4.5.4.2 Unloading the balancing device using hydraulic press tool ..................

4.5.4.3 Restoring the balancing device using a hydraulic press tool ................

4.6

Motors ............................................................................................................

4.6.1

Replacement of motor, axis 1 ....................................................................

4.6.2

Replacement of motor axis 2 .....................................................................

4.6.3


4.6.4


4.6.5


4.6.6


4.7

Gearboxes .......................................................................................................

4.7.1

Replacing the axis 1 gearbox .....................................................................

4.7.2

Replacement of gearbox, axis 2 .................................................................

4.7.3


4.7.4


4.7.5


4.7.6


318

324

331

338

343

350

350

362

287

293

298

298

306

310

313

313

370

377

382

389

250

250

254

259

264

273

283

283

229

231

232

233

233

242

245

5 Calibration 395

5.1

Introduction to calibration ...................................................................................

5.1.1

Introduction and calibration terminology ......................................................

5.1.2

Calibration methods .................................................................................

5.1.3

When to calibrate ...................................................................................

5.2

Synchronization marks and axis movement directions .............................................

5.2.1

Synchronization marks and synchronization position for axes .........................

5.2.2

Calibration movement directions for all axes ................................................

5.3

Updating revolution counters ...............................................................................

5.4

Calibrating with Axis Calibration method ...............................................................

5.4.1

Description of Axis Calibration ..................................................................

5.4.2

Calibration tools for Axis Calibration ...........................................................

5.4.3

Installation locations for the calibration tools ...............................................

5.4.4

Axis Calibration - Running the calibration procedure ......................................

5.5

Calibrating with Calibration Pendulum method ........................................................

5.6

Verifying the calibration ......................................................................................

5.7

Checking the synchronization position ..................................................................

403

408

408

410

412

413

419

420

421

395

395

396

399

400

400

402

6 Decommissioning 423

6.1

Environmental information ..................................................................................

6.2

Scrapping of robot .............................................................................................

6.3

Decommissioning of balancing device ...................................................................

423

425

426



7



7 Robot description 429

7.1

Type A vs type B motors ....................................................................................

429

8 Reference information 431

8.1

Introduction ......................................................................................................

8.2

Applicable standards .........................................................................................

8.3

Unit conversion .................................................................................................

8.4

Screw joints ....................................................................................................

8.5

Weight specifications .........................................................................................

8.6

Standard tools ..................................................................................................

8.7

Special tools ....................................................................................................

8.8

Lifting accessories and lifting instructions ..............................................................

431

432

434

435

438

439

440

444

9 Spare part lists 445

9.1

Spare part lists and illustrations ...........................................................................

445

10 Circuit diagram 447

10.1 Circuit diagrams ................................................................................................

10.2 Validity of circuit diagram 3HAC025744-1 ..............................................................

10.3 Validity of circuit diagram 3HAC13347-1 ................................................................

447

449

450

Index 451

8




Overview of this manual


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.

The manual also contains reference information for all procedures detailed in the manual.

The robot described in this manual has the protection type Standard and Foundry

Plus.

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

Maintenance/repair/installation personnel working with an ABB Robot must:

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

Organization of chapters

The manual is organized in the following chapters:

Chapter

Safety

Contents

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

Installation and commissioning

Required information about lifting and installation of the robot.

Maintenance

Repair

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

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

Calibration Calibration procedures and general information about calibration.



Continues on next page

9



Continued

Chapter Contents

Decommissioning Environmental information about the robot and its components.

Reference information Useful information when performing installation, maintenance or repair work. Includes lists of necessary tools, additional documents, safety standards etc.

Spare part list

Exploded views

Circuit diagram

Complete spare part list shown in exploded views.

Detailed illustrations of the robot with reference numbers to the part list.

Reference to the circuit diagram for the robot.

References

Procedures in this product manual contain references to the following manuals:

Document name

Product manual - IRB 7600 Foundry Prime

Product manual, spare parts - IRB 7600

Product specification - IRB 7600

Product specification - IRB 7600 M2000/M2000A

Circuit diagram - IRB 7600

Document ID

3HAC044350-001

3HAC049113-001

3HAC023934-001

3HAC13491-1

3HAC13347-1

3HAC025744-001

3HAC031045-001

3HAC021313-001

Note

Operating manual - General safety information i

Product manual - IRC5

IRC5 with main computer DSQC 639.

Product manual - IRC5

IRC5 with main computer DSQC1000.

Product manual - S4Cplus M2000

Product manual - S4Cplus M2000A

Operating manual - IRC5 with FlexPendant

User’s guide - S4Cplus (BaseWare OS 4.0)

Operating manual - Calibration Pendulum

Operating manual - Service Information System

Operating manual - Levelmeter Calibration

Technical reference manual - Lubrication in gearboxes

3HAC047136-001

3HAC021333-001

3HAC022419-001

3HAC050941-001

3HAC7793-1

3HAC16578-1

3HAC050944-001

3HAC022907-001

3HAC042927-001

M2004

M2004

M2000/M2000A

Technical reference manual - System parameters

Application manual - Additional axes and stand alone controller

3HAC050948-001

3HAC051016-001 M2004 i

Application manual - External axes 3HAC9299-1 M2000

This manual contains all safety instructions from the product manuals for the manipulators and the controllers.

Additional document references

Document name

Application manual - CalibWare Field 5.0

Document ID

3HAC030421-001






Continued

Revisions

D

E

-

Revision

A

B

C



Description

First edition.

Replaces previous manuals:

• Installation and Commissioning Manual

• Maintenance Manual

• Repair Manual, part 1

• Repair Manual, part 2.

Changes made in the material from the previous manuals:

• Model M2004 implemented.

• Various corrections due to technical revisions, changes in the toolkits etc.

Chapter Calibration replaced with chapter Calibration information .

Following corrections are made:

• In chapter 3: Maintenance in section Exporting the SIS data , the unit seconds for different SIS parameters is replaced by the unit hours .

The change is only valid for RobotWare release 5.0.

Following updates are made:

• In chapter 4: Repair , the sections Removal of complete lower arm and

Refitting of complete lower arm are completed with more detailed information about how to use the glycerin pump.

• Section Document references is completed with article numbers for calibration manuals.

• Section Part list is completed with the spare part number for a variant of the cable harness/brake release unit.

New lubricating oil in the gearboxes. Changes made in the chapter

Maintenance on page 131

and Part list .

• New variant of the robot (IRB 7600 - 500/2.55) implemented throughout the manual.

• Wrist unit updated, new spare part number is specified in

Replacement of complete wrist unit on page 254

and Spare part list .

• Insulated wrist unit implemented, new spare part number is specified in

Replacement of complete wrist unit on page 254

and Spare part list .

Amount of oil differs from non-insulated wrist unit, changes made in sections Type of oil in gearboxes and

Changing oil, axis-6 gearbox on page 201 .

• New section that describes how to replace the bearing at the front eye of the balancing device,

Replacement of spherical roller bearing, balancing device on page 293 .

• Incorrect article numbers for position switches are corrected, section

Installation of position switches (option) on page 113 .

• New section:

Installation of cooling fan for motors (option) on page 96 .

• New section:

Installation of base spacers (option) on page 93

• New section that specifies all the recommended spare parts: Spare part list .

• Repair sections for removal/refitting are restructured into replacement sections.

• Various corrections made, due to technical revisions etc.

Foundry Prime option included.

• New variant of the robot (IRB 7600 - 325/3.1) implemented throughout the manual.

• In chapter 3 Maintenance section Oil in gearboxes type of oil and art.

no. in gearbox axes 1 has been added.

• New product name has been implemented throughout the manual:

"Mobilgear 600 XP 320". Replaces "Mobil Gearlube X320".


11



Continued

Revision

F

G

H

J

Description

• Interval for change of Shell Tivela S 150 has been changed in section

Maintenance schedule .

• Section Service Information System has been removed from the manual. There is a specific manual for SIS. See References .

• Section Chip and dust protection has been removed from the manual.

This option is no longer available.

• Standard tightening torque for M24 Allen head screws has been added in section Screw joints .

• Prerequisites in section Overview

This revision includes the following additions and/or changes:

• Section " WARNING! - Mixed oils may cause severe damage to gearboxes " in chapter Safety, has been integrated in section " Type of oil in gearboxes " in the Maintenance chapter.

• The oil Shell Tivela S150 in gearboxes 1, 2, 3 and 6 has been replaced by Kyodo Yushi TMO 150 . Changes made in chapters Maintenance and

Spare Parts .

• The section " Type of oil in gearboxes " in chapter Maintenance has been updated according to changes made in oil types and intervals for oil change.

• Sections "Robot transportation precaution" and "Securing the robot" are added to the Installation chapter.

• Modified maintenance intervals for oil change in gearboxes.

• Chapter Maintenance, section "Maintenance Schedule": interval for replacement of battery pack changed.

• Section "Type of oil" changed.

This revision include the following addition:

• New WARNING!

added in Safety chapter section Work inside the robot´s working range .

• New WARNING!

added in Safety chapter section WARNING! - Safety risks during work with gearbox oil .

• The text in the introduction to chapters Installation , Maintenance and

Repair has been uppdated concerning the robot being connected to earth when power connected.

• Section Expected component life in chapter Maintenance : The lifetime of certain parts has been updated.

• Section Type of oil in chapter Maintenance has been updated.

• Section Foundry Plus,Cable guard added to Installation chapter.

This revision includes the following additions and/or changes:

• Circuit diagrams are not included in this document but delivered as separate files. See

Circuit diagram on page 447 .

• List of standards updated, see

Applicable standards on page 432 .

• Interval changed for inspection and lubrication of balancing device

(Foundry Prime). See chapter Maintenance section

Maintenance schedule on page 133 .

The chapter Safety updated with:

• Updated safety signal graphics for the levels Danger and Warning , see

Safety signals in the manual on page 43 .

• New safety labels on the manipulators, see

Safety symbols on product labels on page 45 .

• Revised terminology: robot replaced with manipulator .

This revision includes the following updates:

• Maximum deviation changed, see

Securing the base plate on page 80 .

• Corrected part numbers, see Wrist, 3HAC16628-4 .

• Corrected exploded view, see Wrist complete .






Continued

Revision

K

L

M

N



Description

• Added inspection of oil level in gearboxes and inspection of surface treatment in maintenance schedule for Foundry Prime. See section

Activities and intervals, Foundry Prime .

• Text in maintenance schedules concerning lubrication of balancing device bearing changed into concerning all bearings of the balancing device, see

Maintenance schedule on page 133

.

• Replacement of cable harness in Foundry Prime robots added to maintenance schedule, see Activities and intervals, Foundry Prime .


• Removed incorrect article number for fork lift, see

Lifting robot with fork lift on page 67 .

• Information about restricting and extending the working range of axis

1 is now separated, see

Mechanically restricting the working range of axis 1 on page 106

and the new section

Extended working range, axis

1 (option 561-1) on page 95

. Also added signal about option 561-1 in section

Inspecting the axis-1 mechanical stop pin on page 167 .


• A new block, about general illustrations, added in section

How to read the product manual on page 19

.

• Made minor corrections and improvements in the complete instruction for how to replace the axis 1 gearbox, see

Replacing the axis 1 gearbox on page 350

.

• Robot designations are adjusted in sub-headings in section

Robot transportation precautions on page 52 .

• Added new mechanical structure of the lower arm attachment point for robots with protection Foundry Plus and Foundry Prime, see

Replacement of complete lower arm on page 264 , the new section

Replacement of lower arm shaft on page 273

and the exploded view Frame-Lower arm

2 in Product manual, spare parts - IRB 7600 .

• Some general tightening torques have been changed/added, see updated values in

Screw joints on page 435

.

• Added

Safety risks during handling of batteries on page 40

.

• The maximum allowed deviation in levelness of the base plate is changed, see


• Reference to Hilti standard added to the foundation recommendation for the base plate and class designation for foundation is changed to european standard C25/C30 (previously Swedish standard K25/K30), see


• Added attachment plate for axis-2 switch to equipment list, see

Installation of position switches (option) on page 113 .

• Friction washer added to the instruction for replacing axis-2 gearbox and to the exploded view, see

Replacement of gearbox, axis 2 on page 362

and Exploded view .

• Moved all information about Foundry Prime to a separate Product manual, see

References on page 10

for document number.

• Corrected article numbers for the o-rings and removed the removal tool from the equipment list and from the procedure, see

Replacement of gearbox, axis 6 on page 389 .

• Corrected article number for axis-2-3 sealing, see

Replacement of complete lower arm on page 264

and

Replacement of complete upper arm on page 259

.


• A new SMB unit and battery is introduced, with longer battery lifetime.


• Instruction for inspection of oil level updated.

• Spare part number, motor axis 2 corrected.


13



Continued

Revision

P

Q

R

S

Description

• Added information about risks when scrapping a decommissioned robot, see

Scrapping of robot on page 425 .

• Added information in draining instructions and in Safety chapter about draining oil from gear boxes, see

Safety risks during work with gearbox lubricants (oil or grease) on page 41 .

• Information regarding fork lift set 3HAC0604-2 deleted from manual.

• Information regarding oil types added to maintenance schedule.

• New illustrations, and updated repair instructions regarding brake unit cover.

• Spare parts and exploded views are not included in this document but delivered as a separate document. See Product manual, spare parts - IRB 7600


• Information about maintenance kit (3HAC15834-1), and upgrade kit

(3HAC14965-1), deleted from manual.

• The maximum allowed deviation in levelness of the base plate and foundation is changed, see


• Added tightening torque for R1.SMB and 7th axis connector, see

Replacement of cable harness, axes 1-4 on page 233

.

• Minor corrections.


• The inspection of oil level in gearboxes is removed from the maintenance schedule and moved to the cleaning section.

• The instructions for inspection of oil level in gearboxes are updated, see

Inspection activities on page 138

.

• Illustrations of SMB battery RMU improved.


• Article number changed for Fork lift accessory (from 3HAC0604-1 to

3HAC0604-2)

• New standard calibration method introduced (Axis Calibration). See

Calibration on page 395 .

• Tightening torque for securing screw in piston shaft front eye changed, see

Replacing the balancing device on page 298

.

• External brake release unit section removed from the manual.

• Turning disk fixture is removed from special tools for Levelmeter calibration.


• Oil types in maintenance schedule table removed and a reference to the Tech. manual added.

• Maintenance table splitted into several tables.

• Edited information regarding deciding calibration routine in each repair section.

• Added a warning that calibration pin must be inserted in the calibration bushing until it snaps, see

Description of Axis Calibration on page 408 .

• Added warning regarding risk of pinching, in

Description of Axis Calibration on page 408 .

• Added information about inspection of calibration tool prior to usage, see

Examining the calibration tool on page 410 .

• Added information about the calibration procedure, see

Overview of the calibration procedure on the FlexPendant on page 413

,

Restarting an interrupted calibration procedure on page 415

.

• Added information about Axis Calibration when SafeMove is installed, see

Axis Calibration with SafeMove option on page 416

.






Continued

Revision

T

U

V

Description

Published in release R16.2. The following updates are done in this revision:

• Drawing of base plate is not available for purchase, faulty information removed in


• Corrections due to updates in terminology.

• Drawing of tool flange for LeanID added.

Published in release R17.2. The following updates are done in this revision:

• Caution about removing metal residues added in sections about SMB boards.

• Information about minimum resonance frequency added.

• Bending radius for static floor cables added.

• Note regarding VK cover on axis 3 (lower arm) due to removal of hole in new design of the lower arm.

• Cooling fans (option) is available for axes 1 and 2.

• Applicable standards updated

• Added text regarding overhaul in section specification of maintenance intervals.

• Section

Start of robot in cold environments on page 130

added.

• Updated information regarding replacement of brake release board.

• Updated information regarding disconnecting and reconnecting battery cable to serial measurement board.

• Updated information regarding lubrication of gearbox oil for all axis.

• Definition of reference calibration clarified.

Published in release R18.1. The following updates are made in this revision:

• Information added about fatigue to Axis Calibration tool, see

Calibration tools for Axis Calibration on page 410

.

• Updated information about locking liquid in replacement of cable harness, axes 1-4.

• Added sections in

General procedures on page 226

.

• Safety restructured.

• Updated spare part number brake release unit (was DSQC561, is

DSQC1052).

• Type B motors are introduced throughout the manual.

New periodic maintenance activity regarding inspection of the type B motor oil seal.

New gasket at axis-6 motor cable inlet.

• Note added to calibration chapter to emphasize the requirement of equally dressed robot when using previously created reference calibration values.

• Information about myABB Business Portal added.

• Revised tightening torque for gearbox axis 2.

• Added Nickel in Environmental information.

• Changed direction of installed cooling fan on axis-2 motor and removed a faulty image showing the design of the cooling fan. Also added detailed images to installation procedure for the fan.




15

Product documentation, M2000/M2000A

Product documentation, M2000/M2000A

General

The complete product documentation kit for the M2000 robot system, including controller, robot and any hardware option, consists of the manuals listed below:

Product manuals

Manipulators, controllers, DressPack/SpotPack, and most other hardware will be delivered with a Product manual that generally contains:

• Safety information.

• Installation and commissioning (descriptions of mechanical installation or electrical connections).

• Maintenance (descriptions of all required preventive maintenance procedures including intervals and expected life time of parts).

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

• Calibration.

• Decommissioning.

• Reference information (safety standards, unit conversions, screw joints, lists of tools ).

• Spare parts list with exploded views (or references to separate spare parts lists).

• Circuit diagrams (or references to circuit diagrams).

Software manuals

The software documentation consists of a wide range of manuals, ranging from manuals for basic understanding of the operating system to manuals for entering parameters during operation.

A complete listing of all available software manuals is available from ABB.

Controller hardware option manual

Each hardware option for the controller is supplied with its own documentation.

Each document set contains the types of information specified below:

• Installation information

• Repair information

• Maintenance information

In addition, spare part information is supplied for the entire option.

16




Product documentation, IRC5


Categories for user documentation from ABB Robotics

The user documentation from ABB Robotics is divided into a number of categories.

This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.

All documents can be found via myABB Business Portal, www.myportal.abb.com

.

Product manuals

Manipulators, controllers, DressPack/SpotPack, and most other hardware is delivered with a Product manual that generally contains:

• Safety information.

• Installation and commissioning (descriptions of mechanical installation or electrical connections).

• Maintenance (descriptions of all required preventive maintenance procedures including intervals and expected life time of parts).

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

• Calibration.

• Decommissioning.

• Reference information (safety standards, unit conversions, screw joints, lists of tools).

• Spare parts list with corresponding figures (or references to separate spare parts lists).

• Circuit diagrams (or references to circuit diagrams).

Technical reference manuals

The technical reference manuals describe reference information for robotics products, for example lubrication, the RAPID language, and system parameters.

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, software).

• How to install included or required hardware.

• How to use the application.

• Examples of how to use the application.





17


Continued

Operating manuals

The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters.

18




How to read the product manual

How to read the product manual

Reading the procedures

The procedures contain references to figures, tools, material, and so on. The references are read as described below.

References to figures

The procedures often include references to components or attachment points located on the manipulator/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

Remove the rear attachment screws, gearbox.

Note/Illustration

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 and dimensions.

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

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

3.

Action

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 the chapter

Safety on page 21

.

Illustrations

The robot is illustrated with general figures that does not take painting or protection type in consideration.

Likewise, certain work methods or general information that is valid for several robot models, can be illustrated with illustrations that show a different robot model than the one that is described in the current manual.



19


This page is intentionally left blank

1 Safety

1.1.1 Limitation of liability

1 Safety

1.1 General safety information

1.1.1 Limitation of liability

Limitation of liability

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

The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system.

In particular, liability cannot be accepted if injury/damage has been caused for any of the following reasons:

• Use of the robot in other ways than intended.

• Incorrect operation or maintenance.

• Operation of the robot when the safety devices are defective, not in their intended location or in any other way not working.

• When instructions for operation and maintenance are not followed.

• Non-authorized design modifications made in or around the robot.

• Repairs carried out by in-experienced or non-qualified personnel.

• Foreign objects.

• Force majeure.

Nation/region specific regulations

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.

To be observed by the supplier of the complete system

The integrator is responsible that the safety devices necessary to protect people working with the robot system are designed and installed correctly.

When integrating the robot with external devices and machines:

• 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.





21

1 Safety


Continued

The integrator of the final application is required to perform an assessment of the hazards and risks (HRA).

Note

The integrator is responsible for the safety of the final application.

Safe access

The robot system shall be designed to allow safe access to all areas where intervention is necessary during operation, adjustment, and maintenance.

Where it is necessary to perform tasks within the safeguarded space there shall be safe and adequate access to the task locations.

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.

A safety fence is recommended to ensure safeguarded space. Sufficient space must be provided around the manipulator to protect those working with or on it from hazards such as crushing.

The fence or enclosure must be dimensioned 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 the section

Robot motion in the Product specification ).

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

Safe handling

Users shall not be exposed to hazards, including slipping, tripping, and falling hazards.

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

Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly. If any of the buttons do not stop all the robot workcell motion, each emergency stop button must be marked, if more than one is provided, to indicate its designated safety function.

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


22




1 Safety


Continued

Unauthorized modifications of the originally delivered robot are prohibited. Without the consent of ABB it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength could be affected.

CAUTION

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




23

1 Safety

1.1.2 Protective stop and emergency stop

1.1.2 Protective stop and emergency stop

Overview

The protective stops and emergency stops are described in the product manual for the controller.

24




1 Safety

1.2.1 Fire extinguishing

1.2 Safety actions

1.2.1 Fire extinguishing

Note

Use a CARBON DIOXIDE (CO

2

) extinguisher in the event of a fire in the manipulator or controller.




25

1 Safety

1.2.2 Emergency release of the robot axes

1.2.2 Emergency release of the robot axes

Description

In an emergency situation, the brakes on a robot axis can be released manually by pushing a brake release button.

How to release the brakes is described in the section:

•

Manually releasing the brakes on page 77 .

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

Increased injury

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

DANGER

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

Make sure no personnel is near or beneath the robot.

26




1 Safety

1.2.3 Make sure that the main power has been switched off

1.2.3 Make sure that the main power has been switched off

Description

Working with high voltage is potentially lethal. Persons subjected to high voltage may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these personal injuries, switch off the main power on the controller before proceeding work.

Note

Switch off all main power switches in a MultiMove system.

Spot welding cabinet

Wait for 5 minutes to let the capacitors discharge after the power has been switched off.

DANGER

Even if the main switch is switched off, the capacitors can cause electric shock if not given the time to discharge.




27

1 Safety

1.3.1 Safety risks during installation and service work on robots

1.3 Safety risks

1.3.1 Safety risks during installation and service work on robots

Requirements on personnel

Only persons who know the robot and are trained in the operation and handling of the robot are allowed to maintain the robot. Persons who are under the influence of alcohol, drugs or any other intoxicating substances are not allowed to install, maintain, repair, or use the robot.

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

• Those who install or service/maintain the robot must have the appropriate training for the equipment in question and in any safety matters associated with it.

• Personnel should be trained on responding to emergency or abnormal situations.

General risks during installation and service

The instructions in the product manual must always be followed.

Never turn the power on to the robot before it is properly fixed and bolted to its foundation/support.

Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to always lock the main switch on the controller cabinet with a safety lock.

Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to remove the power cable to the controller.

If the robot is installed at a height, hanging, or other than standing directly on the floor, there may be additional risks than those for a robot standing directly on the floor.

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

Never use the robot as a ladder, which means, do not climb on the controller, motors, or other parts during service work. There is a risk of slipping because of the high temperature of the motors and oil spills that can occur on the robot. There is also a risk of the robot being damaged.

To avoid damaging the product, make sure that there are no loose screws, turnings, or other parts inside the product after work has been performed.

Safety risks during operational disturbances

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.





1 Safety

1.3.1 Safety risks during installation and service work on robots

Continued

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.

Spare parts and special equipment

ABB does not supply spare parts and special equipment which have not been tested and approved by ABB. The installation and/or use of such products could negatively affect the structural properties of the robot and as a result of that affect the active or passive safety operation. ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the robot.

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. An external safety function can interact with other machines and peripheral equipment via this interface. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot.

Personal protective equipment

Always use suitable personal protective equipment, based on the risk assessment for the robot installation.

Allergenic material

See

Environmental information on page 423

for specification of allergenic materials in the product, if any.




29

1 Safety

1.3.2 Moving robots are potentially lethal

1.3.2 Moving robots are potentially lethal

Description

Any moving robot is a potentially lethal machine.

When running, the robot 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.

Safe handling

1

2

3

Action Note

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.

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 is described in section How to use the hold-torun function in the Operating manual - IRC5 with FlexPendant .

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

30




1 Safety

1.3.3 First test run may cause injury or damage

1.3.3 First test run may cause injury or damage

Description

After installation and performing service activities, there are several safety risks to take into consideration before the first test run.

Safe handling

Use this procedure when performing the first test run after installation, maintenance, or repair.

DANGER

Running the robot without fulfilling the following aspects, may involve a risk of injury and cause severe damage to the robot.

1

2

3

4

5

6

7

Action

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

Verify that the robot is properly secured to its position by all screws, before it is powered up.

Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed.

Verify that the fixture and work piece are well secured, if applicable.

Install all safety equipment properly.

Make sure all personnel are standing at a safe distance from the robot, and is out of its reach behind safety fences, or similar.

If maintenance or repair has been done, pay special attention to the function of the part that was serviced.

Collision risks

CAUTION

When programming the movements of the robot, always identify potential collision risks before the first test run.




31

1 Safety

1.3.4 Work inside the working range of the robot

1.3.4 Work inside the working range of the robot

WARNING

If work must be carried out within the work area of the robot, then the following points must be observed:

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

• The maximum speed of the robot is limited to 250 mm/s when the operating mode selector is in the 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.

Manual mode with full speed (100%) is not available in USA or Canada.

• Pay attention to the rotating axes of the robot. Keep away from axes to not 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.

• Keep clear of moving parts so that limbs, hands, or fingers do not get trapped or crushed by the robot.

• To prevent anyone else from taking control of the robot, always put a safety lock on the cell door and bring the three-position enabling device with you when entering the working space.

WARNING

NEVER , under any circumstances, stay beneath any of the robot's axes! There is always a risk that the robot will move unexpectedly when robot axes are moved using the three-position enabling device or during other work inside the working range of the robot.

32




1 Safety

1.3.5 Enabling device and hold-to-run functionality

1.3.5 Enabling device and hold-to-run functionality

Three-position enabling device

The three-position 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 three-position 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, operating the robot is impossible.

Note

The three-position enabling device is a push-button located on the teach pendant which, when pressed halfway in, switches the system to MOTORS ON. When the enabling device is released or pushed all the way in, the manipulator switches to the MOTORS OFF state.

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

• The enabling device must never be rendered inoperational 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.

• Anyone entering the working space of the robot must always hold the teach pendant. This is to prevent anyone else from taking control of the robot without his/her knowledge.

Hold-to-run function

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

How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant .




33

1 Safety

1.3.6 Risks associated with live electric parts

1.3.6 Risks associated with live electric parts

Voltage related risks, general

Work on the electrical equipment of the robot must be performed by a qualified electrician in accordance with electrical regulations.

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 main switch to

OFF) when repairing faults, disconnecting electric leads, and disconnecting or connecting units.

The main supply to the robot must be connected in such a way that it can be turned off from outside the working space of the robot.

Make sure that no one else can turn on the power to the controller and robot while you are working with the system. A good method is to always lock the main switch on the controller cabinet with a safety lock.

The necessary protection for the electrical equipment and robot during installation, commissioning, and maintenance is guaranteed if the valid regulations are followed.

Voltage related risks, IRC5 controller

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

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

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

• The main supply/main switch

• The transformers

• The power unit

• The control power supply (230 VAC)

• The rectifier unit (262/400-480 VAC and 400/700 VDC. Note: capacitors!)

• The drive unit (400/700 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 low 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).





1 Safety

1.3.6 Risks associated with live electric parts

Continued

Voltage related risks, tools, material handling devices, etc.

Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged.




35

1 Safety

1.3.7 The unit is sensitive to ESD

1.3.7 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.

Safe handling

1

2

3

Action Note

Use a wrist strap. The wrist strap button is located inside the controller.

Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly.

• Product manual - IRC5

• Product manual - IRC5 Panel Mounted

Controller

Use an ESD protective floor mat.

Use a dissipative table mat.

The mat must be grounded through a current-limiting resistor.

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

36




1 Safety

1.3.8 Hot parts may cause burns

1.3.8 Hot parts may cause burns

Description

During normal operation, many parts become hot. Touching these may cause burns.

There is also a risk of fire if flammable materials are put on hot surfaces.

Safe handling

Always use your hand, at some distance, to feel if heat is radiating from the potentially hot component before actually touching it.

Wait until the potentially hot component has cooled if it is to be removed or handled in any other way.

Do not put anything on hot metal surfaces, e.g. paper or plastic.




37

1 Safety

1.3.9 Safety risks related to pneumatic/hydraulic systems

1.3.9 Safety risks related to pneumatic/hydraulic systems

General

Special safety regulations apply to pneumatic and hydraulic systems.

Note

All components that remain pressurized after separating the machine from the power supply must be provided with clearly visible drain facilities and a warning sign that indicates the need for pressure relief before adjustments or performing any maintenance on the robot system.

Residual energy

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

The pressure must be released in the complete pneumatic or hydraulic systems before starting to repair them.

Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics.

All pipes, hoses, and connections have to be inspected regularly for leaks and damage. Damage must be repaired immediately.

Splashed oil may cause injury or fire.

Safe design

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

Dump valves should be used in case of emergency.

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

38




1 Safety

1.3.10 Brake testing

1.3.10 Brake testing

When to test

During operation, the holding brake of each axis normally wears down. A test can 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 verified as described below:

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

2 Switch the motor to the MOTORS OFF.

3 Inspect and verify that the axis maintains its position.

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




39

1 Safety

1.3.11 Safety risks during handling of batteries

1.3.11 Safety risks during handling of batteries

Description

Under normal conditions of use, the electrode materials and liquid electrolyte in the batteries are not exposed to the outside, provided the battery integrity is maintained and seals remain intact.

There is a risk of exposure only in case of abuse (mechanical, thermal, electrical) which leads to the activation of safety valves and/or the rupture of the battery container. Electrolyte leakage, electrode materials reaction with moisture/water or battery vent/explosion/fire may follow, depending upon the circumstances.

Note

Appropriate disposal regulations must be observed.

Safe handling

Use safety glasses when handling the batteries.

In the event of leakage, wear rubber gloves and chemical apron.

In the event of fire, use self-contained breathing apparatus.

Do not short circuit, recharge, puncture, incinerate, crush, immerse, force discharge or expose to temperatures above the declared operating temperature range of the product. Risk of fire or explosion.

Operating temperatures are listed in

Pre-installation procedure on page 58

.

40




1 Safety

1.3.12 Safety risks during work with gearbox lubricants (oil or grease)

1.3.12 Safety risks during work with gearbox lubricants (oil or grease)

Description

When handling gearbox lubricants, there is a risk of both personal injury and product damage occurring. The following safety information must be regarded before performing any work with lubricants in the gearboxes.

Note

When handling oil, grease, or other chemical substances the safety information of the manufacturer must be observed.

Note

When aggressive media is handled, an appropriate skin protection must be provided. Gloves and goggles are recommended.

Note

Appropriate disposal regulations must be observed.

Note

Take special care when handling hot lubricants.

Safe handling

Warning Description Elimination/Action

Changing and draining gearbox oil or grease may require handling hot lubricant heated up to

90 °C.

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

Hot oil or grease

When working with gearbox lubricant there is a risk of an allergic reaction.

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

Allergic reaction

Possible pressure build-up in gearbox

When opening the oil or grease plug, there may be pressure present in the gearbox, causing lubricant to spray from the opening.

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





41

1 Safety

1.3.12 Safety risks during work with gearbox lubricants (oil or grease)

Continued

Warning

Do not overfill

Description Elimination/Action

Overfilling of gearbox lubricant 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 it with oil or grease.

After filling, verify that the level is correct.

Do not mix types of oil

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 instructions. 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.

Heat up the oil

Specified amount depends on drained volume

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

After filling, verify that the level is correct.

Contaminated oil in gear boxes

When draining the oil make sure that as much oil as possible is drained from the gearbox. The reason for this is to drain as much oil sludge and metal chips as possible from the gearbox.

The magnetic oil plugs will take care of any remaining metal chips.

42




1 Safety

1.4.1 Safety signals in the manual

1.4 Safety signals and symbols

1.4.1 Safety signals in the manual

Introduction to safety signals

This section specifies all dangers that can arise when doing the work described in the user manuals. Each danger consists 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.

• Instruction about how to eliminate danger to simplify doing the work.

Danger levels

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

Symbol xx0200000022 xx0100000002

Designation

DANGER

WARNING

ELECTRICAL

SHOCK

Significance

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, and so on.

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.

Warns for electrical hazards which could result in severe personal injury or death.

xx0200000024 xx0100000003

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.

ELECTROSTATIC

DISCHARGE (ESD)

Warns for electrostatic hazards which could result in severe damage to the product.

xx0200000023





43

1 Safety

1.4.1 Safety signals in the manual

Continued

Symbol Designation

NOTE

Significance

Describes important facts and conditions.

xx0100000004

TIP Describes where to find additional information or how to do an operation in an easier way.

xx0100000098

44




1 Safety

1.4.2 Safety symbols on product labels

1.4.2 Safety symbols on product labels

Introduction to labels

This section describes safety symbols used on labels (stickers) on the product.

Symbols are used in combinations on the labels, describing each specific warning.

The descriptions in this section are generic, the labels can contain additional information such as values.

Note

The safety and health symbols on the labels on the product must be observed.

Additional safety information given by the system builder or integrator must also be observed.

Types of labels

Both the manipulator 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, for example during installation, service, or operation.

The safety labels are language independent, they only use graphics. See

Symbols on safety labels on page 45

.

The information labels can contain information in text (English, German, and

French).

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

• on page ?

Symbols on safety labels

Symbol xx0900000812 xx0900000811

Description

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.

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.





45

1 Safety


Continued

Symbol Description

Prohibition

Used in combinations with other symbols.

xx0900000839 xx0900000813

See user documentation

Read user documentation for details.

Which manual to read is defined by the symbol:

• No text: Product manual .

• EPS: Application manual - Electronic Position Switches .

Before disassemble, see product manual xx0900000816

Do not disassemble

Disassembling this part can cause injury.

xx0900000815

Extended rotation

This axis has extended rotation (working area) compared to standard.

xx0900000814 xx0900000808

Brake release

Pressing this button will release the brakes. This means that the robot arm can fall down.


46




Symbol

1 Safety


Continued

Description

Tip risk when loosening bolts

The robot can tip over if the bolts are not securely fastened.

xx0900000810 xx1500002402

Crush

Risk of crush injuries.

xx0900000817





47

1 Safety


Continued


Heat

Risk of heat that can cause burns. (Both signs are used) xx0900000818

!

xx1300001087

1 xx0900000819

3

4

5

2

6

Moving robot

The robot can move unexpectedly.

xx1000001141

2

4

3

1 xx1500002616


48




Symbol

1 Safety


Continued

Description

Brake release buttons xx0900000820 xx1000001140 xx0900000821

Lifting bolt

Chain sling with shortener xx1000001242

Lifting of robot xx0900000822

Oil

Can be used in combination with prohibition if oil is not allowed.

xx0900000823

Mechanical stop xx0900000824





49

1 Safety


Continued


No mechanical stop xx1000001144

Stored energy

Warns that this part contains stored energy.

Used in combination with Do not disassemble symbol.

xx0900000825

Pressure

Warns that this part is pressurized. Usually contains additional text with the pressure level.

xx0900000826

Shut off with handle

Use the power switch on the controller.

xx0900000827

Do not step

Warns that stepping on these parts can cause damage to the parts.

xx1400002648

50




2 Installation and commissioning

2.1 Introduction


2.1 Introduction

General

This chapter contains assembly instructions and information for installing the IRB

7600 at the working site.

More detailed technical data can be found in the Product specification for the IRB

7600, such as:

• Load diagram

• Permitted extra loads (equipment), if any

• Location of extra loads (equipment), if any.


Before any installation work is commenced, it is extremely important that all safety information is observed.

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

Safety on page 21

before performing any installation work.

Note

If the IRB 7600 is connected to power, always make sure that the robot is connected to protective earth before starting any installation work.

For more information see:





51


2.2 Robot transportation precautions

2.2 Robot transportation precautions

General

This section describes ABB approved transportation precautions for ABB robots.

CAUTION

All transportation in or outside the plant, must be carried out according to the method described in this section.

Transportation in any other way can seriously damage the robot. If the robot is incorrectly transported and the instructions are not followed, the robot is not covered by the warranty and ABB will not accept any compensation claim.

Method 1 - recommended method

Transportation according to method 1 is strongly recommended by ABB.

xx0800000030

Always follow these instructions when transporting an ABB robot according to method 1:

• Always remove the tool before transportation of the robot.

• Always place the robot in the ABB recommended transport position, described in section

Risk of tipping/stability on page 66 .

• Always read and follow the instructions in section

Pre-installation procedure on page 58

Method 2 - transportation with a tool mounted to the robot

Transportation according to method 2 is approved by ABB, only if use of method

1 is not possible.





IRB 7600



Continued

Always follow these instructions when transporting an ABB robot according to method 2:

• Always read and follow the instructions in section

Securing the robot with a transport support on page 56

• Always place the robot in the ABB recommended transport position for robot with tool, described in sub section

Transport position with a transport support on page 54 .

• Always use the recommended transport support described in sub section

Recommended transport support on page 55 .

C

D

A

B xx0800000037

A

B

C

D

Transport Support

Hexagon socket head cap screw M16x140

Threaded bar M10x200

Nut M10





53



Continued

Transport position with a transport support

All transportation of the robot with tool must follow these instructions.

IRB 7600 xx0800000040


54






Continued

Recommended transport support

Always use the recommended transport support when transporting a robot with tool.

IRB 7600 xx0800000039




55


2.3 Securing the robot with a transport support

2.3 Securing the robot with a transport support

General

This section describes how to fit the transport support to the robot in order to secure the robot for transportation. The transport support is required if the robot must be transported with mounted tools.

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.

Fitting the transport support

Illustration for fitting the transport support

B

A xx0800000062


56





2.3 Securing the robot with a transport support

Continued

Fitting the transport support

1

Action

Fit the transport support’s lower end to the robot using the recommended screw joint,

(A) in figure.

Note

Do not tighten the screw.

See attachment point for the specific robot in the section


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


CAUTION

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

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


See attachment point for the specific robot in the section

Transport position with a transport support on page 54

4 Tighten all the attachment screws, (A) and

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

CAUTION

Do not attempt to tighten any attachment screws without first releasing the brakes.

This can seriously damage the robot.

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

Manually releasing the brakes on page 77




57


2.4.1 Pre-installation procedure

2.4 Unpacking

2.4.1 Pre-installation procedure

Introduction

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.

Prerequisites for installation personnel

Installation personnel working with an ABB product must:

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

• conform to all national and local codes.

Checking the pre-requisites for installation

1

2

3

Action

Make a visual inspection of the packaging and make sure that nothing is damaged.

Remove the packaging.

Check for any visible transport damage.

Note

Stop unpacking and contact ABB if transport damages are found.

4

5

6

7

8

9

10

11

Clean the unit with a lint-free cloth, if necessary.

Make sure that the lifting accessory used (if required) is suitable to handle the weight of the robot as specified in:

Weight, robot on page 58

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

Storage conditions, robot on page 60

Make sure that the expected operating environment of the robot conforms to the specifications as described in:

Operating conditions, robot on page 61

Before taking the robot to its installation site, make sure that the site conforms to:

•

Loads on foundation, robot on page 59

•

Protection classes, robot on page 61

•

Requirements, foundation on page 60

Before moving the robot, please observe the stability of the robot:

Risk of tipping/stability on page 66

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

On-site installation on page 67

Install required equipment, if any.

•

Signal lamp (option) on page 104

Weight, robot

The table shows the weight of the robot.

Robot model

IRB 7600

Weight

2500 kg


58






Continued

Note

The weight does not include tools and other equipment fitted on the robot!

Loads on foundation, robot

The illustration shows the directions of the robots stress forces.

The directions are valid for all floor mounted, suspended and inverted robots.

T xy

F z

F xy

T z xx1100000521

F xy

F z

T xy

T z

Force in any direction in the XY plane

Force in the Z plane

Bending torque in any direction in the XY plane

Bending torque in the Z plane

The table shows the various forces and torques working on the robot during different kinds of operation.

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!

WARNING

The robot installation is restricted to the mounting options given in following load table(s).

Floor mounted

Force

Force xy



Endurance load (in operation)

± 14 kN


Max. load (emergency stop)

± 31 kN


59



Continued

Force

Force z

Torque xy

Torque z

Endurance load (in operation)

+32 ± 10 kN

± 42 kNm

± 11 kNm

Max. load (emergency stop)

+39 ± 16 kN

± 72 kNm

± 19.5 kNm

Requirements, foundation

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

Requirement

Flatness of foundation surface

Maximum tilt

Minimum resonance frequency

Value

0.3 mm

Note

Flat foundations give better repeatability of the resolver calibration compared to original settings on delivery from ABB.

The value for levelness aims at the circumstance of the anchoring points in the robot base.

In order to compensate for an uneven surface, the robot can be recalibrated during installation.

If resolver/encoder calibration is changed this will influence the absolute accuracy.

5°

22 Hz

Note

It may affect the manipulator lifetime to have a lower resonance frequency than recommended.

The value is recommended for optimal performance.

Due to foundation stiffness, consider robot mass including equipment.

i

For information about compensating for foundation flexibility, see Application manual - Controller software IRC5 , section Motion Process Mode .

i

The minimum resonance frequency given should be interpreted as the frequency of the robot mass/inertia, robot assumed stiff, when a foundation translational/torsional elasticity is added, i.e., the stiffness of the pedestal where the robot is mounted. The minimum resonance frequency should not be interpreted as the resonance frequency of the building, floor etc. For example, if the equivalent mass of the floor is very high, it will not affect robot movement, even if the frequency is well below the stated 25 Hz. The robot should be mounted as rigid as possibly to the floor.

Disturbances from other machinery will affect the robot and the tool accuracy. The robot has resonance frequencies in the region 10 – 20 Hz and disturbances in this region will be amplified, although somewhat damped by the servo control. This might be a problem, depending on the requirements from the applications. If this is a problem, the robot needs to be isolated from the environment.

Storage conditions, robot

The table shows the allowed storage conditions for the robot:

Parameter

Minimum ambient temperature

Maximum ambient temperature

Maximum ambient temperature (less than 24 hrs)

Maximum ambient humidity

Value

-25° C

+55° C

+70° C

95% at constant temperature

(gaseous only)


60






Continued

Operating conditions, robot

The table shows the allowed operating conditions for the robot:

Parameter

Minimum ambient temperature

Maximum ambient temperature

Maximum ambient humidity

Value

+5° C

+50° C

Max. 95% at constant temperature

Protection classes, robot

The table shows the available protection types of the robot, with the corresponding protection class.

Protection type

Manipulator, protection type Standard

Manipulator, protection type Foundry Plus

Protection class

IP 67

IP 67




61


2.4.2 Working range, IRB 7600 - 150/3.5

2.4.2 Working range, IRB 7600 - 150/3.5

Illustration

The illustration below shows the unrestricted working range of IRB 7600 - 150/3.5: xx0100000101

62







Illustration

The illustration below shows the unrestricted working range of IRB 7600 - 340/2.8: xx0300000296




63


2.4.4 Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55

2.4.4 Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55

Illustration

The illustration below shows the unrestricted working range of IRB 7600 - 400/2.55

and IRB 7600 - 500/2.55: xx0100000100

64







Illustration

The illustration below shows the unrestricted working range of IRB 7600 - 500/2.3: en0100000099




65


2.4.6 Risk of tipping/stability

2.4.6 Risk of tipping/stability

Risk of tipping

If the robot is not fastened to the foundation while moving the arm, the robot is not stable in the whole working area. Moving the arm will displace the center of gravity, which may cause the robot to tip over.

The shipping position is the most stable position.

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

Shipping and transportation position

This figure shows the robot in its shipping position and transportation position.

xx0100000103

WARNING

The robot is likely to be mechanically unstable if not secured to the foundation.

66





2.5.1 Lifting robot with fork lift

2.5 On-site installation

2.5.1 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 on robot

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

xx0400000707

C

D

A

B

Attachment points, spacer and horizontal attachment screws

Attachment points, horizontal attachment screws

Attachment points, vertical attachment screws

Attachment points, horizontal attachment screws




67




Continued

Required equipment

Equipment, etc.

Fork lift accessory, incl. all required hardware

Art. no.

3HAC0604-2

Standard toolkit -

Note

Content is defined in section

Standard tools on page 439

.

Fork lift accessory, 3HAC0604-2

The Fork lift accessory, 3HAC0604-2, is fitted to the robot as shown in the figure below.

xx0200000379

A

B

C

D

Fork lift pocket (2 pcs, 3HAC15766-1 , 3HAC11264-1)

Spacer (2 pcs)

Horizontal attachment screws (4 pcs/ fork lift pocket)

Vertical attachment screws (2 pcs)


68






Continued

Lifting robot with fork lift

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

1

2

Action

If a cooling fan for the axis 1 motor is used, it must be removed in order to use the fork lift device!

Note

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

Note

Release the brakes if required as detailed in section


.

50

°

No load is permitted on the robot if the fork lift set 3HAC0604-2 is used!

0

1

° m xx0200000079

When using fork lift set 3HAC0604-2, no load is permitted on the robot!

xx0200000387

3 Fit the two spacers to the robot and secure.

Attachment points are shown in figure

Attachment points on robot on page 67 .

4

CAUTION

The fork lift pocket weighs 60 kg!





69



Continued

5

Action Note

Secure the longer fork lift pocket to the spacers with four of the horizontal attachment screws and washers.

Note

The screws, which are attached horizontally and vertically, are identical. However, they are tightened with different torque!

Always use original screws (or replacements of equivalent quality: M16, quality 12.9)!

Attachment points on the robot are shown in figure


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

xx0400001068

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

60 Nm.

B Spacers, 2 pcs.

xx0700000655

A Securing screw


70






Continued

7

Action

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

(only valid for the Fork lift accessory

3HAC0604-2)

Note

Note

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

xx0300000464

A Vertical attachment screws, 2 pcs, M16x60. Tightening torque:

270 Nm.


Attachment points on robot are shown in figure


8

CAUTION

The fork lift pocket weighs 22 kg!

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

4 pcs, M16x60.

Tightening torque: 60 Nm.


Attachment points on robot are shown in figure


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

xx0200000380

Reposition harness, if any, before using a fork lift!





71



Continued

Action

11

CAUTION

The IRB 7600 robot weighs 2500 kg.

All lifting accessories used must be sized accordingly!

Note

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

13

WARNING

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

14 Refit the cooling fan to the motor, if any.

Detailed in section

Installation of cooling fan for motors (option) on page 96 .

72





2.5.2 Lifting robot with lifting slings

2.5.2 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 and in the instruction!

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

Illustration, lifting slings

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

xx0200000153

A

B

C

Load hook

Swivelling lifting eyes, 4 pcs

Shortening hook





73


2.5.2 Lifting robot with lifting slings

Continued

D

E

F

I

L

Chain

M12 lifting eye

Eye for lifting accessory

Lifting slings, 4 pcs

Hook


Equipment

Lifting accessory, robot

Article number

3HAC15607-1

Note

Includes user instructions 3HAC15971-2

Slings attached directly onto robot

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

1

2

3

Action

Run the overhead crane to a position above the robot.

Note

Position the robot as detailed in enclosed instruction!

Article number is specified in

Required equipment on page 74 .

Release the brakes, if required, as detailed in section


Fit the lifting accessory to the robot as described in the enclosed instruction!



4

CAUTION



5

WARNING

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

6 Raise overhead crane to lift the robot.

Make sure all hooks and attachments maintain their correct positions while lifting the robot!

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

74





2.5.3 Lifting robot with roundslings

2.5.3 Lifting robot with roundslings

General

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

Notice the recommended robot position shown in the figure below!

Roundslings attached to the robot xx0200000315

A

B

C

Chain sling with shortener, 4250 kg, 3 pcs (0.5 m, 0.5 m, 0.265 m)

Roundsling, 1000 kg, 2 pcs

Roundsling, 2000 kg, 3 pcs (4 m)




75



2.5.3 Lifting robot with roundslings

Continued


Equipment

Chain sling with shortener, 4250 kg, 3 pcs

Roundslings, 1000 kg, 2 pcs

Roundslings, 2000 kg, 3 pcs

Note

Lengths: 0.5 m (2 pcs), 0.265 m (1 pc).

Lengths: 4 m (3 pcs).

Slings attached directly on to robot

The section below details how to attach roundslings to the robot in order to lift the complete robot.

1

Action Note

CAUTION

Attempting to lift the robot in any other position than that recommended may result in the robot tipping over and causing severe damage or injury!

Recommended robot position is described in section

Risk of tipping/stability on page 66

.

2

3

4

5

6

7

CAUTION




Attach the three chain slings with shorteners to the overhead crane hook.

Shown in the figure

Roundslings attached to the robot on page 75

.

Lengths are specified in


Fit the three roundslings, 2000 kg to the robot.

Attach the roundslings to the chain slings hanging from the overhead crane.

Shown in the figure


.

Lengths are specified in


Attach the two roundslings, 1000 kg to the upper arm and the overhead crane hook!

Shown in the figure


.

Raise the overhead crane to lift the robot.

Make sure all hooks and attachments maintain correct position while lifting the robot!


76





2.5.4 Manually releasing the brakes

2.5.4 Manually releasing the brakes

General

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

The brakes may be released by:

• Internal brake release unit: using push buttons on the robot. This requires either the controller to be connected or that power is supplied to the R1.MP

connector, according to the section

Supplying power to connector R1.MP

on page 78 .

Location of brake release unit

The internal brake release unit is located as shown in the figure.

Brake release at base

The figure below shows the unit located at the base.

xx0200000375

Internal brake release unit with push buttons, located on the robot base

Brake release at frame

The figure below shows the unit located at the frame.

xx0200000376

-



Internal brake release unit with push buttons, located on the robot frame


77



2.5.4 Manually releasing the brakes

Continued

Releasing the brakes

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

1

Action Note

The internal brake release unit is equipped with buttons for controlling the axes brakes.

The buttons are numbered according to the numbers of the axes.

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

Supplying power to connector R1.MP on page 78 .

Buttons are shown in figure

Location of brake release unit on page 77 .

2

DANGER

3

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

Make sure no personnel is near or beneath the robot arm!

Release the holding brake on a particular robot axis by pressing the corresponding button on the internal brake release unit.

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 on the robot in order to enable the brake release buttons.

Action Note

1

DANGER

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

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

78 xx0600002937





2.5.5 Lifting the base plate

2.5.5 Lifting the base plate


Equipment

Lifting eye, M16

Lifting slings

Hole configuration

Article number

3HAC14457-4

Note

3 pcs

Length: approx. 2 m xx0200000096

A Attachment holes for lifting eyes (x3)

Lifting, base plate

Action Note

1

2

3

CAUTION

The base plate weighs 353 kg. All lifting accessories used must be sized accordingly.

Fit lifting eyes in specified holes.

Fit lifting slings to the eyes and to the lifting accessory.

Shown in figure

Hole configuration on page 79

.

CAUTION

Lift and move the base plate very slowly. If the base plate starts to swing it is a risk for injuries or damage.





2.5.6 Securing the base plate

2.5.6 Securing the base plate

Base plate, dimensions

D G

F

B

B

H

2x R525

598,31

560,85

487,01

(Ø 800)

12x M24

Ø1 A

455

243,5

A

A

E

0

73,84

111,30

C C

2x 50x45º

857,3

1020

4x48

0.3

Common Zone

E, F, G, H

A

A-A

Ø 45P7

Ø1.5

3x45º

13

(2)

(48)

B-B

(4x)

6,3

(2)

1,6

3x45º

(2)

13

3x R1

45

K

7 c

47

0

+0,5

52,5º

0,25 c

(2)

(2x R22,5)

3x4

3x 90º

C-C D

1,6 xx1000001053

E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact surface to the other)


80






Continued xx0400000715

A Four holes for alternative clamping, 4x Ø18





81



Continued

Base plate, orienting grooves and leveling bolts

The illustration below shows the orienting grooves and attachment holes for leveling bolts in the base plate.

B A

B

A

B

B

A xx1500000312

A

B

Orienting grooves (3 pcs)

Levelling bolts, attachment holes (4 pcs)


82






Continued

Base plate, guide sleeve holes

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

A xx0300000045

A Guide sleeve holes (2 pcs)


Equipment

Base plate

Standard toolkit

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

-

Article number Note

3HAC12937-7 Includes

• guide sleeves, 3HAC12937-3

• levelling screws, 9ADA120-79

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


Standard tools on page 439 .

These procedures include references to the tools required.

Base plate

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

1

Action

Make sure the foundation is levelled.

Note




83




Continued

Action Note

2

CAUTION

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

3

4

5

6

7

8

9

Position base plate in relation to the robot work location using the grooves in the base plate.

Lift the base plate to its mounting position.

Shown in figure

Base plate, orienting grooves and leveling bolts on page 82 .

Detailed in section

on page 79 .

Lifting the base plate

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

Attachment holes: 16 pcs.

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

Shown in figure

Base plate, orienting grooves and leveling bolts on page 82 .

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

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

Recheck the four contact surfaces on the base plate to make sure the base plate is levelled and flat.

If it is not, use pieces of sheet metal or similar to bring the base plate to a levelled position.

Maximum allowed deviation all over the base plate, from one contact surface to the other: 0.3 mm.

84





2.5.7 Orienting and securing the robot

2.5.7 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.

Illustration, robot fitted to base plate

This illustration shows the robot base fitted to the base plate.

xx0100000107

A

B

C

D

Robot attachment bolts and washers, 12 pcs (M24 x 140)

Orienting grooves in the robot base and in the base plate

Levelling screws

Base plate attachment screws

Attachment screws

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

Suitable screws, lightly lubricated:

Quality:

Suitable washer:

Tightening torque:

M24 x 140

Quality 8.8

Thickness: 4 mm

Outer diameter: 44 mm

Inner diameter: 25 mm

725 Nm





85



Continued

Securing the robot

Use this procedure to secure robot to base plate after fitting plate to the foundation.

1

2

3

Action

Lift the robot.

Note

See section

Lifting robot with lifting slings on page 73 .

See section

Lifting robot with roundslings on page 75 .

Move robot to the vicinity of its installation location.

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

Shown in figure

Base plate, guide sleeve holes on page 83 .

Note

One of the guide sleeve holes is elongated!

4

5

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

Fit the bolts and washers in the base attachment holes.

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

Specified in

Attachment screws on page 85 .

Shown in figure

Illustration, robot fitted to base plate on page 85 .

Note

Lightly lubricate screws before assembly!

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


86






Continued

Hole configuration, base

This illustration shows the hole configuration used when securing the robot.

xx0300000046

Cross section, guide sleeve hole

This illustration shows the cross section of the guide sleeve holes.

xx0100000109




87


2.5.8 Fitting equipment on robot

2.5.8 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

All equipment and cables used on the robot, must be designed and fitted not to damage the robot and/or its parts.

Illustration, fitting of extra equipment on lower arm

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

Make sure not to damage the robot cabling on the inside of the lower arm when fitting extra equipment. Always use appropriate attachment screws!

xx0700000722

Robot variant

IRB 7600 - 500/2.55

IRB 7600 - 500/2.3

IRB 7600 - 400/2.55

IRB 7600 - 340/2.8

IRB 7600 - 325/3.1


88

A

2442 mm

2192 mm

2442 mm

2692 mm

2942 mm




Robot variant

IRB 7600 - 130/3.5



Continued

A

3398 mm xx0100000120

Illustration, fitting of extra equipment on upper arm

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

xx0100000116





89




Robot variant

IRB 7600 - 500/2.55

IRB 7600 - 500/2.3

IRB 7600 - 400/2.55

IRB 7600 - 340/2.8

IRB 7600 - 325/3.1

IRB 7600 - 150/3.5

A

1056 mm

806 mm

1056 mm

1306 mm

1556 mm

2012 mm

Illustration, fitting of extra equipment on frame

The mounting holes available for fitting extra equipment on the frame are shown below.

xx0100000117


90







Tool flange, standard

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

xx0100000119





91



Continued

Tool flange, LeanID

The illustration below shows the tool flange for option 780-4 LeanID.

12x

30°

12 H7

15min 16max

0,07 A

2 X

B

1,6

I

15°

3,2

2,5

G

12x M16 min 24

Drill max 25,5 flat bottom hole

0,3 A B

1x45

200

12 H7

15min 30max

0,07 A

I

5°

1 x 45

SECTION I-I

0,08 CD

A

0,04 A xx1600000980

Fastener quality

When fitting tools on the turning disk (see the figures above), only use screws with quality 12.9.

Standard screws with quality 8.8 may be used when fitting other equipment to the mounting holes.

92




2.5.9 Installation of base spacers (option)

Illustration, installation of base spacers


2.5.9 Installation of base spacers (option) xx0500001570

A

B

C

Base spacer (4 pcs)

Guide sleeve (4 pcs)

Attachment screws and washers (12 pcs)


Equipment

Base spacers

Art. no.

3HAC021899-002

Base plate

Standard toolkit -

3HAC12937-7



Note

Includes mounting set with attachment screws and mounting instruction.




93



2.5.9 Installation of base spacers (option)

Continued

Equipment

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

Art. no.

Note


Installation, base spacers

The procedure below details how to fit the base spacers between the robot and the base plate.

Action Note

1

DANGER

Turn off all:

• electric power supply to the robot

• hydraulic pressure supply to the robot

• air pressure supply to the robot

Before entering the robot working area.

2

3

4

5

6

7

Unfasten the robot from the foundation, if fastened, and lift it away with lifting slings.

Make sure the robot is positioned in the most stable position; the transport position!

Install the base plate to the foundation, if not used previously.

Fit the four base spacers and guiding sleeves to the base plate.

Detailed in section

Lifting robot with lifting slings on page 73 .

Detailed in section

Securing the base plate on page 80

.

Shown in the figure

Illustration, installation of base spacers on page 93

.

Lift the robot with lifting slings and move it to the prepared base plate.

Guide the robot with the guiding sleeves as lowering it towards the base plate and spacers.

Fasten the robot base to the spacers with enclosed attachment screws and washers.

M24 x 240, tightening torque: 775 Nm.

8

DANGER

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

First test run may cause injury or damage on page 31 .

94





2.5.10 Extended working range, axis 1 (option 561-1)

2.5.10 Extended working range, axis 1 (option 561-1)

Overview

The working range of axis 1 can be increased from standard range to extended ±

220º.

Extending the working range

1

Action

Remove the mechanical stop pin from axis

1 (A).

Note/Illustration xx0400001034

2

3

Option 561-1 requires installation of option

810-1 Electronic Position Switch es.

Configure Electronic Position Switches.

See Application manual - Electronic Position Switches .

Redefine the software working range limitations in the system parameters, topic

Motion . The Arm parameters Upper Joint

Bound and Lower Joint Bound must be changed to 3.84 respectively -3.84. The values are in radians, that is 3.84 radians

= 220 degrees.

How to define the range of movement in

RobotWare 4.0 is detailed in User’s guide - S4Cplus (BaseWare OS 4.0), chapter System Parameters - topic Manipulator .

The system parameters that must be changed ( Upper joint bound and Lower joint bound ) are described in Technical reference manual - System parameters .




95


2.5.11 Installation of cooling fan for motors (option)

2.5.11 Installation of cooling fan for motors (option)

General

A cooling fan can be installed on the motors of axes 1 or 2.

Cooling fans for axes 1 and 2 can not be combined!

The cabling for the fans is available in different designs:

• complete cabling, including connections for both cooling fans and position switches, at axes 1 and 2. Installation of this complete cabling is detailed in section

Installation of cable harness for position switches and fans on page 121 .

• separate cabling for axis 1 or 2, including only connections for the cooling fans on axes 1 or 2. Installation of this cabling is detailed in section

Installation, separate fan cabling axis 1 or 2 on page 100 .

If both cooling fans and position switches are installed on the robot, the complete cabling must be used! It can not be combined with the separate cabling.

Location of cooling fans

The fans are installed on the motors, axes 1 or 2, as shown in the figure below.

xx1800000169

A

B

Cooling fan, axis 1

Cooling fan, axis 2 xx1800000170


96




Cooling fan



Continued

The details of the cooling fan are shown in the figure below.

xx0500002158

A

B

C

D

Fanbox

Attachment screws, fanbox plates (9 pcs)

Groove in the connector

Tightening screws, fanbox (3 pcs)


Equipment Article number

Cooling fan 3HAC15374-1

Cabling cooling fan, axes 1 or 2.

3HAC023599-001

Plate for customer connections

3HAC025778-001

Note

Additional cabling to and inside the controller

Material set fan axes 1 and

2

-

3HAC023999-001

Choose this cabling if equipping the robot with cooling fans on axis 1 or 2.

An additional connection plate must be fitted to the robot base, if not already installed. The plate is shown in the figure

Plate for customer connections, at base on page 98

.

Specified in section

Position switch cables, robot base to controller (option) on page 127 .

The set includes:

• fan axes 1 & 2 cable harness

• plate, customer

• attachment screws and nuts.




97




Continued


Cable harness inside controller

3HAC025488-001

Locking liquid -

Note

Standard toolkit

Circuit diagram


-

-

Loctite 243. Used for the three tightening screws.



.

See chapter



Plate for customer connections, at base xx0500002301

A

B


Attachment screws, 3 pcs, M6x16 quality 8.8-A2F


98






Continued

Installation, fan

The procedure below details how to install the cooling fan on any of the motors, axes 1-3 .

Action Note

1

DANGER

Turn off all:





2 Prepare the fanbox for installation:

• disassemble the two parts of the box by removing the nine attachment screws

• loosen the three tightening screws , to avoid damaging the surfaces of the motor when fitting the fanbox

• turn the connector to the correct position; axis 1: groove pointing inwards, as shown in the figure

Cooling fan on page 97

. Positions for axis 2 and 3 are shown in the figure

Location of cooling fans on page 96 .

Shown in the figure

Cooling fan on page 97

.

3 Temporarily lift the motor cabling out of the way of the current motor to make room for the fanbox.

4

5

Fit the parts of the fanbox to the motor and reassemble with the nine attachment screws .

Lift the box (axis 1) so that it does not rest directly on the robot and secure the box with the three tightening screws, using locking liquid. Tighten them properly so that the box is firmly attached to the motor.

6 Install the cabling and make adjustments in RobotWare, as described in the following procedures.

Separate cabling for axis 1 or 2

The figure below shows the cabling used only for the fan on axis 1 or 2.

xx0500002173





99



Continued

A

B

C

Cable bracket

Connector R1.SW2/3, connected to the robot base

Connector R3.FAN2, connected to the fan of axis 1 or 2

Installation, separate fan cabling axis 1 or 2

The procedure below details how to install the separate cabling for the cooling fan of axis 1 or 2.

1

Action

Move the robot to its calibration position.

Note

This is detailed in section

Synchronization marks and synchronization position for axes on page 400

.

2

DANGER

3

Turn off all:





Remove the rear cover plate from the robot base.

4

5 xx1800000161

Remove the cable bracket (A) Shown in the figure

Separate cabling for axis 1 or 2 on page 99

Fit the plate for customer connections , if not already fitted, to the connection plate of the robot base.

Art. no. is specified in

Required equipment on page 97

.

6 Run the cabling up through the base and frame, beneath the balancing device.

xx1800000162


100






Continued

7

Action

Secure the cable bracket to the bracket of the robot cabling inside the frame.

Run the cable underneath the robot cabling and out through the side of the frame, at motor, axis

1 . The correct cable run is shown in the figure to the right!

Note

Note

There is a risk of the balancing device damaging the cable if it is not protected by the robot cabling!

8

9

10

11 xx0500002174

A Cable bracket. Also shown in the figure

Separate cabling for axis 1 or 2 on page 99

.

Connect the connector R3.FAN2 to the fan of axis

1 or 2.

Note

Fans on both axis 1 and 2 can not be used at the same time!

Connect the connector R1.SW2/3 to the base of the robot. Make sure that the cabling, run through the frame and base, is not twisted and runs freely from the robot cabling.

Refit the rear cover plate to the robot base.

Install additional cabling to and inside the controller.

Also make adjustments in RobotWare, as described in the following procedure.

Cabling is specified in section

Position switch cables, robot base to controller (option) on page 127

.

Adjustments in RobotWare

1

Action

Modify the settings in RobotWare to include the cooling fans.

Note

RobotWare 4.0: modify the settings in RobInstall. RobotWare 4.063 and older must be updated with a newer release.

RobotWare 5.0: change the settings in the

Modifying options dialogue, by using the

Modify Controller System Wizard in the System Builder of RobotStudio. Read more about modifying the system in Operating manual -

RobotStudio .



101



2.5.12 Installation of Foundry Plus Cable guard (option no. 908-1)

2.5.12 Installation of Foundry Plus Cable guard (option no. 908-1)

Introduction

How to install the Foundry Plus Cable guard is described in the instruction delivered with the cable guard.

Separate instructions for IRB 2600, 4600, 6620, 6640, 6650S, 6660 and 7600 are available in English, German, French, Spanish and Italian and can be found for registered users on myABB Business Portal (www.myportal.abb.com) and delivered with the Cable guard, article number 3HAC035933-001.

102





2.5.13 Loads fitted to the robot, stopping time and braking distances

2.5.13 Loads fitted to the robot, stopping time and braking distances

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

Incorrectly defined loads may result in operational stops or major damage to the robot.

References

Load diagrams, permitted extra loads (equipment) and their positions are specified in the product specification. The loads must be defined in the software.

• User’s guide - S4Cplus (BaseWare OS 4.0)

• Operating manual - IRC5 with FlexPendant

Stopping time and braking distances

The performance of the motor brake depends on if there are any loads attached to the robot. For more information, see product specification for the robot.




103


2.5.14 Signal lamp (option)

2.5.14 Signal lamp (option)

Description

A signal lamp with a yellow fixed light can be mounted on the robot, as a safety device.

Installation

See the assembly instruction delivered with the signal lamp.

Function

The lamp is active in MOTORS ON mode.

Further information

Further information about the MOTORS ON/MOTORS OFF mode may be found in the product manual for the controller.

104





2.6.1 Axes with restricted working range

2.6 Restricting the working range

2.6.1 Axes with restricted working range

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 axes 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 . Note 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.

Note

Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures.




105


2.6.2 Mechanically restricting the working range of axis 1

2.6.2 Mechanically restricting the working range of axis 1

General

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

Mechanical stops, axis 1

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

xx0300000049

A

B

Additional mechanical stop

Stop pin


Equipment, etc.

Mechanical stop for axis 1, 7.5°

Mechanical stop for axis 1, 15°

Standard toolkit -

Article number

3HAC11076-1

3HAC11076-2

Note

Includes attachment screws and an assembly drawing.

Includes attachment screws and an assembly drawing.







Continued

Equipment, etc.

User’s guide - S4Cplus (BaseWare OS

4.0) (BaseWare 4.0)


-


Article number is specified in section

References on page 10 .

Installation, mechanical stops axis 1

Use this procedure to fit the additional mechanical stops to axis 1 of the robot. An assembly drawing is also enclosed with the product.

Action Note

1

DANGER

Turn off all:





2

3

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

Mechanical stops, axis 1 on page 106

.


Adjust the software working range limitations

(system parameter configuration) to correspond to the mechanical limitations.




4

WARNING

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

Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision.




107




General

The working range of axis 2 is limited by fixed mechanical stops and can be reduced by adding up to six additional mechanical stops with 15 graduation in respective direction.


The illustration shows the mounting position of the mechanical stops on axis 2.

xx0300000047

A

B

Additional mechanical stops

Fixed mechanical stop


Equipment, etc.

Mechanical stop set, axis 2

Art. no.

3HAC11077-1

Standard toolkit -

Note

Includes six stops, 3HAC11407-1, each one restricting the working range by

15°.

Includes attachment screws.



.


108






Continued

Equipment, etc.

User’s guide - S4Cplus

(BaseWare OS 4.0) (Robot-

Ware 4.0)


-

Art. no.

Note

Art. no. is specified in section



Use the procedure to fit the mechanical stops for axis 2 to the robot. An assembly drawing is also enclosed with the product.

Action Note

1

DANGER

Turn off all:





2

3

Fit and tighten the additional stops in a row, starting from the fixed stop.


Shown in the figure


.

The software working range limitations must be redefined to correspond to the changes in the mechanical limitations of the working range.




4

WARNING






109




General

The working range of axis 3 is limited by fixed mechanical stops and can be reduced by adding additional mechanical stops with 20 graduation in respective direction.


The illustration shows the mounting position of the mechanical stops on axis 3.

The figure shows IRB 7600 but the principle is the same.

xx0300000048

A

B

C

Additional mechanical stops

Fixed mechanical stop

Attachment screw M16x60 quality 12.9


110







A

B

Mechanical stop pin, axis 3

Attachment screw and washer


Equipment, etc.

Mechanical stop set, axis 3

Art. no.

3HAC13128-2

Standard toolkit

User’s guide - S4Cplus (Base-

Ware OS 4.0) (RobotWare 4.0)


-

-

Note

Includes six stops, one with 80° restriction, 3HAC12708-4 (use when limitation angle >=80), and five with

20°, 3HAC 12708-2.

Includes attachment screws.



.

Art. no. is specified in section






111



Continued


Use the procedure to fit the mechanical stops for axis 3 to the robot. An assembly drawing is also enclosed with the product.

Action Note

1

DANGER

Turn off all:





2

3

Fit and tighten the additional stops in a row, starting from the fixed stop.


Shown in the figure


Note

The software working range limitations

(system parameters) must be redefined to correspond to the changes in the mechanical limitations of the working range.




4

WARNING



112





2.6.5 Installation of position switches (option)

2.6.5 Installation of position switches (option)

General

Position switches can be installed on axes 1-3. The position switches include cams as shown in the figures below. The system parameter configuration must also be updated.

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

• Fitted by ABB Robotics 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 kits to be completely fitted to the robot and adjusted by the user.


Description

Position switch, axis 1

Art. no.

3HAC15715-1



3HAC15715-2

3HAC15715-3

Cabling, position switches and cooling fans, axes 1, 2 and 3

3HAC15390-1

Plate for customer connections 3HAC025778-001

Note

Includes position swtich and plate for customer connections.

Includes only the position switch.

Includes only the position switch.

Cabling to be installed on the robot.

Additional cabling to and inside the controller

Connector kit R1.SW1

Connector kit R1.SW2/3

-

3HAC17252-1

3HAC17253-1

An additional connection plate must be fitted to the robot base, if not already installed. The plate is shown in the figure

Plate for customer connections, at base on page 120 .

Specified in section

Robot cabling and connection points on page 125 .





113



Continued

Axis 1

The illustration below shows the position switch for axis 1. There is no extra cabling installed on the robot, as for axes 2 and 3. Instead the switch is connected directly to the connector in the base, R1.SW1.

xx0100000158

A

B

C

D

E

F


Cam

Set screw, cam (cam stop)

Protection sheet

Rail

Rail attachment


114




Axis 2



Continued

The illustration below shows the position switch for axis 2. In addition to the shown components, cabling must also be installed from the switch to the robot base.

xx0100000159

A

B

C

E

F


Cam


Rail

Rail Attachment





115



Continued

Axis 3

The illustration below shows the position switch for axis 3. In addition to the shown components, cabling must also be installed from the switch to the robot base.

Specifications xx0100000160

A

B

C

E

F


Cam


Rail

Rail attachment

Maximum voltage/current for the position switches:

Parameter

Voltage

Current

Value

Max. 50 VDC

Max. 1 A


116






Continued

Connections

The position switches are 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 kit is recommended, art.

no. is specified in

Required equipment on page 113 !

• R1.SW2/3 at the robot base. Customer connection kit is recommended, art.

no. is specified in


Further information about the cables and connection points, see section

Robot cabling and connection points on page 125

.

Fitting and adjusting cams and stops

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

1

2

3

4

5

6

Action

Cut the cam to a suitable length.

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

Note

Use a sharp knife and rubber hammer or similar.

Shown in

Illustration, cutting the cam on page 118 .

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

Cut the part of the cam running in the profile to 90°!

Also see

Illustration, cutting the cam on page 118

below!

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

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

Shown in

Illustration, adjust and secure cams on page 118 .

Install the cabling for axes 2 and/or 3.

Detailed in section

Installation of cable harness for position switches and fans on page 121 .





117



Continued

Illustration, adjust and secure cams

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

xx0100000113

A

B

C

Cam stop, M5 nut and M5 x 6 set screw

Adjustable cam

Profile

Illustration, cutting the cam

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

xx0100000114

A Remove the gray section


118




Illustration, attachment plate for axis-2 switch

A








119



Continued

Plate for customer connections, at base xx0500002301

A

B


Attachment screws, 3 pcs, M6x16


120




Cable harness for position switches and fans, axes 1-3




A

B

C

Cable bracket, frame

Cable bracket, lower arm

Cable bracket, upper arm

R1.SW2/3 Connected to the robot base

R3.FAN2

Connected to the fan of axis 1 or 2

R3.FAN3

Connected to the fan of axis 3

R2.SW2

R2.SW3

Connected to the position switch of axis 2

Connected to the position switch of axis 3

Installation of cable harness for position switches and fans

The procedure below details how to fit the complete cable harness for position switches and cooling fans to the robot.

1

2

Action


Note

DANGER

Turn off all:









121



Continued

3

Action

Remove the rear cover (A) from the robot base and replace the protection (B) with a plate for customer connections (if not already mounted).

Note

4

5

Run the cabling through the base and frame of the robot, up beneath the balancing device.

Run and secure the cabling inside the frame as detailed below and as shown in the figure to the right:

• Secure the cable bracket (A) to the bracket of the robot cabling.

• Run the cable for the fan of axis 1 or

2 under the robot cabling and through the side of the frame at motor axis 1.

• Secure the cabling going up to the axis 3 fan and position switch with existing velcro strap (B), attached around the robot cabling.

• Connect the connector R2.SW2 to the position switch of axis 2.

Note

There is a risk of the balancing device damaging the fan cable if it is not protected by correct routing underneath the robot cabling!

xx0500002306

Art. no. for the plate is specified in


xx0500002309

A Cable bracket, frame. Also shown in the figure

Cable harness for position switches and fans, axes 1-3 on page 121

.

B Velcro strap

C Connector R2.SW2


122






Continued

6

Action

Connect the connector R3.FAN2 to the fan of either axis 1 or axis 2.

If no fan is used, strap the cabling together with the motor cabling so that the connector stays close to the frame, as shown in the figure to the right.

Note

7 Run the remaining cable harness up through the lower arm and:

• secure with the bracket, lower arm , as shown in the figure to the right.

• connect the connector R2.SW3 to the position switch of axis 3.

• secure the cable going to the fan of axis 3, together with the robot cabling with a velcro strap.

xx0500002312

8 xx0500002313

A Bracket, lower arm. Also shown in the figure

Cable harness for position switches and fans, axes 1-3 on page 121 .

B Bracket for robot cabling

C Connector R2.SW3

D Velcro strap

Secure the axis 3 fan cable with the bracket, upper arm .

Shown in the figure

Cable harness for position switches and fans, axes 1-3 on page 121

.




123




Continued

9

Action

Connect the connector R3.FAN3 to the fan of axis 3. If no fan is used, strap the cable together with the robot cabling.

Note xx0500002314

10

11

12

Connect the connector R1.SW2/3 to the base of the robot. Make sure that the cabling, run through the base, frame and lower arm, is not twisted and is running free from the robot cabling.

Refit the rear cover to the robot base.

Install additional cabling to and inside the control cabinet.

Cabling is specified in section:

•


124





2.7.1 Robot cabling and connection points

2.7 Electrical connections

2.7.1 Robot cabling and connection points

Introduction

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

Robot cables

Description

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 125 .

Position switch cables (option)

Also includes fan cables.

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

Also handles supply to and feedback from cooling fans.



.

Fan cables (option)

Customer cables (option)

Handles supply to and feedback from any cooling fan on the robot.


Fan cables (option) on page 128 .

Handles communication with equipment fitted on the robot by the customer, low voltage signals and high voltage power supply + protective ground.

The customer cables also handle databus communication.

See the product manual for the controller, see document number in


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) or Application manual - External axes (M2000) , see document number in

References on page 10

.

Robot cables

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

Cable sub-category

Robot cable, power

Robot cable, signals

Description

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

Connection point, cabinet

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

XS1

XS2

Connection point, robot

R1.MP

R1.SMB





125



Continued

Robot cable, power

Cable

Robot cable, power: 7 m




Art. no.

3HAC026787-001

3HAC026787-002

3HAC026787-003

3HAC026787-004

Robot cable, signals

Cable

Robot cable signal, shielded: 7 m




Art. no.

3HAC7998-1

3HAC7998-2

3HAC7998-3

3HAC7998-4

Bending radius for static floor cables

The minimum bending radius is 10 times the cable diameter for static floor cables.

A

B xx1600002016

A

B

Diameter

Diameter x10


126






Continued

Grounding and bonding point on manipulator

There is a grounding/bonding point on the manipulator base. The grounding/bonding point is used for potential equalizing between control cabinet, manipulator and any peripheral devices.

xx1500001601

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 sections and

Installation of position switches (option) on page 113

.

Cabling between robot base and controller

In a M2000 and M2000A robot system, the cables specified below are used for both position switches and cooling fans.

In a M2004 robot system, however, the cables below are only used for position switches. Cabling for the cooling fans is specified in the table

Fan cables (option) on page 128 .

Cable Art. no.

Position switch cable, axis 1, 7 m


3HAC13175-1

3HAC13175-2



3HAC13175-3

3HAC13175-4

Position switch cable, axes 2 and 3, 7 m 3HAC13176-1




Connection point, robot

R1.SW

R1.SW

R1.SW

R1.SW

R1.SW2/3

R1.SW2/3

R1.SW2/3

R1.SW2/3

Connection point, cabinet

XS8

XS8

XS8

XS8

XS58

XS58

XS58

XS58




127




Continued

Cabling inside control cabinet

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

Additional cabling must also be connected inside the control cabinet when installing fans for robot systems M2000 and M2000A (fan cabling for M2004 runs all the way from the robot base to the inside of the cabinet and the additional cabling specified below is therefor not needed).

-

Connection point 2 inside cabinet

Cable Art. no.

Bracket in the cabinet wall (M2000 and M2000A)

3HAB7286-5

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

Harness position switch (M2000) 3HAC15899-1

Harness position switch (M2000A) 3HAC14617-1

Harness position switch axis 1

(M2004)

3HAC021117-001

Harness position switch axes 2 and

3 (M2004)

3HAC021116-001

Cable harness fans (M2000)

Cable harness fans (M2000A)

3HAC15666-1

3HAC17832-1

-

Connection point 1 inside cabinet

-

XS58

XS58

XS8

XS58

XS57

XS57

-

XP57

XP57

XT8.1 and XT8.2

XT58.1 and

XT58.2

XT31

XT31:10

XT31:12

Fan cables (option)

These cables are not included in the standard delivery, but are included in the delivery if the fan option is ordered. The cables are completely pre-manufactured and ready to plug in.

Cabling to be installed on the robot is specified in section

Installation of cooling fan for motors (option) on page 96

.

Cabling between robot base and control cabinet, cooling fans, M2004

The cables specified below are specific for the IRC5 controller and used when the robot is equipped with cooling fans. The cabling for the cooling fans runs all the way from the robot base to the inside of the cabinet. Fans can also be ordered without cables.

If equipping the robot with cooling fans, use the cabling specified below. The cables for cooling fans listed below are used together with a distributing cable, also specified below.

Cable

Harness - cooling, 7 m

Art. no.

3HAC022723-001

Harness - cooling, 15 m 3HAC022723-004

Harness - cooling, 22 m 3HAC022723-005

Connection point

Distributing cable: R1.FAN.SW2/3

Inside cabinet: A43.X10 and A43.X11











Continued

Cable

Harness - cooling, 30 m

Art. no.

3HAC022723-006

Connection point






129


2.8 Start of robot in cold environments

2.8 Start of robot in cold environments

Introduction

This section describes how to start the robot in a cold environment if it is not starting the normal way.

Problems with starting the robot

Event message from Motion Supervision

Use this procedure if an event message indicates a problem with Motion supervision at start-up. More information about Motion Supervision is found in Technical reference manual - System parameters .

1

2

3

Action

Turn off Motion Supervision.

Start the robot.

When the robot has reached normal working temperature, the Motion Supervision can be turned on again.

Note

Robot stopping with other event message

Use this procedure if the robot is not starting.

1

Action

Start the robot with its normal program but with reduced speed.

Note

The speed can be regulated with the

RAPID instruction VelSet .

Adjusting the speed and acceleration during warm-up

Depending on how cold the environment is and what program is being used, the speed might need to be ramped up until reached maximum. The table shows examples of how to adjust the speed:

Work cycles

3 Work cycles

5 Work cycles

5 Work cycles

5 Work cycles

More than 5 Work cycles

AccSet

20, 20

40, 40

60, 60

100, 100

100, 100

Speed/velocity v100 (100 mm/s) v400 (400 mm/s) v600 (600 mm/s) v1000 (1000 mm/s)

Max.

If the program consists of large wrist movements, it is possible that the reorientation velocity, which is always high in predefined velocities, needs to be included in the ramping up.

130




3 Maintenance

3.1 Introduction

3 Maintenance


Structure of this chapter

This chapter describes all the maintenance activities recommended for the IRB

7600.

It is based on the maintenance schedule found at 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 the information required to perform the activity, including required tools and materials.

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


Observe all safety information before conducting any service work.

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

Safety on page 21

before performing any service work.

Note

If the IRB 7600 is connected to power, always make sure that the IRB 7600 is connected to protective earth before starting any maintenance work.






131

3 Maintenance

3.2.1 Specification of maintenance intervals

3.2 Maintenance schedule and expected life

3.2.1 Specification of maintenance intervals

Introduction

The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 7600:

• Calendar time: specified in months regardless of whether the system is running or not.

• Operating time: specified in operating hours. More frequent running means more frequent maintenance activities.

• SIS: specified by the robot's SIS (Service Information System). A typical value is given for a typical work cycle, but the value will differ depending on how hard each part is run. The SIS used in M2000 and M2000A is further described in the section

Service Information System, M2000 on page 217

.

The SIS used in M2004 is further described in the Operating manual - Service

Information System .

Overhaul

Depending on application and operational environment a complete overhaul may be necessary in average around 40000 hours.

ABB Connected Services and its Assessment tools can help you to identify the real stress level of your robot, and define the optimal ABB support to maintain your robot working.

Contact your local ABB Customer Service to get more information.

132




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 following table.

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 the section

Expected component life on page 137

Instructions for how to perform the different maintenance activities are found in sections:

•

Inspection activities on page 138

•

Changing/replacement activities on page 181

•

Cleaning activities on page 212

Activities and intervals, standard equipment

The following tables specifies the required maintenance activities and intervals.

Inspecting activities

Maintenance activity

Equipment

Cleaning Robot

Interval Detailed in section

Inspection

Inspection

Motor seal i

Balancing device

-

Every:

• 12 months

Every:

• 6 months

Cleaning the IRB 7600 on page 214

Inspecting the motor seal on page 138

Inspecting the balancing device on page 158

i ii

Inspection

Inspection

Inspection

Inspection

Robot harness

Information labels

Dampers

Mechanical stops

Every:

12 months ii

Every:

•

Every:

•

Every:

•

12 months

12 months

12 months

Inspecting the cable harness on page 164

Inspecting the information labels on page 177

Inspecting the damper on axes 2 to 5 on page 171

•

Inspecting the axis-

1 mechanical stop pin on page 167

•

Inspecting the mechanical stops on axes 1, 2, and 3 on page 169

Only valid for robots that are equipped with Type B motors.

Type B motors include evacuation on the motor flange to indicate failure of primary sealing between the gearbox and the motor. Robots with protection type Foundry Plus have a sight glass installed in the evacuation holes.

See

Type A vs type B motors on page 429

.

Replace when damage or cracks is detected or life limit is approaching that specified in section

Expected component life on page 137 .




133


3 Maintenance


Continued

Changing activities

Note

It is very important not to mix different types of oil. The oil change intervals are determined based on the generation of the robot. For more information, see

Technical reference manual - Lubrication in gearboxes .


Equipment

Changing

Changing

Changing

Changing

Changing

Changing

Changing

Interval

Oil in axis-1 gearbox, robot generation 1:

Every:

• 12,000 hours

Oil in axis-1 gearbox, robot generation 2 and 3:

First change when DTC reads: i

6,000 hours

Second change when DTC

i

reads:

24,000 hours

Following changes:

Every 24,000 hours


Every:

• 12,000 hours


First change when DTC reads:

i

6,000 hours


i

reads:

24,000 hours

Following changes:

Every 24,000 hours


Every:

• 12,000 hours



i

6,000 hours


i

reads:

24,000 hours

Following changes:

Every 24,000 hours

Oil in axis-4 primary gearbox, all generations:


6,000 hours

i


i

reads:

24,000 hours

Following changes:

Every 24,000 hours

Detailed in section

•

Changing oil, axis-1 gearbox on page 183

Do not mix with other oils!

•


•


•


•




•



•






3 Maintenance


Continued i


Equipment

Changing

Changing

Changing

Changing

Changing

Changing

Interval

Oil in axis-4 secondary gearbox, robot generation 1:

Every:

• 12,000 hours

Oil in axis-4 secondary gearbox, robot generation 2 and 3:


6,000 hours

i


i

reads:

24,000 hours

Following changes:

Every 24,000 hours

Oil in axis-5 primary gearbox, all generations:


i

6,000 hours


i

reads:

24,000 hours

Following changes:

Every 24,000 hours

Oil in axis-5 secondary gearbox, robot generation 1:

Every:

• 12,000 hours

Oil in axis-5 secondary gearbox, robot generation 2 and 3:


i

6,000 hours


i

reads:

24,000 hours

Following changes:

Every 24,000 hours

Oil in axis-6 gearbox, all generations:


6,000 hours

i


i

reads:

24,000 hours

Following changes:

Every 24,000 hours

DTC = Duty Time Counter. Shows the operational time of the robot.

Detailed in section

•


•



•


•




•



•






135

3 Maintenance


Continued

Miscellaneous activities


Equipment

Cleaning Robot

Interval Detailed in section

-

Cleaning the IRB 7600 on page 214

Overhaul Robot Every:

40,000 hours

Replacement Battery pack, measurement system of type

RMU101 or

RMU102 (3-pole battery contact)

36 months or battery low alert i

Replacement Battery pack, measurement system with 2-pole battery contact, e.g.

DSQC633A

Battery low alert ii

Expected component life on page 137

Replacing the SMB battery on page 204

Replacing the SMB battery on page 204

Lubrication Balancing device bearings

Every:

12,000 hours iii i ii iii

The battery low alert (38213 Battery charge low ) is displayed when the battery needs to be replaced.

The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced.

See the replacement instruction for more details.

The battery low alert (38213 Battery charge low ) is displayed when remaining backup capacity

(robot powered off) is less than 2 months. The typical lifetime of a new battery is 36 months if the robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be extended with a battery shutdown service routine. See Operating manual - IRC5 with

FlexPendant for instructions.

Always lubricate the front eye bearing after refitting the shaft of the balancing device.

Activities and intervals, optional equipment

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

Equipment Interval Note Detailed in section Maintenance activity

Inspection

Inspection

Inspection

Inspection

Signal lamp Every:

12 months

Inspecting the UL lamp on page 179

Mechanical stop axes 1-2-3

Every:

12 months

Mechanical stops in addition to the fixed stops

Inspecting the mechanical stops on axes

1, 2, and 3 on page 169

Position switches, axes 1-

2-3

Every:

12 months

Inspecting the position switch on axes 1,

2, and 3 on page 173

Motor fans, axes

1-2-3

Every 12 months

Inspect the fans for contamination that could hinder the air supply. Clean if necessary.

-

136




3 Maintenance

3.2.3 Expected component life

3.2.3 Expected component life

General

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

Expected component life - protection type Standard

Component

Cable harness

Normal usage i

Expected life

40,000 hours ii

Note

Not including:

• Possible SpotPack harnesses

• Optional upper arm harnesses

Cable harness

Extreme usage iii

20,000 hours

ii

Not including:

• Possible SpotPack harnesses

• Optional upper arm harnesses

Balancing device

Gearboxes v

40,000 hours

40,000 hours iv i

Examples of "normal usage" in regard to movement: most material handling applications and limited use of bending backwards mode of axis 3.

ii

Severe chemical or thermal environments, or similar environments, can result in shortened life expectancy.

iii iv The given life for the balancing device is based on a test cycle of 4,000,000 cycles that starts from the initial position and goes to maximum extension, and back. Deviations from this cycle will result in differences in expected life!

v

Examples of "extreme usage" in regard to movement: press tending, very severe palletizing applications, major use of axis 1 movement and major use of bending backwards of axis 3.

Depending on application, the lifetime can vary. The Service Information System (SIS) that is integrated in the robot software can be used as guidance when planning gearbox service for the individual robot. This applies to gearboxes on axes 1, 2, 3 and 6. The lifetime of gearbox axes 4 and 5 is not calculated by SIS (See the Operating manual - Service Information System ). In some applications, such as Foundry or Washing, the robot can be exposed to chemicals, high temperature or humidity, which can have an effect on the lifetime of the gearboxes. Contact the local ABB

Robotics Service team for more information.

The SIS for an IRC5 system is described in the Operating manual - Service Information System .

For an M2000 system, the SIS is described in section

Service Information System, M2000 on page 217

.




137

3 Maintenance

3.3.1 Inspecting the motor seal

3.3 Inspection activities

3.3.1 Inspecting the motor seal

Purpose of evacuation holes

This section is only valid for robots that are equipped with Type B motors.

The motors include evacuation on the motor flange to indicate failure of primary sealing between the gearbox and the motor.

More information is found in

Type A vs type B motors on page 429 .

Location of evacuation hole on motor

The evacuation hole is located on each motor flange. The figure shows axis-1 motor as an example.

xx1500001057

Plug in the evacuation hole

Robots with protection type Standard have a protection filter installed in the evacuation hole.

Robots with protection type Foundry Plus have a transparent plug/sight glass installed in the evacuation holes.

xx1800000101

Protection filter (Standard).


138 xx1800000102

Transparent plug (Foundry Plus).




3 Maintenance

3.3.1 Inspecting the motor seal

Continued

Inspecting the evacuation hole

Action

1

DANGER

Turn off all:

• electric power supply

• hydraulic pressure supply

• air pressure supply to the robot, before entering the robot working area.

2

WARNING

Handling gearbox oil involves several safety risks.

Before proceeding, please read the safety information in the section


Note

3 Do a leakage check of the sight glass/evacuation hole of each motor.

If any oil is available on the sight glass or if any oil has been spilled out from the evacuation hole, replacement of the motor is recommended.

xx1500001057

Replacing of motors is described in the repair chapter

Motors on page 313 .




139

3 Maintenance

3.3.2 Inspecting the oil level in axis-1 gearbox

3.3.2 Inspecting the oil level in axis-1 gearbox

Location of gearbox

The axis-1 gearbox is located between the frame and base as shown in the following figure.

xx0200000111

A

B

C

D

E

Gearbox axis 1

Oil plug, filling

Motor, axis 1

Oil plug, inspection (not available in all designs)

Label, specifies type of oil in the axis 1 gearbox


Equipment, etc.

Lubricating oil

Standard toolkit -

Art. no.

See

Type and amount of oil in gearboxes on page 181 .

Note



.


140




3 Maintenance


Continued

Equipment, etc.


Art. no.

Note


Inspection through the oil plug, filling

Use this procedure to inspect the oil level in the axis-1 gearbox, when the oil plug for inspection (shown in figure

Location of gearbox on page 140 )

is not available .

Action Note

1

WARNING

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


2

3

4

5

6

7

DANGER

Turn off all:




Make sure that the oil temperature is +25°C

±10°C.

Remove the motor, axis 1.

This is a precaution to reduce the temperature dependency of the measurement.

Detailed in section

Removal, motor axis 1 on page 315 .

Measure the oil level through the motor hole.

Required oil level: 35-45 mm to the motor hole.

Adjust the oil level, if required.

Where to find type of oil and total amount is detailed in


Filling and draining detailed in


Refit the motor, axis 1.

Detailed in section

Refitting, motor axis 1 on page 316 .

8

WARNING

Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in Technical reference manual - Lubrication in gearboxes .





141

3 Maintenance


Continued

Inspection through the oil plug, inspection

Use this procedure to inspect the oil level in the axis-1 gearbox, when the oil plug for inspection (shown in figure

Location of gearbox on page 140 )

is available .

Action Note

1

WARNING



Safety risks during work with gearbox lubricants (oil or grease) on page 41

.

2

3

DANGER

Turn off all:





±10°C.

4

5

Open the oil plug, inspection .

Measure the oil level.

Required oil level: 0-10 mm


Shown in the figure

Location of gearbox on page 140

.

A

142

6 Adjust the oil level, if required.

7

8

Refit the oil plug, inspection.

WARNING


B

C xx1400002785

A Oil plug hole

B Required oil level

C Gearbox oil



Detailed in section


.





3 Maintenance



Different designs

The cover of the axis-2 gearbox is available in different designs, with different locations of the oil plug hole for filling. The oil plug hole of the later design is located

33 mm lower than on the earlier design. The measured distance to the oil level varies, depending on the design of the cover.

Oil plug, early design

The axis-2 gearbox is located in the lower arm rotational center. The following figure shows the early design of the gearbox cover.

D

B

A

C xx0300000068

A

B

C

D

Gearbox, axis 2 (behind the motor attachment, not shown in figure)

Oil plug, filling (early design)

Oil plug, draining

Label, specifies the type of oil in the axis-2 gearbox





143

3 Maintenance


Continued

Oil plug, later design

The axis-2 gearbox is located in the lower arm rotational center. The following figure shows the later design of the gearbox cover.

D

A

E

B

C

D

A

B

C xx0200000112

C

D

E

A

B

Gearbox, axis 2 (behind the motor attachment, not shown in figure)

Oil plug, filling/inspection (later design)

Oil plug, draining

Label, specifies the type of oil in axis-2 gearbox

Oil plug, ventilation (later design)


Equipment etc.

Lubricating oil

Standard toolkit


-

Art. no.

See


Note



.


Inspecting the oil level in axis-2 gearbox

Use this procedure to inspect the oil level in the axis-2 gearbox.

Action Note

1

WARNING




144




3 Maintenance


Continued

Action Note

2

3

4

5

DANGER

Turn off all:





±10°C.


Open the oil plug, filling/inspection (two different designs).

Read more about the differences in


!

A Measure the oil level.

Required oil level, early design: 30-45 mm

Required oil level, later design: 0-15 mm


7

8

Refit the oil plug, filling.

WARNING


B

C xx1400002785

A Oil plug hole


C Gearbox oil

Shown in the figures

Oil plug, early design on page 143

or

Oil plug, later design on page 144

!


Type and amount of oil in gearboxes on page 181

.

Detailed in section

Filling, oil on page 188

.





145

3 Maintenance




The axis-3 gearbox is located in the upper arm rotational center as shown in the following figure.

xx0200000113

A

B

C

D

Gearbox, axis 3

Oil plug, filling/inspection

Oil plug, draining

Label, specifies the oil type of axis-3 gearbox


Equipment

Lubricating oil

Standard toolkit -

Art. no.

See


Note



.





3 Maintenance


Continued

Equipment


Art. no.

Note




Action Note

1

WARNING



2 Move the robot to the calibration position.

Detailed in section


.

3

4

5

6

DANGER

Turn off all:





±10°C.

Open the oil plug, filling/inspection .


Shown in the figure


!

A



B

C xx1400002785

A Oil plug hole


C Gearbox oil





147

3 Maintenance


Continued

7

Action


8

9

Refit the oil plug.

WARNING


Note



.

Detailed in section


.


148




3 Maintenance




The axis-4 gearbox is located at the rear of the upper arm as shown in the following figure.

xx0200000107

A

B

C

D

E

F

G

Upper arm housing

Cover, axis-4 gearbox

Oil plug, filling/inspection, secondary gearbox

Oil plug, draining, secondary gearbox

Oil plug, filling/inspection, primary gearbox

The oil plug for draining of the primary gearbox is not shown in the figure

Label, specifies the type of oil in the axis-4 secondary gearbox

Label, specifies the type of oil in the axis-4 primary gearbox


Equipment, etc.

Lubricating oil

Art. no.

See


Note




149


3 Maintenance


Continued

Equipment, etc.

Standard toolkit


-

Art. no.

Note






Action Note

1

WARNING



2 Move the robot to the calibration position.


Synchronization marks and synchronization position for axes on page 400 .

3

4

5

6

DANGER

Turn off all:





±10°C.


Open the oil plug, filling/inspection, in the primary gearbox.

Shown in the figure


!

A Measure the oil level.


B

C xx1400002859

A Oil plug hole


C Gearbox oil


150




3 Maintenance


Continued

7

8

9

Action

Add oil if required.

Note



.

Detailed in section


.

Open the oil plug, filling/inspection, in the secondary gearbox.

Shown in the figure


!



A

10 Add oil if required.

11

12

Refit the oil plugs.

WARNING


B

C xx1400002785

A Oil plug hole


C Gearbox oil



.

Detailed in section


.





151

3 Maintenance




The axis-5 gearbox is located in the wrist unit as shown in the following figure.

A

B

C

D

E

F G

C

D

E

F

G xx0200000108

A

B

Wrist housing


The oil plug for draining of the primary gearbox is on the opposite side of the wrist housing, not shown in the figure.


Oil plug, draining/inspection, secondary gearbox


Oil plug, filling, secondary gearbox






3 Maintenance


Continued


Equipment etc.

Lubricating oil

Standard toolkit


-

Art. no.

See


Note




Inspecting oil level in axis-5 gearbox


Action Note

1

WARNING



2 Run the robot to the calibration position.



3

4

5

6

DANGER

Turn off all:





±10°C.

Open the oil plug, filling/inspection , in the primary gearbox .


Required oil level to the upper edge of the filling and inspection oil plug hole (a): 80-96 mm


Shown in the figure


.




xx0500002222


153

3 Maintenance


Continued

7

Action


8

9

Open the oil plug, draining/inspection , in the secondary gearbox .



Note



Detailed in section


Shown in the figure


.

A


11

12


WARNING


B

C xx1400002785

A Oil plug hole


C Gearbox oil



Detailed in section



154




3 Maintenance




The axis-6 gearbox is located in the center of the wrist unit as shown in the following figure.

xx0200000114

A

B

C

D

Gearbox, axis 6

Oil plug, filling/inspection (notice the different locations of the plug, shown as

B

1 and B

2

)

Oil plug, draining (can be located on the turning disk instead)

Label, specifies the type of oil in gearbox axis 6


Equipment

Lubricating oil

Standard toolkit -

Art. no.

See


.

Note






155


3 Maintenance


Continued

Equipment


Art. no.

Note




Action Note

1

WARNING




2 Move axes 3 and 5 to a horizontal position, and make sure that the oil plug, filling and inspection

(B1 or B2) is facing upwards.

Shown in the figure


.

3

DANGER

Turn off all:





4

5

6

Make sure that the oil temperature is +25°C ±10°C.


Open the oil plug, filling and inspection .

Open the oil plug, draining .

This is a precaution to avoid vacuum effects by allowing air to enter at the top of the gearbox.

Note

If equipment that covers the oil plug, draining is fitted on the robot so that the oil plug cannot be opened, then this step can be skipped.

7 Slowly turn axis 4, while adjusting axis 6 so that the oil plug, filling and inspection always faces upwards.

Turn axis 4 until the axis-4 angle reads:

• -36° to -39° for oil plug position B1

• -80° to -83° for oil plug position B2


156




3 Maintenance


Continued

8

Action

Inspect the oil level in the hole for the oil plug, filling and inspection .

The oil should reach all the way up to the external edge of the thread for the oil plug, filling and inspection .

Note

C xx1400002786

Note

If the oil plug, draining is not opened, then use a clean, narrow object, for example an oil stick or a cable tie, to gently poke the oil surface. This will avoid surface tension from stopping air to enter into the gearbox.

A

B

A Oil plug hole


C Gearbox oil




.

Detailed in section



10 Refit the oil plugs.

11

WARNING





157

3 Maintenance

3.3.8 Inspecting the balancing device

3.3.8 Inspecting the balancing device

General

Several points are to be checked on the balancing device during the inspection.

This section describes how to perform the inspection regarding:

• dissonance

• damage

• leakage

• contamination / lack of free space.

Action at detected faults

If any faults are detected during the inspection, a maintenance may be performed according to specific maintenance kits.

If the balancing device is an older model, it must in some cases be upgraded instead! The instruction for the current inspection details if a fault requires a maintenance / upgrade and the table below specifies the different models and which of the two actions they require.

The article number of the balancing device is located on a label at the rear cover, shown in the figure

Inspection points, balancing device on page 159

.

Balancing device, art. no.

3HAC10538-1

3HAC14675-1

Action at detected faults

Upgrade

Maintenance


158




3 Maintenance


Continued

Inspection points, balancing device

The balancing device is located at the top rear of the frame as shown in the figure.

The figure also shows the inspection points, further described in the instructions.

xx0300000580

E

F

G

A

B

C

D

Balancing device

Piston rod (inside)

Shaft, including securing screw

Ear, bearing and o-rings

Label with article number

Inspect the surroundings

Bearing, balancing device attachments


The table below specifies the equipment used if damage is detected on the balancing device. See section

Action at detected faults on page 158

to determine whether to perform maintenance or upgrade!

Art. no.

Equipment, etc.

Spare part no.

Maintenance kit, bearings and seals

3HAC14962-1



Note

Includes:

• kit with bearings, orings and seals only

• instructions for maintenance.


159


3 Maintenance


Continued

Equipment, etc.

Spare part no.

Securing screw

Art. no.

Note

Includes

• kit with piston rod, support shaft etc.

Securing screw in the shaft.

M16 x 180

Locking liquid must be used when fitting the screw (Loctite

243)!

Toolkit for maintenance

Puller for separator

Separator

Standard toolkit

3HAC15943-1

4552-2 (Bahco)

4551-C (Bahco)

3HAC15571-1

Used for removing the spherical roller bearings.

Used for removing the spherical roller bearings.



.



Check for dissonance

The check points are shown in the figure


.

1

2

3

Check for dissonance from...

If dissonance is detected...

• bearing at the link ear

• bearings at the balancing devices attachments.

... perform maintenance or upgrade according to given instructions in Maintenance kit, bearings and seals /

Upgrade kit. The replacement of the bearing at the ear is also detailed in section


Art. no. for the kit and the documentation are specified in section


To decide whether to perform maintenance or upgrade, see section

Action at detected faults on page 158 .

• balancing device (a tapping sound, caused by the springs inside the cylinder).

...replace the balancing device or consult ABB Robotics.

How to replace the device is detailed in section

Replacing the balancing device on page 298 . This section also

specifies the spare part number!

• piston rod (squeaking may indicate worn plain bearings, internal contamination or insufficient lubrication).

... perform maintenance or upgrade according to given instructions in Maintenance kit, complete / Upgrade kit.






160




3 Maintenance


Continued

Check for damage

Check for damages, such as scratches, general wear, uneven surfaces or incorrect positions.

The check points are shown in the figure


.

1

2

Check for damage on...

If damage is detected...

• the piston rod (part of the piston rod that is visible at the front of the balancing device).

... perform maintenance or upgrade according to given instructions in Maintenance kit, complete / Upgrade kit.





• the securing screw in the front ear shaft.

Also check the tightening torque (50 Nm).

...replace.

Dimension is specified in section


.

Check for leakage

The front ear of the balancing device is lubricated with grease. After filling, excessive grease may normally be forced out between the shaft and the sealing ring in the sealing spacer. This is normal behaviour and must not be confused with incorrect leaks from the ear.

Leaks at the o-rings and/or sealings, are not acceptable and must be attended to immediately in order to avoid any damage to the bearing!





161

3 Maintenance


Continued

Check the o-rings in the front ear of the balancing device for leaks, as shown and detailed below.

xx0300000284

E

F

C

D

A

B

Shaft

O-ring

Sealing spacer

Sealing ring in sealing spacer

Correct way out for excessive grease from inside the front ear

Incorrect leakage from the front ear

1

2

3

Action

Clean the area at the front ear from old grease.

Run the robot for some minutes, in order to move the balancing device piston.

Note

Check the o-rings at the front ear for leakage.

Replace the o-rings, if any leaks are detected.

Excessive grease from between the shaft and the sealing ring is normal and is not considered as a leak!

The o-rings are included in the Maintenance kit, bearings and seals , already assembled with sealing spacers and sealing rings.

Art. no. for the kit is specified in


.

The replacement of the complete bearing is also detailed in section


Incorrect leakage is shown in the previous figure.





3 Maintenance


Continued

Check for contamination / lack of free space

Action

1

DANGER

Turn off all:





2 Check that there are no obstacles inside the frame, that could prevent the balancing device from moving freely. See the figure


.

Keep the areas around the balancing device clean and free from objects, such as service tools.




163

3 Maintenance

3.3.9 Inspecting the cable harness

3.3.9 Inspecting the cable harness

Location of cable harness, axes 1-4

The robot cable harness, axes 1-4, is located as shown in the figure below.

xx0200000097

A

B

C

D

Lower arm

Cables attached with velcro straps and mounting plate

Connectors at cable harness division point, R2.M5/6

Connectors at base


Equipment, etc.

Standard toolkit


Circuit diagram

-

Art. no.

Note



.


See chapter

Circuit diagram on page 447

.





3 Maintenance


Continued

Inspection, cable harness 1-4

The procedure below details how to inspect the cable harness of axes 1-4.

Action Note

1

DANGER

Turn off all:





2

3

4

5

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

Check the connectors at the division point and at the base.

Shown in the figure

Location of cable harness, axes 1-4 on page 164

.

Check that velcro straps and the mounting plate are properly attached to the frame. Also check the cabling, leading into the lower arm.

Make sure it is attached by the straps and not damaged.

Location is shown in the figure

Location of cable harness, axes 1-4 on page 164 .

A certain wear of the hose at the entrance to the lower arm is natural.

Replace the cable harness if wear, cracks or damage is detected.

Described in


.

Location of cabling axes 5-6

The robot cable harness, axes 5-6, is located as shown in the figure below.

xx0200000155

A

B

C

Cable attachment, upper arm tube

Cable attachment, rear of upper arm

Connectors at cable harness division point, R2.M5/6





165

3 Maintenance


Continued

Inspection, cable harness, axes 5-6

The procedure below details how to inspect the cable harness of axes 5-6.

Action Note

1

DANGER

Turn off all:





2

3

4

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

Check the attachments at the rear of the upper arm and in the upper arm tube.

Check the connectors at the cable harness division.

Make sure the attachment plate is not bent or in any other way damaged.

Shown in the figure

Location of cabling axes 5-6 on page 165 .

Replace the cable harness if wear, cracks or damage is detected.

Described in section


166




3 Maintenance

3.3.10 Inspecting the axis-1 mechanical stop pin

3.3.10 Inspecting the axis-1 mechanical stop pin

WARNING

Mechanical stop pin can not be fitted onto robot if option 810-1 Electronic Position

Switch is used.

WARNING

Mechanical stop pin can not be fitted onto robot if option 561-1 Extended work range axis 1 is used.

Location of mechanical stop pin

The axis-1 mechanical stop is located as shown in the figure.

xx0200000151

A Mechanical stop pin


Visual inspection, no tools are required.





167

3 Maintenance

3.3.10 Inspecting the axis-1 mechanical stop pin

Continued

Inspecting, mechanical stop pin

Use this procedure to inspect the axis-1 mechanical stop pin.

Action Note

1

DANGER

Turn off all:




2 Inspect the axis-1 mechanical stop pin.

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

Note

The expected life of gearboxes can be reduced after collision with the mechanical stop.

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

168




3 Maintenance

3.3.11 Inspecting the mechanical stops on axes 1, 2, and 3

3.3.11 Inspecting the mechanical stops on axes 1, 2, and 3

Location of the mechanical stops

The figure below shows the location of the additional mechanical stops on axes

1, 2 and 3.

xx0200000150

A

B

Additional stop

Fixed stop


Equipment etc.

Mechanical stop ax 1




Standard toolkit

Art. no.

3HAC11076-1

3HAC11076-2

-

3HAC11077-1

3HAC13128-2

Note

Limits the robot working range to

7.5°.

Limits the robot working range to

15°.







169

3 Maintenance

3.3.11 Inspecting the mechanical stops on axes 1, 2, and 3

Continued

Inspection, mechanical stops

The procedure below details how to inspect the additional mechanical stops on axes 1, 2 and 3.

Action Note

1

DANGER

Turn off all:




2 Check the additional stops on axes 1, 2 and 3 for damage.

Shown in the figure

Location of the mechanical stops on page 169 .

3

4

Make sure the stops are properly attached.

Correct tightening torque: 115 Nm.

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

Correct attachment screws:

• Axis 1: M16 x 35

• Axis 2: M16 x 50

• Axis 3: M16 x 80



170




3 Maintenance

3.3.12 Inspecting the damper on axes 2 to 5

3.3.12 Inspecting the damper on axes 2 to 5

Location of dampers

The figure below shows the location of all the dampers to be inspected.

xx0200000099

A

B

C

D

Damper, axis 2 (2 pcs)





Equipment

Damper axis 2

Damper axis 3



Art. no.

3HAC12990-1

3HAC11750-1

Note

Replace if damaged!

Replace if damaged!


171


3 Maintenance

3.3.12 Inspecting the damper on axes 2 to 5

Continued

Equipment

Damper axis 4

Damper axis 5

Standard toolkit -

Art. no.

3HAC13564-1

3HAC10503-8

Note

Replace if damaged!

Replace if damaged!



Inspection, damper axis 2-5

The procedure below details how to inspect the dampers, axis 2-5.

Action Note

1

DANGER

Turn off all:




2

3

4

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

In order to inspect dampers, axis 4, the two covers on top of the upper arm must be removed!

Shown in the figure

Location of dampers on page 171

.

Check attachment screws for deformation.

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



172




3 Maintenance

3.3.13 Inspecting the position switch on axes 1, 2, and 3

3.3.13 Inspecting the position switch on axes 1, 2, and 3

Location of position switches

The position switches, axes 1, 2 and 3, are located as shown in the figures below.

xx0100000158

E

F

C

D

A

B


Cam

Set screw, cam

Protection sheet

Rail

Rail attachment





173

3 Maintenance


Continued

The illustration below shows the position switch for axis 2.

xx0100000159

C

E

F

A

B


Cam

Set screw, cam

Rail

Rail attachment


174




3 Maintenance


Continued

The illustration below shows the position switch for axis 3.

xx0100000160

A

B

C

E

F


Cam

Set screw, cam

Rail

Rail attachment


Equipment, etc.




Spare part no.

3HAC15715-1

3HAC15715-2

3HAC15715-2

Note

To be replaced in case of detected damage.






175


3 Maintenance


Continued

Equipment, etc.

Standard toolkit


-

Spare part no.

Note



.


Inspection, position switches

The procedure below details how to inspect the position switch, axes 1, 2 and 3.

See the figure

Location of position switches on page 173

to locate the different components to be inspected.

Action

1

DANGER

2

3

4

5

6

Turn off all:




Check the position switch!

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

Check the rail!

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

Check the cams!

• Check that the rollers has 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.

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 space inside the sheets is clean enough not to disturb the function of the position switch.

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

176




3 Maintenance

3.3.14 Inspecting the information labels

3.3.14 Inspecting the information labels

Location of labels

These figures show the location of the information labels to be inspected. The symbols are described in section

Safety symbols on product labels on page 45 .

xx0200000100

D

E

F

A

B

C

-

I

G

H

Warning label concerning high temperature

Warning sign, symbol of a lightning flash (located on motor cover)

Instruction label

Warning label concerning brake release

Warning label, tools are not allowed around the balancing device during operation

Warning label concerning shutting off power

Label, type of oil in gearbox


Label, type of grease in ear

Information labels at gearboxes and at robot base, specifying which oil is used in gearboxes




177


3 Maintenance

3.3.14 Inspecting the information labels


M

N

O

J

K

L

Instruction label concerning lifting the robot

Warning label concerning risk of tipping

Foundry logotype

Warning label concerning stored energy

Information label, specifying with type of oil is used in gearboxes of each axis


Required tools and equipment

Visual inspection, no tools are required.

Inspecting, labels

Action Note

1

DANGER

Turn off all:




2

3

Inspect the labels, located as shown in the figures.

Replace any missing or damaged labels.

Article numbers for the labels and plate set is specified in

Spare part lists on page 445 .

178




3 Maintenance

3.3.15 Inspecting the UL lamp

3.3.15 Inspecting the UL lamp

Location of UL-lamp

The UL-lamp is located as shown in figure below. Notice that the location can vary depending on how the customer harness for axes 4-6 is mounted.

xx0200000117

C

D

A

B

UL signal lamp

Warning sign

Warning label

Position for cable gland


Equipment, etc.

Signal lamp

Standard toolkit


-

Spare part no.

3HAC10830-1

Note


Includes UL signal lamp, 3HAC 13097-

1, Warning label, 3HAC 4431-1,

Warning sign, 3HAC 1589-1



.






179

3 Maintenance

3.3.15 Inspecting the UL lamp

Continued

Inspection, UL-lamp

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

1

2

Action

Check that the UL-lamp is lit, when the motors are in operation ("motors ON").

Note

If the lamp is not lit, trace the fault!

• Check whether the UL-lamp is broken. If so, replace it.

• Check the cable connections.

• Measure the voltage in connectors motor axis 3

(=24V).

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

Part no. is specified in


!

180




3 Maintenance

3.4.1 Type of lubrication in gearboxes

3.4 Changing/replacement activities

3.4.1 Type of lubrication in gearboxes

Introduction

This section describes where to find information about the type of lubrication , article number and the amount of lubrication in the specific gearbox. It also describes the equipment needed when working with lubrication.

Type and amount of oil in gearboxes

Information about the type of lubrication , article number as well as the amount in the specific gearbox can be found in Technical reference manual - Lubrication in gearboxes available for registered users on myABB Business Portal, www.myportal.abb.com

.

Before starting any inspection, maintenance, or changing activities of lubrication, always contact the local ABB Service organization for more information.

For ABB personnel: Always check ABB Library for the latest revision of the manual

Technical reference manual - Lubrication in gearboxes , in order to always get the latest information of updates about lubrication in gearboxes. A new revision will be published on ABB Library immediately after updates.

Location of gearboxes

The figure shows the location of the gearboxes.

xx0400000798

A

B

C

Axis 1 gearbox

Axis 2 gearbox

Axis 3 gearbox





181

3 Maintenance

3.4.1 Type of lubrication in gearboxes

Continued

D

E

F

G

H

Axis 4 primary gearbox

Axis 4 secondary gearbox

Axis 5 primary gearbox

Axis 5 secondary gearbox

Axis 6 gearbox

Equipment

Equipment

Oil dispenser

Nipple for quick connect fitting, with o-ring

Note

Includes pump with outlet pipe.

Use the suggested dispenser or a similar one:

• Orion OriCan article number 22590

(pneumatic)

182




3 Maintenance

3.4.2 Changing oil, axis-1 gearbox

3.4.2 Changing oil, axis-1 gearbox


The axis 1 gearbox is located between the frame and base as shown in the figure below.

The oil is drained with a hose that may be reached behind the rear cover of the robot base.

xx0200000111

C

D

A

B

E

Gearbox, axis 1

Oil plug, filling

Motor, axis 1

Oil plug, inspection (not in all designs)

Label, specifies the type of oil in the gearbox





183

3 Maintenance


Continued

Oil plug in the base

In some early versions of the robot, the oil plug for draining may be located in the base, as shown in the figure below.

xx0300000065

A Oil plug in the base


Equipment, etc.

Lubricating oil

Art. no.

See


.

Oil collecting vessel

Oil exchange equipment 3HAC17313-1

Standard toolkit -


Amount

See


Note

Capacity: 8,000 ml.


Special tools on page 440

.



.


Note

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


184




3 Maintenance


Continued

Draining, oil, gearbox axis 1

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

When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in


Action Note

1

WARNING




.

2

3

4

5

6

7

8

9

DANGER

Turn off all:




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

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

Some early versions of the robot has the oil draining plug in the base as shown in the figure

Oil plug in the base on page 184

instead of the hose.

Place an oil vessel close to the hose end.

Vessel capacity specified in


.

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

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

Note

CAUTION

Drain as much oil as possible. See


The draining is time-consuming.

Elapsed time depends on the temperature of the oil.

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

Close the rear cover by securing it with its attachment screws.





185

3 Maintenance


Continued

Filling, oil, gearbox axis 1

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



Action Note

1

WARNING




.

2

3

4

DANGER

Turn off all:




Open the oil plug, filling .

Shown in the figure


.

Refill the gearbox with lubricating oil .

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

Inspecting the oil level in axis-1 gearbox on page 140 .



5

6

WARNING


Refit the oil plug, filling.


186




3 Maintenance



Location of oil plugs

The axis-2 gearbox is located in the lower arm rotational center, underneath the motor attachment.

D

A

E

B

C

D

A

B

C xx0200000112

C

D

A

B

E

Gearbox, axis 2

Oil plug, filling/inspection (later design)

Oil plug, draining

Label, specifies the type of oil in the gearbox

Oil plug, ventilation (later design)

The early design of the gearbox cover is shown in

Oil plug, early design on page 143 .


Equipment, etc.

Lubricating oil

Art. no.

See


Oil collecting vessel -

Oil exchange equipment

3HAC021745-001

Standard toolkit -

Amount

See


Note

Note!

Do not mix with other oil types!

Capacity: 5,000 ml.



.







187

3 Maintenance


Continued

Draining, oil

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



Action Note

1

DANGER

Turn off all:





2

WARNING



3

4

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

Shown in the figure

Location of oil plugs on page 187 .

Vessel capacity is specified in


.

CAUTION

Note


Safety risks during work with gearbox lubricants

(oil or grease) on page 41

.

Draining is time-consuming. Elapsed time varies depending on the temperature of the oil.

Refit the oil plug.


Filling, oil

Use this procedure to fill oil into the axis-2 gearbox.



Action Note

1

DANGER

Turn off all:






188




3 Maintenance


Continued

Action Note

2

WARNING




3

4

Remove the oil plug for filling and the plug from the vent hole.

Shown in the figure

Location of oil plugs on page 187

.

Refill the gearbox with clean lubricating oil.

The correct oil level is detailed in section

Inspecting the oil level in axis-2 gearbox on page 143

.



5

WARNING


6 Refit the oil plug.





189

3 Maintenance




The axis-3 gearbox is located in the upper arm rotational center as shown in the following figure.

xx0200000113

A

B

C

D

Gearbox, axis 3

Oil plug, filling

Oil plug, draining

Label, specifies the type of oil in gearbox


Equipment, etc.

Lubricating oil

Art. no.

See


.

Amount Note

See


Note!

Do not mix with other oil types!





Draining, oil

3 Maintenance


Continued

Equipment, etc.

Art. no.


Amount


Standard toolkit

-

-

Note



.

Capacity: 5,000 ml.



The procedure below details how to drain oil from the gearbox, axis 3.



Action Note

1

DANGER

Turn off all:





2

WARNING



.

3

4

5

Remove the oil plug, filling .

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

Shown in the figure

Location of gearbox on page 190 .

Vessel capacity is specified in


.

CAUTION

Note



Draining is time-consuming. Elapsed time varies depending on the temperature of the oil.

Refit the oil plug.






191

3 Maintenance


Continued

Filling, oil

The procedure below details how to fill oil into the gearbox, axis 3.



Action Note

1

DANGER

Turn off all:





2

WARNING




.

3

4

Remove the oil plug, filling.

Shown in the figure


.

Refill the gearbox with clean lubricating oil.

The correct oil level is detailed in section


.



5

WARNING


6

Note

Do not mix Kyodo Yushi TMO 150 with other oil types!

7 Refit the oil plug.


192




3 Maintenance



Different types of oil

The primary and secondary gear may require different types of oil, that must never be mixed!

If they are mixed, the gear must be rinsed according to section

Flushing a contaminated gearbox on page 212

.


The axis 4 gearbox is located at the rear of the upper arm as shown in the figure below.

xx0200000107

A

B

C

D

E

F

G



Upper arm housing

Cover, axis 4 gearbox

Oil plug, filling, secondary gear

Oil plug, draining, secondary gear

Oil plug, filling, primary gearbox (draining not shown in figure, located further down on the motor flange)

Label, specifies the type of oil in the secondary gear

Label, specifies the type of oil in the primary gear


193


3 Maintenance


Continued


Equipment, etc.

Lubricating oil

Oil collecting vessel, primary gearbox

Oil collecting vessel, secondary gearbox


3HAC17313-1

Standard toolkit -

Art. no.

See


.

Amount

See


.

Note

Capacity: 1,000 ml.

Capacity: 4,000 ml.


Special tools on page 440 .



Draining, oil, gearbox axis 4

The procedure below details how to drain the oil from the gearbox, axis 4.



Action Note

1

WARNING




.

2

3

4

Open the oil plug, draining, secondary gear .

Shown in the figure


.

Drain the oil from the secondary gearbox by running the upper arm -45° from calibration position.



Run the robot back to its calibration position.

Detailed in section


5

DANGER

Turn off all:





194




3 Maintenance


Continued

6

7

Action

Drain the primary gear by opening the oil plug, draining, primary gearbox.

CAUTION



Refit the both oil plugs, draining.

Note




Filling, oil, gearbox axis 4




Action Note

1

WARNING




.

2

3

4

DANGER

Turn off all:




Refill the secondary gear with lubricating oil through the oil plug, filling, secondary gear .



.

Shown in the figure


.

Refill the primary gearbox with oil through the oil plug, filling, primary gear . Make sure the air is ventilated through the oil plug during filling, to avoid overpressure in the gearbox.



Kyodo Yushi TMO 150

Shown in the figure


.



.

5

WARNING





195


3 Maintenance


Continued

6

Action

Refit the both oil plugs, filling.

Note

Shown in the figure


.


196




3 Maintenance




The primary and secondary gear may require different types of oil, that must never be mixed!

If they are mixed, the gear must be rinsed according to section

Flushing a contaminated gearbox on page 212

.


The axis-5 gearbox is located in the wrist unit as shown in the following figure.

A

B

C

D

E

F G xx0200000108

A

B

C

Wrist housing


The oil plug for draining of the primary gearbox is on the opposite side of the wrist housing, not shown in the figure.





197


3 Maintenance


Continued

F

G

D

E

Oil plug, draining/inspection, secondary gearbox





Equipment, etc.

Lubricating oil

Art. no.

See


.

Note




Standard toolkit -

Capacity: 1 liter

Capacity: 4 liters


Special tools on page 440 .



Note


Draining oil, axis-5 gearbox

The procedure below details how to drain the oil from the gearbox, axis 5.



Action Note

1

WARNING




2

3

4

DANGER

Turn off all:




Open the oil plug, draining, primary gearbox .

Drain the oil from the primary gearbox.

Vessel capacity: 1 liter





3 Maintenance


Continued

5

6

7

8

Action

Run axis 4 to a position +90° from the calibration position.

Open the oil plug, draining/inspection, secondary gearbox .

Drain the oil from the secondary gear.

Note

Shown in the figure


Vessel capacity: 4 liters

CAUTION




Shown in the figure



Filling oil, axis-5 gearbox




Action Note

1

WARNING




.

2

3

4

DANGER

Turn off all:




Refill the primary gearbox with lubricating oil through the oil plug, filling . Make sure the air is ventilated through the oil plug during filling, to avoid overpressure in the gearbox.





Shown in the figure


Refill the secondary gearbox with lubricating oil through the oil plug, filling .





Shown in the figure





199


3 Maintenance


Continued

Action

5

6

WARNING



Note

Shown in the figure



200




3 Maintenance




The axis-6 gearbox is located in the center of the wrist unit as shown in the following figure.

xx0200000114

A

B

C

D

Gearbox, axis 6

Oil plug, filling/inspection (notice the different locations of the plug, shown as

B

1 and B

2

)


Label, specifies the type of oil in gearbox axis 6


Equipment, etc.

Lubricating oil

Art. no.

See


.



3HAC17313-1

Amount

See


Note

Vessel capacity: 1,000 ml.



.




201


3 Maintenance


Continued

Equipment, etc.

Standard toolkit -

Art. no.

Amount Note



Note


Draining oil, gearbox axis 6

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



Action Note

1

WARNING




.

2 Move the wrist so that the oil plug, d raining of axis

6 gearbox faces downwards.

If the oil plug, draining is located on the turning disc, rotate the disc so that the plug faces downwards.

Shown in the figure

Location of gearbox on page 201 !

3

4

DANGER

Turn off all:




Drain the oil from gearbox 6 by removing the oil plug. Collect the oil with a suitable vessel.

Vessel capacity: 1000 ml.

CAUTION



Measure the amount of oil drained.







3 Maintenance


Continued

Filling oil, gearbox axis 6

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



Action Note

1

WARNING




.

2 Run the robot to a position where the oil plug, filling (B1 or B2) of axis 6 gearbox, is facing upwards.

If the oil plug for draining is located on the turning disk, rotate the disk so that the oil plug faces upwards.

3

4

5

DANGER

Turn off all:




Remove the oil plug, filling .

Shown in the figure


Refill the wrist with lubricating oil .

Make sure the air is ventilated through the oil plug during filling, to avoid overpressure in the gearbox.

If the plug hole for draining is located on the turning disk, the air is ventilated through the open plug hole.



6

7

WARNING


Refit the both oil plugs.





203

3 Maintenance

3.4.8 Replacing the SMB battery

3.4.8 Replacing the SMB battery

Note

The battery low alert (38213 Battery charge low ) is displayed when the battery needs to be replaced. The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced.

For a SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or

RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.

For a SMB board with 2-pole battery contact (DSQC), the typical lifetime of a new battery is 36 months if the robot is powered off 2 days/week or 18 months if the robot is powered off 16 h/day. The lifetime can be extended for longer production breaks with a battery shutdown service routine. See Operating manual - IRC5 with FlexPendant for instructions.

WARNING

See instructions for batteries,

Safety risks during handling of batteries on page 40

.


204




3 Maintenance


Continued

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.

Battery pack with a 2-pole battery contact (DSQC) xx0200000238

A

B

C

SMB battery cover

SMB battery pack with 2-pole battery contact.

Battery cable





205

3 Maintenance


Continued

Battery pack with a 3-pole battery contact (RMU)

A

B xx1300000308

A Battery pack RMU

B Battery holder


Note

There are two variants of SMB units and batteries. One with 2-pole battery contact

(DSQC) and one with 3-pole battery contact (RMU). The variant with the 3-pole battery contact has longer lifetime for the battery.

It is important that the SMB unit uses the correct battery. Make sure to order the correct spare parts. Do not exchange battery contacts!

Equipment, etc.

Battery unit

Standard toolkit

Circuit diagram -

-

Spare part no.

For spare part no.

see:

•

Spare part lists on page 445

Note

Battery includes protection circuits. Only replace with a specified spare part or an ABBapproved equivalent.



See chapter


.

Removing, battery

Use this procedure to remove the SMB battery.

1

Action


Note

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





3 Maintenance


Continued

Action

2

DANGER

Turn off all:




Note

3

ELECTROSTATIC DISCHARGE (ESD)

The unit is sensitive to ESD. Before handling the unit please read the safety information in the section

The unit is sensitive to ESD on page 36

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

Shown in figure

Location of SMB battery on page 205 .

CAUTION

Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards which can result in hazardous failures.

5

6

Pull out the battery and disconnect the battery cable .

Remove the SMB battery.

Battery includes protection circuits. Only replace with a specified spare part or with an ABB- approved equivalent.

Shown in figure


Shown in figure


Refitting, battery

Use this procedure to refit the SMB battery.

Action

1

DANGER

Turn off all:




2


The unit is sensitive to ESD. Before handling the unit please read the safety information in the section


Note




207


3 Maintenance


Continued

3

Action Note

Reconnect the battery cable and install the battery pack into the SMB/battery recess.



Note

Shown in figure

Location of SMB battery on page 205

.

A

RMU batteries are installed together with a battery holder to be properly secured inside the recess.

See figure.

4

5

B xx1300000308

A Battery pack RMU

B Battery holder

Secure the SMB battery cover with its attachment screws.

Shown in figure

Location of SMB battery on page 205

.

Update the revolution counters.

Detailed in chapter Calibration section

Updating revolution counters on page 403

.

6

DANGER



208




3 Maintenance

3.5.1 Lubrication of spherical roller bearing, balancing device

3.5 Lubrication activities

3.5.1 Lubrication of spherical roller bearing, balancing device

Location of bearing

The spherical roller bearing is located at the front ear of the balancing device, as shown in the figure below.

Note!

The balancing device must be mounted on the robot when lubricating the bearing!

xx0200000109

A

B

C

D

Ear (spherical roller bearing located inside)

Lubrication nipple or securing screw

Sealing spacer

Hole through which the shaft is pressed


Equipment, etc.

Grease



Art. no.

3HAC042534-001

Note

Optimol PDO, 150 ml


209


3 Maintenance


Continued

Equipment, etc.

Lubrication nipple

Grease pump -

Art. no.

Note

M6.

Lubrication, balancing device bearing (Design 1)

The procedure below details how to lubricate the spherical roller bearing.

Action Note

1

DANGER

Turn off all:





2

3

Lubricate the spherical roller bearing through the lubrication nipple in the ear with grease.

Art. no. and amount is specified in


Fill until excessive grease is forced out between the shaft and the sealing spacer.

Shown in the figure

on page 209 !

Location of bearing


Clean the area from any excessive grease and check the area once again after operation of the robot, in order to make sure there is no incorrect leakage from the o-rings.

Read more about the inspection in section Inspection, balancing device -

Check for leakage on page 161 .

Lubrication, balancing device bearing (Design 2)

The procedure below details how to lubricate the spherical roller bearing.

Action Note

1

DANGER

2

Turn off all:





Lubricate the spherical roller bearing through the lubrication nipple in the ear with grease.

Fill until excessive grease is forced out through the hole of the lower securing screw.

Art. no. and amount is specified in


Shown in the figure

Location of bearing on page 209 !


Refit the lower securing screw and washer.

M6 x 10, washer: D=6,4/12 T=1,6






3 Maintenance


Continued

3

Action Note

Clean the area from any excessive grease and check the area once again after operation of the robot, in order to make sure there is no incorrect leakage from the o-rings.

Read more about the inspection in section Inspection, balancing device -





211

3 Maintenance

3.6.1 Flushing a contaminated gearbox

3.6 Cleaning activities

3.6.1 Flushing a contaminated gearbox


As the Shell Tivela S 150 is not compatible with mineral oil, contamination with other types of oils used in the gearboxes is not accepted. Equipment used in handling of Tivela S 150 must be carefully cleaned.

This section details how to flush the primary gears of axis 4 and 5, and the gearbox of axis 6 in case of contamination with other type of oil.


Equipment

Lubricating oil

Art. no.

3HAC032140-001

Note

Kyodo Yushi TMO 150

Amount: 700 ml for each gearbox and flush.

Three flushes required.


Syringe + plastic hose

Standard toolkit

-

-

3HAC15571-1

D inside

=4 mm, L= 400 mm.


on page 439

.

Standard tools

Service program

Create a program with motions on axis 3, 4, 5 and 6. There is no need to remove the tool and equipment installed on the robot if the Service program can be created and is possible to run.

Recommended motion

• axis 3: ± 15 degrees

• axis 4-6: maximum working range with regard to the installation (limitation: axis 4 and 5: ± 90 degrees, axis 6: ± 180 degrees).

Draining the gearbox properly

The contaminated gearbox must be drained properly before and during the flushing procedure:

• Axis 4 gearbox: open both oil plugs (filling and draining) and run axis 3 in different directions. Draw out the last volume (approx. 40 –60 ml) by using a syringe with a prepared hose end.

• Axis 5 gearbox: open both oil plugs (filling and draining) and run axis 4 back and forward until the oil draining has stopped.

• Axis 6 gearbox: open both oil plugs (filling and draining) and run axis 5 and

6 in different directions until the oil draining has stopped.


212




Flushing

3 Maintenance

3.6.1 Flushing a contaminated gearbox

Continued

4

5

6

7

The procedure below details how to flush a contaminated gearbox. The procedure is the same for all gearboxes.

1

2

3

Action Note

Run the Service program until the castings of the gearboxes axis 4, 5 and 6 have reached a temperature of about 30-35º C. Use the finger tips to measure the temperature.

Recommended service program described in section

Service program on page 212

.

Drain the gearbox properly.

Fill the gearbox with 700 ml of lubricating oil .

Described in section above:

Draining the gearbox properly on page 212

.

Kyodo Yushi TMO 150

Art. no . is specified in


Refit the oil plug.

Run the Service program at low speed (25%) during

10 minutes.

Drain the gearbox properly.


Repeat the steps above until the gearbox is flushed three times.




213

3 Maintenance

3.6.2 Cleaning the IRB 7600

3.6.2 Cleaning the IRB 7600

WARNING

Turn off all electrical power supplies to the manipulator before entering its work space.

General

To secure high uptime it is important that the IRB 7600 is cleaned regularly. The frequency of cleaning depends on the environment in which the product works.

Different cleaning methods are allowed depending on the type of protection of the

IRB 7600.

Note

Always verify the protection type of the robot before cleaning.

Oil spills

Oil spills from gearboxes

Use the following procedure if any oil spills are detected that can be suspected to originate from a gearbox.

1 Inspect that the oil level in the suspected gearbox is according to the recommendations, see

Inspection activities on page 138 .

2 Write down the oil level.

3 Inspect the oil level again after, for example, 6 months.

4 If the oil level is decreased then replace the gearbox.

Oil spills discolors painted surfaces

Oil spills on painted surfaces of the robot can result in discoloration.

Note

After all repair and maintenance work involving oil, always wipe the robot clean from all surplus oil.

Special cleaning considerations

This section specifies some special considerations when cleaning the robot.

• Always use cleaning equipment as specified. Any other cleaning equipment may shorten the life of the robot.

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

• Never point the water jet at connectors, joints, sealings, or gaskets.

• Do not use compressed air to clean the robot.

• Never use solvents that are not approved by ABB to clean the robot.

• Do not spray from a distance closer than 0.4 m.





3 Maintenance


Continued

• Do not remove any covers or other protective devices before cleaning the robot.

Cleaning methods

The following table defines what cleaning methods are allowed depending on the protection type.

Protection type

Cleaning method

Vacuum cleaner

Yes

Wipe with cloth Rinse with water High pressure water or steam

No Standard Yes. With light cleaning detergent.

Yes. It is highly recommended that the water contains a rust-prevention solution and that the manipulator is dried afterwards.

i

Foundry Plus Yes Yes. With light cleaning detergent or spirit.

Yes. It is highly recommended that the water contains a rust-prevention solution.

Yes i

.

It is highly recommended that the water and steam contains rust preventive, without cleaning detergents.

Perform according to section

Cleaning with water and steam on page 215 .

Cleaning with water and steam

Instructions for rinsing with water

ABB robots with protection types Standard , Foundry Plus , Wash , or Foundry Prime can be cleaned by rinsing with water (water cleaner).

1

I

The following list defines the prerequisites:

• Maximum water pressure at the nozzle: 700 kN/m

2

(7 bar)

I

• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters

• Maximum flow: 20 liters/min

I

Typical tap water pressure and flow

Instructions for steam or high pressure water cleaning

ABB robots with protection types Foundry Plus , Wash , or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner.

2

The following list defines the prerequisites:

• Maximum water pressure at the nozzle: 2500 kN/m

2

(25 bar)

• Fan jet nozzle should be used, min. 45° spread

• Minimum distance from nozzle to encapsulation: 0.4 meters

• Maximum water temperature: 80° C

1

2

See

Cleaning methods on page 215

for exceptions.

See

Cleaning methods on page 215

for exceptions.





215

3 Maintenance


Continued

Cables

Movable cables need to be able to move freely:

• Remove waste material, such as sand, dust and chips, if it prevents cable movement.

• Clean the cables if they have a crusty surface, for example from dry release agents.

Cooling fans

Inspect the air supply inlet of the the motor cooling fans. Clean to remove any contamination that could hinder the air supply.

216




3 Maintenance

3.7.1 Using the SIS system

3.7 Service Information System, M2000

3.7.1 Using the SIS system

General

This is a brief description of how to use the Service Information System, SIS for

M2000 robot systems. Details may be found in:

• Service Information System, SIS

• Defining the SIS input parameters

• Setting the SIS parameters

• Importing/exporting SIS data

• Reading the SIS output logs

The section is only valid for M2000 systems. For information regarding M2004 robot systems, see additional documentation, Operating manual - Service

Information System . Article number is specified in section


Basic procedure

1

2

3

4

5

6

7

Action

Determine which of the system functions you require.

Reference

These are described in

Description of

Service Information System (SIS) on page 218

.

Define what values are adequate and suitable for your application in your production environment.

Recommendations on how to define these are given in

SIS system parameters on page 221

.

Enter these parameters in the system.

How to do this is detailed in

Setting the

SIS parameters on page 222 .

Run the robot in normal operation.

Reset the counter if a repair is made, or if a counter for any other reason is restarted.

The TPU displays for resetting any SIS value are shown in

Description of Service

Information System (SIS) on page 218

.

When a time limit, set in the parameters, is exceeded, a message may be read on the

Tech Pendant Unit (TPU).

How to access this is detailed in

Reading the SIS output logs on page 223 .

If the log containing the message is to be available from an external PC, or if the SIS parameters are to be entered from an external PC, a set of software tools are available to build such an application.

These are described in

Exporting the SIS data on page 224

.




217

3 Maintenance

3.7.2 Description of Service Information System (SIS)

3.7.2 Description of Service Information System (SIS)

General

Supervised functions

The following counters are available:

• Calendar time counter, a general alarm based on calendar time

• Operation time counter, a general alarm based on operational time

• Gearbox 1 operation time counter, based on percentage of the axis 1 gearbox service interval




Counters are reset when maintenance has been performed.

The counter status is displayed after running the service routine for maintenance.

Status “OK” indicates that no service interval limit has been exceeded by that counter.

Calendar time

Service Information System (SIS) is a software function within the robot controller, which simplifies maintenance of the robot system. It supervises the operating time and mode of the robot, and alerts the operator when a maintenance activity is scheduled.

Maintenance is scheduled by setting the system parameters of the type SIS

Parameters, see section

Setting the SIS parameters on page 222

. All system parameters are described in User´s Guide - System Parameters .

This is a clock within the control system that keeps track of the service interval, based on calendar time.

When the calendar time limit for maintenance is reached, a message is displayed on the TPU. How to access this is detailed in section


The following information is available about the calendar time in the service routine.

Prev service

Elapsed time

Next service

Remaining time

Date when the counter was reset last time, i.e. after the last service.

Elapsed time since the counter was reset the last time.

Date when next scheduled service is planned. This date is calculated using system parameters, as detailed in section

Setting the

SIS parameters on page 222

.

Remaining time to next scheduled service date.


218




3 Maintenance


Continued

Operation time

This is a function within the control system that keeps track of the amount of time the "MOTORS ON" signal is active, i.e. the amount of time the robot is in the operating mode.

When the operation time limit for maintenance is reached, a message is displayed on the TPU. How to access this is detailed in section


The following information is available about the operation time in the service routine.

Service interval

Elapsed time

Remaining time

The specified service interval until another service will be required.

This parameter was entered manually as detailed in section

Setting the SIS parameters on page 222 .

Operation time since the service interval was set the last time.

Remaining operation time until the time set in service interval has expired.

Gearbox

Based on measurements, torque and RPM, for example, the system calculates an expected service interval for each gearbox. When service is due, a message will be shown on the TPU. How to access this is detailed in section

Reading the SIS output logs on page 223

.

The following information is available about the joint service status in the service routine.

Joint x OK

Joint x NOK

Joint x N/A

Service status for axis x, i.e. the automatically calculated time parameter has not been exceeded.

The service interval for the axis in question has been reached.

No service time parameter calculation available.

Applies to axes 4 and 5 (IRB 6600 and IRB 7600).

The following information is available for the axis service status in the service routine.

Consumed time

Elapsed time

Remaining time

The consumed time as a percentage of the total amount of time.

Operation time for axis x since calculation began.

Remaining operation time for axis x until the service time parameter value has been reached.

Reset values

Counters may be reset at any time by running the service routine.

When resetting, the counter variables are reset. The variables are described in section

Exporting the SIS data on page 224

!

Service interval exceeded

When the service time has been exceeded for the selection made, an error message

(Service interval exceeded!) is displayed.





219

3 Maintenance


Continued

No data available

When no data is available for the selection made, a message (No data available!) is displayed when trying to display the data.

220




3 Maintenance

3.7.3 SIS system parameters

3.7.3 SIS system parameters

General

This section details the system parameters that may be set with estimated values.

The values can be defined by the operating organization as knowledge of the robot's working conditions are accumulated.

Since the counters are to be used for purposes defined by the user, ABB cannot give any recommendations regarding their definitions.

Operation time limit (service level)

The number of operation hours selected as service interval.

E.g. by setting the value "20,000", the SIS will save this as the nominal time for activating the alarm, not counting the percentage described below.

Operation time warning

A percentage of the "Operation time limit" specified above.

E.g. by setting the value "90", the SIS will alert the operator 18,000 hours after an operation time "Reset" was made the last time.

Calendar time limit (service level)

The number of calendar years selected as service interval.

E.g. by setting the value "2", the SIS will save this as the nominal time for activating the alarm, not counting the percentage described below.

Calendar time warning

A percentage of the "Calendar time limit" specified above.

E.g. by setting the value "90", the SIS will alert the operator after 90% of two years, i.e. 657 days after a calendar time "Reset" was made the last time.

Gearbox warning

A percentage of the gearbox service interval as calculated by the system. E.g. by setting the value "90", the SIS will alert the operator after 90% of the expected service interval of each gearbox.

The robot system automatically detects and stores all required variables to calculate the expected service interval (estimated remaining lifetime) of each gearbox. This is done by extrapolating data from earlier operation into a function of time, using a formula including:

• input and output torque

• gearbox spindle speed

• other variables




3 Maintenance

3.7.4 Setting the SIS parameters

3.7.4 Setting the SIS parameters

General

If the SIS system is to function properly, a number of parameters must be set. This is detailed below.

Procedure M2000

This is an instruction of how to enter SIS parameters to the M2000 robot system.

1

2

3

4

5

Action Note

Open "System parameters" using the TPU.

Detailed in the User's Guide.

Go to "System parameters/Manipulator/types 2".

Select "0 SIS parameters" and press "Enter".

Select the required system

The parameter list is displayed.

Select the required parameters by stepping up and down through the parameter list.

Available parameters are described in section

SIS system parameters on page 221 .

222




3 Maintenance

3.7.5 Reading the SIS output logs

3.7.5 Reading the SIS output logs

General

Whenever a set condition has expired (e.g. max allowed operation time before service), a message to this effect will be shown in the Operational log.

Access to logs

How to open a log and show its contents is detailed in the User's Guide, chapter

Service .

Available messages

The following messages may be shown:

Available in:

Calendar time

Calendar time

Operation time

Operation time

Gearbox time

Gearbox time

SIS message in the log:

Meaning:

Service Message

Service is due!

X calendar days since last service.

The manually set calendar time limit has expired.

How to set the limit is detailed in section


Proceed with the required service as detailed in chapter

Repair on page 225

or chapter


depending on which type of service.

Service Message

X calendar days to next service.

Service Message

Service is due!

X production hours since last service.

X number of calendar days remain until the manually set calendar time limit expires.

How to set the value determining when the message is to be shown, is detailed in section


The manually set operation time limit has expired.

How to set the limit is detailed in section



Repair on page 225

or chapter



Service Message

X production hours to next service.

X number of operation hours remain until the manually set operation time limit expires.



Service Message

Gearbox x requires service!

The automatically calculated gearbox time limit has expired.


Repair on page 225

or chapter



Service Message

X% of the service interval has expired for gearbox x!

X percent of gearbox hours remain until the automatically calculated gearbox time limit expires.






3 Maintenance

3.7.6 Exporting the SIS data

3.7.6 Exporting the SIS data

General

This section describes the available variables for entering SIS parameters as well as showing any values of exceeded time limits as detected by the SIS counters.

In a M2000 robot system, the values can be read on a PC using "Webware SDK".

How to access these variables and how to perform the actual programming sequences are detailed in the robot system User's Guide.

Definitions

The table below defines the names and functions of all software variables available for communication between the SIS and an external computer.

Signal sisRestartDate sisCalendarT sisTotRunT sisRunT sisL10h_1 sisL10h_Time_1 sisL10h_2 sisL10h_Time_2 sisL10h_3 sisL10h_Time_3 sisL10h_6 sisL10h_Time_6

Unit seconds seconds Calendar time seconds Operation time seconds Operation time hours seconds hours seconds hours seconds hours hours

Counter type

Calendar time

Gearbox time

Gearbox time

Gearbox time

Gearbox time

Gearbox time

Gearbox time

Gearbox time

Gearbox time

Function

The date on which the supervision was started/reset last time.

The number of hours since start/last reset.

Total number of operation hours since the system was started. Corresponds to the operating time counter on the control cabinet.

The number of operation hours since start/last reset of the operation time counter. Corresponds to the operating time counter on the control cabinet.

Estimated life of gearbox axis 1

Operation time of gearbox axis 1







224




4 Repair

4.1 Introduction

4 Repair


Structure of this chapter

This chapter describes all repair activities recommended for the IRB 7600 and any external unit.

It is made up of separate procedures, each describing a specific repair activity.

Each procedure contains all the information required to perform the activity, for example spare parts numbers, required special tools, and materials.

WARNING

Repair activities not described in this chapter must only be carried out by ABB.

Otherwise damage to the mechanics and electronics may occur.


The details of the equipment required to perform a specific repair activity are listed in the respective procedures.

The details of equipment are also available in different lists in the chapter

Reference information on page 431

.


There are general safety information and specific safety information. The specific safety information describes the danger and safety risks while performing specific steps in a procedure. Make sure to read through the chapter

Safety on page 21

before commencing any service work.

Note

If the IRB 7600 is connected to power, always make sure that the IRB 7600 is connected to earth before starting any repair work.






225

4 Repair

4.2.1 Performing a leak-down test

4.2 General procedures

4.2.1 Performing a leak-down test

When to perform a leak-down test

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


Equipment, etc.

Leak-down tester

Leak detection spray -

-


Performing a leak-down test

1

2

3

Action

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

Note

Remove the upper oil plug on the gear and replace it with the leak-down tester.

Regulators, which are included in the leak-down test, may be required.

Use caution, apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer.

Correct value:

0.2-0.25 bar (20-25 kPa)

CAUTION

The pressure must under no circumstance be higher than 0.25 bar (20-25 kPa). Also during the time when the pressure is raised.

4

5

6

7

8

Disconnect the compressed air supply.

Wait for approximately 8-10 minutes and make sure that no pressure loss occurs.

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

If any pressure drop occurred, then localize the leak

as described in step 7.

If no pressure drop occurred, then remove the leakdown tester and refit the oil plug. The test is complete.

Spray any suspected leak areas with the leak detection spray. Bubbles indicate a leak.

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

226




4 Repair

4.2.2 Mounting instructions for bearings

4.2.2 Mounting instructions for bearings

General

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

Equipment

Equipment, etc.

Grease

Article number

3HAB3537-1

Note

Used to grease the bearings, if not specified otherwise.

Assembly of all bearings

Attend to the following instructions while mounting a bearing on the robot.

1

2

3

Action

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

Note

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

Bearing rings, inner rings, and roller elements must not be subjected to direct impact. The roller elements must not be exposed to any stresses during the assembly work.

Assembly of tapered bearings

Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot.

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

1

Action

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

Note

Note

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

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

Greasing of bearings

Note

This instruction is not valid for solid oil bearings.





227

4 Repair

4.2.2 Mounting instructions for bearings

Continued

The bearings must be greased after assembly according to the following instructions:

• 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 following description:

• 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.

228




4 Repair

4.2.3 Mounting instructions for seals

4.2.3 Mounting instructions for seals

General

This section describes how to mount different types of seals onto the robot.

Equipment

Equipment, etc.

Grease

Article number

3HAB3537-1

Note

Used to lubricate the seals.

Rotating seals

The procedure below describes 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.

1

2

3

4

Action

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).

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

Note

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

Fill 2/3 of the space between the dust tongue and sealing lip with grease. The rubber coated external diameter must also be greased, unless otherwise specified.


Equipment on page 229 .

Mount the seal correctly with a mounting tool.

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

Make sure no grease left on the robot surface.





229

4 Repair

4.2.3 Mounting instructions for seals

Continued

Flange seals and static seals

The following procedure describes how to fit flange seals and static seals.

1

2

3

4

Action

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.

Clean the surfaces properly in accordance with the recommendations of ABB.

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

Tighten the screws evenly when fastening the flange joint.

O-rings

The following procedure describes how to fit o-rings.

1

2

3

4

5

Action Note

Ensure that the correct o-ring size is used.

Check the o-ring for surface defects, burrs, shape accuracy, or deformation.

Check the o-ring grooves.

The grooves must be geometrically correct and should be free of pores and contamination.

Defective o-rings may not be used.

Lubricate the o-ring with grease.

Defective o-rings, including damaged or deformed o-rings, may not be used.

Tighten the screws evenly while assembling.

Make sure that no grease is left on the robot surface.

230




4 Repair

4.2.4 Cut the paint or surface on the robot before replacing parts

4.2.4 Cut the paint or surface on the robot before replacing parts

General

Follow the procedures in this section whenever breaking the paint of the robot during replacement of parts.


Equipment

Cleaning agent

Knife

Spare parts

Lint free cloth

Touch up paint Standard/Foundry

Plus, ABB Orange

3HAC037052-001

Removing

Note

Ethanol

1

Action

Cut the paint with a knife in the joint between the part that will be removed and the structure, to avoid that the paint cracks.

Description

2 Carefully grind the paint edge that is left on the structure to a smooth surface.

xx0900000121




231

4 Repair

4.2.5 The brake release buttons may be jammed after service work

4.2.5 The brake release buttons may be jammed after service work

Description

The brake release unit has push-buttons for the 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.

DANGER

If 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

1

2

3

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

4

Action

Make sure the power is turned off.

Remove the push-button guard, if necessary.

Verify that the push-buttons of the brake release unit are working by pressing them down, one by one.

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

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.

232




4 Repair

4.3.1 Replacement of cable harness, axes 1-4

4.3 Complete robot

4.3.1 Replacement of cable harness, axes 1-4

Location of cable harness

The cable harness for axes 1-4 is run throughout the base, frame and lower arm as shown in the figure below.

The brake release unit can be located at two alternative places, either at the rear of the base or at the side of the frame. Depending on the location, the two types of harnesses are distinguished some from each other! Any differences are pointed out in the procedures!

xx0100000140

1

2

A

B

C

D

Alternative with brake release at frame

Alternative with brake release at base

Connector at robot base, R1.MP and R1.SMB

Connectors at motor 1; R2.FB1 and R2.MP1


Connectors at serial measurement board; R1.SMB1-3, R1.SMB4-6, R1.SMB1.7,

R2.FB7 and R2.SMB. Battery connector X3 R1.G and R2.G. If brake release located at the frame: also connectors X8, X9 and X10!




233


4 Repair


Continued

E

H

J

K

F

G

L

M

N

Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and

R2.H2


Connectors at cable harness separation; R2.M5/6



Rear cover plate

Connector R1.MP

Connector R1.SMB

Connection of earth cable


Equipment, etc.

Cable harness, axes 1-4

Spare part no.

3HAC12782-1

Cable harness, axes 1-4

3HAC14940-1

Locking liquid

Standard toolkit


Circuit diagram

-

Art. no.

Note

Brake release located at base.

Brake release located in frame.

Loctite 243

Used to secure the attachment screws for the attachment plate inside the frame.




See chapter


.

Removal, cable harness, axes 1-4

The procedure below details how to remove the cable harness, axes 1-4.

1

Action

In order to facilitate refitting of cable harness, run the robot to the specified position:

• Axis 1: 0 °

• Axis 2: 0 °

• Axis 3: 0 °

• Axis 4: 0 °

• Axis 5: +90 °

• Axis 6: no significance

Note

Axes 2 and 3 may be tilted slightly to improve access.


234




4 Repair


Continued

Action Note

2

DANGER

Turn off all:





3

4

5

6

7

8

9

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

Shown in the figure

Location of cable harness on page 233

.

Disconnect the earth cable .

Attachment point is shown in the figure


!

Disconnect connectors R1.MP and R1.SMB

.

Attachment points are shown in the figure

Location of cable harness on page 233 .

Pull the cable and connectors up through the cable guide in the center of the frame.

Disconnect all connectors at motors 1 and 2.

Specified and shown in the figure

Location of cable harness on page 233 !

Open the SMB cover carefully.

The cable 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!

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

R1.SMB4-6 from the SMB unit.

Disconnect X8, X9 and X10 if the brake release board is located in frame.

xx0200000118





235

4 Repair


Continued

10

Action

Remove

• the cable gland (A), by removing the four attachment screws from inside the SMB recess

(B)

• the attachment plate (C), by removing the attachment screws and the velcro strap (D).

Note

Note

Different robot versions are fitted with different versions of the attachment plate. When replacing the cable harness, make sure the correct one is used to avoid cable failure.

11 Remove the cable gland securing the cables inside the lower arm.

xx0300000560

• A: Cable gland

• B: Attachment screws, cable gland

• C: Attachment plate

• D: Velcro strap


236




4 Repair


Continued

12

Action

Remove the cable gland securing the cables to the arm house.

Note xx0100000143

13

14

15

Remove the velcro strap from the harness at the cable fixing bracket at the arm house.

Shown in the figure


.

Disconnect connector R2.M5/6 at the cable division point.

Shown in the figure


!

Disconnect all connectors at motor 3 and motor 4.



16 Gently pull the cable harness out.

Refitting, cable harness, axes 1-4

The procedure below details how to refit the cable harness, axes 1-4.

Action Note

1

DANGER

2

Turn off all:





In order to facilitate refitting of cable harness, move the robot to the specified position:

• Axis 1: 0 degrees




• Axis 5: +90 degrees


Axes 2 and 3 may be tilted slightly to improve access.




237


4 Repair


Continued

3

4

5

6

7

Action Note

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

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

Make a note of the correct positions of the connectors!

Reconnect connectors R1.MP and R1.SMB

at the rear cover plate.

Tightening torque for R1.SMB: 10

Nm.

Make a note of the correct positions of the connectors!


Location of cable harness on page 233 .

Reconnect the earth cable.



Refit the rear cover plate to the robot with its attachment screws.

Shown in the figure


.

Reconnect all connectors at motors 1 and 2.




238




4 Repair


Continued

8

Action Note

Secure the cable gland (A) with four attachment screws (B) from inside the SMB recess.

Secure the correct attachment plate (C) to the cable gland with its two attachment screws, using locking liquid.

Refit the velcro strap (D).

Locking liquid is specified in


.

Note

Different robot versions are fitted with different versions of the attachment plate. Make sure the correct one is used to avoid cable failure.

xx0300000560

• A: Cable gland

• B: Attachment screws, cable gland

• C: Attachment plate

• D: Velcro strap





239

4 Repair


Continued

9

Action

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

R1.SMB4-6 to the SMB unit.

Reconnect X8, X9 and X10 if the brake release board is located in frame.

Reconnect R1.G if it has been disconnected.

Note

10 Secure the SMB cover with its attachment screws.

If cabling is used for 7th axis (option), refit the connector R2.FB7 to the SMB cover and tighten with 6 Nm.

11

WARNING

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

The brake release buttons may be jammed after service work on page 232 !

12

13

Pull the cable harness through the lower arm.

Refit the cable gland securing the cables inside the lower arm.

xx0200000118

14 Refit the cable gland securing the cables to the arm house.

Make sure not to twist the harness!

xx0100000142


240


xx0100000143



4 Repair


Continued

15

16

17

18

Action

Reconnect all connectors at motor 3 and motor

4.

Note



Reconnect the connector R2.M5/6 gently at the cable division point.

Be careful not to bend the attachment plate when fastening the screws!

Shown in the figure


!

M6, 2 pcs.

Secure the cable harness to the upper arm house by refitting the velcro strap to the cable bracket at the upper arm house.

Shown in the figure


!

Fit a cable protection to the lower arm, if not already mounted, with two securing screws (A),

M6x16.

Secure the cable harness with two velcro straps

(B), with a distance of approximately 180 mm. Fix the strap by wrapping it two turns around the largest cable before wrapping around the complete harness.

xx0500002320

19

20

21

22

Refit the cable harness to the guide plate axis 2 .

Shown in the figure


.

Refit the velcro strap at the guide plate axis 2.

Shown in the figure


.

If the connection between the SMB battery and the SMB unit has been broken, the revolution counters must now be updated!

DANGER

Detailed in the Calibration chapter

- section

Updating revolution counters on page 403 .






4 Repair


4.3.2 Replacement of cable harness, axes 5-6

Location of cable harness ax 5-6

The location of the cable harness, axes 5-6, is shown in the figure below.

xx0100000145

C

D

E

A

B

Cable attachment, upper arm

Cable attachment, rear

Connector at cable harness division; R2.M5/6




Equipment, etc.

Cable harness ax.5-6

Spare part no.

3HAC11440-1

Note

Gasket

Standard toolkit


-

3HAC033489-001 Recommended to be changed for

Foundry Plus robots.








4 Repair


Continued

Equipment, etc.

Circuit diagram

Spare part no.

Note

See chapter


.

Removal, cable harness, axes 5-6

The procedure below details how to remove the upper arm cable harness.

Note

1

Action

Position the upper arm as follows:




2

DANGER

Turn off all:





3 Remove the left hand side wrist cover by unscrewing its attachment screws.

4

Note

Axis 5 must be oriented in the correct position (+90º) to allow the motor 6 cover to open!

8

9

5

6

7

Disconnect all connectors at motor 5 and motor 6.

Specified in the figure

Location of cable harness ax 5-6 on page 242 .

Remove the plastic cover on the rear of the upper arm, by removing the attachment screws.

Remove the spiral plate by unscrewing the screw at the bottom of the spiral cup.

Remove eventual cable straps from the harness.

Disconnect connector R2.M5/6 at the cable harness division .

Shown in the figure

Location of cable harness ax 5-6 on page 242

.

10

11

Remove the cable attachment inside the upper arm.

Gently pull the cable harness out.

Refitting, cable harness, axes 5-6

The procedure below details how to refit the upper cable harness.

Note

1

Action

Position the upper arm as follows:







243


4 Repair


Continued

3

4

5

2

6

7

Action

Gently insert the cable harness from the rear into the upper arm.

Pull the small spiral plate past motor 5.

Route the cables outside the heat protection plate.

Note

Secure the small plate to the large plate. Secure the spiral cup with its attachment screw in the bottom of the cup.

Secure any excess cable length tightly to the large plate in the wrist housing, using cable straps.

Use the attachment holes in the large plate intended for the cable straps!

Excess cable length may be present if upper arm length is not the maximum.

Reconnect all connectors at motor 5 and motor 6.

Specified in the figure


.

8

9

10

11

12

Secure the cable with the cable attachment inside the upper arm.

Refit the left hand side wrist cover with its attachment screws.

Reconnect connector R2.M5/6 gently at the cable harness division with two screws, M6.



Add Loctite to screw before fastening. Screw 3HAB3409-25,

Washer 3HAC062379-001

Shown in the figure

M6, 2 pcs.


Refit the plastic cover on the rear of the upper arm.

Update the revolution counters.

Detailed in section


.

244




4 Repair

4.3.3 Replacement of complete arm system

4.3.3 Replacement of complete arm system

Location of complete arm system

The complete arm system is defined as the complete robot except for the base and gearbox axis 1, that is the upper and lower arms, balancing device and frame.

This is shown in the figure below.

xx0100000150

D

E

F

A

B

C

Gearbox, axis 1

Motor, axis 1

Base attachment screws

Upper arm

Lower arm

Frame





245

4 Repair


Continued

G

H

Balancing device

Block for calibration


Equipment, etc.

Lifting device, robot

Guide pins, M12 x 130

Standard toolkit -

Art. no.

-

3HAC15607-1

Note

Instruction 3HAC15971-2 enclosed!

Used to guide the complete arm system when refitting.



.



Deciding calibration routine

Decide which calibration routine to be used, based on the information in the table.

Depending on which routine is chosen, action might be required prior to beginning the repair work of the robot, see the table.

1

Action

Decide which calibration routine to use for calibrating the robot.

• Reference calibration. External cable packages (DressPack) and tools can stay fitted on the robot.

• Fine calibration. All external cable packages (DressPack) and tools must be removed from the robot.

Note

If the robot is to be calibrated with reference calibration:

Find previous reference values for the axis or create new reference values. These values are to be used after the repair procedure is completed, for calibration of the robot.

If no previous reference values exist, and no new reference values can be created, then reference calibration is not possible.

Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values.

Creating new values requires possibility to move the robot.

Read more about reference calibration for

Axis Calibration in

Reference calibration routine on page 409

.


Pendulum Calibration in Operating manual - Calibration Pendulum .

If the robot is to be calibrated with fine calibration:

Remove all external cable packages

(DressPack) and tools from the robot.

Removal, complete arm system

The procedure below details how to lift and remove the complete arm system.

1

Action

Decide which calibration routine to use, and take actions accordingly prior to beginning the repair procedure.

Note





4 Repair


Continued

2

Action Note

Position the robot in its most stable position, as shown in the figure to the right.

If the brakes need to be released, see section


.

xx0100000103

3

DANGER

Turn off all:




4

5

6

7

8

Drain the oil from the gearbox, axis 1.

Detailed in section

Changing oil, axis-

1 gearbox on page 183

.

Disconnect the cabling in the rear of the robot base and remove the cable support plate inside of the base.

Pull the disconnected cabling up through the center of the axis-1 gearbox.


Detailed in section

Removal, motor axis 1 on page 315 .


9

CAUTION

The complete arm system weighs 2000 kg! All lifting equipment used must be sized accordingly!

10

11

Fit the lifting device and adjust it as detailed in enclosed instruction.



!

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!

Remove the block for calibration from the bottom of the frame.

Shown in the figure

Location of complete arm system on page 245

!




247


4 Repair


Continued

12

13

Action Note

Remove the arm system from the base by unscrewing the 24 base attachment screws.

Shown in the figure


!

Lift the arm system and secure it in a safe area.

Make sure all hooks and attachments maintain in correct position while lifting the robot!


Refitting, complete arm system

The procedure below details how to refit the complete arm system to the robot.

Action Note

1

DANGER

Turn off all:




2

CAUTION

The complete arm system weighs 2000 kg!

All lifting equipment used must be sized accordingly!

3

4

5

Fit and adjust the lifting device as detailed in enclosed instruction.



.

Lift the complete arm system and move it at very low speed, making sure it does not tip!

Make sure the lift is done completely level, adjust the length of the chains as detailed in enclosed instruction!

Make sure all the hooks and attachments maintain in correct position while lifting the robot!

Fit two guide pins, M12 x 130, in the frame attachment holes as shown in the figure to the right.

Fit one guide pin next to the guiding hole

(for the spring pin in the gearbox) and the other guide pin straight across the frame.


248 xx0300000070

The figure above shows a view from below of the frame.

A Attachment holes for the guide pins, M12.

B Guiding hole for the spring pin located in the gearbox, axis 1.




4 Repair


Continued

6

7

8

Action Note

Look through the empty mounting hole of motor axis 1, to assist in aligning the assembly during refitting of the arm system.

The guiding pin in the gearbox must be fitted to the guiding hole of the frame (B).

Lower the arm system with guidance from the guide pins previously fitted to the frame.

This is a complex task to be performed with outmost care in order to avoid injury or damage!

Refit 22 of the 24 attachment screws before the arm system is completely lowered.

Remove the guide pins and secure the arm system to the base with the 24 base attachment screws and washers.

Shown in the figure


.

24 pcs, M12 x 110; 12.9 quality UN-

BRAKO, tightening torque: 110 Nm.

Reused screws may be used, providing they are lubricated as detailed in section


before fitting.

9

10

Refit the block for calibration at the bottom of the frame.

Shown in the figure


.


Detailed in section

Refitting, motor axis

1 on page 316

.

11

12

13

Perform a leak-down test.

Detailed in section

Performing a leakdown test on page 226

.

Refill the gearbox axis 1 with lubricating oil.

Detailed in section

Filling, oil, gearbox axis 1 on page 186

.

Recalibrate the robot.

Pendulum Calibration is described in Operating manual - Calibration Pendulum , enclosed with the calibration tools.

Axis Calibration is described in

Calibrating with Axis Calibration method on page 408 .

General calibration information is included in section

Calibration on page 395

.

14

DANGER


First test run may cause injury or damage on page 31

.




249

4 Repair

4.4.1 Replacing turning disk

4.4 Upper and lower arm

4.4.1 Replacing turning disk

Location of turning disk

The turning disk is located in the center of the wrist unit as shown in the figure below.

xx0100000129

A

B

C

Turning disk

Oil plug, filling (oil plug for draining is located on the opposite side of the tilthouse)

Turning disk attachment screws, 33 pcs


Equipment, etc.

Turning disk, dia. 250

Spare part no.

3HAC13193-1

Turning disk, insulated 3HAC023124-002

O-ring

Art. no.

21522012-433

Grease

Standard toolkit -

3HAB3537-1

Note

Does not include o-ring!

Must be replaced when replacing the turning disk!

Used to lubricate the o-ring.



.


250




4 Repair


Continued

Equipment, etc.

Other tools and procedures may be required.

See references to these procedures in the step-by-step instructions below.

Spare part no.

Art. no.

Note


Removing turning disk

Use the procedure to remove the turning disk.

Action Information

1

DANGER

Turn off all:





2

3

4

Drain the oil from gearbox 6.

Remove the attachment screws (33 pcs) securing the turning disk.

Remove the turning disk .

Shown in the figure

Location of turning disk on page 250

.

xx1000001135





251

4 Repair


Continued

Refitting turning disk

Use this procedure to refit the turning disk.

Action Information

1

DANGER

Turn off all:





2 Lubricate the o-ring with grease and fit it to the rear of the turning disk.



3

4 xx0100000130

O-ring, turning disk

Secure the turning disk with its attachment screws .

Attachment screws:

• M10 x 25, 12.9 quality UNBRAKO

• Tightening torque: 50 Nm .



before fitting.

Refill the gearbox, axis 6, with oil.


252




Action

5

DANGER



.

Information

4 Repair


Continued




253

4 Repair

4.4.2 Replacement of complete wrist unit

4.4.2 Replacement of complete wrist unit

Location of wrist unit

The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.

A more detailed view of the component and its position may be found in Exploded views in Product manual, spare parts - IRB 7600 .

xx0100000147

D

E

F

G

H

A

B

C

Wrist unit

Wrist unit attachment screws and washers

Attachment, cable harness axis 5-6

Connectors at cable harness division; R2.M5/6

Turning disk

Cover, axis 5

Rear cover

View with cable harness mounted on robot


Equipment, etc.

Wrist

Art. no.

For spare part number, see


.

Note





4 Repair


Continued

Equipment, etc.

Friction washer

Art. no.

3HAC11755-1

Note

A new friction washer must always be used when refitting the wrist unit.

Lifting tool, wrist unit

Standard toolkit

Calibration Pendulum toolkit

Calibration tool box, Axis Calibration

3HAC055412-001


Circuit diagram -

-

3HAC12734-1

3HAC15716-1



Complete kit that also includes operating manual.

Required if Calibration Pendulum is the valid calibration method for the robot.

Delivered as a set of calibration tools.

Required if Axis Calibration is the valid calibration method for the robot.


See chapter

page 447 .

Circuit diagram on




1

Action Note










Axis Calibration in


.









255


4 Repair


Continued

Removal, wrist unit

The procedure below details how to remove the complete wrist unit.

1

Action


Note

2

DANGER

3

4

5

Turn off all:





Remove all equipment fitted to the turning disk.

Turn axis 4 to a position where the cover, axis 5 faces upwards.

Remove the cover, axis 5, by unscrewing its attachment screws.

Shown in the figure

Location of wrist unit on page 254

.

6

CAUTION

The complete wrist unit weighs 200 kg! All lifting equipment used must be sized accordingly!

7

8

9

10

11

12

13

14

15

Fit the lifting tool, wrist unit to the two holes on the sealing surface against the cover, axis 5.

Remove the rear cover by unscrewing its attachments.



If required, cut any cable ties securing the cables in order to fit the tool.

Shown in the figure


.

Disconnect connector R2.M5/6 at the rear cable division point .

Shown in the figure


.

Remove all cable attachment inside the upper arm and at the rear of the robot.

Slightly raise the wrist unit to unload the screw joint, facilitating removal of the attachment screws.

Do not remove the attachments from the cabling!

Remove the wrist unit attachment screws and washers .

Pull the cabling forwards through the upper arm tube.

Make sure the attachments do not get stuck inside the tube!

Remove the friction washer between the wrist unit and the upper arm tube.

A new washer must always be used on reassembly.

Lift the wrist unit down and place it on a secure surface.


256




4 Repair


Continued

Refitting, wrist unit

The procedure below details how to refit the complete wrist unit.

Action Note

1

DANGER

Turn off all:





2

CAUTION

The complete wrist unit weighs 200 kg! All lifting equipment used must be sized accordingly!

3 Remove the cover, axis 5 from the wrist unit to be fitted. Fit the lifting tool, wrist unit to the wrist unit.



.

4

5

6

7

8

9

Lift the wrist unit and move it to its mounting position.

Fit a new friction washer between the upper arm tube and the wrist unit.



.

Gently pull the wrist unit cable harness through the upper arm and out the rear.

Secure the wrist unit with its attachment screws and washers.

Screws: M12 x 50, UNBRAKO quality 12.9, tightening torque:

115 Nm.



before fitting.

Secure the cable harness with the cable attachment inside the upper arm as well as at the rear of the upper arm.

Make sure the cabling is not twisted!

Remove the lifting tool and refit the cover, axis 5 with its attachment screws.

Shown in the figure


.

10

11

Refit any cable ties that were previously cut during disassembly.

Reconnect connector R2.M5/6 at the rear cable division point.

Shown in the figure


.

12 Refit the rear cover with its attachment screws.

13 Check the oil levels at gearboxes axis 5 and 6.

Shown in the figure


.

Detailed in sections:

•


•






257

4 Repair


Continued

14

Action


15 Refit any equipment previously removed from the turning disk.

16

DANGER



Note

Pendulum Calibration is described in Operating manual - Calibration

Pendulum , enclosed with the calibration tools.


Calibrating with Axis Calibration method on page 408

.



.

258




4 Repair

4.4.3 Replacement of complete upper arm

4.4.3 Replacement of complete upper arm

Location of upper arm

The upper arm is located on top of the robot as shown in the figure below.

A more detailed view of the component and its position may be found in chapter

Exploded views in Product manual, spare parts - IRB 7600 .

xx0100000148

F

G

D

E

H

J

K

A

B

C

Upper arm

Attachment screws, upper arm

Connectors at cable harness division; R2.M5/6

Rear cable attachment

Oil plug, draining

Oil plug, filling

Attachment hole, M12

Sealing between lower arm and gearbox 3

Attachment holes for lifting device, upper arm

Attachment holes for lifting eye





259

4 Repair


Continued


Equipment, etc.

Sealing, axis 2/3

Washer

Standard toolkit

Lifting eye, M12

Lifting device, upper arm

Lifting tool (chain)

Hoisting block

Guide pins, sealing axis 2/3

Art. no.

3HAC17213-1

-

3HAC11828-1

-

3HAC14457-3

3HAC15536-1

3HAC15556-1

3HAC14627-2

Note

Always use a new sealing when reassembling!

Replace if damaged!



Guide pins, sealing axis 2/3 3HAC14627-3

Standard hoisting block, capacity 200 kg.

80 mm.

For guiding "Sealing, axis 2/3".

100 mm

For guiding "Sealing, axis 2/3".






1

Action




Note







Axis Calibration in


.










4 Repair


Continued

Removal, upper arm

The procedure below details how to remove the complete upper arm.

1

2

3

Action


Run the upper arm to a horizontal position.

Note

DANGER

Turn off all:





4

CAUTION

The complete upper arm weighs 450 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel!

5

6

7

8

9

10

11

12

13

14

15

Fit the lifting eye to the unit.

attachment hole in the wrist Shown in the figure

Location of upper arm on page 259

.



.

Fit one of the pieces included in the lifting device, upper arm to the attachment holes for lifting device, upper arm using the included attachment screws.

Shown in the figure


.



.

Run the lifting chain from the rear lifting point through the overhead crane hook, through the hoisting block to the lifting eye in the front.



.

Use the hoisting block to adjust the tension in the chain in order to lift the upper arm completely level.


Detailed in section


Disconnect connector R2.M5/6 at the rear cable division point as well as all remaining connections to the upper arm.

Disconnect all connectors inside motors 3 and 4.

Remove all brackets securing cabling to the upper arm by unscrewing their attachment screws respectively.

Raise the lifting equipment to take the weight of the upper arm.

Carefully remove the upper arm attachment screws .

Make sure that the upper arm is lifted in a completely level position in all planes in order not to damage the upper arm!

Shown in the figure


.

30 pcs.

Lift the upper arm and place it on a secure surface.




261


4 Repair


Continued

16

Action

Remove the sealing from the lower arm.

Note

Refitting, upper arm

The procedure below details how to refit the upper arm to the robot.

Action Note/Illustration

1

DANGER

Turn off all:





2 Fit the new sealing, axis 2/3 onto the axis-3 gearbox and keep it in place by also fitting the two guide pins, sealing axis 2/3 in two of the attachment screw holes on the gearbox, see figure to the right.




.

xx0200000125

Holes for guide pins in the gearbox.

3

CAUTION

The complete upper arm weighs 450 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel!

4

5

6

Fit the lifting eye to the attachment hole in the wrist unit.

Shown in the figure


.



.

Fit one of the pieces included in the lifting device, upper arm to the attachment holes for lifting device, upper arm using the included attachment screws.

Shown in the figure


.



.

Run the lifting chain from the rear lifting point through the overhead crane hook, through the hoisting block to the lifting eye in the front.



.





4 Repair


Continued

7

8

9

10

11

12

13

14

15

16

17

Action

Use the hoisting block to adjust the tension in the chain in order to lift the upper arm completely level.

Lift the upper arm and move it to its mounting position.


Fit the three washers to be placed beneath the attachment screws.

Make sure the washers are not scarred or pitted in the surface facing the screw heads. If both washer sides are damaged, replace the washer. Art. no. is specified in


.

Insert the attachment screws.

Do not remove the guide pins until the attachment screws are tightened as detailed below!

In some cases, removing the plastic mechanical stops may be required before fitting the upper arm.

If guide pins are removed before the screws are tightened, the sealing can be involuntarily moved into wrong position.

Secure the lower arm to gearbox axis 3 with the upper arm attachment screws .

30 pcs: M16 x 50. Tightening torque: 300 Nm.

Shown in the figure


.

Remove the guide pins and fit the two remaining attachment screws. Tighten them as detailed above!

Refit any cabling removed during the removal process.

Reconnect all connectors inside motors 3 and 4.

Reconnect connector R2.M5/6 gently at the rear cable division point.


Refill the gearbox with oil.

Detailed in section

page 192

.

Filling, oil on






.



.

18

DANGER






4 Repair

4.4.4 Replacement of complete lower arm

4.4.4 Replacement of complete lower arm

Location of lower arm

The lower arm is located as shown in the figure below.

xx0100000149

A

B

C

D

Lower arm

Pivot point, axis 2

Front shaft, balancing device, including securing screw

Attachment for lifting eye, M12, balancing device

Attachment points, lower arm

The lower arm attachment points are located as shown in the figure below:

• The figure (1) shows gearbox 3, but the location of sealing axis 2/3 in relation to the gearbox is identical for axis 3.

• The figure (2) shows a cut view through the lower arm pivot point in axis 2

(item B in the figure above!), valid for robots with protection Standard.


264




4 Repair



401

402

403

404

405

406

409

A

B

C

D

E

201

202

204

Gearbox

Lower arm

Balancing device piston rod ear

Frame

Shaft hole

Sealing, axis 2/3

Attachment screw

Washer

Bearing

Thrust washer

Bushing

Retaining ring

Shaft

Protection plug

Protection washer





265

4 Repair


Continued

Components, lower arm shaft for robots with protection Foundry Plus and Foundry Prime

The figure shows components fitted to the lower arm shaft when the robot has protection Foundry Plus and Foundry Prime.

xx1100000954

F

G

H

C

D

A

B

E

L

M

J

K

Bearing

Thrust washer

Bushing

Shaft for the lower arm

Set screw with cup point, M4x6 (2 pcs)

Hexagon bolt M8x190

Conical spring washer 8.4x16x1.6

Shaft tap

Shaft for the sealing cover

O-ring

Sealing cover

Radial sealing with dust lip


Equipment, etc.

Bearing

Sealing, axis 2/3

VK cover

Article number

3HAC4310-1

3HAC17213-1

3HAA2166-23

Note

Always use a new bearing.

Always use a new sealing.

Replace if damaged.

Only used on lower arms with a hole in the upper end (axis 3).





4 Repair


Continued

Equipment, etc.

Lifting tool, lower arm

Article number

3HAC14691-1

Note

Tool that may be rented from ABB.

Includes

• Guidances, 3HAC14445-1

The guidings are used for guiding the sealing, axis 2/3.

Rotation tool

Lifting eye M12

Puller tool, balancing device shaft

Hydraulic pump, 80 MPa

3HAC17105-1

3HAC14457-3

3HAC12475-1

3HAC13086-1


(Glycerin)

3HAC021563-012

Press device, axis 2 shaft 3HAC021600-001

Press tool, axis 2 bearing 3HAC13453-1

Power supply -

Used to lift the balancing device.

Used to pull out the shaft from the balancing device front ear.

To be used together with the press device, axis 2 shaft and the puller tool.

To be used together with the press tool, axis 2 shaft and the puller tool.

24 VDC, 1.5 A.

For releasing the brakes.

Retaining ring pliers

Standard toolkit


-

-

3HAC15716-1

Calibration tool box, Axis

Calibration

3HAC055412-001












1

Action




Note




267


4 Repair


Continued

Action Note







Axis Calibration in


.






Removal, lower arm

The procedure below details how to remove the complete lower arm.

1

Action


Note

2

DANGER

Turn off all:





3

4

5

6

7

Remove the upper arm.

Detailed in section

Replacement of complete upper arm on page 259

.

Disconnect and remove the cables from inside the lower arm.

Release any cable attachments.

Detailed in section

Replacement of cable harness, axes 1-4 on page 233 .

Apply the lifting eye to the balancing device and raise to unload the device.



Attachment is shown in the figure

Location of lower arm on page 264

.

Unload the balancing device in order to make the piston rod and front ear adjustable when pulling the front shaft out.

Detailed in section

Unloading the balancing device using hydraulic press tool on page 306 .

Remove the securing screw from the balancing device front shaft.

Shown in the figure

Location of lower arm on page 264 .


268




4 Repair


Continued

8

Action Note

Apply the shaft puller tool to the shaft through the hole in the frame.

The shaft has a M20 thread diameter and a 40 mm depth of thread, as shown in the figure to the right.

Pull the shaft out using the puller tool and the hydraulic pump.



xx0300000060

Note

The dimension of the shaft puller tool is M20. Do not mix up with the shaft press tool used when mounting the shaft.

9

10

Lower the balancing device until it rests safely against the bottom of the frame, out of reach from the lower arm.

Move the lower arm backwards to the lowest position possible.

xx0300000015

11

CAUTION

The lower arm weighs 225 kg! All lifting equipment used must be sized accordingly!

12

13

14

15

16

17

Apply the lifting tool to the lower arm.




Detailed in section

Changing oil, axis-

2 gearbox on page 187 .

Raise the tool to unload the lower arm.

Remove the lower arm shaft and all additional components, as detailed in section

Replacement of lower arm shaft on page 273 .

Remove the lower arm attachment screws and washers that attaches the lower arm to the gearbox 2.

Shown in the figure

Attachment points, lower arm on page 264

.

Lift the lower arm down and place it on a secure surface.




269


4 Repair


Continued

18

19

Action Note

Remove the bearing and thrust washer from the shaft hole in the lower arm.

Shown in the figure


.

On reassembly a new bearing must be used!


Shown in the figure


.

On reassembly a new sealing must be used!

Refitting, lower arm

The procedure below details how to refit the lower arm to the robot.

Action Note

1

DANGER

Turn off all:





2 If the lower arm is designed with a hole, fit a new VK-cover on a new lower arm or replace existing if damaged.

Spare part number is specified in


.

xx1700000917

3 Fit the two guidings in the attachment holes of the lower arm.

Included in the lifting tool, lower arm, article number is specified in


.


270


xx0200000262

A Attachment holes for the two guidings.



4 Repair


Continued

4

Action

Fit the new sealing, axis 2/3 on the guidings.

Note




.

5

CAUTION

The lower arm weighs 225 kg! All lifting equipment used must be sized accordingly!

6

7

8

Apply the lifting tool to the lower arm.



.

Lift the lower arm and move it to its mounting position.

In case the holes of the lower arm and the ones of the gearbox axis 2 doesn´t match, use power supply to release the motor axis 2 brakes and rotate the pinion and gear with the rotation tool.

Connect power supply to connector

R2.MP2:

• + : pin 2

• -: pin 5

9 xx0200000165

The rotation tool (A) is used beneath the motor cover, directly on the motor shaft as shown in the figure above!



.

Secure the lower arm with 28 of the 30 attachment screws and washers in gearbox 2.

30 pcs: M16 x 50; tightening torque:

300 Nm.

Shown in the figure


.

10

11

12

Remove the guidings and secure the two remaining attachment screws as detailed above!

Refit the lower arm shaft and all additional components, as detailed in section


.

Refit and restore the balancing device.

Detailed in section

Refitting, balancing device on page 302 .

13 Refit the upper arm.

14

15


Refill the axis 2 gearbox with oil.

Detailed in section

Refitting, upper arm on page 262 .

Detailed in section


.

Detailed in section

Filling, oil on page 188 .




271


4 Repair


Continued

16

17

Action Note

Refit and reconnect all cables inside the lower arm.

Refit removed cable attachments.

Detailed in section

Refitting, cable harness, axes 1-4 on page 237 .


Pendulum Calibration is described in

Operating manual - Calibration Pendulum , enclosed with the calibration tools.



.



18

DANGER



272




4 Repair

4.4.5 Replacement of lower arm shaft

4.4.5 Replacement of lower arm shaft

Prerequisites

This section details how to remove and refit the lower arm shaft as a step in the procedure of removing/refitting the complete lower arm. To perform the procedure described in this section, it is required that the preceding instructions in section


are followed! These include:

• removing the upper arm

• removing the cabling in the lower arm

• unloading the balancing device and removing the front eye shaft

• draining the oil in gearbox axis 2

• unloading the lower arm with specific lifting equipment.

Components, lower arm shaft for robots with protection Standard

The figure shows components fitted to the lower arm shaft when the robot has protection Standard.

xx0300000487

C

D

A

B

E

F

Protection plug

Lower arm shaft (axis 2 shaft)

Thrust washer

Bearing

Protection washer

Retaining ring





273

4 Repair


Continued

Components, lower arm shaft for robots with protection Foundry Plus

The figure shows components fitted to the lower arm shaft when the robot has protection Foundry Plus.

xx1100000954

F

G

H

C

D

A

B

E

L

M

J

K

Bearing

Thrust washer

Bushing

Shaft for the lower arm

Set screw with cup point, M4x6 (2 pcs)

Hexagon bolt M8x190

Conical spring washer 8.4x16x1.6

Shaft tap

Shaft for the sealing cover

O-ring

Sealing cover

Radial sealing with dust lip


Equipment

Bearing

Puller device, axis 2 shaft

Press device, axis 2 shaft


For spare part number see:

•


.

Always use a new bearing when reassembling!

3HAC021563-001

3HAC021600-001





4 Repair


Continued


Hydraulic pump, 80 MPa 3HAC13086-1

Hydraulic pump, 150 MPa (Glycerin)

3HAC021563-012

Press tool, axis 2 bearing

Retaining ring plier

Isopropanol

Grease

3HAC13453-1

-

11771012-208

3HAB3537-1

Note

Rust preventive 3HAC026621-001

Locking liquid (only for robots with protection Foundry Plus and

Foundry Prime)

3HAB7116-1

For cleaning the shaft.

For lubrication of the bearing.

For lubrication of the shaft.

Equivalent:

• Mercasol 3106

Loctite 243

Puller device for removal of axis 2 shaft

The illustration below shows the puller tool used to remove the lower arm shaft

(axis 2 shaft).

xx0400001029

A

B

Nipple for the hydraulic pump

Nipple for the glycerin pump





275

4 Repair


Continued

Press device for refitting of axis 2 shaft

The illustration below shows the press tool used to refit the lower arm shaft (axis

2 shaft).

xx0400001030

A

B

C

Nipple for the hydraulic pump

Nipple for the glycerin pump

Indicator

Removal, lower arm shaft from robot with protection Standard

Use this procedure to remove the lower arm shaft if the robot has protection

Standard.

If encountering any problems when removing the shaft, contact ABB Robotics!


1

WARNING

This procedure is a step in the complete procedure of removing the lower arm! Make sure all the preceding steps specified in


are made before removing the lower arm shaft!

2 Remove the protection plug.

Shown in the figure

Components, lower arm shaft for robots with protection

Standard on page 273

!





4 Repair


Continued

3

4


Remove the protection washer and the retaining ring.

Shown in the figure

Components, lower arm shaft for robots with protection

Standard on page 273

!

Use a plier for the retaining ring.

Fit the puller device to the shaft as shown in the figure to the right.



xx0300000010

5

6

7

Fit both the hydraulic pump and the glycerin pump to the puller device.



The attachments on the tool are shown in figure

Puller device for removal of axis

2 shaft on page 275 .

Increase the pressure of the glycerin pump and, at the same time, pull out the shaft with the puller tool by increasing the pressure of the hydraulic pump.

Note!

Do not exceed the limit of maximum pressure classified for the pumps!

Remove the bearing and thrust washer from the shaft hole in the lower arm, recommendable after removing the complete lower arm as detailed in section

Replacement of complete lower arm on page 264 .





277

4 Repair


Continued

Removal, lower arm shaft on robot with protection Foundry Plus

Use this procedure to remove the lower arm shaft if the robot has protection Foundry

Plus.

If encountering any problems when removing the shaft, contact ABB Robotics!

Action Note

1

WARNING

This procedure is a step in the complete procedure of removing the lower arm! Make sure all the preceding steps specified in


are made before removing the lower arm shaft!

2

3

4

5

6

7

Remove the two set screws .

Remove the shaft sealing cover .

Remove the sealing cover .

Remove the radial sealing , if the lower arm is to be replaced with a new one.

If the same lower arm is refitted, the radial sealing can be left in the lower arm.

Shown in the figure

Components, lower arm shaft for robots with protection Foundry Plus on page 274

.

Remove the hexagon bolt with the washer and shaft tap .

Fit the puller device to the shaft as shown in the figure to the right.



!

xx0300000010


278




4 Repair


Continued

8

Action Note

Fit both the hydraulic pump and the glycerin pump to the puller device.



.

The attachments on the tool are shown in figure

Puller device for removal of axis 2 shaft on page 275

.

9 Increase the pressure of the glycerin pump and, at the same time, pull out the shaft with the puller tool by increasing the pressure of the hydraulic pump.

Note!


10 Remove the bearing and thrust washer from the shaft hole in the lower arm, recommendable after removing the complete lower arm as detailed in section

Replacement of complete lower arm on page 264 .

Refitting, lower arm shaft on robot with protection Standard

Use this procedure to refit the lower arm shaft if the robot has protection Standard.

1

2

Action

Clean the shaft with isopropanol and lubricate it with grease .

If the robot is going to work in a water jet application cell:

Apply Mercasol 3106 on the Support shaft axis 2.

• Apply Mercasol 3106 on both sides of the thrust washer, all around the bearing and on surface on the shaft.




A

A

Apply mercas

• A: Mercasol on marked areas.

3

4

Push the shaft in by hand.

Refit the thrust washer to the shaft.

5

6

Apply the press device, axis 2 shaft against the shaft.

Tighten the M16 nut.

Also shown in the figure

Components, lower arm shaft for robots with protection Standard on page 273 !







279


4 Repair


Continued

7


Fit both the hydraulic pump and the glycerin pump to the press device.



The attachments on the tool are shown in the figure

Press device for refitting of axis 2 shaft on page 276 .

8 Set the indicator on the press device to zero.

Shown in the figure


9 Press in the shaft with the hydraulic cylinder by setting the pressure of the hydraulic pump to approximately 35-55 MPa and the pressure of the glycerin pump to 55 MPa.

10 Increase the pressure of the both pumps alternately until the correct value is reached with the indicator on the press tool.

Correct value: 2.45 mm ± 0.15 mm.

Note


11 When a correct value is reached, release the pressure from the glycerin pump first, then from the hydraulic pump (approximately 1/2 minute after), in order to avoid movement of the shaft.

12 Remove the press device, axis 2 shaft.

13 Apply grease to the location of the shaft where the bearing is to be mounted.



14 Press in the new bearing with the press tool, axis

2 bearing .




15

16

Refit the protection washer and the retaining ring .

Refit the protection plug .

Shown in the figure

Components, lower arm shaft for robots with protection Standard on page 273

.

17 Proceed with the refitting procedure of the lower arm, detailed in section


.

Refitting, lower arm shaft on robot with protection Foundry Plus

Use this procedure to refit the lower arm shaft if the robot has protection Foundry

Plus.

1

Action

Clean the shaft with isopropanol and lubricate it with grease .





280




4 Repair


Continued

2

Action

If the robot is going to work in a water jet application cell:

Apply Mercasol 3106 on the support shaft axis 2.

• Apply Mercasol 3106 on both sides of the thrust washer, all around the bearing and on surface on the shaft.


A

A

6

7

3

4

5

Apply mercas

A Mercasol on marked areas.

Push the shaft in by hand.

Refit the thrust washer to the shaft.

Also shown in the figure

Components, lower arm shaft for robots with protection Foundry Plus on page 274 !



Apply the press device, axis 2 shaft against the shaft.

Tighten the M16 nut.


Fit both the hydraulic pump and the glycerin pump to the press device.



The attachments on the tool are shown in the figure


8 Set the indicator on the press device to zero.

Shown in the figure


9 Press in the shaft with the hydraulic cylinder by setting the pressure of the hydraulic pump to approximately 35-55 MPa and the pressure of the glycerin pump to 55 MPa.

10 Increase the pressure of the both pumps alternately until the correct value is reached with the indicator on the press tool.

Correct value: 2.45 mm ± 0.15 mm.

Note!


11 When a correct value is reached, release the pressure from the glycerin pump first, then from the hydraulic pump (approximately 1/2 minute after), in order to avoid movement of the shaft.

12 Remove the press device, axis 2 shaft.

13 Apply grease to the location of the shaft where the bearing is to be mounted.






281


4 Repair


Continued


14 Press in the new bearing with the press tool, axis

2 bearing .




15

16

Fit a radial sealing to the lower arm, if there is none left during removal of the arm.

Refit the hexagon bolt with a spring washer and a shaft tap through the hole in the lower arm shaft.

Shown in the figure

Components, lower arm shaft for robots with protection Foundry Plus on page 274 .

17 Fit the shaft for the sealing cover onto the hexagon bolt and tighten the bolt with torque: 24 Nm.

18 Check the o-ring in the sealing cover. Replace if damaged.

19 Refit the sealing cover onto the shaft. Press it tightly against the radial sealing while tightening the set screws. Use locking liquid.

20 Proceed with the refitting procedure of the lower arm, detailed in section


.

282




4.5 Frame and base

4.5.1 Replacing the 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.

A B C D

4 Repair

4.5.1 Replacing the SMB unit


E xx0200000203

F

E

F

G

H

J

A

B

C

D

G H J

Brake release unit

Brake unit cover

Hexagon nut

Pins

Battery unit

SMB cover

Attachment screw, (2 pcs)

Attachment screw, brake unit cover (2 pcs)

Pins

Note

There are different variants of SMB units and batteries. The variant with the

3-pole battery contact has longer lifetime for the battery.

It is important that the SMB unit uses the correct battery. Make sure to order the correct spare parts. Do not replace the battery contact!




283


4 Repair


Continued

Equipment, etc.

SMB unit

Standard toolkit

Circuit diagram -

-

Article number

For spare part number, see:


Note



.

See chapter


Removing, SMB unit

Use this procedure to remove the SMB unit.

1

2

Action

Move the robot to the calibration position.

DANGER

Turn off all:




Note

3


The unit is sensitive to ESD. Before handling the unit read the safety information in section


4 Remove the SMB cover by unscrewing its attachment screws.

Shown in the figure

Location of

SMB unit on page 283 .

CAUTION

Clean cover from metal residues before opening.

Metal residues can cause shortage on the boards which can result in hazardous failures.

5

6

7

Use caution and remove the connectors X8, X9 and

X10 from the brake release board, if need of more space.

Remove the nuts and washers from the guide pins that secure the board.

Shown in the figure

Location of

SMB unit on page 283 .

Use caution and disconnect the connectors from the

SMB unit when pulling the board out.

Connectors R1.SMB1-3,

R1.SMB4-6 and R2.SMB


284




4 Repair


Continued

8

Action

Disconnect the battery cable by pressing down the upper lip of the R2.G connector to release the lock while pulling the connector upwards.

Note xx1700000993

Refitting, SMB unit

Use this procedure to refit the SMB unit.

Action

1

DANGER

Turn off all:




Note

2




3

4

5

6

7

Connect the battery cable to the SMB unit.

Make sure the lock on the battery cable connector R2.G snaps into place during refitting.

Shown in the figure

Location of SMB unit on page 283 .

Connect all connectors to the SMB board:

R1.SMB1-3, R1.SMB4-6 and R2.SMB



.

Shown in the figure


Fit the SMB unit onto the guide pins .

Secure the SMB unit to the pins with the nuts and washers.

If disconnected, reconnect the connectors X8,

X9 and X10 to the brake release board.

Be careful not to damage the sockets or pins.

Make sure the connector and its locking arms are snapped down properly.

X9

X8

X10 xx1700000978





285

4 Repair


Continued

8

9

Action Note

Secure the SMB cover with its attachment screws.

If cabling is used for 7th axis (option), refit the

7th axis connector to the SMB cover and tighten with 6 Nm.

Shown in the figure


Update the revolution counter!

See


.

10

DANGER



286




4 Repair

4.5.2 Replacement of brake release board

4.5.2 Replacement of brake release board

Different designs

Depending on the robot version, the brake release board may be located either at the base or at the frame. The following two figures show the different locations.

The early design includes a brake release board with or without push buttons, located at the base. The later design instead includes a brake release board with push buttons, placed together with the SMB unit on the left hand side of the frame.

The different designs are not compatible.

Location of brake release board, base

The early design includes a brake release board with or without push buttons, located at the base as shown in the figure below.

xx0200000127

A

B

Brake release circuit (brake release unit inside)

Attachment screws, brake release circuit, 4 pcs





287

4 Repair


Continued

Location of brake release board, frame

The later design includes a brake release board with push buttons, placed together with the SMB unit on the left hand side of the frame as shown in the figure below.

A B C D

E xx0200000203

F G H J

H

J

F

G

C

D

A

B

E

Break release unit

Break unit cover

Hexagon nut

Pins

Battery unit

SMB cover

Attachment screw, (2 pcs)

Attachment screw, brake unit cover (2 pcs)

Pins


Equipment, etc.

Brake release circuit without buttons, at base

Spare part number Note

3HAC14219-1 Brake release at the base, according to figure

Location of brake release board, base on page 287 .

Includes brake release unit 3HAC14228-1.

Brake release circuit with buttons, at base

3HAC12989-1

Brake release unit with harness, at frame

3HAC065021-001

Brake release at the base, according to figure


Includes brake release board 3HAC16036-

1.

Brake release unit at the frame, according to figure

Location of brake release board, frame on page 288

.

DSQC1052





4 Repair


Continued

Equipment, etc.

Push button guard

Standard toolkit


Spare part number Note

-

3HAC2744-1


on page 439 .

Standard tools


Removal of brake release circuit, located at base

The procedure below details how to remove the brake release board, located at the rear of the base. See the figure

Location of brake release board, base on page 287

.

Action Note

1

DANGER

Turn off all:




2




3

4

5

Remove the cover at the rear of the base.

Unscrew the four attachment screws, brake release circuit on the outside of the base.

Shown in the figure


Disconnect the cable from the brake release circuit and remove the circuit from the base.





289

4 Repair


Continued

Removal of brake release board, located on frame

The procedure below details how to remove the brake release board, located on the side of the frame. See the figure


.

Action Note

1

DANGER

Turn off all:




2

ELECTROSTATIC DISCHARGE

(ESD)



3

4

5

6

Remove the

SMB cover.

push button guard from the Shown in the figure


.

The guard must be removed to ensure a correct refitting of the brake release unit.

Remove 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


.

Take a picture or make notes of how the robot cabling is positioned in regard to the brake release board.

Disconnect the connectors X8, X9 and X10 from the brake release board.

X9

X8

X10 xx1700000978

7

8

9

Unscrew the two attachment screws, brake release unit.

Shown in the figure


!

Unscrew the two attachment screws and nuts, brake unit cover , and remove the brake unit cover .

Shown in the figure


!

Remove the brake release board from the plate.

Shown in the figure


!


290




4 Repair


Continued

Refitting of brake release circuit, located at base

The procedure below details how to refit the brake release circuit, located at the rear of the base. See the figure


Action Note

1




2

3

4

5

Place the brake release unit in the base of the robot.

Spare part no. is specified in


Shown in the figure


.

Reconnect the cable to the brake release unit.

Secure the SMB cover with its attachment screws.

Shown in the figure


.

Refit the cover of the rear of the base.

Refitting of brake release board, located on frame

The procedure below details how to refit the brake release board, located on the side of the frame. See the figure

Location of brake release board, frame on page 288 .

Action Note

1




2

3

4

5

Fit the brake release board on the plate with the attachment screws.

Make sure the board is positioned as straight as possible on the plate! The push buttons can otherwise get jammed when the SMB-cover is refitted.

Maximum tightening torque: 5 Nm.

Shown in the figure




.

Place the brake unit cover on the brake release unit .

Secure the brake unit cover with the two attachment screws and nuts, brake unit cover .

Connect the connectors X8, X9 and X10 to the brake release board.

Be careful not to damage the sockets or pins.

Make sure the connector and its locking arms are snapped down properly.

X9

X8

X10




xx1700000978


291

4 Repair


Continued

6

Action Note

Verify that the robot cabling is positioned correctly, according to previously taken picture/notes.

Make sure that the white cables run like shown in the figure.

WARNING

Screened cables must not get in contact with the brake release board after installation.

Eliminate all risks of contact between screened cables and the brake release board.

292 xx1700001155

7 Refit the SMB cover with its attachment screws.

Shown in the figure


8

WARNING

Before continuing any service work, follow the safety procedure in section

The brake release buttons may be jammed after service work on page 232

!

9

10

11

Refit the push button guard on the SMB cover.

Shown in the figure


Press the push buttons 1 to 6, one at a time, to make sure that the buttons are moving freely and do not stay in any locked position.

If the battery has been disconnected the revolution counters must be updated.

Detailed in section


12

DANGER






4 Repair

4.5.3 Replacement of spherical roller bearing, balancing device

4.5.3 Replacement of spherical roller bearing, balancing device

Location of bearing

The bearing is located at the front ear of the balancing device, as shown in the figure below.

xx0500002249

A

B

C

D

E

Spherical roller bearing

Sealing ring

O-ring

Sealing spacer

Front ear of balancing device


Equipment

Spherical roller bearing

Sealing spacer

O-ring

Sealing ring

Grease

Spare part no.

3HAA2167-17

3HAC12988-1

3HAB3772-76

3HAC11581-6

Art. no.

3HAB3537-1



Note

2 pcs required.

2 pcs required.

2 pcs required.

For lubrication of the components.


293


4 Repair


Continued

Equipment

Toolkit



Spare part no.

Art. no.

3HAC15943-1

Note

The tools in the set are shown in the section Tool set.


Tool set

The parts of the tool set for replacing the spherical roller bearing are shown in the figure.

xx0500002259

D

E

F

A

B

C

Threaded bar

Dolly

Press tool for removal of bearing

Press tool for refitting of bearing

Hexagon nut M12 (2pcs)

Plain washer 13x24x2,5 (2pcs)

Removal, spherical roller bearing

Use this procedure to remove the spherical roller bearing from the balancing device front ear.

Action Note

1

DANGER

Turn off all:









4 Repair


Continued

2

3

4

5

Action

Remove the balancing device from the robot.

Remove the both sealing spacers with a screwdriver or any equal tool.

Note

Detailed in section

Replacing the balancing device on page 298 .

Shown in the figure

Location of bearing on page 293

.

Insert the threaded bar through the bearing.

Fit the press tool and dolly to the threaded bar.

Secure with the nut and washer at each end.

xx0500002255

A Threaded bar 3HAC15945-1

B Dolly 3HAC15948-1

C Press tool 3HAC15941-1

6 Press out the bearing from the front ear.

Refitting, spherical roller bearing

Use this procedure to refit the spherical roller bearing to the balancing device front ear.

Action Note

1

DANGER

Turn off all:





2 Grease the inside walls of the front ear.





295

4 Repair


Continued

3

Action Note

Insert the threaded bar through the new bearing and place it at the front ear. Fit also the press tool and the dolly to the bar as shown in the figure to the right.

Secure with the nut and washer at each end.



.

4

5

6 xx0500002257


B Dolly 3HAC15948-1


Press in the bearing properly inside the ear.

Apply grease to the new sealing rings and o-rings and fit one of each to the new sealing spacers . Also, grease the sealing spacers.

Spare part no:s are specified in


.

Press in the sealing spacers with the press tools, as shown in the figure to the right.

Secure the press tool and dolly with nuts and washers.

Note

Fit the sealing spacers one at a time!

7

8

Refit the balancing device to the robot.

xx0500002258


B Dolly 3HAC15948-1


Detailed in section

Refitting, balancing device on page 302

.

Lubricate the spherical roller bearing in the ear.

Detailed in section

Lubrication of spherical roller bearing, balancing device on page 209

Note

The balancing device must be mounted on the robot when lubrication is performed!

9 Make sure no incorrect leakage occurs. It could indicate damaged o-rings.







4 Repair


Continued

Action

10

DANGER



.

Note




297

4 Repair

4.5.4.1 Replacing the balancing device

4.5.4 Replacement of balancing device

4.5.4.1 Replacing the balancing device

Location of balancing device

The balancing device is located on rear top of the frame as shown in the figure below.

xx0100000139

D

E

F

G

H

A

B

C

Balancing device

Rear cover

Support shaft inside (included in balancing device 3HAC14675-1)

Attachment screws, rear cover

Balancing device shaft, including screw and washer

Bearing attachment

Parallel pin (inside bearing attachment)

Attachment screws, bearing attachment





4 Repair


Continued

Attachment points, balancing device

The attachment points for the lifting tools etc. are located as shown in the figure below.

xx0600002653

A

B

C

D

Attachment hole for lifting eye, M12

Attachment hole for securing screw that secures the bearing attachment to the balancing device (protection plug fitted normally)

Hole in frame to access the balancing device front eye shaft with the puller/press tool

Attachment hole for locking screw that secures the lower arm to the frame





299

4 Repair


Continued


Equipment

Balancing device

O-ring

Locking screw

Securing screw

Bearing grease

Grease

Locking liquid

Grease pump

Guide pins M16 x 300

Lifting eye M12


Press tool, balancing device


Press tool, balancing device shaft

Hydraulic cylinder

Hydraulic pump, 80

MPa

Standard toolkit

Spare part no.

See


.

Art. no.

-

3HAB3772-44

3HAB3409-90

9ADA183-66

3HAB3537-1

3HAA1001-294

-

3HAC13120-5

3HAC14457-3

3HAC15556-1

3HAC020902-001

Note

Includes:

• balancing device

3HAC14675-1 or

3HAC023018-001

• o-ring 3HAB3772-44

(2 pcs)

2 pcs , to be replaced if damaged! (included with the new balancing device)

M16 x 90

For securing the lower arm.

M12 x 35, 2 pcs required

For securing the bearing attachments to the balancing device when lifting.

For lubricating the o-rings and the shaft.

150 ml, Optimol PDO

For lubrication of spherical roller bearing in ear, in case of new balancing device.

Loctite 243

To apply to the securing screw in the shaft.

To lubricate spherical roller bearing.

Always use guide pins in pairs!

-

3HAC12475-1

3HAC17129-1

3HAC11731-1

3HAC13086-1

To be used with the press and puller tools.

To be used with the hydraulic cylinder.




300




4 Repair


Continued

Equipment


Spare part no.

Art. no.

Note


Removal, balancing device

The procedure below details how to remove the balancing device.

1

Action

Move the lower arm to a position close to the calibration position.

Note

2

DANGER

Turn off all:





3 Secure the lower arm to the frame by inserting the locking screw into the attachment hole in the frame.

Attachment hole for the locking screw is shown in the figure

Attachment points, balancing device on page 299 .



4

CAUTION

The balancing device weighs 300 kg! All lifting equipment used must be sized accordingly!

5

6

7

Fit the lifting eye, M12 to the balancing device and raise to unload the weight.



Attachments are shown in the figure

Attachment points, balancing device on page 299

.

Unload the balancing device with the press tool in order to make the piston rod and front ear adjustable when pulling the shaft out.



Detailed in section

Unloading the balancing device using hydraulic press tool on page 306

.

Remove the securing screw and washer from the balancing device shaft.

Shown in the figure

Location of balancing device on page 298 !





301

4 Repair


Continued

8

Action Note

Apply the puller tool, balancing device shaft to the shaft through the hole in the frame.

The shaft has a M20 thread diameter, as shown in the figure to the right.

Pull the shaft out using the puller tool and the hydraulic pump.



The hole in the frame is shown in the figure

Attachment points, balancing device on page 299 !

xx0300000060

Note

The dimension of the shaft puller tool is M20. Do not mix up with the shaft press tool used when mounting the shaft.

9

10

11

12

13

Restore the balancing device.

Detailed in section

Restoring the balancing device using a hydraulic press tool on page 310

.

Secure the two bearing attachments to the balancing device by replacing the protection plug on the outside of each attachment, with securing screws.

The protection plugs must be refitted after refitting the balancing device, do not loose them!

Shown in the figure

Attachment points, balancing device on page 299 !

Dimensions for the securing screws are specified in


.

Remove the two bearing attachments from the frame by unscrewing their four attachment screws.

Shown in the figure


Make sure the parallel pins inside are not lost!

Fit two guide pins through the upper holes of the bearing attachments, to the frame.



Lift the balancing device gently backwards to a secure area, allowing the bearing attachments to slide on the guide pins.

Note

Make sure not to burden the guide pins with the weight of the balancing device!

Refitting, balancing device

The procedure below details how to refit the balancing device.

Action Note

1

DANGER

Turn off all:









4 Repair


Continued

2

3

4

5

6

Action Note

Secure the lower arm to the frame by inserting the locking screw into the attachment hole in the frame.



!

Attachment hole is shown in the figure


.

Secure the bearing attachments to the balancing device with securing screws .

Shown in the figure


!

Dimension of the securing screws is specified in


.

Refit the two parallel pins in the frame.

Shown in the figure


Fit two guide pins to the upper holes in the frame, where the bearing attachments are to be attached.

Fit the lifting eye to the balancing device.



!

Attachments are shown in the figure


.

7

8

9

10

11

12

CAUTION

The balancing device weighs 300 kg! All lifting equipment used must be sized accordingly!

Lift the balancing device and bring it forward, gliding the bearing attachments on to the guide pins.

Note

Make sure not to burden the guide pins with the weight of the balancing device!

Remove the guide pins.

Secure the rear of the balancing device by fastening the two bearing attachments to the frame with their four attachment screws.

Shown in the figure


4 pcs, M16x90, 12.9 quality UN-

BRAKO, tightening torque: 300 Nm.



before fitting.

Remove the screws from outside of the bearing attachments and refit the protection plugs.

Raise the balancing device to a position where the balancing device shaft may be inserted through the piston shaft front eye.





303

4 Repair


Continued

13

14

15

16

17

18

Action

Unload the balancing device with the press tool.

Lubricate the shaft with grease.

Note

Detailed in section

Unloading the balancing device using hydraulic press tool on page 306

.



!

For an easier reassembling of the shaft, the piston rod may be pressed out more than necessary and then pressed in when fitting the shaft.



!

Apply the shaft press tool to the lubricated shaft .

Fit the shaft to the piston shaft front eye through the hole in the frame, using the shaft press tool and the hydraulic pump .

The hole in the frame is shown in the figure


!



!

Note

Make sure the shaft is pressed all the way to the bottom.

Refit the securing screw and washer into the shaft using locking liquid.

M16 x 180, tightening torque: 120

Nm.



Lubricate the bearing in the ear with grease through the lubricating nipple, with a grease pump.

Fill until excessive grease pierces between the shaft and the sealing spacer.

Art. no. and amount are specified in


Lubrication is further detailed in section

Lubrication of spherical roller bearing, balancing device on page 209

.

Restore the balancing device.

Detailed in section

Restoring the balancing device using a hydraulic press tool on page 310

.

19

DANGER

The rear cover of the balancing device is a safety device for the piston rod during operation! Make sure the cover is properly secured before commissioning of the robot!


304




4 Repair


Continued

20

Action

Remove the locking screw that secures the lower arm to the frame.

Note

21

DANGER



xx0200000454

1 Attachment hole for the securing screw.




305

4 Repair

4.5.4.2 Unloading the balancing device using hydraulic press tool

4.5.4.2 Unloading the balancing device using hydraulic press tool

Prerequisite

This section details how to unload the balancing device using the hydraulic press tool.

The lower arm must be secured before unloading the balancing device! How to secure the lower arm is detailed in the current repair activity, for example removal of the balancing device.

DANGER

There is a high tensioned spring inside the balancing device, incorrect handling may cause injuries and damage property.

Press tool and hydraulic cylinder

The figure below shows the hydraulic cylinder mounted on the press tool.

The press tool includes two press devices that are used to different models of the balancing device.

xx0200000174

A

B

Press block

Hydraulic cylinder


306




4 Repair


Continued

C

D

E

F

G

Press device

Bolt, press device

Moving pin with marking

Bolt (4 pcs)

Pin, attached to the fix plate


Equipment, etc.


Hydraulic cylinder


Standard toolkit -

Art. no.

3HAC020902-001

3HAC11731-1

3HAC13086-1

Note

Includes

• press device 3HAC15767-2

• press device 3HAC18100-1

Choose the correct device, depending on model of balancing device.

To be used with the press tool.

To be used with the hydraulic cylinder.



.

Using the correct press device

The different designs of the balancing device require different versions of the press device, included in the complete press tool. The table below specifies which press device to use to which balancing device.

The article number of the balancing device may be found on a label at the rear of the balancing device.

Balancing device

Art. no: 3HAC14675-2

Press device

Art. no: 3HAC15767-2 (for balancing device 3HAC14675-1) xx0300000605

Art. no: 3HAC023018-001 xx0300000600

Art. no: 3HAC18100-1 (for balancing device 3HAC023018-001) xx0700000423




xx0300000599


307

4 Repair


Continued

Unloading the balancing device

The procedure below details how to use the press tool in order to unload the balancing device. How to remove the press tool, is detailed in section

Restoring the balancing device using a hydraulic press tool on page 310 .

1

2

Action Note

Fit the moving pin to the current press device.

Choose the correct press device, according to the table

Using the correct press device on page 307 .

The moving pin is shown in the figure

Press tool and hydraulic cylinder on page 306 .

Fit the correct press device and moving pin to the press tool. Secure with the bolt, press device.

Shown in the figure

Press tool and hydraulic cylinder on page 306 .

Note

Make sure the bolt is secured properly!

3 Remove the rear cover of the balancing device, by unscrewing the attachment screws .

DANGER

DO NOT! remove any other screws then the rear cover attachment screws.

5

6

4

7 xx0200000175

• E: Rear cover attachment screws,

4 pcs

Remove the o-ring from the balancing device end.

Remove the support shaft.

Fit the press tool to the rear of the balancing device with enclosed bolts.

Tighten them properly!



.

See the figure

Press tool and hydraulic cylinder on page 306

.

Fit the hydraulic cylinder to the press tool.



.

See the figure


.

8 Connect the hydraulic pump to the cylinder.



.

9 Increase the pressure and press until the marking on the moving pin indicates the correct position (in level with the pressure block).

See the figure


.

Do not apply more pressure than necessary, it could damage bearings and sealings at the shaft.

10 Turn the fix plate to position "Closed" in order to lock the tool in loaded condition.

See the figure


.

11 Unload the hydraulic cylinder.





4 Repair


Continued

Action

12 The hydraulic cylinder may now be removed from the tool, when necessary.

Note




309

4 Repair

4.5.4.3 Restoring the balancing device using a hydraulic press tool

4.5.4.3 Restoring the balancing device using a hydraulic press tool

Overview

This section details how to restore the balancing device and how to remove the press tool from the device.

DANGER

There is a high tensioned spring inside the balancing device, incorrect handling may cause injuries and damage property.

Press tool and hydraulic cylinder

The figure below shows the hydraulic cylinder mounted on the press tool.

The press tool includes two press devices that are used to different models of the balancing device.

xx0200000174

C

D

E

A

B


310

Press block

Hydraulic cylinder

Press device

Bolt, press device

Moving pin with marking




4 Repair


Continued

F

G

Bolt (4 pcs)

Pin, attached to the fix plate


Equipment, etc.

Hydraulic cylinder


Locking liquid

Standard toolkit

-

Art. no.

3HAC11731-1

3HAC13086-1

3HAC15571-1

Note

To be used with press tool.

To be used with hydraulic cylinder.

Loctite 577

Used to secure the attachment screws of the rear cover at the end of the balancing device.



Sikaflex 521FC

Restoring the balancing device

The procedure below details how to restore the balancing device, that is removing the press tool.

1

2

3

7

8

4

5

6

Action Note

Refit the hydraulic cylinder to the press tool, in case it has been removed.

Shown in the figure


.

Press with the cylinder and the hydraulic pump until the fix plate is movable again. Turn the pin on the fix plate to position "Open".

Shown in the figure


!

Do not apply more pressure than necessary, it could damage bearings and sealings at the shaft.

Unload the hydraulic cylinder and make sure the moving pin indicates that the tool has returned to its starting position.

Shown in the figure


!

Remove the hydraulic cylinder.

Remove the press tool by unscrewing the bolts.

Shown in the figure


!

Lubricate and refit the o-ring at the end of the balancing device.

Refit the support shaft to the balancing device.

Make sure the o-ring is seated properly! Replace if damaged.

Lubricate and refit the o-ring on the support shaft.

Make sure the o-ring is seated properly! Replace if damaged.





311

4 Repair


Continued

9

Action

Refit the rear cover to the balancing device with its attachment screws, using locking liquid. Apply sikaflex 521FX on the cover.

Note

10

DANGER

The rear cover of the balancing device is a safety device for the piston rod during operation! Make sure the cover is properly secured before commissioning of the robot!

xx0200000175

• E: 4 pcs: M10x30, tightening torque: 50 Nm.



.

312




4 Repair

4.6.1 Replacement of motor, axis 1

4.6 Motors

4.6.1 Replacement of motor, axis 1

Note

This procedure requires calibration of the robot.

The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory. Always use the same calibration method as used at the factory.

Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant.

Location of motor

The motor axis 1 is located on the left hand side of the robot as shown in the figure below.

xx0100000123

A

B

C

D

Motor, axis 1

Cable gland cover, motor axis

Cover for connector access

Motor attachment screws





313

4 Repair


Continued


Equipment, etc.

Spare part no.

Motor including pinion See


.

Art. no.

O-ring

Mobilux EP 2

Grease

Removal tool, motor

M12x

Lifting tool, motor ax

1, 4, 5

Extension 300mm for bits 1/2"

Power supply

Standard toolkit


Calibration tool box,

Axis Calibration



Circuit diagram

-

21522012-430

-

3HAB3537-1

Note

Includes

• motor

• pinion

• o-ring 21522012-

430.

Must be replaced when reassemling the motor.

Used to lubricate the motor clutch.

Used to lubricate the oring.

Always use the removal tools in pairs!

3HAC14973-1

3HAC14459-1

3HAC12342-1

-

-

24 VDC, max. 1,5 A




.

3HAC15716-1

3HAC055412-001


Required if Calibration

Pendulum is the valid calibration method for the robot.




See chapter


.


314




4 Repair


Continued




1

Action Note










Axis Calibration in


.






Removal, motor axis 1

The procedure below details how to remove motor, axis 1.

Note

1

Action


2

DANGER

Turn off all:





3 Remove the cover for connector access on top of the motor by unscrewing its four attachment screws.





315

4 Repair


Continued

4

Action

Remove the cable gland cover at the cable exit by unscrewing its two attachment screws.

Note

Note

Make sure the gasket is not damaged!

5

6

7

8 xx0200000199

• A: Cable gland cover

Disconnect all connectors beneath the motor cover.

Apply lifting tool, motor axis 1, 4, 5 to the motor.



.

In order to release the brakes, connect the 24 VDC power supply.

Connect to connector R2.MP1

• +: pin 2

• -: pin 5

Remove the motor by unscrewing its four attachment screws and plain washers.

If required, use the extension 300mm for bits 1/2" .

Shown in the figure

Location of motor on page 313 .



.

9

CAUTION

The motor weighs 32 kg! All lifting equipment used must be sized accordingly!

10

11

Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.

Remove the motor by gently lifting it straight up.

Refitting, motor axis 1

The procedure below details how to refit motor, axis 1.

Action Note

1

DANGER

2

Turn off all:





Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the oring with grease.

Art no. is specified in


.


316




4 Repair


Continued

Action Note

3

CAUTION


7

8

4

5

6

9

10

11

12

13

Apply the lifting tool, motor axis 1, 4, 5 to the motor.



.

In order to release the brake, connect the 24 VDC power supply.


• +: pin 2

• -: pin 5

Fit the motor, making sure the motor pinion is properly mated to gearbox of axis 1.

Make sure the motor is turned the correct way, that is connection of motorcable forwards. .

Make sure the motor pinion does not get damaged!

Fit the clutch on the pinion on the motor.

Secure the motor with its four attachment screws and plain washers.

M10 x 40, tightening torque: 50

Nm.

Disconnect the brake release voltage.

Reconnect all connectors beneath the motor cover.

Refit the cable gland cover at the cable exit with its two attachment screws.

Make sure the cover is tightly sealed!

Refit the motor cover with its four attachment screws.

Recalibrate the robot!








.

14

DANGER






317

4 Repair

4.6.2 Replacement of motor axis 2

4.6.2 Replacement of motor axis 2


The motor, axis 2, is located on the left-hand side of the robot as shown in the figure below.

xx0100000124

A

B

C

Motor, axis 2

Cable gland cover, motor axis 2

Hole for lock screw


Equipment, etc.

Motor axis 2

Spare part no.

See


Art. no.

O-ring

Grease

Locking screw

Removal tool, motor

M12x


21522012-430

3HAB3537-1

3HAA1001-266

3HAC14973-1

3HAC15521-1

Note

Includes:

• motor

• pinion

• o-ring 2152 2012-430

Must be replaced when reassembling motor!

For lubricating the o-ring.

M16 x 60

For securing the lower arm.


For guiding the motor.

Guides are to be used in pairs!





4 Repair


Continued

Equipment, etc.


Spare part no.

Lifting tool, motor ax

2, 3, 4


Extension bar, 300 mm for bits 1/2"

Power supply

Rotation tool

Standard toolkit



Axis Calibration

Art. no.

3HAC15521-2

Note


Guides are to be used in pairs!

3HAC15534-1

3HAC12342-1

3HAC12342-1

-

-

3HAC17105-1

3HAC15716-1

3HAC055412-001

24 VDC, 1.5 A


Used to rotate the motor pinion when mating it to the gear when brakes are released with 24VDC power supply.








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

Circuit diagram See chapter


.




1

Action




Note




319


4 Repair


Continued

Action Note







Axis Calibration in


.






Removal, motor

The procedure below details how to remove the motor, axis 2.

1

2

Action Note


Move 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 .

Shown in the figure


3

DANGER

Turn off all:





4

5

6

7

8

Lock the lower arm by inserting the lock screw into the hole.

Art. no. and dimension is specified in


Drain the oil from gearbox, axis 2.

Detailed in the section


Remove the cover on top of the motor by unscrewing its four attachment screws.


Shown in the figure








4 Repair


Continued

9

Action

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!

Note

Use the lock screw to lock the lower arm, as detailed above!

10 In order to release the brake, connect the 24 VDC power supply.


• +: pin 2

• -: pin 5

11 Remove the motor by unscrewing its four attachment screws and plain washers.

12 Fit the two guide pins in two of the motor attachment holes.



Shown in the figure


13 If required, press the motor out of position by fitting the removal tool, motor to the remaining motor attachment holes.



Shown in the figure

Location of motor on page 318


.

14 Remove the removal tools and fit the lifting tool, motor axis 2, 3, 4 to the motor.



15

CAUTION


16 Lift the motor to get the pinion away from the gear.


17 Remove the motor by gently lifting it straight out and place it on a secure surface. Disconnect the brake release voltage.

Refitting, motor

The procedure below details how to refit the motor axis 2.

Action Note

1

DANGER

Turn off all:








321


4 Repair


Continued

2

3

Action Note

Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the o-ring with grease.



.

Foundry Plus :

If the motor is a new spare part, the evacuation hole protection filter must be replaced with a transparent plug/sight glass (enclosed with the spare part delivery). Remove the protection filter and install the transparent plug/sight glass.

Tightening torque, transparent plug: 25

Nm ±10%.

Tightening torque, protection filter: 10

Nm ±10%.

xx1800000101

Protection filter

(Standard).

xx1800000102

Transparent plug

(Foundry Plus).

xx1600000576

4

5

6

In order to release the brake, remove the cover on top of the motor and connect the 24

VDC power supply.


• +: pin 2

• -: pin 5

Fit the lifting tool, motor axis 2, 3, 4 to the motor.



.

Fit the two guide pins in the two lower motor attachment holes.



.

Shown in the figure


.

7

8

9

CAUTION


Lift the motor and guide it onto the guide pins, as close to the correct position as possible without pushing the motor pinion into the gear.

Make sure that the motor is turned the right direction, that is the cables facing downwards.

Remove the lifting tool and allow the motor to rest on the guide pins.


322




4 Repair


Continued

10

Action Note

Use the rotation tool in order to rotate the motor pinion when mating it to the gear (see the figure to the right). Fit the motor, making sure the motor pinion is properly mated to the gear of gearbox axis 2 and that it does not get damaged.



.

11

12

13

14

15

16

17

18

19

20 xx0200000165

The rotation tool is used beneath the motor cover, directly on the motor shaft as shown in the figure above.

• A: Rotation tool


Secure the motor with four attachment screws and plain washers.

If required, use the extension 300mm for bits

1/2" .

M10 x 40, tightening torque: 50 Nm.



before fitting.



Connect in accordance with markings on connectors.


Shown in the figure


.

Refit the cover on top of the motor with its four attachment screws.


Remove the lock screw from the hole for lock screw.

Shown in the figure


.

Perform a leak down test.

Detailed in

Performing a leak-down test on page 226

.











21

DANGER



.



323


4 Repair




The motor axis 3 is located on the left hand side of the robot as shown in the figure below.

xx0200000186

A

B

C

Motor axis 3


Motor attachment holes (4 pcs)


Equipment, etc.

Motor, axis 3

Spare part no.

See


.

Art. no.

O-ring

Mechanical stop axis 3

21522012-430

Grease

Removal tool, motor M12x

3HAC12708-2

3HAB3537-1

3HAC14973-1

Note

Includes:

• motor

• pinion

• o-ring 21522012-430.


May be used to fix axis 3.

Use attachment screws 3HAB

3409-86 (M16 x 60).







4 Repair


Continued

Equipment, etc.

Lifting tool, motor ax 2, 3, 4

Bolts M16x60

(for mechanical stop axis 3)

Washers (for mechanical stop axis 3)

Guide pins M10 x

100

Guide pins M10 x

150


Rotation tool

Spare part no.

Art. no.

3HAC15534-1

3HAB3409-86

3HAA1001-186

Power supply

Standard toolkit




Circuit diagram

Note

3HAC15521-1 For guiding the motor.

3HAC15521-2 For guiding the motor.

3HAC12342-1

-

-

3HAC17105-1 Used to rotate the motor pinion when mating it to the gear when brakes are released with

24 VDC power supply.

24 VDC, max. 1.5 A




3HAC15716-1

3HAC055412-001






See chapter

on page 447

.

Circuit diagram





325

4 Repair


Continued




1

Action Note










Axis Calibration in


.






Removal, motor

The procedure below details how to remove motor, axis 3.

1

2

Action


Note

Unload the upper arm of the robot by either:

• Move the robot to a position where the turning disk rests against the foundation (recommended).

• Use a fork lift to rest the upper arm onto.

• Use lifting slings and an overhead crane to rest the upper arm.

• Use a mechanical stop to rest the upper arm. Fit the mechanical stop in the attachment hole (A) with tightening torque: 115 Nm.

xx0300000051

Fit the mechanical stop to the third and final attachment hole (A), below the fixed stop (B) in the upper arm. See the figure above!





4 Repair


Continued

Action Note

3

DANGER

Turn off all:





4

5

6

7

8

Drain the oil from gearbox axis 3.

Detailed in section


.

Remove any equipment hindering access to motor axis 3.


Remove the cable gland cover at the cable exit by unscrewing its two securing screws.

Shown in the figure




9 Unscrew the motors four attachment screws and plain washers .

Shown in the figure


10 Fit the two guide pins in two of the motor attachment screw holes.



11 Press the motor out of position by fitting removal tool, motor to the remaining motor attachment screw holes.




12

13

Apply the lifting tool, motor axis 2

,3, 4 to the motor.

CAUTION




14 Lift the motor to get the pinion away from the gear.

15 Remove the motor by gently lifting it straight out and disconnect the brake release voltage.

Make sure the motor pinion is not damaged!





327

4 Repair


Continued



Action Note

1

DANGER

Turn off all:





2

3

Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate it with grease .



.

Foundry Plus :


Tightening torque, transparent plug:

25 Nm ±10%.

Tightening torque, protection filter:

10 Nm ±10%.

xx1800000101

Protection filter

(Standard).

xx1600000576 xx1800000102

Transparent plug

(Foundry Plus).

4

5




.

Fit the two guide pins in the two lower motor attachment holes.



.

Shown in the figure


6

CAUTION


7

8

9

Lift the motor and guide it onto the guide pins, as close to the correct position as possible without pushing the motor pinion into the gear.

Remove the lifting tool and allow the motor to stay on the guide pins.



• +: pin 2

• -: pin 5





4 Repair


Continued

10

Action Note

Use the rotation tool in order to rotate the motor pinion when mating it to the gear!

Fit the motor, making sure the motor pinion is properly mated to the gear of gearbox, axis 3.



.


Make sure the motor is turned the right direction, that is the cables facing forwards.

11

12 xx0200000165

The rotation tool is used beneath the motor cover, directly on the motor shaft as shown in figure above.

• A: Rotation tool.




4 pcs: M10 x 40, tightening torque:

50 Nm.



.

13

14

15



Connect in accordance with markings on connectors.



Shown in the figure


.

16

17

18

19

20



Remove the equipment used to unload the upper arm.



Performing a leak-down test on page 226

.





.





.



.




329


4 Repair


Continued

Action

21

DANGER



Note

330




4 Repair




The motor axis 4 is located on the left-hand side of the upper arm as shown in the figure below.

xx0200000202

A

B

C

Motor, axis 4


Motor attachment holes (4 pcs)


Equipment, etc.

Motor including pinion

O-ring



Grease

Loctite 574, Flange sealant





Art. no.

Note

See spare part number in


.

Includes:

• motor

• pinion

• o-ring 21522012-430

21522012-430 Must be replaced when reassembling motor!

3HAC14459-1

3HAC15534-1

3HAB3537-1

12340011-116

3HAC14459-1

3HAC15534-1

Used to lubricate the o-ring.

Option Foundry Plus

To be used if the upper arm is positioned vertically.

To be used if the upper arm is positioned horizontally.


331


4 Repair


Continued

Equipment, etc.


Art. no.

3HAC14973-1




Rotation tool

3HAC15521-1

3HAC15521-2

3HAC12342-1

3HAC17105-1

Power supply

Standard toolkit


-

-

3HAC15716-1


3HAC055412-001

Note




Used to rotate the motor pinion when mating it to the gear when brakes are released with 24 VDC power supply.

24 VDC, max. 1,5 A




.







Circuit diagram See chapter


.




1

Action




Note


332




4 Repair


Continued

Action Note







Axis Calibration in


.








1

2

Action


Move the upper arm to one of the basic positions:

• upper arm is pointed straight up. This position enables the motor to be replaced without draining the gear oil, which in turn saves time.

• upper arm is close to horizontal. This position is recommended if the gearbox is also to be replaced, i.e. when the gearbox oil has to be drained anyway.

Note

3

DANGER

Turn off all:





4

5

In horizontal position: unload the upper arm to avoid movement of the axis, with one of the given methods:

• move the upper arm to a position where the turning disk rests against the foundation (recommended)

• use a fork lift or an overhead crane and lifting slings to rest the weight of the upper arm.

In horizontal position: drain the gearbox, axis 4.

Detailed in section

Draining, oil, gearbox axis 4 on page 194 .




333


4 Repair


Continued

6

7

8

9

Action Note

Remove the cable gland cover at the cable exit of the motor by unscrewing its two attachment screws.

Shown in the figure


.




In order to release the brake, connect the



• +: pin 2

• -: pin 5

10

CAUTION


11 Unscrew the motors four attachment screws and plain washers.

Shown in the figure


.

12 Fit the two guide pins in two of the motor attachment screw holes.

13 If required, press the motor out of position by fitting removal tool, motor to the motor attachment screw holes.

14 Fit the lifting tool to the motor.




Choose the correct lifting tool:

• lifting tool, motor axis 1, 4 and 5, if the upper arm is positioned vertically.

• lifting tool, motor axis 2, 3 and 4, if the upper arm is positioned horizontally.



15 Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.

16 Remove the motor by gently lifting it straight out.




Action Note

1

DANGER

Turn off all:









4 Repair


Continued

2

3

Action Note




.

Foundry Plus :


Tightening torque, transparent plug: 25

Nm ±10%.

Tightening torque, protection filter: 10 Nm

±10%.

xx1800000101

Protection filter

(Standard).

xx1800000102

Transparent plug

(Foundry Plus).

xx1600000576

4

CAUTION


5

6

7

8

Fit the lifting tool to the motor.

In order to release the brakes, connect the


Connect to connector R2.MP4:

• +: pin 2

• -: pin 5

Fit the two guide pins in two of the motor attachment holes.

Choose the correct lifting tool:

• lifting tool, motor axis 1, 4 and 5, if the upper arm is positioned vertically

• lifting tool, motor axis 2, 3 and 4, if the upper arm is positioned horizontally.



.

Fit the motor with guidance of the pins, making sure the motor pinion is properly mated to the gear of gearbox 4.



.

Shown in the figure







335

4 Repair


Continued

9

Action Note

Use the rotation tool in order to rotate the motor pinion when mating it to the gear!

Fit the motor, making sure the motor pinion is properly mated to the gear, axis 4.



.


Make sure the motor is turned the right direction, that is the cables facing forwards.

10

11

12

13

14

15 xx0200000165

The rotation tool is used beneath the motor cover, directly on the motor shaft as shown in figure above.

• A: Rotation tool.




4 pcs: M10 x 80, tightening torque: 50 Nm.



.






Shown in the figure


16

17

18

Perform a leak-down test if the gearbox has been drained.



.

Refill the gearbox with oil if drained.


Filling, oil, gearbox axis 4 on page 195

.







.


336




Action

19

DANGER



.

Note

4 Repair


Continued




337

4 Repair




The motor axis 5 is located in the rear of the wrist unit as shown in the figure below.

Notice that the left hand side cover already is removed in the figure!

xx0100000127

A

B

C

Motor, axis 5


Heat protection plate


Equipment, etc.

Motor, axis 5

O-ring

Grease

Standard toolkit




Power supply

Art. no.

Note

See


.

Includes:

• motor

• pinion

• o-ring 21522012-430

21522012-430 Must be replaced when replacing motor!

-

3HAB3537-1 For lubricating the o-ring.



3HAC15521-1

3HAC15521-2

3HAC14459-1



For lifting the motor in a vertical position

24 VDC, 1.5 A.


Extension 300mm for bits 1/2" 3HAC12342-1

Removal tool, motor M12x 3HAC14973-1 Always use the removal tools in pairs!





4 Repair


Continued

Equipment, etc.


Art. no.

3HAC15716-1


3HAC055412-001


Circuit diagram

Note






See chapter

page 447

.

Circuit diagram on




1

Action Note










Axis Calibration in


.








Note

1

Action





339


4 Repair


Continued

2

Action

Move the robot to a position where the motor in axis

5 is pointed straight up. This position enables the motor to be replaced without draining the gear oil, which in turn saves time.

Note

3

DANGER

Turn off all:





8

9

4

5

6

7

Remove the left hand side cover of the wrist unit by unscrewing its six attachment screws.

The motor is accessible behind the rear part of the cover.

Remove the heat protection plate by unscrewing its two attachment screws.

Shown in the figure


.



Shown in the figure


.




• +: pin 2

• -: pin 5

10

CAUTION


11

12

13

14

15

16


If required, use the extension 300 mm for bits 1/2 .






Fit the two guide pins in two of the motor attachment screw holes.



If required, press the motor out of position by fitting removal tool, motor to the motor attachment screw holes.



Always use the removal tools in pairs and diagonally!

Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.

Remove the motor by gently lifting it straight out.



340




4 Repair


Continued


The procedure below details how to refit the motor, axis 5.

Action Note

1

DANGER

Turn off all:





2 Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the o-ring with grease .



.

3

CAUTION


4

5

6

7

8


In order to release the brakes, connect the 24 VDC power supply to the motor.


• +: pin 2

• -: pin 5




.

Fit the motor, with guidance from the pins, making sure the motor pinion is properly mated to the gear of gearbox, axis 5.


Make sure the motor is turned the right direction, that is the cables facing forward.

If necessary, use the rotation tool in order to rotate the motor pinion when mating it to the gear!



.

9 xx0200000165

The rotation tool (A) is used beneath the motor cover, directly on the motor shaft as shown in figure above.


M10 x 40, 12.9 quality.


If required, use the extension 300 mm for bits 1/2" . Art. no. is specified in


.

10

11






341


4 Repair


Continued

12

13

14

Action Note


Shown in the figure




Refit the heat protection plate with its two attachment screws.

Shown in the figure


15

16

17

If cables are loose, place them correctly and tie them up with cable ties.

Refit the left hand side cover of the wrist unit with its six attachment screws.






.



.

18

DANGER



342




4 Repair




The motor axis 6 is located in the center of the wrist unit as shown in the figure below.

xx0100000128

A Motor, axis 6


Equipment, etc.

Motor, axis 6

O-ring

Gasket

Gasket, cover

Removal tool, motor

M10x


Spare part no.

See spare part number in


.

21522012-430

Art. no.

Note

Includes:

• motor

• pinion

• o-ring


Must be replaced when replacing motor

3HAC048560-001 i

3HAC063071-001 ii

3HAC033489-001

3HAC14972-1

Must be replaced when opening cover.


3HAC12342-1




343


4 Repair


Continued

Equipment, etc.

Power supply

Grease

Loctite 574, Flange sealant

Standard toolkit

Spare part no.

-

Art. no.

3HAB3537-1

12340011-116

Note

24 VDC, 1.5 A



Option Foundry Plus



Axis Calibration


See references to these procedures in the stepby-step instructions below.

Circuit diagram i ii

Only fits type A motor.

See


.

Only fits type B motor.

See


.

-

-

3HAC15716-1

3HAC055412-

001



.






See chapter

on page 447 .

Circuit diagram




1

Action




Note


344




4 Repair


Continued

Action Note







Axis Calibration in


.






Removal, motor


Note

Robots with protection type Foundry Plus or Foundry Prime require special repair routines to maintain the tightness level, in addition to the procedure below, described in

Replacement of the motor axis 6 (Foundry Plus) on page 347 .

1

2

Action


Move the robot to one of the recommended positions:

• to a position where the motor in axis 6 is pointed straight up. This position enables the motor to be replaced without draining the gear oil, which in turn saves time.

• to a position where the motor in axis 6 is close to horizontal. This position may be selected when the gearbox is to be replaced, i.e. when the gearbox oil has to be drained anyway.

Note

3

DANGER

Turn off all:





4

5

In horizontal position: drain the oil from the axis 6 gearbox.

Detailed in section

Draining oil, gearbox axis 6 on page 202

.

Remove the rear motor cover by unscrewing the five attachment screws.




345


4 Repair


Continued

6

7

Action Note

Disconnect all connectors beneath the cover.



• +: pin 2

• -: pin 5

8

9


If required, use the extension 300mm for bits 1/2".



.

If required, press the motor out of position by fitting removal tool, motor to the motor attachment screw holes.



.


10 Lift the motor carefully to get the pinion away from the gear and disconnect the brake release voltage.


11 Remove the motor by gently lifting it straight out.



Note

Robots with protection type Foundry Plus or Foundry Prime require special repair routines to maintain the tightness level, in addition to the procedure below, described in

Replacement of the motor axis 6 (Foundry Plus) on page 347 .

5

6

1

2

3

4

Action


Note



In order to release the brake, connect the 24

VDC power supply.


• +: pin 2

• -: pin 5




Fit the motor, with guidance from the pins, making sure the motor pinion is properly mated to the gear of gearbox, axis 6.

Make sure the pinion on the motor shaft is not damaged!


Secure the motor with its four attachment screws and plain washers.

If required, use extension 300mm for bits 1/2" .

4 pcs: M8 x 25, tightening torque: 24

Nm.



7

8

9

10



Refit the cover on top of the motor with its five attachment screws.

Perform a leak-down test (if the gearbox has been drained).


Detailed in section


.





4 Repair


Continued

11

12

Action Note

Refill the gearbox with oil, if it has been drained.

Detailed in section

Filling oil, gearbox axis 6 on page 203

.

Re-calibrate the robot.





.



13

DANGER



Replacement of the motor axis 6 (Foundry Plus)

Robots with protection type Foundry Plus require special repair routines to maintain the tightness level.

The repair must be done according to the previous repair procedure with the following additions.

1

Action

Move the robot to one of the recommended positions:

• to a position where the motor in axis 6 is pointed straight up. This position enables the motor to be replaced without draining the gear oil, which in turn saves time.

• to a position where the motor in axis 6 is close to horizontal. This position may be selected when the gearbox is to be replaced, that is when the gearbox oil has to be drained anyway.

Note

2

DANGER

Turn off all:





3 In horizontal position: drain the oil from the axis 6 gearbox.

Detailed in section:

Draining oil, gearbox axis 6 on page 202

.





347

4 Repair


Continued

4

Action

Remove the rear motor cover by unscrewing the five attachment screws.

Note

5 Continue to remove the motor unit, according to step 6 and forwards in

Removal, motor on page 345

.

xx1500002524

• A: Motor unit

• B: Connection box

• C: Attachment screw (5 pcs)

• D: Rear motor cover

• E: Gasket

6

Note

Keep the old rear motor cover with the air nipple.


348




4 Repair


Continued

7

Action

Remove the protection strip on the gasket and mount it on the motor .

Note

8

9

Apply Mercasol 3106 on the motor end cover .

Apply Loctite 574 flange sealant on the contact surface.

xx1500002425

• A: Attachment screw (4pcs)

Mercasol 3106

• B: Motor unit

• C: O-ring

• D: Sikaflex in screw recesses

• E: Tilt house

• F: Washer

• G: Rear motor cover

• H: Sealing

• J: Loctite 574

10

11

Apply grease on the o-ring on the motor .

Continue to refit the new motor according to section,

Refitting, motor on page 346

.

xx1400000992




349

4 Repair

4.7.1 Replacing the axis 1 gearbox

4.7 Gearboxes

4.7.1 Replacing the axis 1 gearbox


The axis 1 gearbox is located between the frame and base as shown in the figure.

xx0100000133

-

D

E

A

B

C

Gearbox, axis 1

Oil plug, filling

Attachment screws, gearbox to frame

Frame

Base

Attachment screws, base to gearbox (not shown in figure)


Equipment, etc.

Gearbox

O-ring

O-ring


350

Art. no.

For spare part no.

see:

•


.

Note

Includes:

• gearbox

• all o-rings and sealing rings

3HAB3772-54

3HAB3772-55

Replace if damaged!

Replace if damaged!




4 Repair


Continued

Equipment, etc.

Sealing ring

Grease

Support, base and gear 1

Lifting accessory, base

Lifting accessory

(chain)

Guide pins



Axis Calibration

Standard toolkit

Art. no.

3HAC11581-4

3HAB3537-1

3HAC15535-1

3HAC15560-1

3HAC15556-1

Note

Replace if damaged!

For lubricating the o-rings.

-

3HAC15716-1

3HAC055412-001

2 pcs, M16x150.

Used for guiding the gearbox into place in the base.














1

Action




Note





351

4 Repair


Continued

Action Note







Axis Calibration in


.






Removal, gearbox axis 1

Use this procedure to remove gearbox, axis 1.

1

2

Action


Move the robot to its most stable position, shown in the figure to the right.

Note xx0300000022

3

4

5

6

DANGER

Turn off all:




Drain the axis 1 gearbox.

Remove the complete arm system.

Unfasten the robot base from the foundation by removing the base attachment screws.

See


Detailed in section

Replacement of complete arm system on page 245 .





7

Action

Attach the lifting accessory, base and gear

1 and the lifting tool (chain) to the gearbox and base.

Note

4 Repair



Specified in


8

CAUTION

The base and axis 1 gearbox weighs 310 kg + 200 Kg.


9

10

Lift the robot base including the axis 1 gearbox to allow the base and gear 1 support be fitted on each sides of the base.



.

Secure the support to the base and to the foundation.

Make sure the base remains in a stable position before performing any work underneath the base!

xx1000000364

A Support base (4 pcs)





353

4 Repair


Continued

11

Action

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.

Note xx1000001385

12 Unscrew the attachment screws and remove the washers.

xx0300000612

A Bottom plate

B Rear connector plate

C Attachment screw

D Groove


354 xx0200000227

A view from below:

• A: Oil drain hose

• B: Attachment screws, gearbox axis 1, 18 pcs

• C: Washers, 3 pcs




13

Action

Remove the cable guide in the center of gearbox 1 by unscrewing its attachment screws.

Note

4 Repair


Continued

14

CAUTION

The gearbox weighs 200 Kg.


15

16

Lift the gearbox away with the already mounted lifting tools.

Turn the gearbox, and remove the protection pipe by unscrewing two attachment screws.

Note

Move the protective pipe over to the new gearbox.

xx1000001387 xx1400000786





355

4 Repair


Continued

Refitting, gearbox axis 1

Use this procedure to refit gearbox, axis 1.

1

Action Note

Fit the support, base and gear 1 to the base.

Mounting of the support, base and gear

1 is detailed in section

Removal, gearbox axis 1 on page 352 .

2 xx1000000364

A Support base (4 pcs)

Make sure the two o-rings on the circumference of the gearbox are seated properly in their respective groove. Lubricate them with grease .



xx0200000055

• A: Guide pin

• C: O-ring 3HAB 3772-54

• D: O-ring 3HAB 3772-55

• E: Sealing ring 3HAC 11581-4


356




4 Repair


Continued

3

Action

Make sure the small o-ring around the oil hole is fitted properly!

Note

4 xx1000001392

Attach the lifting accessory, base and gear 1 and the lifting tool (chain) to the gearbox.

Specified in


.

5 xx1000001395

Fit two guide pins in two of the attachment holes in the gearbox, parallel to each other.

Specified in


.

6

CAUTION

The gearbox weighs 200 Kg.





357


4 Repair


Continued

7

Action

Lift the gearbox.

Make sure the guide pin in the bottom face of the gearbox is properly aligned with the base.

Note xx1000001389

8 xx1000001391

Lift gearbox axis 1 onto the guide pins and lower it carefully to its mounting position.



358




4 Repair


Continued

9

Action

Secure the gearbox with its attachment screws and washers.

Note

18 pcs, M16 x 90, 12.9 quality UN-

BRAKO.

Tightening torque: 300 Nm



before fitting.

10 Refit the cable guide in the center of gearbox

1 with its attachment screws.

xx0200000227

A view from below:

• A: Oil drain hose

• B: Attachment screws, gearbox axis 1, 18 pcs

• C: Washers, 3 pcs xx1000001393





359

4 Repair


Continued

11

Action Note

Refit the bottom plate underneath the robot base by pushing it into the groove and fitting the attachment screw.

If removed, also refit the rear connector plate.

1 screw: M6 x 8.

Note

Direct the bends on the bottom plate downwards!

12

CAUTION

The base and axis 1 gearbox weighs 310 kg

+ 200 Kg.


xx0300000612

• A: Bottom plate

• B: Rear connector plate

• C: Attachment screw

• D: Groove

13

14

15

Lift the robot base and gearbox 1 and remove the base and gear support.

Secure the base to the mounting site.

See

Orienting and securing the robot on page 85

.

Refit the complete arm system.

Detailed in section

Replacing the axis

1 gearbox on page 350 .

CAUTION

This is a complex task to be performed with utmost care in order to avoid injury or damage!

16 Perform a leak-down test.

17

18



See section

Performing a leak-down test on page 226 .

See


.





.



.


360




4 Repair


Continued

Action

19

DANGER



.

Note




361

4 Repair

4.7.2 Replacement of gearbox, axis 2

4.7.2 Replacement of gearbox, axis 2


The axis 2 gearbox is located in the lower arm rotational center as shown in the figure below.



xx0100000135

E

F

G

A

B

C

D

-

I

-

Gearbox, axis 2 (behind motor attachment not shown in figure )

Motor, axis 2

Oil plug, filling

Oil plug, draining

Front gearbox attachment screws

Attachment holes, fixture lower arm

Motor attachment

Hole for locking screw, lower arm, M16 x 60

Sealing (between gearbox and motor attachment, not shown in figure )

Friction washer (between the gearbox and lower arm, not shown in figure )


362




4 Repair


Continued


Equipment, etc.

Gearbox, axis 2

O-ring

Sealing, axis 2/3

Grease

Standard toolkit

Lifting tool, gearbox axis 2

Fixture lower arm

Locking screw, lower arm

Spare part number


3HAC12641-1 Includes gearbox and oring

3HAB3772-51

3HAC17213-1

-

3HAB3537-1

A new sealing must be used on each assembly!




3HAC12731-1

3HAC13660-1




3HAC13120-2

3HAC13120-3

3HAC13120-5

M16 x 60 8.8.

Included in the fixture, lower arm.

To be used in pairs!

To be used in pairs!

For guiding the gearbox.

Always use the guide pins in pairs.

Guide pins, sealing ax 2/3,

80mm

Guide pins, sealing ax 2/3,

100mm



Calibration


3HAC14627-2

3HAC14627-3

3HAC15716-1

3HAC055412-

001

For guiding the sealing axis 2/3. Guides are to be used in pairs!

For guiding the sealing axis 2/3. Guides are to be used in pairs!











363

4 Repair


Continued




1

Action Note










Axis Calibration in


.






Removal, gearbox

2

3

The procedure below details how to remove gearbox, axis 2.

1

Action


Note

Remove any equipment fitted to the turning disk.

Run the robot to the calibration position. The upper arm may be directed in three different ways, shown in figure to the right.

The lowered position, as in figure A, is recommended as it gives the least load on the tool.

xx0200000260


364




4 Repair


Continued

Action Note

4

5

6

7

DANGER

Turn off all:





If the robot is fitted with moveable mechanical stops on axis 2 (not stock equipment), these must be removed at this point.

The attachment holes of the mechanical stops are used to attach the fixture, lower arm.

Secure the lower arm to the frame by inserting the locking screw into the hole.



!

Shown in the figure


Fit the fixture, lower arm to prevent the lower arm from falling.

• Make sure that both adjusters (B) on the fixture are screwed back.

• Align the fixture with the frame and lower arm.

• Tighten the four M16 bolts (C) on the inside of the frame, in attachment holes, with tightening torque: 220 Nm.

• Screw in the two adjusters (B) until they rest against the flats on the lower arm.

Tighten by hand.

• Lock, using the two ring nuts (D).

• Tighten the two M12 bolts (E) in the attachment holes, fixture lower arm with tightening torque: 91 Nm.



!

Attachment holes for the fixture are shown in the figure


Make sure the fixture is pressed tightly against the lower arm before securing with screws!

8 Unload the balancing device shaft by using a specific press tool.

9

10

Drain the gearbox, axis 2.


xx0200000261

• A: Locking screw, lower arm

Detailed in section

Unloading the balancing device using hydraulic press tool on page 306 .

Detailed in section

Draining, oil on page 188

.

Detailed in section

Removal, motor on page 320 .





365

4 Repair


Continued

11

Action

Remove the 30 rear gearbox attachment screws

(A) from inside the lower section of the lower arm.

Note xx0300000064

12

13

Remove the motor attachment by unscrewing the front gearbox attachment screws.

Fit the lifting tool, gearbox axis 2 , to the motor attachment and secure it with the hook on the tool.

Remove the motor attachment.

14

CAUTION

The gearbox weighs 125 kg! All lifting equipment used must be sized accordingly!

Shown in the figure




.

15

16

17

Fit the lifting tool, gearbox axis 2 , to the gearbox.



.

Fit two guide pins in 180° relation to each other instead of the removed front attachment screws.



.

If required, apply an M16 screw to the hole shown in the figure to press it free.



.

18

19

Remove the gearbox using an overhead crane or similar.

Remove the friction washer and clean it.

xx0200000033

• A: M16 holes for pressing the gearbox out





4 Repair


Continued

20

Action


Note

On reassembly a new sealing must be used!

Art. no. is specified in the refitting instructions


!


The procedure below details how to refit the gearbox, axis 2.

Action Note

1

DANGER

Turn off all:





2 Fit the guide pins, sealing axis 2/3 on gearbox, axis 2.

Only the holes showed in figure beside are allowed to be used to the guide pins!

3

4

5

6 xx0200000125

Holes for guide pins, sealing axis 2/3 on gearbox 2.




.

Fit the new sealing, axis 2/3 on gearbox, axis 2, with guidance from the guide pins.

Fit two guide pins, M16 180° in relation to each other in the attachment holes in the frame.

Fit the cleaned friction washer onto the guide pins.



.

Fit the lifting tool, gearbox axis 2 , to the gearbox.



.





367

4 Repair


Continued

7

Action

Make sure the o-ring is fitted to the rear of the gearbox. Lightly grease the o-ring.

Note



.

8

9

10

11

12 xx0100000136

A O-ring, gearbox, axis 2

Lift the gearbox to its mounting position.

Fit the gearbox onto the guide pins and slide it into position.

Remove the lifting tool.

Make sure the gearbox is seated properly.

In a similar way, fit the lifting tool to the motor flange. Lock the tool with the hook.

Lift it and slide it onto the guide pins.


Insert and secure 18 of the 20 attachment screws on the front of the motor attachment.

Remove the guide pins and tighten the remaining two screws.

Tightening torque: 280±15 Nm.



before fitting.

13 Remove the guide pins and tighten the remaining two screws as above.


368




4 Repair


Continued

14

Action

Insert and secure 28 of the 30 attachment screws on the inside of the lower arm.

Note xx0300000064




before fitting.

15 Remove the guide pins, sealing axis 2/3 and tighten the remaining two screws as above.

16 Refit the motor.

17

18



19

20

21

22

23

24

Restore the balancing device by removing the balancing device tools.

Remove the fixture, lower arm.

Remove the locking screw, lower arm.

Detailed in section

Restoring the balancing device on page 311 .

Refit any mechanical stops if such were removed during disassembly.

Refit any equipment to the turning disc if such was removed during assembly.






.



25

Detailed in section

Refitting, motor on page 321

.

Detailed in section


Detailed in section

Filling, oil on page 188 .

DANGER





369


4 Repair




The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.



xx0100000137

D

E

F

G

H

A

B

C

Gearbox, axis 3

Attachment screws, gearbox

Oil plug, filling

Oil plug, draining

Motor, axis 3

Attachment screws, upper arm

Attachment screws, motor

Sealing, axis 2/3 (between lower arm and gearbox 3)






Equipment, etc.

Gearbox

O-ring

Grease

Sealing, axis 3

Mechanical stop axis

3

Washers (for mechanical stop axis 3)

Bolt, M16x60 (for mechanical stop axis

3)

Lifting eye M16



Guide pins, sealing ax

2/3, 80mm

Guide pins, sealing ax

2/3, 100mm

Standard toolkit



Axis Calibration

4 Repair


Continued

Art. no.

Note



Includes

• gearbox

• o-ring.

Does not include the sealing, axis 2/3!

3HAB3772-51

3HAB3537-1

3HAC17213-1

1 pc on the gearbox.

Replace if damaged.

For lubricating the o-rings.

3HAC12708-2

A new sealing must be used on each assembly!

Used to secure the upper arm. Use attachment screws 3HAB3409-86

(M16 x 60).

3HAA1001-186

3HAB3409-86

-

3HAC14457-4

3HAC13120-4

3HAC13120-5

3HAC14627-2

3HAC14627-3

3HAC15716-1

3HAC055412-001


Use guides in pairs!



For guiding the axis-3 sealing.


For guiding the axis-3 sealing.













371

4 Repair


Continued

Equipment, etc.


Art. no.

Note





1

Action Note










Axis Calibration in


.








1

Action


Note


372




4 Repair


Continued

Action Note

2

3

4

DANGER

Turn off all:





Secure the upper arm in a horizontal position using round slings.



Remove the motor, axis 3 .

Detailed in section

Removal, motor on page 326

.

Note

When removing the motor axis 3, the brake on axis

3 is released. Make sure the upper arm is secured and disabled to move!

5

6

7

8

9

10

Remove the upper arm .

Remove the sealing, axis 2/3 between the gearbox and lower arm.

Detailed in section

Removal, upper arm on page 261 .

On reassembly a new sealing must be used! Art.

no. is specified in


Place the upper arm safely on a workbench, in a fixture or similar.

Remove the attachment screws, gearbox.

Shown in the figure


.

Fit the two guide pins in 180° relation to each other in the gearbox attachment screw holes.



Fit the lifting eye to the gearbox, in one of the attachment screw holes that attaches the gearbox to the lower arm .

If required, use screws in the holes

(A) shown in the figure to the right to press the gearbox free.




3HAC022033-001 Revision: V xx0200000033

• A: M16 holed for pressing the gearbox out


373


4 Repair


Continued

Action

11

CAUTION

The gearbox weighs 125 kg! All lifting accessories used must be sized accordingly!

Note

12 Remove the gearbox, with guidance from the guide pins, using an overhead crane or similar.


The procedure below details how to refit gearbox, axis 3.

Action Note

1

DANGER

Turn off all:





2

3

Turn the upper arm in such a position that the gear mating surface faces upwards.

Fit two guide pins in 180° relation to each other in the holes in the upper arm, used for the gearbox attachment screws.



4

CAUTION

The gearbox weighs 125 kg! All lifting accessories used must be sized accordingly!

5 Fit the lifting eye to the gearbox.




374




4 Repair


Continued

6

Action Note

Make sure the o-ring is fitted to the rear of the gearbox. Apply grease to it to make sure it sticks in its groove during assembly!

Replace if damaged!



7

8

9

10

11

12

13

14 xx0100000136

• A: O-ring, gearbox axis 3

Lift the gearbox to its mounting position.

Turn the gearbox to align the attachment screw holes with those in the upper arm.

Fit the gearbox onto the guide pins and slide it into position.

Make sure the o-rings are seated properly and the gearbox correctly oriented!


Secure the gearbox with 18 of the 20 gearbox attachment screws.

Remove the guide pins and tighten the remaining two screws.

20 pcs: M16 x 90; 12.9 quality UNBRAKO, tightening torque: 300 Nm.



before fitting.

Refit the upper arm with a new sealing, axis 2/3 .



Detailed in section

Refitting, upper arm on page 262 .

Refit the motor.


Detailed in section

Refitting, motor on page 328 .



Calibrating with Axis

Calibration method on page 408

.



.





375

4 Repair


Continued

Action

15

DANGER



Note

376




4 Repair




The axis 4 gearbox is located at the rear of the upper arm as shown in the figure below.



xx0100000144

I

G

H

J

K

D

E

F

A

B

C



Upper arm housing

Gearbox, axis 4


Attachment screws, cover axis 4


Oil plug, draining, secondary gearbox

Gear, Z3

Gear attachment screws

Motor, axis 4

Motor flange

Oil plug, filling, primary gearbox (draining not shown in figure)


377


4 Repair


Continued


Equipment, etc.

Gear axis 4

O-ring

O-ring

Friction washer

Gasket, cover axis 4

Grease



Standard toolkit



Calibration


Spare part no.

3HAC17810-1

3HAC10122-27

Art. no.

3HAB3772-49

3HAB3772-50

Note

Includes all o-rings!

Replace if damaged!

Replace if damaged!

2 pcs. Must be replaced at assembly!

-

3HAC11423-3

3HAB3537-1

3HAC15521-1

3HAC15521-2

For lubrication of gearbox, motor and motor attachment mating surfaces.

Always use the guide pins in pairs!

Always use the guide pins in pairs!



3HAC15716-1

3HAC055412-

001









1

Action




Note


378




4 Repair


Continued

Action Note







Axis Calibration in


.








Note

1

Action


2

DANGER

Turn off all:





3

4

5

6

7

8

9

Drain the oil from the primary gearbox through the oil plug, draining.

Drain the oil from the secondary gearbox through the oil plug, draining.

Detailed further in section


Shown in the figure


Draining is further detailed in section


Remove the plastic housing from the cover, axis 4 gearbox.

Remove the its

Loosen the cover, axis 4 gearbox attachment screws.

gear attachment screws move the gear Z3.


by unscrewing but do not re-

Shown in the figure


Shown in the figure


Detailed in section

Removal, motor axis 4 on page 333

.

Remove gear Z3 from the gearbox by unscrewing the 15 gear attachment screws .

If required, insert screws into three holes in gear Z3 to press it out.

Shown in the figure





379


4 Repair


Continued

10

11

Action

Remove the motor flange attachment screws and plain washers.

Note

Shown in the figure


Pull the motor flange and gearbox, axis 4 out along with the friction washers.

If required, insert screws into two holes in the gearbox to press it out.

M10.


The procedure below details how to refit the gearbox of axis 4.

Action Note

1

DANGER

2

3

4

Turn off all:





Make sure the two o-rings on the circumference of the gearbox are seated properly in their grooves respectively. Lightly lubricate the orings with grease.



Lubricate the gearbox, motor and motor attachment mating surfaces with grease.



Fit four guide pins symmetrically in the attachment holes in the upper arm housing.

5 xx0200000067

A Attachment holes for guide pins, M10



Fit two new friction washers onto the guide pins.



Note

Make sure the surface beneath the friction washers is clean and dry!


380




4 Repair


Continued

6

Action

Push in the gearbox, axis 4, and the motor flange .

If necessary, use screws in the attachment holes to press in the motor flange.

Note

Shown in the figure


Note

Make sure the motor flange is oriented correctly by observing the oil plugs as shown in the figure

Replacement of gearbox, axis 4 on page 377 .

7

8

9

10

11

Secure the motor flange to the upper arm housing with 16 of the 18 washers and attachment screws.

Secure with locking liquid.


65 Nm.

Remove the guide pins and secure the remaining two attachment screws as specified in previous step.


Detailed in section

Refitting, motor axis 4 on page 334

.

Refit gear Z3 to the gearbox with its gear attachment screws .

Shown in the figure



115 Nm.

6 pcs: M16 x 60: tightening torque:

300 Nm.

Replace the gasket, cover axis 4 .



12 Refit the cover, axis 4 gearbox with its attachment screws and secure with locking liquid.


Shown in the figure



14

15

16

Refill the primary gearbox with oil.

Refill the secondary gearbox with oil.


Detailed in section

Performing a leakdown test on page 226 .


Filling, oil, gearbox axis 4 on page 195 .


Filling, oil, gearbox axis 4 on page 195 .







17

DANGER





381


4 Repair




The axis 5 gearbox is located in the wrist unit as shown in the figure below.



xx0100000146

G

H

E

F

K

L

A

B

C

D

N

Wrist housing


Attachment screws, cover axis 5

Oil plug, secondary, filling

Oil plug, secondary, draining

Gear, Z3

Wheel unit

Attachment screws, gear Z3

Gearbox, axis 5

Oil plug, primary, filling (draining plug on the opposite side of the wrist housing, not shown in figure)

VK-cover





4 Repair


Continued

O Attachment screws, bearing washer, M6 x 16


Equipment, etc.

Gear axis 5

O-ring

O-ring

Friction washer

VK-cover

Gasket, cover

Grease

Locking liquid

Isopropanol

Standard toolkit

Lifting eye M12

Removal tool, wheel unit





Calibration


See references to these procedures in the stepby-step instructions below.

Spare part no.

3HAC17810-1

3HAC10122-27

-

Art. no.

3HAB3772-49

3HAB3772-50

Note

Includes all o-rings!

Replace if damaged!

Replace if damaged!

2 pcs. Must be replaced at assembly!

3HAA2166-24

3HAC 11409-5

Must be replaced!

3HAB3537-1 For lubricating the o-rings and the packing box.

3HAB7116-1

11771012-208

Loctite 243

To clean surface beneath VKcover.

3HAC14457-3

3HAC15814-1

3HAC15521-1

3HAC15521-2

3HAC15716-1

3HAC055412-

001



.

2 pcs required!

For lifting the gearbox.

For removing and lifting the wheel unit.












383

4 Repair


Continued




1

Action Note










Axis Calibration in


.







The procedure below details how to remove the gearbox, axis 5.

1

Action


Note

2

DANGER

3

4

5

6

Turn off all:





Drain the oil from the primary gearbox.

Drain the oil from the secondary gearbox.

Detailed in section


.

Detailed in section


.


Detailed in section

Replacement of motor, axis 5 on page 338 .

Remove the cover, axis 5 gearbox by unscrewing its attachment screws .

Shown in the figure






4 Repair


Continued

7

8

9

10

11

12

Action Note

Remove gear Z3 from the gearbox by unscrewing its attachment screws (let axis 6 turn to the stop).

If necessary, insert screws into the three holes in gear Z3 to remove it.

Shown in the figure


6 pcs: M16 x 60.

9 pcs: M12 x 50.

Remove the wheel unit.

Detailed in following section

( Removal, wheel unit on page 385 ).

Remove the gearbox, axis 5 by unscrewing its attachment screws and removing the washers .

Shown in the figure


18 pcs: M10 x 40.

Apply two lifting eyes to the gearbox, axis 5, in opposite positions.



Remove the gearbox by gently lifting it straight out.

Remove the friction washers, located beneath the gearbox, from the wrist housing.

Removal, wheel unit

The procedure below details how to remove the wheel unit.

1

2

3

Action

Drain the oil from the secondary gearbox.

Note

Detailed in section


Remove the cover, axis 5 gearbox by unscrewing its attachment screws .

Shown in the figure


Make a short cut in the center of the VK-cover and remove it from the wheel unit by bending it off.

Shown in the figure


Note

Avoid damaging screws or surfaces beneath, when removing the cover!

4 Unscrew the attachment screws, bearing washer located beneath gear Z4.

Turn the gear Z4 in order to reach all the srews.

Shown in the figure


and in the figure below!

7 pcs: M6 x 16.





385

4 Repair


Continued

5

Action

Remove the attachment screws, gear Z4 .

Note

6

7 xx0200000068

A Gear Z4

B Surface beneath VK-cover

C VK-cover

D Attachment screws, gear Z4,

21 pcs: M16

E Attachment screws, bearing washer, 7 pcs: M6

Apply the removal tool to the center hole of gear

Z4 to press the wheel unit free.



!

Remove the wheel unit by gently lifting it straight out.


Action Note

1

DANGER

Turn off all:





2

3

4

5

6

Make sure the two o-rings on the circumference of the gearbox are seated properly in their grooves respectively. Lightly lubricate the o-rings with grease .



.

Fit two guide pins in the housing.

Refit the two new wrist housing.

friction washers (2 pcs) in the



.



.

Apply two lifting eyes to the gearbox, axis 5 , in opposite positions.

Refit the gearbox, axis 5 to the wrist housing, by gently lowering it straight down, using the guide pins.



.

Shown in the figure


.





4 Repair


Continued

7

8

9

10

Action

Secure the gearbox with 16 of the 18 attachment screws and washers.

Note

18 pcs: M10 x 40: tightening torque: 65 Nm.

Shown in the figure


.

Remove the guide pins and fit the remaining two attachment screws as specified in the previous step.

Refit the gear Z3 to the gearbox, axis 5 with its attachment screws.

9 pcs: M12 x 50; 12.9 quality UN-

BRAKO, tightening torque: 115

Nm.

6 pcs: M16 x 60: tightening torque: 300 Nm.

Shown in the figure


.



before fitting.

Refit the wheel unit.

Detailed in the following procedures (

Refitting, wheel unit on page 388

).

11

12

13

Replace the gasket .



.

Refit the cover, axis 5 gearbox with its attachment screws and secure with locking liquid.

14 pcs, tightening torque: 10 Nm.

Shown in the figure


.


Detailed in section

Refitting, motor axis 5 on page 341 .


15

16

17

Refill the primary gearbox with oil.

Refill the secondary gearbox with oil.


Detailed in section



Filling oil, axis-5 gearbox on page 199

.


Filling oil, axis-5 gearbox on page 199

.





.



.

18

DANGER






387


4 Repair


Continued

Refitting, wheel unit

The procedure below details how to refit the wheel unit.

4

5

1

2

3

Action

Clean the wheel unit and the tube mating surfaces.

Note

Lubricate packing box with grease.

Apply

Z4.

removal tool to the center hole of the gear



.



.

Refit wheel unit by gently lowering it straight down.

Gently knock on the wheel unit with a plastic mallet, to press it all the way down.

Note

Make sure the bearing reaches the bottom, before continuing the mounting!

6 Fasten the bearing washer with its attachment screws and secure with locking liquid .

Turn the gear Z4 in order to reach all the screws.

388

7

8

9 xx0200000068

A Gear Z4

B Surface beneath VK-cover

C VK-cover

D Attachment screws, gear

Z4, 21 pcs: M16

E Attachment screws, bearing washer, 7 pcs: M6

Clean the surface beneath the VK-cover with isopropanol.

Secure the wheel unit with attachment screws, gear

Z4.

21 pcs: M16 x 90; 12.9 quality

UNBRAKO, tightening torque: 300

Nm.



before fitting.

Refit the VK-cover.



.

Shown in the figure


.

10 Proceed with step 11 in the refitting detailed in the previous procedure (procedure

Refitting, gearbox axis 5 on page 386 ).




4 Repair




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

xx0100000131

A

B

C

D

-

E

Gearbox, axis 6

Attachment screws, gearbox

Washers

Oil plug, filling


O-ring (not shown in the figure)


Equipment, etc.

Gearbox

Washers

Art. no.

Note



Includes o-ring.

3HAC10122-13 Not included in the gearbox. Replace if damaged!




389


4 Repair


Continued

Equipment, etc.

O-ring

Grease

Flange sealant

Standard toolkit



Axis Calibration

-

Art. no.

3HAB3772-49

3HAB3772-83

3HAB3537-1

12340011-116

3HAC15716-1

3HAC055412-001

Note

Must be replaced when reassembling gearbox!


Loctite 574



.











1

Action




Note







Axis Calibration in


.




390




4 Repair


Continued

Action




Note



1

Action


Note

2

DANGER

Turn off all:





3

4

5

6

Drain the oil from gearbox, axis 6.

Remove the turning disk .


Draining oil, gearbox axis 6 on page 202 .


Removing turning disk on page 251

.

Remove the gearbox by unscrewing its 18 attachment screws and two washers.

Shown in the figure


.

If required, apply M10 screws to the holes shown in the figure to the right, to press the gearbox out.

xx0200000220

• A: M10 holes for pressing out the gearbox





391

4 Repair


Continued

Action

Foundry Plus:

Remove old Loctite 574 flange sealant residues and other contamination from the contact surfaces.

Note

7 Remove the gearbox axis 6 by lifting it out carefully.

xx1400001123

Be careful not to damage the motor pinion!

Refitting, gearbox

The procedure below details how to refit gearbox, axis 6.

Action Note

1

DANGER

Turn off all:





2 Make sure the o-ring is fitted to the rear of the gearbox. Lubricate the o-ring with grease.



.


392 xx0200000221

• A: O-ring, gearbox axis 6




4 Repair


Continued

3

4

Action Note

Release the holding brake of motor axis 6.



.

Foundry Plus:

Apply Loctite 574 flange sealant on the contact surface.

xx1400001122

5

6

7

8

9

10

Insert the unit.

gearbox, axis 6 into the wrist

Fit the both washers and secure the gearbox with the attachment screws .

Shown in the figure


18 pcs: M10 x 50; 12.9 quality Gleitmo,




before fitting.

Refit the turning disc .



.

Shown in the figure


Make sure the gears of the gearbox mate with the gears of the motor!

Perform a leak-down test .


Refitting turning disk on page 252

.


Performing a leakdown test on page 226 .




Filling oil, gearbox axis 6 on page 203 .






.

11

DANGER



.




393


5 Calibration

5.1.1 Introduction and calibration terminology

5 Calibration

5.1 Introduction to calibration

5.1.1 Introduction and calibration terminology

Calibration information

This chapter includes general information about the recommended calibration methods and also the detailed procedures for updating the revolution counters, checking the calibration position etc.

Detailed instructions of how to perform Axis Calibration are given on the

FlexPendant during the calibration procedure. To prepare calibration with Axis

Calibration method, see


Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools.

Calibration terminology

Term

Calibration method

Synchronization position

Calibration position

Standard calibration

Fine calibration

Reference calibration

Update revolution counter

Synchronization mark

Definition

A collective term for several methods that might be available for calibrating the ABB robot. Each method contains calibration routines.

Known position of the complete robot where the angle of each axis can be checked against visual synchronization marks.

Known position of the complete robot that is used for calibration of the robot.

A generic term for all calibration methods that aim to move the robot to calibration position.

A calibration routine that generates a new zero position of the robot.

A calibration routine that in the first step generates a reference to current zero position of the robot. The same calibration routine can later on be used to recalibrate the robot back to the same position as when the reference was stored.

This routine is more flexible compared to fine calibration and is used when tools and process equipment are installed.

Requires that a reference is created before being used for recalibrating the robot.

Requires that the robot is dressed with the same tools and process equipment during calibration as during creation of the reference values.

A calibration routine to make a rough calibration of each manipulator axis.

Visual marks on the robot axes. When marks are aligned, the robot is in synchronization position.




5 Calibration

5.1.2 Calibration methods

5.1.2 Calibration methods

Overview

This section specifies the different types of calibration and the calibration methods that are supplied by ABB.

Types of calibration

Type of calibration Description Calibration method

Standard calibration The calibrated robot is positioned at calibration position.

Standard calibration data is found on the SMB

(serial measurement board) or EIB in the robot.

For robots with RobotWare 5.04 or older, the calibration data is delivered in a file, calib.cfg, supplied with the robot at delivery. The file identifies the correct resolver/motor position corresponding to the robot home position.

Axis Calibration or Calibration Pendulum i

Levelmeter calibration

(alternative method)

Absolute accuracy calibration (optional)

Based on standard calibration, and besides positioning the robot at synchronization 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 calibration data is found on the SMB (serial measurement board) in the robot.

For robots with RobotWare 5.05 or older, the absolute accuracy calibration data is delivered in a file, absacc.cfg, supplied with the robot at delivery. The file replaces the calib.cfg file and identifies motor positions as well as absolute accuracy compensation parameters.

A robot calibrated with absolute accuracy has a sticker next to the identification plate of the robot.

To regain 100% absolute accuracy performance, the robot must be recalibrated for absolute accuracy!

CalibWare xx0400001197 i

The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory. Always use the same calibration method as used at the factory.


If no data is found related to standard calibration, Calibration Pendulum is used as default.


396




5 Calibration


Continued

Brief description of calibration methods

Calibration Pendulum method

Calibration Pendulum is a standard calibration method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S).

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 - Calibration Pendulum , which describes the method and the different routines further.

Axis Calibration method

Axis Calibration is a standard calibration method for calibration of IRB 7600 and is the most accurate method for the standard calibration. It is the recommended method in order to achieve proper performance.

The following routines are available for the Axis Calibration method:

• Fine calibration

• Update revolution counters

• Reference calibration

The calibration equipment for Axis Calibration is delivered as a toolkit.

An introduction to the calibration method is given in this manual, see


The actual instructions of how to perform the calibration procedure and what to do at each step is given on the FlexPendant. You will be guided through the calibration procedure, step by step.

Levelmeter calibration - alternative method

Levelmeter calibration is referred to as the alternative method for calibration of

ABB robots because of the less accurate values obtained during calibration. The method uses the same principles as Calibration Pendulum, but does not have as good of mechanical tolerances to the toolkit parts as the standard method with

Calibration Pendulum.

This method may, after calibration, require modifications in the robot program and is therefore not recommended.

The calibration equipment (Levelmeter 2000) for levelmeter calibration is ordered as separate parts for each robot, and includes the Operating manual - Levelmeter

Calibration , which describes the method and the different routines further.

CalibWare - Absolute Accuracy calibration

To achieve a good positioning in the Cartesian coordinate system, Absolute

Accuracy calibration is used as a TCP calibration. The CalibWare tool guides through the calibration process and calculates new compensation parameters.

This is further detailed in the Application manual - CalibWare Field 5.0

.

If a service operation is done to a robot with the option Absolute Accuracy, a new absolute accuracy calibration is required in order to establish full performance.




397


5 Calibration


Continued

For most cases after motor and transmission replacements that do not include taking apart the robot structure, standard calibration is sufficient. Standard calibration also supports wrist exchange.

References

Article numbers for the calibration tools are listed in the section


.

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the Operating manual - Calibration Pendulum , which describes the method and the different routines further.

398




5 Calibration

5.1.3 When to calibrate

5.1.3 When to calibrate

When to calibrate

The system must be calibrated if any of the following situations occur.

The resolver values are changed

If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration, according to information in this manual.

If the robot has absolute accuracy calibration, it is also recommended, but not always necessary to calibrate 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 the transmission.

The revolution counter memory is lost

If the revolution counter memory is lost, the counters must be updated. See


. 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 reach ability of a robot is changed, it needs to be recalibrated for new resolver values.

If the robot has absolute accuracy calibration, it needs to be calibrated for new absolute accuracy.




399

5 Calibration

5.2.1 Synchronization marks and synchronization position for axes

5.2 Synchronization marks and axis movement directions

5.2.1 Synchronization marks and synchronization position for axes

Introduction

This section shows the position of the synchronization marks and the synchronization position for each axis.

Synchronization marks, IRB 7600

The illustration below shows the location of the synchronization marks on specific plates and directly in the casting at axes 2 and 3.

The figure shows IRB 6600, but the scales and their positions are the same.

xx0200000176

B2

C1

C2

A1

A2

B1

D

E

F

Synchronization mark, axis 1 (early design)

Synchronization mark, axis 1 (later design)





Synchronization mark, axis 4




400




5 Calibration

5.2.1 Synchronization marks and synchronization position for axes

Continued

Synchronization marks at axes 2 and 3

The synchronization 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 synchronization position. One of the marks is more narrow than the other and should be positioned within the limits of the wider mark.




401

5 Calibration

5.2.2 Calibration movement directions for all axes

5.2.2 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 and so on. Positive directions are shown in the graphic below.

Calibration service routines will handle the calibration movements automatically and these might be different from the positive directions shown below.

Manual movement directions, 6 axes

Note!

The graphic shows an IRB 7600. The positive direction is the same for all

6-axis robots, except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction!

402 xx0200000089




5 Calibration

5.3 Updating revolution counters

5.3 Updating revolution counters

Introduction

This section describes how to do a rough calibration of each manipulator axis by updating the revolution counter for each axis, using the FlexPendant.

Step 1 - Manually running the manipulator to the synchronization position

Use this procedure to manually run the manipulator to the synchronization position.

1

2

3

Action Note

Select axis-by-axis motion mode.

Jog the manipulator to align the synchronization marks.

See


When all axes are positioned, update the revolution counter.

Step 2 - Updating the revolution counter with the TPU on page 404

(BaseWare 4.0).

Step 2 - Updating the revolution counter with the FlexPendant on page 405 .

Correct calibration position of axis 4 and 6

When jogging the manipulator to synchronization position, it is extremely important to make sure that axes 4 and 6 of the following mentioned manipulators are positioned correctly. The axes can be calibrated at the wrong turn, resulting in an incorrect manipulator calibration.

Make sure the axes are positioned according to the correct calibration values, not only according to the synchronization marks. The correct values are found on a label, located either on the lower arm, underneath the flange plate on the base or on the frame.

At delivery the manipulator is in the correct position, do NOT rotate axis 4 or 6 at power up before the revolution counters are updated.

If one of the following mentioned axes are rotated one or more turns from its calibration position before updating the revolution counter, the correct calibration position will be lost due to non-integer gear ratio. This affects the following manipulators:

Manipulator variant

IRB 7600

Axis 4

Yes

Axis 6

Yes

If the synchronization marks seem to be wrong (even if the motor calibration data is correct), try to rotate the axis one turn, update the revolution counter and check the synchronization marks again (try both directions, if needed).





403

5 Calibration


Continued

Step 2 - Updating the revolution counter with the TPU

Use this procedure to update the revolution counter with the TPU (BaseWare 4.0).

Note

1

Action

Press the button Miscellaneous then ENTER to select the service window.

xx0100000194

2 Select Calibration from the View menu.

The Calibration window appears.

If there is more than one unit connected to the manipulator, they will be listed in the window.

xx0100000201

3 Select the desired unit and choose Rev Counter Update from the Calib menu.

The Revolution Counter Update window appears.

xx0100000202

4

5

6

Select the desired axis and press Incl to include it (it will be marked with an x) or press All to select all axes.

Press OK when all axes that are to be updated are marked with an x.

CANCEL returns to the Calibration window.

Press OK again to confirm and start the update.

CANCEL returns to the Revolution Counter Update window.





5 Calibration


Continued

7

Action Note

At this point, it is recommended that the revolution counter values are saved to a diskette.

Not required.

8

CAUTION

If a revolution counter is incorrectly updated, it will cause incorrect manipulator positioning, which in turn may cause damage or injury!

Check the synchronization position very carefully after each update.

How to perform the check is detailed in section

Checking the synchronization position on page 421 .

Step 2 - Updating the revolution counter with the FlexPendant

Use this procedure to update the revolution counter with the FlexPendant (IRC5).

1

Action

On the ABB menu, tap Calibration .

xx1500000942





405

5 Calibration


Continued

2

Action

All mechanical units connected to the system are shown with their calibration status.

Tap the mechanical unit in question.

xx1500000943

3 This step is valid for RobotWare 6.02 and later.

Calibration method used at factory for each axis is shown, as well as calibration method used during last field calibration.

Tap Manual Method (Advanced) .


406 xx1500000944




4

Action

A screen is displayed, tap Rev. Counters .

5 Calibration


Continued en0400000771

5

6

7

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.

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 .

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 selected revolution counters and removes the tick from the list of axes.

8

CAUTION

If a revolution counter is incorrectly updated, it will cause incorrect manipulator positioning, which in turn may cause damage or injury!

Check the synchronization position very carefully after each update. See

Checking the synchronization position on page 421

.




5 Calibration

5.4.1 Description of Axis Calibration

5.4 Calibrating with Axis Calibration method

5.4.1 Description of Axis Calibration

Instructions for Axis Calibration procedure given on the FlexPendant


This manual contains a brief description of the method, additional information to the information given on the FlexPendant, article number for the tools and images of where to fit the calibration tools on the robot.

Overview of the Axis Calibration procedure

The Axis Calibration procedure applies to all axes, and is performed on one axis at the time. The robot axes are both manually and automatically moved into position, as instructed on the FlexPendant.

A fixed calibration pin/bushing is installed on each robot axis at delivery.

The Axis Calibration procedure described roughly:

• A removable calibration tool is inserted by the operator into a calibration bushing on the axis chosen for calibration, according to instructions on the

FlexPendant.

WARNING

Calibrating the robot with Axis Calibration requires special calibration tools from ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel.

WARNING

The calibration tool must be fully inserted into the calibration bushing, until the steel spring ring snaps into place.

• During the calibration procedure, RobotWare moves the robot axis chosen for calibration so that the calibration tools get into contact. RobotWare records values of the axis position and repeats the coming-in-contact procedure several times to get an exact value of the axis position.

WARNING

Risk of pinching! The contact force for large robots can be up to 150 kg.

Keep a safe distance to the robot.

• The axis position is stored in RobotWare with an active choice from the operator.





5 Calibration

5.4.1 Description of Axis Calibration

Continued

Routines in the calibration procedure

The following routines are available in the Axis Calibration procedure, given at the beginning of the procedure on the FlexPendant.

Fine calibration routine

Choose this routine to calibrate the robot when there are no tools, process cabling or equipment fitted to the robot.

Reference calibration routine

Choose this routine to create reference values and to calibrate the robot when the robot is dressed with tools, process cabling or other equipment.

If calibrating the robot with reference calibration there must be reference values created before repair is made to the robot, if values are not already available.

Creating new values requires possibility to move the robot. The reference values contain positions of all axes, torque of axes and technical data about the tool installed. A benefit with reference calibration is that the current state of the robot is stored and not the state when the robot left the ABB factory. The reference value will be named according to tool name, date etc.


When reference calibration is performed, the robot is restored to the status given by the reference values.

Note

Update revolution counters

Choose this routine to make a rough calibration of each manipulator axis by updating the revolution counter for each axis, using the FlexPendant.

Validation

When calibrating the robot with the reference calibration routine, the robot must be dressed with the same tools, process cabling and any other equipment as when the reference values were created.

In the mentioned routines, it is also possible to validate the calibration data.

Position of robot axes

The axis chosen for calibration is automatically run by the calibration program to its calibration position during the calibration procedure.

In order for the axis to be able to be moved to calibration position, or in order for getting proper access to the calibration bushing, other axes might need to be jogged to positions different from 0 degrees. Information about which axes are allowed to be jogged will be given on the FlexPendant. These axes are marked with Unrestricted in the FlexPendant window.




5 Calibration

5.4.2 Calibration tools for Axis Calibration

5.4.2 Calibration tools for Axis Calibration

Calibration tool set

The calibration tools used for Axis Calibration are designed to meet requirements for calibration performance, durability and safety in case of accidental damage.

The calibration tool will eventually break from fatigue after longer period of use and then needs to be replaced. There is no risk for bad calibrations as long as the calibration tool is in one piece.

WARNING

Calibrating the robot with Axis Calibration requires special calibration tools from

ABB. Using other pins in the calibration bushings may cause severe damage to the robot and/or personnel.

Equipment, etc.


Axis Calibration

Article number

3HAC055412-001

Note



Examining the calibration tool

Check prior to usage

Before using the calibration tool, make sure that the tube insert, the plastic protection and the steel spring ring are present.

WARNING

If any part is missing or damaged, the tool must be replaced immediately.

xx1500001914

A

B

C

Tube insert

Plastic protection

Steel spring ring


410




5 Calibration

5.4.2 Calibration tools for Axis Calibration

Continued

Periodic check of the calibration tool

If including the calibration tool in a local periodic check system, the following measures should be checked.

• Outer diameter within Ø12g4 mm, Ø8g4 mm or Ø6g5 mm (depending on calibration tool size).

• Straightness within 0.005 mm.

xx1500000951

A Outer diameter

Identifying the calibrating tools

It is possible to make the calibration tool identifiable with, for example, an RFID chip. The procedure of how to install an RFID chip is described below.

2

Note

1

The tool identifier is NOT delivered from ABB, it is a customized solution.

Action

It is possible to use any RFID solution, with the correct dimensions. ABB has verifed function on some suppliers fulfilling the requirements of NFC compatible devices (13.56 Mhz) according to ISO

14443 or ISO 15693.

Note

Note

The maximum dimensions on the RFID chip must not exceed Ø7.9 mm x 8.0 mm, Ø5.9 mm x 8.0

mm or Ø3.9 mm x 8.0 mm (depending on calibration tool size).

There is a cavity on one end of the calibration tool in which the RFID chip can be installed.

Install the RFID chip according to supplier instructions.

Install the chip in flush with the tool end.




5 Calibration

5.4.3 Installation locations for the calibration tools

5.4.3 Installation locations for the calibration tools

Location of fixed calibration items

The figure shows how the robot is equipped with items for installation of calibration tools for Axis Calibration (fixed calibration pins and/or bushings). The figure does not show installed calibration tools.

A fixed calibration pin and a bushing for the movable calibration tool are located on each axis as follows.

Spare parts xx1500000894

The fixed calibration pin for axis 1 is installed on a removable tower. The tower will need to be removed if electronic position switches are fitted to the robot. Keep the tower in a safe location for future recalibration needs and mark it with robot serial number to ensure that the correct one is refitted.

When calibration is not being performed, a protective cover and an o-ring should always be installed on the fixed calibration pin as well as a protective plug, included a sealing, in the bushing. Replace damaged parts with new, if needed.

Spare part

Protection cover and plug set

Article number

3HAC056806-001

Note

Contains replacement calibration pin covers and protective plugs for the bushing.

412




5 Calibration

5.4.4 Axis Calibration - Running the calibration procedure

5.4.4 Axis Calibration - Running the calibration procedure

Required tools

The calibration tools used for Axis Calibration are designed to meet requirements for calibration performance, durability and safety in case of accidental damage.

WARNING

Calibrating the robot with Axis Calibration requires special calibration tools from

ABB. Using other pins in the calibration holes may cause severe damage to the robot and/or personnel.

Equipment, etc.


Calibration

Article number

3HAC055412-001

Note



Required consumables

Consumable

Clean cloth

Spare parts

Spare part

Protection cover and plug set

-


Article number

3HAC056806-001

Note

Contains replacement calibration pin covers and protective plugs for the bushing.

Overview of the calibration procedure on the FlexPendant


Use the following list to learn about the calibration procedure before running the

RobotWare program on the FlexPendant. It gives you a brief overview of the calibration procedure sequence.

After the calibration method has been called for on the FlexPendant, the following sequence will be run.

1 Choose calibration routine. The routines are described in

Routines in the calibration procedure on page 409

.

2 Choose which axis/axes to calibrate.

3 The robot moves to synchronization position.

4 Validate the synchronization marks.

5 The robot moves to preparation position.

6 Remove the protective cover from the fixed pin and the protection plug from the bushing, if any, and install the calibration tool.




413


5 Calibration


Continued

7 The robot performs a measurement sequence by rotating the axis back and forth.

8 Remove the calibration tool and reinstall the protective cover on the fixed pin and the protection plug in the bushing, if any.

9 The robot moves to verify that the calibration tool is removed.

10 Choose whether to save the calibration data or not.

Calibration of the robot is not finished until the calibration data is saved, as last step of the calibration procedure.

Preparation prior to calibration

The calibration procedure is described in the FlexPendant while conducting it.

Action Note

1

DANGER

While conducting the calibration, the robot needs to be connected to power.

Make sure that the robots working area is empty, as the robot can make unpredictable movements.

2 Wipe the calibration tool clean.

Use a clean cloth.

Note

The calibration method is exact. Dust, dirt or color flakes will affect the calibration value.

Starting the calibration procedure

Use this procedure to call for the Axis Calibration method on the FlexPendant.

1

Action

On the ABB menu, tap Calibration .

Note xx1500000942


414




5 Calibration


Continued

2

Action

All mechanical units connected to the system are shown with their calibration status.

Tap the mechanical unit in question.

Note xx1500000943

3 Calibration method used at factory for each axis is shown, as well as calibration method used for the robot during last field calibration.

Tap Run Calibration Method . The software will automatically call for the procedure for the valid calibration method.

The FlexPendant will give all information needed to proceed with Axis

Calibration.

xx1500000944

4 Follow the instructions given on the FlexPendant.

A brief overview of the sequence that will be run on the FlexPendant is given in

Overview of the calibration procedure on the FlexPendant on page 413 .

Restarting an interrupted calibration procedure

If the Axis Calibration procedure is interrupted before the calibration is finished, the RobotWare program needs to be started again. Use this procedure to take required action.

Situation Action

The three-position enabling device on the

FlexPendant has been released during robot movement.

Press and hold the three-position enabling device and press Play .




415


5 Calibration


Continued

Situation

The RobotWare program is terminated with

PP to Main .

Action

Remove the calibration tool, if it is installed, and restart the calibration procedure from the beginning. See

Starting the calibration procedure on page 414

.

If the calibration tool is in contact the robot axis needs to be jogged in order to release the calibration tool. Jogging the axis in wrong direction will cause the calibration tool to break. Directions of axis movement is shown in

Calibration movement directions for all axes on page 402

Axis Calibration with SafeMove option

To be able to run Axis Calibration SafeMove needs to be unsynchronized. The Axis

Calibration routine recognizes if the robot is equipped with SafeMove and will force

SafeMove to unsynchronize automatically.

However, SafeMove may generate other warning messages anytime during the

Axis Calibration routine.

Safety controller not synchronized - SafeMove message

1

Action

SafeMove generates the message "Safety controller not synchronized".

Note

2

3 xx1500002480

Confirm unsynchronized state by pressing Acknowledge to continue Axis Calibration procedure.

Restart Axis Calibration procedure by pressing

Play .


416




5 Calibration


Continued

Unsynchronized speed exceeded - SafeMove message while saving robot data

1

Action

SafeMove generates the message "Unsynchronized speed exceeded" while saving robot data.

Note xx1500002481

2

3

Press Acknowledge to continue Axis Calibration procedure.


Play .

Unsynchronized time limit expired - SafeMove message anytime during Axis Calibration routine

1

Action

SafeMove generates the message "Unsynchronized time limit expired" (anytime).

Note

2

3 xx1500002482

Press OK to continue Axis Calibration procedure.


Play .





417

5 Calibration


Continued

After calibration

1

2

Action

Check the o-ring on the fixed calibration pin.

Replace if damaged or missing.

Reinstall the protective cover on the fixed calibration pin on each axis, directly after the axis has been calibrated.

Replace the cover with new spare part, if missing or damaged.

Note

3 Reinstall the protective plug and sealing in the bushing on each axis, directly after the axis has been calibrated. Ensure that the sealing is not damaged.

Replace the plug and the sealing with new spare part, if missing or damaged.

xx1600002102

Protection cover and plug set:

3HAC056806-001.

xx1500000952

Protection cover and plug set:

3HAC056806-001.

418




5 Calibration

5.5 Calibrating with Calibration Pendulum method

5.5 Calibrating with Calibration Pendulum method

Where to find information for Calibration Pendulum

Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools.




419

5 Calibration

5.6 Verifying the calibration

5.6 Verifying the calibration

Introduction

Always verify the results after calibrating any robot axis to verify that all calibration positions are correct.

Verifying the calibration

Use this procedure to verify the calibration result.

1

2

3

4

Action Note

Run the calibration home position program twice.

Do not change the position of the robot axes after running the program!

See

Checking the synchronization position on page 421 .

Adjust the synchronization marks when the calibration is done, if necessary.



Write down the values on a new label and stick it on top of the calibration label.

The label is located on the lower arm.

Remove any calibration equipment from the robot.

420




5 Calibration

5.7 Checking the synchronization position

5.7 Checking the synchronization position

Introduction

Check the synchronization position of the robot 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 FlexPendant.

Using a MoveAbsJ instruction on the TPU, S4Cplus

Use this procedure to create a program that runs all the robot axes to their synchronization position.

Note

1

Action

Create the following program:

MoveAbsJ [[0,0,0,0,0,0], [9E9,

9E9,9E9,9E9,9E9,9E9]]

\NoEOffs, v1000, z50, Tool0

2

3

Run the program in manual mode.

Check that the synchronization marks for the axes align correctly. If they do not, update the revolution counters.

See


and


Using a MoveAbsJ instruction

Use this procedure to create a program that runs all the robot axes to their synchronization position.

1

2

3

4

Action

On ABB menu tap Program editor .

Create a new program.

Use MoveAbsJ in the Motion&Proc menu.

Create the following program:

MoveAbsJ [[0,0,0,0,0,0],

[9E9,9E9,9E9,9E9,9E9,9E9]]

\NoEOffs, v1000, fine, tool0

Note

5

6

Run the program in manual mode.


See


and






421

5 Calibration

5.7 Checking the synchronization position

Continued

Using the jogging window on the TPU, S4Cplus

Use this procedure to jog the robot to synchronization position of all axes.

1

Action

Open the Jogging window.

Illustration/Note xx0100000195

2 Select running axes-by-axes.

xx0100000196

3

4

Manually run the robot axes to a position where the axis position value read on the

TPU, is equal to zero.


See


and


.

Using the jogging window

Use this procedure to jog the robot to the synchronization position of all axes.

1

2

3

4

5

Action

On the ABB menu, tap Jogging .

Note

Tap Motion mode to select group of axes to jog.

Tap to select the axis to jog, axis 1, 2, or

3.

Manually run the robots axes to a position where the axis position value read on the

FlexPendant, is equal to zero.


See


and


422




6 Decommissioning

6.1 Environmental information


6.1 Environmental information

Symbol

The following symbol indicates that the product must not be disposed of as common garbage. Handle each product according to local regulations for the respective content (see table below).

xx1800000058

Hazardous material

The table specifies some of the materials in the product and their respective use throughout the product.

Dispose components properly according to local regulations to prevent health or environmental hazards.

Material

Batteries, NiCad or Lithium

Copper

Cast iron/nodular iron

Steel

Neodymium

Plastic/rubber

Oil, grease

Aluminium

Nickel

Example application

Serial measurement board

Cables, motors

Base, lower arm, upper arm

Gears, screws, base frame, and so on.

Brakes, motors

Cables, connectors, drive belts, and so on.

Gearboxes

Covers, synchronization brackets

Turning disc (foundry)

Oil and grease

Where possible, arrange for oil and grease to be recycled. Dispose of via an authorized person/contractor in accordance with local regulations. Do not dispose of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration must be carried out under controlled conditions in accordance with local regulations.




423



6.1 Environmental information

Continued

Also note that:

• Spills can form a film on water surfaces causing damage to organisms.

Oxygen transfer could also be impaired.

• Spillage can penetrate the soil causing ground water contamination.

424





6.2 Scrapping of robot

6.2 Scrapping of robot

Important when scrapping the robot

DANGER

When a robot is disassembled while being scrapped, it is very important to remember the following before disassembling starts, in order to prevent injuries:

• Always remove all batteries. If a battery is exposed to heat, for example from a blow torch, it will explode.

• Always remove all oil/grease in gearboxes. If exposed to heat, for example from a blow torch, the oil/grease will catch fire.

• When motors are removed from the robot, the robot will collapse if it is not properly supported before the motor is removed.




425


6.3 Decommissioning of balancing device

6.3 Decommissioning of balancing device

General

There is much energy stored in the balancing device. Therefore a special procedure is required to dismantle it. The coil springs inside the balancing device exert a potentially lethal force unless dismantled properly.

The device must be dismantled by a decommissioning company.


Equipment

Standard toolkit

Protective clothing that also covers face and hands

Cutting torch with a long shaft

-

-


-

Art. no.

Note



.

Must protect against spatter of sparks and flames.

For opening housing and cutting coils.

The long shaft is a safety requirement.


DANGER

Do not under any circumstances, deal with the balancing device in any other way than that detailed in the product documentation! For example, attempting to open the balancing device is potentially lethal!

Action on field, decommissioning

The procedure below details the actions to perform on field, when the balancing device is to be decommissioned.

1

2

Action Note

Remove the balancing device from the robot.

Detailed in section

Replacing the balancing device on page 298

.

Send the device to a decommissioning company.

Make sure the decommissioning company is well informed about the stored energy built up by high tensioned compression springs and that the device contains some grease.

The following procedure contains useful information about decommissioning.


426






Continued

Decommissioning at decommissioning company, balancing device

The instruction below details how to decommission the balancing device. Contact

ABB Robotics for further consultation.

Action Note

1

DANGER

There is stored energy built up by high tensioned compression springs inside the balancing device! When a coil is cut the released tension creates a spatter of sparks and flames.

The working area must be free of flammable materials. Position the balancing device so that the spatter will be directed away from personnel.

2 Clamp the device at the working location.

Place the device at ground level so that the hole and spring coils are cut from a more safe distance.

3

DANGER

The hole must be cut as specified in the figure. Pieces can be ejected from the cylinder at high speed if the hole is cut larger than specified!

4 Cut a hole in the housing as shown in the figure.

Use a cutting torch with a long shaft.

The measurements shown below are maximum values!

xx0200000082





427



Continued

Action

5

DANGER

There is stored energy built up by high tensioned compression springs inside the balancing device! When a coil is cut the released tension creates a spatter of sparks and flames.

The working area must be free of flammable materials. Position the balancing device so that the spatter will be directed away from personnel.

Note

6

7

Cut the coils of the springs inside the housing as specified below:

• Outer spring: cut at least five coils!

• Middle spring: cut at least four coils!

• Inner spring: cut at least four coils!

Use a cutting torch with a long shaft.

Double-check the number of coils cut and make sure all the tension in the springs are removed.

428




7 Robot description

7.1 Type A vs type B motors


7.1 Type A vs type B motors

Identifying the motor visually

Type B motors include evacuation on the motor flange to indicate failure of primary sealing between the gearbox and the motor. Robots with protection type Foundry

Plus have a sight glass installed in the evacuation holes.

Use the images to identify which type of motor is installed on each robot axis.

Type A motor Type B motor xx1500001058

No evacuation on type A motors.

xx1500001057

The type B motor include evacuation on the motor flange.

Identifying the motor by article number

Use the table to identify which type of motor is installed on each robot axis by article number. The article numbers specified are found in WebConfig.

Contact ABB Service for further assistance regarding which motor type is installed on the robot, if needed.

Note

Robot axis

1

2

Article number

Type A motor

3HAC057539-001

3HAC060565-001

(Foundry Prime)

3HAC057540-001

3HAC057541-001

3HAC060566-001

(Foundry Prime)

The article numbers in the table can not be used for ordering spare parts. The numbers are only used for identification of installed motors.

See Product manual, spare parts - IRB 7600 for spare part numbers.

Article number

Type B motor

3HAC062338-001

N/A

500

2.55

X

500

2.3

X X

X

400

2.55

340

2.80

X

325

/3.10

X

150

3.50

X

3HAC062339-001

3HAC062340-001

N/A

X

X X

X

X

X

X




429



7.1 Type A vs type B motors

Continued

Robot axis

3

4

5

6

Article number

Type A motor

3HAC057540-001

3HAC060566-001

(Foundry Prime)

3HAC057543-001

3HAC036644-002

(Foundry Prime)

3HAC057543-001

3HAC060567-001

(Foundry Prime)

3HAC057544-001

3HAC060568-001

(Foundry Prime)

Article number

Type B motor

3HAC062339-001

N/A

3HAC062341-001

N/A

3HAC062341-001

N/A

3HAC062342-001

N/A

500

2.55

X

X

X

X

500

2.3

X

X

X

X X

X

X

X

X

X

X

X

400

2.55

340

2.80

X

X

X

X

325

/3.10

X

150

3.50

X

X

X

X

X

X

X

Interchangeable parts

Use the table to see if type A and type B motors are interchangeable on each robot axis.

1

2

3

4

5

Robot axis Motor replacement from type A to type B

Fully interchangeable.




Partly interchangeable.

Requirements/notes for replacing type A motor with type B motor

Replacement to type B requires replacement of the left hand side wrist cover. Spare part number for the cover that fits the type B motor:

3HAC062450-005 (ABB Orange) / 3HAC062450-

004 (Graphite White).

430

6 Not interchangeable.

xx1800000129

The complete wrist unit must be replaced.




8 Reference information

8.1 Introduction



General

This chapter includes general information, complementing the more specific information in the different procedures in the manual.




431


8.2 Applicable standards

8.2 Applicable standards

Note

The listed standards are valid at the time of the release of this document. Phased out or replaced standards are removed from the list when needed.

Standards, EN ISO

The product is designed in accordance with the requirements of:

Standard

EN ISO 12100:2010

EN ISO 13849-1:2015

EN ISO 13850:2015

EN ISO 10218-1:2011

ISO 9787:2013

ISO 9283:1998

Description

Safety of machinery - General principles for design - Risk assessment and risk reduction

Safety of machinery, safety related parts of control systems -

Part 1: General principles for design

Safety of machinery - Emergency stop - Principles for design

Robots for industrial environments - Safety requirements -Part

1 Robot

Robots and robotic devices -- Coordinate systems and motion nomenclatures

Manipulating industrial robots, performance criteria, and related test methods

Classification of air cleanliness

Ergonomics of the thermal environment - Part 1

EMC, Generic emission

EN ISO 14644-1:2015 i

EN ISO 13732-1:2008

EN 61000-6-4:2007 +

A1:2011

IEC 61000-6-4:2006 +

A1:2010

(option 129-1)

EN 61000-6-2:2005

IEC 61000-6-2:2005

EN IEC 60974-1:2012 ii

EN IEC 60974-10:2014

ii

EMC, Generic immunity

Arc welding equipment - Part 1: Welding power sources

Arc welding equipment - Part 10: EMC requirements

EN IEC 60204-1:2006 Safety of machinery - Electrical equipment of machines - Part

1 General requirements i ii

IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)

Only robots with protection Clean Room.

Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standards

Standard

EN 614-1:2006 + A1:2009

EN 574:1996 + A1:2008

Description

Safety of machinery - Ergonomic design principles - Part 1:

Terminology and general principles

Safety of machinery - Two-hand control devices - Functional aspects - Principles for design






8.2 Applicable standards

Continued

Other standards

Standard

ANSI/RIA R15.06

ANSI/UL 1740

CAN/CSA Z 434-14

Description

Safety requirements for industrial robots and robot systems

Safety standard for robots and robotic equipment

Industrial robots and robot Systems - General safety requirements




433


8.3 Unit conversion

8.3 Unit conversion

Converter table

Use the following table to convert units used in this manual.

Quantity

Length

Weight

Weight

Pressure

Force

Moment

Volume

Units

1 m

1 kg

1 g

1 bar

1 N

1 Nm

1 L

3.28 ft.

2.21 lb.

0.035 ounces

100 kPa

0.225 lbf

0.738 lbf-ft

0.264 US gal

39.37 in

14.5 psi

434





8.4 Screw joints

8.4 Screw joints

General

This section describes how to tighten the various types of screw joints on the IRB

7600.

The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.

UNBRAKO screws

UNBRAKO is a special type of screw recommended by ABB for certain screw joints.

It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.

Whenever used, this is specified in the instructions, and in such cases, no other type of replacement screw is allowed. Using other types of screws will void any warranty and may potentially cause serious damage or injury.

Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint. Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this the screw must be discarded and replaced with a new one.

When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used.

Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the repair, maintenance or installation procedure descriptions.

In such cases, proceed as follows:

1 Apply lubricant to the screw thread.

2 Apply lubricant between the plain washer and screw head.

3 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

Molycote 1000 (molybdenum disulphide grease)

Article number

11712016-618

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 following tables. 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.




435



8.4 Screw joints

Continued

• Always tighten the joint by hand, and never use pneumatic 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% !

Oil-lubricated screws with slotted or cross-recess head screws

The following table specifies the recommended standard tightening torque for oil-lubricated screws with slotted or cross-recess head screws.

Note

A special torque specified in the repair, maintenance or installation procedure overrides the standard torque.

Oil-lubricated screws with allen head screws

The following table specifies the recommended standard tightening torque for oil-lubricated screws with allen head screws.

Note


Dimension

M5

M6

M8

M10

M12

M16

M20

M24

10

24

47

82

Tightening torque (Nm)

Class 8.8, oil-lubricated

Tightening torque (Nm) Tightening torque (Nm)



6 -

-

34

67

115

-

40

80

140

200

400

680

290

560

960

340

670

1150

Lubricated screws (Molycote, Gleitmo or equivalent) with allen head screws

The following table specifies the recommended standard tightening torque for screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head screws.

Note


Dimension Tightening torque (Nm)

Class 10.9, lubricated i

28 M8


436


Class 12.9, lubricated

i

35





8.4 Screw joints

Continued

Dimension Tightening torque (Nm)

Class 10.9, lubricated i


Class 12.9, lubricated

i

M10

M12

M16

55

96

235

70

120

280

M20 460 550 i

M24 790 950

Lubricated with Molycote 1000, Gleitmo 603 or equivalent

Water and air connectors

The following table specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass .

Note


1/8

1/4

3/8

1/2

3/4

Dimension

15

20

40

70

Tightening torque Nm -

Nominal


Min.


Max.

12 8 15

10

15

30

55

20

25

50

90




437


8.5 Weight specifications

8.5 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 highlighted in this way.

To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.

Example

Following is an example of a weight specification in a procedure:

Action Note

CAUTION

The robot weighs 2500 kg.


438





8.6 Standard tools

8.6 Standard tools

General

All service (repairs, maintenance, and installation) procedures contains 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 following table.

This way, the tools required are the sum of the standard toolkit and any tools listed in the instruction.

Contents, standard toolkit

1

1

1

1

1

1

1

2

1

1

1

1

Qty Tool

Ring-open-end spanner 8-19 mm

Socket head cap 5-17 mm

Torx socket no: 20-60

Box spanner set

Rem.

Torque wrench 10-100 Nm

Torque wrench 75-400 Nm

Ratchet head for torque wrench 1/2

Hexagon-headed screw M10x100

Hex bit socket head cap no. 14 socket 40 mm L=100 mm

Hex bit socket head cap no. 14 socket 40 mm L=20 mm To be shortened to 12 mm

Hex bit socket head cap no. 6 socket 40 mm L=145 mm

Hex bit socket head cap no. 6 socket 40mm bit L=220 mm




439


8.7 Special tools

8.7 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 the section


, and of special tools, listed directly in the instructions and also gathered in this section.

Basic tools

The following table specifies the tools in the basic toolkit (3HAC15571-3) that are used for the current robot model. This toolkit is necessary primary when removing and refitting the motors.

The tools are also listed directly in the instructions.

Description


Guide pins M8 x 100

Guide pins M8 x 150



Lifting tool, wrist unit





Rotation tool

Mechanical stop axis 3

Bolts M16 x 80 (for mechanical stop axis 3)

Washers (for mechanical stop axis 3) 2

Standard toolkit (content described in section


)

1

1

2

2

1

2

1

2

1

1

2

2

2

Qty

1

Art. no.

3HAC12342-1

3HAC15520-1

3HAC15520-2

3HAC15521-1

3HAC15521-2

3HAC12734-1

3HAC14459-1

3HAC15534-1

3HAC14972-1

3HAC14973-1

Fits motors, axes 1, 2, 3, 4 and 5.

3HAC17105-1

3HAC12708-2

3HAB3409-89

3HAA1001-186

3HAC15571-1

Special tools

The following table 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 in the product manual.

Description

Fixture lower arm






440

2

1

2

2

Qty

1

Art. no.

3HAC13660-1

3HAC022637-001

3HAC13120-2

3HAC13120-3

3HAC13120-4





8.7 Special tools

Continued

Description


Guide pins, sealing ax 2/3, 100mm

Guide pins, sealing ax 2/3, 80mm

Holder for bits (Stahlwille 736/40 S 5/16")

Hydraulic cylinder


Hydraulic pump, 150 MPa (Glycerin)

Lifting accessory, base

Lifting accessory, robot

Lifting accessory, upper arm

Lifting eye VLBG M12

Lifting eye M12

Lifting eye M16


Lifting tool, gearbox axis 2

Measuring tool

Oil injector / max 500 MPa

Press tool, axis 2 bearing

Puller device, axis 2 shaft

Press device, axis 2 shaft


Press tool, balancing device shaft


Removal tool, wheel unit

Support, base

Tool set balancing device

Art. no.

3HAC13120-5

3HAC14627-3

3HAC14627-2

3HAC029090-001

3HAC11731-1

3HAC13086-1

3HAC021563-012

3HAC15560-1

3HAC15607-1

3HAC15536-1

3HAC16131-1

3HAC14457-3

3HAC14457-4

3HAC15556-1

3HAC12731-1

6896134-GN

3HAC021590-001

3HAC13453-1

3HAC021563-001

3HAC021600-001

3HAC020902-001

3HAC17129-1

3HAC12475-1

3HAC15814-1

3HAC15535-1

3HAC15943-1

1

1

1

1

1

1

1

1

1

1

1

1

2

2

1

1

1

1

1

1

1

1

1

Qty

2

1

1

Tools that may be rented

The following table specifies the tools that may be rented from ABB in order to perform certain service procedures as described in the Product manual.

The special tools are also listed directly in the instructions.

Description

Lifting tool, lower arm

Art. no.

3HAC14691-1

Note

Includes

• Guidances, 3HAC14445-1





441


8.7 Special tools

Continued

Calibration equipment, Levelmeter (alternative method)

The following table specifies the calibration equipment required when calibrating the robot with the alternative method, Levelmeter Calibration.

Note Description

Angle bracket

Calibration bracket

Calibration tool ax1

Levelmeter 2000 kit

Measuring pin

Sensor fixture

Sensor plate

Sync. adapter

Art. no.

68080011-LP

3HAC13908-9

3HAC13908-4

6369901-347

3HAC13908-5

68080011-GM

3HAC0392-1

3HAC13908-1

Includes one sensor.

Calibration equipment, Calibration Pendulum

The following table specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method.

The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.

Always use the same calibration method as used at the factory.



Description


Art. no.

3HAC15716-1

Note


Calibration equipment, Axis Calibration

The following table specifies the calibration equipment needed when calibrating the robot with the Axis Calibration method.

The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory.

Always use the same calibration method as used at the factory.



Description Art. no.


3HAC055412-

001

Note




442





8.7 Special tools

Continued

Oil exchange equipment

The following table specifies the recommended equipment for oil exchange.

Description


Art. no.

3HAC021745-001

Note

Includes:

• Vacuum pump with regulator, hose and coupling

• Couplings and adapters

• Pump (manual) with hose and coupling

• Graduated measuring glass

• Oil gun

• User instructions.




443


8.8 Lifting accessories and lifting instructions

8.8 Lifting accessories and lifting instructions

General

Many repair and maintenance activities require different pieces of lifting accessories, which are specified in each procedure.

The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories.

This implies that the instructions delivered with the lifting accessories should be stored for later reference.

444




9 Spare part lists

9.1 Spare part lists and illustrations

9 Spare part lists

9.1 Spare part lists and illustrations

Location

Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.myportal.abb.com

.




445


10 Circuit diagram

10.1 Circuit diagrams


10.1 Circuit diagrams

Overview

The circuit diagrams are not included in this manual, but are available for registered users on myABB Business Portal, www.myportal.abb.com

.

See the article numbers in the tables below.

Controllers

Product

Circuit diagram - IRC5

Circuit diagram - IRC5 Compact

Article numbers for circuit diagrams

3HAC024480-011

3HAC049406-003

Circuit diagram - IRC5 Panel Mounted Controller

3HAC026871-020

Circuit diagram - Euromap 3HAC024120-004

Circuit diagram - Spot welding cabinet 3HAC057185-001

Robots

Product


Circuit diagram - IRB 140 type C








Circuit diagram - IRB 1600/1660




Circuit diagram - IRB 4400/4450S


Circuit diagram - IRB 6400RF

Circuit diagram - IRB 6600 type A

Circuit diagram - IRB 6600 type B




3HAC031408-003

3HAC6816-3

3HAC025611-001

3HAC028647-009

3HAC036446-005

3HAC025691-001

3HAC025691-001

3HAC046307-003

3HAC2800-3

3HAC021351-003

3HAC039498-007

3HAC6670-3

3HAC029570-007

3HAC9821-1

3HAC029038-003

3HAC8935-1

3HAC13347-1

3HAC025744-001

3HAC13347-1

3HAC025744-001


447



10.1 Circuit diagrams

Continued

Product


Circuit diagram - IRB 6620 / IRB 6620LX


Circuit diagram - IRB 6650S





Circuit diagram - IRB 910SC


3HAC025090-001

3HAC025090-001

3HAC025744-001

3HAC13347-1

3HAC025744-001

3HAC025744-001

3HAC029940-001

3HAC043446-005

3HAC13347-1

3HAC025744-001

3HAC050778-003

3HAC056159-002

448





10.2 Validity of circuit diagram 3HAC025744-1

10.2 Validity of circuit diagram 3HAC025744-1

Is this circuit diagram valid for your robot?

The validity of the circuit diagram depends on which cable harness is fitted to the robot.

Check the article number of the cable harness fitted to the robot and see page 3 of the circuit diagram in order to determine if the diagram is valid for the harness or not.

Where to find the article number

Label on the cable harness

Action

The label is located at the connectors in the base.

Remove the rear cover plate to see the label.

WebConfig




449


10.3 Validity of circuit diagram 3HAC13347-1

10.3 Validity of circuit diagram 3HAC13347-1

Is this circuit diagram valid for your robot?

The validity of the circuit diagram depends on which cable harness is fitted to the robot.

Check the article number of the cable harness fitted to the robot.

Where to find the article number

Label on the cable harness

WebConfig

Action

-

The label is located at the connectors in the base.

Remove the rear cover plate to see the label.

This circuit diagram is valid for the following cable harness assemblies:

Robot

IRB 6600

IRB 6650, IRB 6650S

IRB 7600

Cable harness

3HAC 14940-1

3HAC 16331-1

3HAC 14940-1

Revision all all revision 0-2

For remaining cable harness assemblies, see section

Validity of circuit diagram

3HAC025744-1 on page 449 .

450




Index

Index

A

Absolute Accuracy, calibration, 397

aluminum

disposal, 423

ambient humidity

operation, 61

storage, 60

ambient temperature

operation, 61

storage, 60

assembly instructions, 51

assessment of hazards and risks, 22

Axis Calibration, 408

calibration tool

article number, 410, 413

examining, 410

installation position, 412

overview of method, 408

procedure on FlexPendant, 413

protective cover and protection plug, 412–413

B

balancing device, replacement, 298

balancing device bearing, replacement, 293

base plate

guide pins, 80 securing, 80

batteries

disposal, 423

handling, 40

battery

replacing, 204, 283

battery pack

replacing, interval, 136

battery shutdown

service routine, 204, 283

brakes

testing function, 39

C

cabinet lock, 28, 34

cable harness axes 1-4, replacement, 233

cabling

position switches, 113

cabling, robot, 125

cabling, robot axes 1-4, 234

cabling, robot axes 5-6, 242

cabling between robot and controller, 125

calibrating

robot, 408

roughly, 403

calibrating robot, 408

calibration

Absolute Accuracy type, 396

alternative method, 397

Levelmeter calibration, 397

rough, 403

standard type, 396

verification, 420

when to calibrate, 399

calibration, Absolute Accuracy, 397

calibration manuals, 398

calibration marks, 400

calibration position




jogging to, 422 jogging to, TPU, 422

scales, 400 calibration scales, 400

CalibWare, 396

carbon dioxide extinguisher, 25

cast iron

disposal, 423

cleaning, 214

climbing on robot, 28

Cold environments, 130

connecting the robot and controller, cabling, 125

connection

external safety devices, 29

copper

disposal, 423

D

damage to mechanical stop, 167

danger levels, 43

dimensions

frame, 90

lower arm, 88

upper arm, 89

direction of axes, 402

E

enabling device, 33

environmental information, 423

EPS, 95

equipment on robot, 88

ESD

damage elimination, 36 sensitive equipment, 36

expected life, 137

extended working range, axis 1, 95

external safety devices, 29

extra equipment

fastener quality, 92

frame, 90

lower arm, 88 robot, 88

upper arm, 89

F

fastener quality for extra equipment, 92

fire extinguishing, 25

fitting equipment on robot, 88

FlexPendant

jogging to calibration position, 422

MoveAbsJ instruction, 421

updating revolution counters, 405

fork lift, 67

foundation

requirements, 60

frame

dimensions, 90

G

gearbox axis 1, replacement, 350



gearboxes

location of, 181

grease

disposal, 423

guide pins, base plate, 80

451

Index

H hanging

installed hanging, 28

hazardous material, 423

height

installed at a height, 28

hold-to-run, 33

HRA, 22

humidity

operation, 61

storage, 60

I

information labels location, 177

inspecting

information labels, 177

mechanical stop, 167

motor seal, 138

inspecting oil levels

axis-6, 155

axis-5, 152

axis-4, 149

axis-3, 146

axis-2, 143

axis-1, 140

installation

mechanical stop axis 1, 106



installing


installing equipment on robot, 88

instructions for assembly, 51

integrator responsibility, 21

intervals for maintenance, 133

L labels

robot, 45

leak-down test, 226

Levelmeter calibration, 397

lifting accessory, 438

lifting robot

with fork lift, 67

with lifting slings, 73

with roundslings, 75

lifting slings, robot, 73

limitation of liability, 21

Lithium

disposal, 423

loads on foundation, 59

lower arm

dimensions, 88

lower arm shaft, replacement, 273

lubrication

amount in gearboxes, 181 type of lubrication, 181

M magnesium

disposal, 423

maintenance schedule, 133

mechanical stop

axis 1, 106

axis 2, 108

axis 3, 110

mechanical stop location, 167

452

motor axis 1, replacement, 313





motor brakes

releasing, 77

motor seal

inspecting, 138


TPU, 421

N

nation specific regulations, 21

negative directions, axes, 402

neodymium

disposal, 423

NiCad

disposal, 423

nodular iron

disposal, 423

O oil

amount in gearboxes, 181

disposal, 423

type of oil, 181

oil change

safety risks, 41

oil level

gearbox axis-6, 155

gearbox axis-5, 152

gearbox axis-4, 149

gearbox axis-3, 146

gearbox axis-2, 143

gearbox axis-1, 140

operating conditions, 61

P pedestal

installed on pedestal, 28

plastic

disposal, 423

position switches

cabling on robot, 113 installing, 113

positive directions, axes, 402

product standards, 432

protection classes, 61 protection type, 61

protective equipment, 29 protective wear, 29

R

region specific regulations, 21

release brakes, 26

releasing motor brakes, 77

replacement

balancing device, 298

bearing, balancing device, 293

cable harness axes 1-4, 233

gearbox axis 1, 350

gearbox axis 3, 370

gearbox axis 6, 389

lower arm shaft, 273

motor axis 1, 313

motor axis 2, 318




Index

motor axis 3, 324

motor axis 4, 331

motor axis 6, 343

requirements on foundation, 60

responsibility and validity, 21

restricting

working range axis 1, 95, 106

working range axis 2, 108

working range axis 3, 110

revolution counters

storing on FlexPendant, 405

storing on TPU, 404

updating, 403

risk of tipping, 66

robot

labels, 45

protection class, 61 protection types, 61

symbols, 45

roundslings attached to robot, 75

rubber

disposal, 423

S safety

brake testing, 39

ESD, 36

fire extinguishing, 25

moving robots, 30

release robot axes, 26

signal lamp, 104

signals, 43 signals in manual, 43 symbols, 43

symbols on robot, 45

test run, 31

working range, 32

safety equipment

mechanical stop, 106




safety fence, 22

safety risk

electric parts, 34

hot parts, 37

hydraulic system, 38

installation, 28

oil change, 41

operational disturbance, 28

pneumatic system, 38

service work, 28

voltage, 34

safety signals

in manual, 43

safety standards, 432

safety zones, 22

scales on robot, 400

schedule for maintenance, 133

screw joints, 435

securing

base plate, 80

securing, robot, 85

securing, upper arm, 326

securing the robot to foundation, attachment screws, 85

signal lamp, 104

signals




safety, 43

SMB

replacing, 283

SMB battery

extension of lifetime, 204, 283 replacing, 204, 283

special tools, 440

speed

adjusting, 130

stability, 66

standards, 432

ANSI, 433

CAN, 433

EN, 432

EN IEC, 432

EN ISO, 432

start of robot in cold environments, 130

steel

disposal, 423

storage conditions, 60

symbols

safety, 43

synchronization position, 403

sync marks, 400

system integrator requirements, 21

T temperatures

operation, 61

storage, 60

testing

brakes, 39

three-position enabling device, 33

tightening torque


tools

Axis Calibration, 442 calibration equipment, Levelmeter, 442

Calibration Pendulum, 442

for service, 440

oil exchange equipment, 443

torques on foundation, 59

TPU

jogging to calibration position, 422



transporting the robot, 56 transport support, 56

type A motors, 429 type B motors, 429

U


upper arm

dimensions, 89

V

validity and responsibility, 21

velocity

adjusting, 130

verifying calibration, 420

W

weight, 58

balancing device, 301, 303

base plate, 79, 84

complete arm system, 247–248

453

Index

gearbox, 366, 374

lower arm, 269, 271

motor, 334–335, 340–341

robot, 72, 74, 76, 353, 355, 357, 360, 438

upper arm, 261–262

wrist unit, 256–257

working range

IRB 7600 - 150/3.5, 62

IRB 7600 - 340/2.8, 63

IRB 7600 - 400/2.55, 64

IRB 7600 - 500/2.3, 65

IRB 7600 - 500/2.55, 64

restricting axis 1, 106



Z zero position

checking, 421

454




ABB AB, Robotics

Robotics and Motion

S-721 68 VÄSTERÅS, Sweden

Telephone +46 (0) 21 344 400

ABB AS, Robotics


Nordlysvegen 7, N-4340 BRYNE, Norway

Box 265, N-4349 BRYNE, Norway

Telephone: +47 22 87 2000

ABB Engineering (Shanghai) Ltd.

Robotics and Motion

No. 4528 Kangxin Highway

PuDong District

SHANGHAI 201319, China

Telephone: +86 21 6105 6666

ABB Inc.


1250 Brown Road

Auburn Hills, MI 48326

USA

Telephone: +1 248 391 9000 abb.com/robotics


ABB IRB 7600 Series, IRC5 Compact, M2000, M2000A Product Manual

Product manual

Table of contents

Overview of this manual

Product documentation, M2000/M2000A

Product documentation, IRC5

How to read the product manual

1 Safety

2 Installation and commissioning

3 Maintenance

4 Repair

5 Calibration

6 Decommissioning

7 Robot description

8 Reference information

9 Spare part lists

10 Circuit diagram

Index

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Table of contents