ABB IRB 260 Product Manual

Product manual

Articulated robot

IRB 260

M2004

Product manual

IRB 260

M2004

Document ID: 3HAC026048-001

Revision: A

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 gurantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

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

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

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

© Copyright 2006-2008 ABB All rights reserved.

ABB AB

Robotics Products

SE-721 68 Västerås

Sweden

Table of Contents

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

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

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

1 Safety 13

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

1.2.3.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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

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

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

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

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

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

1.3.4 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

1.3.5 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2 Installation and commissioning 37

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

2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

2.2.2 Working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.3.1 Lifting of robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

2.3.3 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.3.4 Fitting equipment on the robot and robot dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

2.3.5 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

2.3.6 Load diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

2.3.7 Installation of signal lamp (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

2.4.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

2.4.3 Installation of position switch, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2.4.4 Mechanically restricting the working range of axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

2.4.5 Mechanically restricting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

2.5.1 Connectors on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

2.5.2 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

3HAC026048-001 Revision: A 3


3 Maintenance 75

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

3.2 Maintenace schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

3.3.1 Inspection of information labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

3.4 Changing activites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

3.4.1 Oil in gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

3.4.2 Oil change, gearbox axis 6 (wrist unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

3.4.3 Replacement of SMB battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4 Repair 85

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

4.3 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

4.3.1 Replacement of cable unit, axes 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

4.3.2 Replacement of cable unit, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

4.4 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

4.4.1 Replacement of shaft and bearings, tilthouse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

4.4.2 Replacement of turning disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

4.4.3 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

4.4.4 Replacement of linkage - upper rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

4.4.5 Replacement of linkage - lower rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

4.4.6 Replacement of linkage - link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

4.5 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

4.5.1 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

4.5.2 Replacement of parallel bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

4.6 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

4.6.1 Replacement of SMB unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

4.6.2 Replacement of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

4.6.3 Replacement of parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

4.7 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

4.7.1 Replacement of motor, axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151




4.8 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

4.8.1 Replacement of gearbox, axis 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

4.8.2 Replacement of gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

5 Calibration information 175

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

5.4 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

4 3HAC026048-001 Revision: A


6 Reference information 183

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

6.2 Applicable safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

6.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

6.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

6.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

6.6 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

6.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

6.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

7 Spare part lists and exploded views 201

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

7.2 Spare parts - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

7.3 Spare parts - cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

7.4 Spare parts - robot IRB 260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

7.5 Spare parts - axes 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

7.6 Spare parts - upper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

7.7 Spare parts - tilthouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

7.8 Spare parts - linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

7.9 Spare parts - material set cabling axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

8 Circuit diagram 223

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Index 225




Overview

Overview

About this manual

This manual contains instructions for:

• mechanical and electrical installation of the robot

• maintenance of the robot

• mechanical and electrical repair of the robot.

Usage

This manual should be used during:

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

• maintenance work

• repair work.

Who should read this manual?

This manual is intended for:

• installation personnel

• maintenance personnel

• repair personnel.

Prerequisites

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

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

Organization of chapters

The manual is organized in the following chapters:

Chapter

Safety

Contents

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

Required information about lifting and installation of the robot.

Installation and commissioning

Maintenance

Repair

Calibration information

Decommissioning

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

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

Procedures that does not require specific calibration equipment.

Environmental information about the robot and its components.

3HAC026048-001 Revision: A

Continues on next page

7

Overview

Continued

References

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

Product specification

Document name

Product specification - IRB 260

Product manual

Document name

Product manual IRC5

Operating manual

Document name

IRC5 with FlexPendant

Calibration Pendulum

Service Information System - IRC5

Application manual

Document name

Additional axes and stand alone controller

Technical reference manual

Document name

System parameters

Document ID

3HAC025046-001

Document ID

3HAC021313-001

Document ID

3HAC16590-1

3HAC16578-1

3HAC025709-001

Document ID

3HAC021395-001

Document ID

3HAC17076-1

Revisions

Revision

-

A

Description

First edition

Changes made in:

• Prerequisites in section Overview


Product documentation, M2004

Product documentation, M2004

General

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

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

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

M2004 robot systems.

Product manuals

All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts:

Product manual, procedures

• Safety information

• Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software)

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

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

• Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

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

• Part list

• Foldouts or exploded views

• Circuit diagrams

The product manual published as a PDF consists of only one file where the two parts are presented together, as one Product manual.

RobotWare manuals

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

• RAPID Overview: An overview of the RAPID programming language.

• RAPID reference manual : Description of all RAPID instructions.

• Technical reference manual - System parameters: Description of system parameters and configuration workflows.



9

Product documentation, M2004

Continued

Application manuals

Specific applications (e.g. 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 (e.g. cables, I/O boards, RAPID instructions, system parameters)

• How to use the application

• Examples of how to use the application

Operating manuals

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

• Getting started - IRC5 and RobotStudio Online

• Operator’s manual - IRC5 with FlexPendant

• Operator’s manual - RobotStudio Online

• Trouble shooting manual for the controller and robot


How to read the product manual

How to read the product manual

Reading the procedures

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

References to figures

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

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

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

Action

8.

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, i.e. article number, dimension.

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

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

Action

3.

Fit a new sealing, axis 2 to the gearbox.


Art. no. is specified in Required equipment on page xx .

Safety information

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

Read more in chapter Safety on page 13

.


How to read the product manual


1 Safety

1.1. Introduction

1 Safety

1.1. Introduction

Overview

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

• general safety aspects, important to attend to before performing any service work on the robot. These are applicable for all service work and are found in section

General safety information on page 14

.

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

How to avoid and eliminate the danger is either detailed directly in the procedure, or further detailed in separate instructions, found in section

Safety related instructions on page 29

.


1 Safety

1.2.1. Safety in the robot system

1.2 General safety information

1.2.1. Safety in the robot system

Validity and responsibility

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

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

Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, e.g. User's Guide and Product

Manual.

Connection of external safety devices

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

Limitation of liability

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

Related information

Type of information Detailed in document Section

Installation of safety devices Product manual for the robot

Changing robot modes

Installation and commissioning

Operators manual (RobotWare 5.0) Operating modes

Restricting the working space Product manual for the robot Installation and commissioning


1 Safety

1.2.2.1. Safety risks during installation and service work on robot

1.2.2. Safety risks

1.2.2.1. Safety risks during installation and service work on robot

Overview

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

General risks during installation and service

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

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

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

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

Nation/region specific regulations

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

Non-voltage related risks

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

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

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

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

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

• Be aware of stored heat energy in the controller.

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

To be observed by the supplier of the complete system

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

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



1 Safety

1.2.2.1. Safety risks during installation and service work on robot

Continued

Complete robot

Safety risk

Hot components!

Description

Removed parts may result in collapse of robot!

Caution!

Motors and gears are HOT after running the robot!

Touching the motors and gears may result in burns!

Warning!

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

Cabling

Safety risk

Cable packs are sensitive to mechanical damage!

Description

Caution!

The cable packs are sensitive to mechanical damage!

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

Gearboxes and motors

Safety risk

Gears may be damaged if excessive force is used!

Description

Caution!

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


1 Safety

1.2.2.2. Safety risks related to tools/workpieces

1.2.2.2. Safety risks related to tools/workpieces

Safe handling

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

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

Safe design

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

CAUTION!

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


1 Safety

1.2.2.3. Safety risks related to pneumatic/hydraulic systems

1.2.2.3. Safety risks related to pneumatic/hydraulic systems

General

Special safety regulations apply to pneumatic and hydraulic systems.

Residual energy

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

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

Safe design

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

• Dump valves should be used in case of emergency.

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


1 Safety

1.2.2.4. Safety risks during operational disturbances

1.2.2.4. Safety risks during operational disturbances

General

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

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

• Care must be taken at all times.

Qualified personnel

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

Extraordinary risks

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


1 Safety

1.2.2.5. Risks associated with live electric parts

1.2.2.5. Risks associated with live electric parts

Voltage related risks, general

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

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

Voltage related risks, controller IRC5

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

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

• Units inside the controller, e.g. I/O modules, can be supplied with power from an external source.

• The mains supply/mains switch

• The transformers

• The power unit

• The control power supply (230 VAC)

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

• The drive unit (700 VDC)

• The drive system power supply (230 VAC)

• The service outlets (115/230 VAC)

• The customer power supply (230 VAC)

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

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

• Additional connections.

Voltage related risks, robot

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

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

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

Voltage related risks, tools, material handling devices, etc

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


1 Safety

1.2.3.1. Safety fence dimensions

1.2.3. Safety actions

1.2.3.1. Safety fence dimensions

General

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

Dimensioning

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

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


1 Safety

1.2.3.2. Fire extinguishing

1.2.3.2. Fire extinguishing

NOTE!

Use a CARBON DIOXIDE (CO

2

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


1 Safety

1.2.3.3. Emergency release of the robot’s arm

1.2.3.3. Emergency release of the robot’s arm

Description

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

How to release the brakes is detailed in section:

•

Manually releasing the brakes on page 45 .

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

Increased injury

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


1 Safety

1.2.3.4. Brake testing

1.2.3.4. Brake testing

When to test

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

How to test

The function of each axis' motor holding brakes may be checked as detailed below:

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

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

3. Check that the axis maintains its position.

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


1 Safety

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

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

NOTE!

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

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


1 Safety

1.2.3.6. Safe use of the Teach Pendant Unit

1.2.3.6. Safe use of the Teach Pendant Unit

NOTE!

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

To ensure safe use of the Teach Pendant Unit, the following must be implemented:

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

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

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


1 Safety

1.2.3.7. Work inside the manipulator's working range

1.2.3.7. Work inside the manipulator's working range

WARNING!

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

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

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

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

• Test the motor brake on each axis, according to section

Brake testing on page 24 .


1 Safety

1.2.3.8. Translate the information on safety and information labels

1.2.3.8. Translate the information on safety and information labels

Labels on the product

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

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

•

Inspection of information labels on page 78

Translation possibilities

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

Add a local language to the label by:

• using a transparent sticker over the standard label with text added in a fourth language.

Drawings detailing the design (text, figure, dimensions) of the standard labels can be ordered from ABB. Notice that each label is identified according to the article number located in the lower corner of the label.

Example of transparent sticker

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

28 xx0500002517

A Free space for adding a fourth language


1 Safety

1.3.1. Safety signals, general

1.3 Safety related instructions

1.3.1. Safety signals, general

General

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

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

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

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

Danger levels

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

Symbol danger warning

Designation

DANGER

WARNING

ELECTRICAL

SHOCK

Signification

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

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

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

Electrical shock

CAUTION caution

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



29

1 Safety

1.3.1. Safety signals, general

Continued

Symbol Designation Signification

ELECTROSTATIC

DISCHARGE (ESD)

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

Electrostatic discharge

(ESD)

NOTE Note symbols alert you to important facts and conditions.

Note

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

Tip


1 Safety

1.3.2. DANGER - Moving manipulators are potentially lethal!

1.3.2. DANGER - Moving manipulators are potentially lethal!

Description

Any moving manipulator is a potentially lethal machine.

When running the manipulator, it may perform unexpected and sometimes irrational movements. However, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the manipulator working range.

Elimination

Action Note/Illustration

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

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

2. If possible, use the hold-to-run button whenever possible.

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

How to use the hold-to-run control in

RobotWare 5.0 is detailed in section How to use the hold-to-run function in the

Operating manual - IRC5 with Flex-

Pendant.

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


1 Safety

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

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

Description

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

Elimination

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

Action

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

2. Install all safety equipment properly!

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

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


1 Safety

1.3.4. WARNING - The unit is sensitive to ESD!

1.3.4. WARNING - The unit is sensitive to ESD!

Description

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

Elimination

Action Note

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

2. Use an ESD protective floor mat.

The mat must be grounded through a currentlimiting resistor.

3. Use a dissipative table mat.

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


1 Safety

1.3.5. WARNING - Safety risks during work with gearbox oil

1.3.5. WARNING - Safety risks during work with gearbox oil

Description

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

Warnings and elimination

Warning Description Elimination / Action

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

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

-

Hot oil!

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

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

-

Possible pressure build up in gearbox!

-

Do not overfill!

-

Do not mix types of oil!

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

• damage seals and gaskets

• completely press out seals and gaskets

• prevent the manipulator from moving freely.

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

After filling, check the correct oil level.

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

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

Always use the type of oil specified by the manufacturer!

Warm oil drains quicker than cold oil.

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

-

Heat up the oil!

34



1 Safety


Continued

Warning

-

Specified amount depends on drained volume!

Description Elimination / Action

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

After refilling, check the oil level.


1 Safety



2 Installation and commissioning

2.1. Introduction



General

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

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



2.2.1. Pre-installation procedure

2.2 Unpacking

2.2.1. Pre-installation procedure

General

Checking the pre-requisites for installation

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

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

2. Make sure the robot is not damaged, by visually inspecting it.

3. Make sure the lifting device to be used is fit to handle the weight of the robot as specified

in Weight, robot on page 38

.

4. If the robot is not to be installed directly, it must be stored according to the specifications

in Storage conditions on page 39

.

5. Make sure the appointed operating environment of the robot conforms to the

specifications outlined in Operating conditions on page 39 .

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

Loads on foundation on page 38 ,

Requirements on foundation on page 39 and Protection classes on page 39 .

7. When these prerequisites are met, the robot may be taken to its installation site as

described in Lifting of robot on page 42 .

Weight, robot

These instructions are to be used when unpacking and installing the robot for the first time.

They also contain information useful later during re-installation of the robot.

Robot model

IRB 260

Weight

340 kg

Loads on foundation

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

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

IRB 260

Forces and torques

Force xy

Force z

Torque Mxy

Torque Mz

Endurance load

(operation)

± 1400 N

+ 3500 N ± 1100 N

± 2100 Nm

± 700 Nm

Max. load (emergency stop)

± 2900 N

+ 3500 N ± 2300 N

± 3900 Nm

± 950 Nm

38




2.2.1. Pre-installation procedure

Continued

Requirements on foundation

The table below shows the requirements of the foundation where the robot is to be fitted:

Requirement Value

Min. levelity

Max. tilt

Min. resonance frequency

0.5 mm

5°

30 Hz

Storage conditions

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

Parameter Value

Min. ambient temperature, storage

Max. ambient temperature, storage

-25° C

+55° C

Max. ambient temperature, storage (less than 24 hrs) +70° C

Max. ambient humidity, storage Max. 95% at constant temperature

Operating conditions

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

Parameter Value

Min. ambient temperature

Max. ambient temperature

Max. ambient humidity

+5° C

+45° C

Max. 95% at constant temperature

Protection classes

The table below shows the protection class of the main parts of the robot system:

Equipment Protection class

Robot IRB 260 IP 67



2.2.2. Working range

2.2.2. Working range

Working range

This section specifies the working areas of the robot models.

IRB 260

The extreme positions of the robot are specified at the tool flange center (dimensions in mm).

xx0500001926

A

B

C

Position at mechanical stop

Position at maximum working range, axis 2

Tool flange center

Positions in the working range

The table below specifies the positions inside the working range, shown in the figure above.

Position in figure Position (mm) Angles (º)

40

3

4

1

2

5

X

870

510

446

515

607

Z

1139

1246

722

218

-73

Axis 2

0

-28

-28

60

85

Axis 3

0

-17

31

119

119



Type of motion

6

7

Position in figure Position (mm)

X

1506

1313

Z

210

1148


2.2.2. Working range

Continued

Angles (º)

Axis 2

85

42

Axis 3

26

-17

Type of motion

Rotation motion

Arm motion

Arm motion

Turn motion



2.3.1. Lifting of robot

2.3 On-site installation

2.3.1. Lifting of robot

Methods for lifting

Required equipment

The robot can be lifted with:

• lifting slings, or

• lifting chains.

Equipment

Overhead crane

Lifting slings

Lifting chains, 3 pcs

Specification

Lifting capacity: 500 kg.

-

Lengths:

• axis 2: 950 mm

• axis 3: 920 mm

• upper arm: 680 mm

Liftings slings - attachment and axis position

The lifting slings are attached to the robot as shown in the figure below. The axis positions are specified below the figure.

42 xx0500002140

Axis 2 position:

Axis 3 position:

-10º

+35º





Continued

Lifting chains - attachment and axis position

The lifting chains are attached to the robot as shown in the figure below. The axis positions are specified below the figure.

xx0500002141

A

B

Axis 2 position:

Axis 3 position:

C

-28º

+17º

Lifting chain, axis 2

Lifting chain, axis 3

Lifting chain, upper arm



43



Continued

Lifting of robot

The procedure below details how to lift the complete robot.

Action Note

1. Move the robot to the correct lifting position.

If necessary, release the brakes of affected axis, according to section

Manually releasing the brakes on page 45 .

Depending on the method of lifting, the correct axis positions are shown in:

•

Liftings slings - attachment and axis position on page 42

•

Lifting chains - attachment and axis position on page 43 .

2.

CAUTION!

The robot weighs 340 kg! All lifting equipment used must be sized accordingly!

3. Attach the lifting equipment to the robot as shown in the previous figures and lift the robot.



2.3.2. Manually releasing the brakes

2.3.2. Manually releasing the brakes

General

The holding brakes of each axis’ motor are of an electromechanical type and are released when voltage is applied. This section details how to release the brakes, using the internal brake release unit, in order to enable the axes to move manually.

The brake of each motor can also be released by connecting an external voltage supply directly on the motor connector, see the circuit diagram or the repair procedures for each motor (section

Motors on page 151 ).

Releasing the brakes using the brake release unit

The procedure below details how to release the holding brakes using the internal brake release unit.


1.

Action

-

Danger!

When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways! Make sure no personnel is near the robot arm!

2. If the robot is not connected to the controller, power must be supplied to the connector

R1.MP.

3. The internal brake release unit is located at the base of the robot and equipped with buttons for controlling the holding brakes for each axis separately. The buttons are numbered according to the numbers of the axes.

To release the brake on a particular robot axis, push the corresponding button on the internal brake release panel and keep it depressed.

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

Detailed in section

Supplying power to connector R1.MP on page 46

.

xx0500001930



45


2.3.2. Manually releasing the brakes

Continued

Supplying power to connector R1.MP

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


1.

Action

-

Caution!

Be careful not to interchange the 24 VDC and 0V pins! If they are mixed up, damage can be caused to a resistor diode and to the system board.

2. Connect an external power supply to connector

R1.MP, at the robot base.

Supply:

• +24 V on pin B8

• 0 V on pin C10

3. Release the brakes with the brake release unit as detailed in the previous procedure. xx0200000167



2.3.3. Orienting and securing the robot

2.3.3. Orienting and securing the robot

General

This section details how to orient and secure the robot to the foundation in order to safely run the robot. The requirements for the foundations are shown in the tables and figures below.

Bolting requirements

When bolting a base plate or the base to a concrete floor, follow the general instructions for expansion-shell bolts. The screw joint must be able to withstand the stress loads defined in section

Loads on foundation on page 38 .

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:

M16 x 50

Quality 8.8

Thickness: 3 mm

Outer diameter: 30 mm

Inner diameter: 17 mm

190 Nm

Hole configuration

The figure below shows the hole configuration of the robot base, used when securing the robot. Cross section is shown in the following figure.

xx0200000181



47


2.3.3. Orienting and securing the robot

Continued

Cross section, guide sleeve hole

The figure below shows the cross section of the guide sleeve holes (from previous figure):

Guide sleeves xx0200000182

Two guide sleeves can be fitted to the two rear bolt holes to allow the same robot to be remounted without re-adjusting the program.

Equipment

Guide sleeves

Art. no.

2151 0024-169



2.3.4. Fitting equipment on the robot and robot dimensions

2.3.4. Fitting equipment on the robot and robot dimensions

General

This section shows the dimensions and available mounting holes on the robot.

Main dimensions xx0500001928

A

B

C

At maximum working range axis 3

Mounting hole for safety lamp

Mounting hole for external air hose



49



Continued

Fitting equipment on the robot

50 xx0500002102

C

D

A

B

M8 (3x) Depth 16 mm, R=77

M8 (3x) Depth 16 mm, R=92

Max. 35 kg total

The rear side of the robot



Turning radius, axis 2



Continued xx0500001929



51



Continued

Turning disk, dimensions

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

52 xx0500001932



2.3.5. Loads

2.3.5. Loads

General

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

CAUTION!

Incorrect defined loads may result in operational stops or major damage in bearings.

References

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

Product Specification . The loads must also be defined in the software as detailed in User's

Guide (RobotWare 4.0), or Operating manual (RobotWare 5.0).

Stop time and braking distances

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



2.3.6. Load diagram

2.3.6. Load diagram

Load diagram, IRB 260-30/1.5

The figure below shows the maximum permitted load mounted on the robot tool flange at different positions (center of gravity).

54 xx0500002100



2.3.7. Installation of signal lamp (option)

2.3.7. Installation of signal lamp (option)

General

As an option, a signal lamp can be installed on the robot. The lamp is activated when the controller is in the MOTORS ON state.

Signal lamp on robot

The signal lamp is installed on the upper arm, as shown in the figure below.

xx0500002125

F

G

D

E

A

B

C

Indicator lamp

Lamp holder

O-ring

Cable gland

Bracket

Attachment screws, 2 pcs

Cabling for the signal lamp (included in the robot cabling for axis 6)



55


2.3.7. Installation of signal lamp (option)

Continued


Equipment

Signal lamp

Standard toolkit -

Spare part no.

3HAC025254-001

Note

Includes all components shown in the previous figure.

The contents are defined in section Standard toolkit on page 190 , in part 2 of the Product

manual.

Installation, signal lamp

The procedure below details how to install the signal lamp on the robot.

Note

1.

Action

-

Danger!

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

2. Connect the two cables to the signal lamp. Run the cables from inside the upper

arm, as shown in the figure Signal lamp on robot on page 55

.

Connectors R3.H1 and R3.H2.

3. Fit the signal lamp to the upper arm by securing the bracket with two attachment screws.

2 pcs; M6x16.

Shown in the figure Signal lamp on robot on page 55

.

4. Make sure that the lamp is lit when the controller is in MOTORS ON mode.



2.4.1. Introduction

2.4 Restricting the working range

2.4.1. Introduction

General

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

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

The working range of the following axes may be restricted:

• Axis 1, hardware (mechanical stop and position switch)

• Axis 2, hardware (mechanical stop). Note! The axis 2 stop is a fixed stop that must be installed during operation of robot!

• Axis 3, hardware (mechanical stop). Note! The axis 3 stop is a fixed stop that must be installed during operation of robot!

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

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



2.4.2. Mechanically restricting the working range of axis 1

2.4.2. Mechanically restricting the working range of axis 1

Restrictions in the working range

The working range of axis 1 can be restricted within the area from 50º to 140º as shown in the figure below. The restrictions are made by fitting two extra stops to the robot base.

xx0500002105

Location of the mechanical stop, axis 1

The extra mechanical stop is fitted to the robot base as shown in the figure below.

Note! The stop must only be mounted in the direction shown below!

58 xx0200000205

1

2

3

Stop, axis 1, removable

Plain washer

Hex socket head cap screw





Continued


Equipment Art. no.

Note

Stop, axis 1

Technical reference manual - System parameters (RobotWare 5.0)

-

3HAB 7298-1 Includes:

• removable stop (2 pcs)

• plain washers (4 pcs)

• hex socket head cap screw (4 pcs, M12x30)

• drill template (1 pc)

Art. no. is specified in section

References on page 8

.

Fitting, mechanical stop axis 1

The procedure below details how to fit a mechanical stop to the robot base.

Action Note

1. Decide where to fit the extra mechanical stops, according to the figure

Location of where to drill holes for extra stops on page 60

.

2. Make a copy of the drill template, enclosed with the mechanical stop.

The template is also shown in the

figure Drill template on page 62

in scale 1:1.

3. Use the template to mark the center of the two holes on each stop.

Place the template edge edge with the robot base, as shown in the figure

Location of where to drill holes for extra stops on page 60 .

4. Drill the holes through, Ø 10.2. Cut threads,

M12.

5. Fit the stops to the robot base, but without tightening the screws.

Note! The stops must be mounted in correct direction, as shown in the

figure Location of where to drill holes for extra stops on page 60

.

If necessary; correct the angle of impact.

6. Turn axis 1 manually and check the working range between the stops.

7. Tighten the screws.

8. The software working range limitations must be re-defined to correspond to the changes in the mechanical limitations of the working range.

How to define the range of movement in RobotWare 5.0 is detailed in the

Technical reference manual - System parameters- chapter Motion .

9.

-

Warning!

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



59



Continued

Location of where to drill holes for extra stops

The figure below shows the drill pattern used when drilling for mechanical stops on axis 1.

60 xx0200000206

A

B

C

D

*

Maximum working range, axis 1

Minimum working range, axis 1

Drilling pattern enclosed with the mechanical stop.

This mounting direction only

The minimum and maximum measurement between the mechanical stops. The difference between the measurement and the minimum and maximum working range is 2 x 4º, which corresponds to the width of the stop pin (at the frame).





Continued

Hidden stiffening ribs and forbidden drilling sector xx0600002647

C

D

Drilling not allowed inside this sector!

Center lines for the hidden stiffening ribs



61



Continued

Drill template

62 xx0200000207



2.4.3. Installation of position switch, axis 1

2.4.3. Installation of position switch, axis 1

General

This section details how to install the position switch to axis 1.

Location of position switch, axis 1

The position switch is installed between the frame and the base, as shown in the figure below.

xx0600002676

E

F

G

C

D

A

B

Position switch

Attachment screws, position switch (2 pcs for each switch) M4 x 16

Holder ring

Attachment screws, holder ring, 6 pcs: M8 x 12

Cam

Attachment screws, cam, (8 pcs for each cam) M6 x 12

Attachment plate



63



Continued

K

L

I

H

M

N

O

P

Attachment screws, attachment plate (2 pcs) M6 x 16

Shims

Bracket

Attachment screws, bracket (2 pcs) M6 x 30

Mechanical stop

Cable straps

Attachment screw, clamp

Clamp


All parts are included in the delivery of the kits specified below. An instruction of how to cut the cams is also enclosed in the kit.

Equipment

Position switch axis 1



Art. no.

3HAC12062-1

3HAC12062-2

3HAC12062-3

Note

Includes one switch.

Includes two switches.

Includes three switches.

Installation, position switch axis 1

The procedure below details how to install the position switch to the robot.

Note

1.

Action

64

-

Danger!


2. Fit the two holder rings underneath the frame with the six attachment screws.

Shown in the figure Location of position switch, axis 1 on page 63

.

6 pcs, M8 x 12.

3. Cut the cams according to instructions, enclosed with the position switch kit.

4. Fit the cams to the holder ring with the attachment screws.


.

M6 x 12.

5. Fit the complete bracket to the base of the robot with the two attachment screws.


.

6. Fit the attachment plate to the base of the robot with the two attachment screws.

Fit the switches to the attachment plate.

Adjust the height of the switches with

shims until each roller aligns with corresponding cam.

Note! Make sure the cabling has clearance to the mechanical stop at the base!

2 pcs, M6 x 16.


.



Action

7. Secure the cabling with straps and

clamps.

8. Connect the position switch cabling.



Continued

Note

Shown in the figure

Location of position switch, axis 1 on page 63 .

The cabling and connection points are

specified in section Position switch cables, robot base to control cabinet (option) on page 73

.





General

The stops are installed as standard, not movable and must always be installed during operation of the robot!

Restrictions in working range

The mechanical stops are not movable or optional! They function as solid stops and must be installed during robot operation. The working range of axis 2 cannot be restricted further.

Location of mechanical stops xx0500002036

A

B

C

Mechanical stop (spacer), long

Mechanical stop (spacer), short

Fixed stops



Note

Spacer, axis 2 3HAC025740-001 Long.

Spacer, axis 2


-

3HAC025741-001 Short.


References on page 8 .

Standard toolkit The contents are defined in section

Standard toolkit on page 190 , in part 2 of the

Product manual.

66





Continued

Installation, mechanical stops axis 2

The procedure below details how to fit the mechanical stops to the axis 2.

Action Note

1. Move the robot to its calibration position. Shown in section Calibration scales and correct axis position on page 178

.

2.

3.

-

Danger!


-

Danger!

The two mechanical stops must be installed correctly on axis 2! The robot may never be run without the stops fitted!

4. Fit the two spacers directly next to the fixed stops of axis 2, with attachment screws.

2 + 4 pcs: M8x25. Tightening torque: 17 Nm.

5. Fit the dampers to the mechanical stops.

xx0500002037

• A: Attachment holes for the short stop (spacer)

• B: Attachment holes for the long stop

(spacer)



67



Continued

Action Note


7.

How to define the range of movement in

RobotWare 5.0 is detailed in the Technical reference manual - System parameters- chapter Motion .

-

Warning!






General

The stop of axis 3 is installed as standard, not movable and must always be installed during operation of robot!

Restrictions in working range

The mechanical stop is not movable or optional! It functions as a solid stop and must be installed during robot operation. The working range of axis 3 cannot be restricted further.

Location of mechanical stop

The figure below shows the location of the mechanical stop on axis 3.

xx0500002039

A Mechanical stop, axis 3



Mechanical stop, axis 3

Locking liquid


-

Standard toolkit -

-

3HAC024253-001

Note

Loctite 243



.

The contents are defined in section

Standard toolkit on page 190 , in part 2 of the

Product manual.



69



Continued

Installation, mechanical stop

The procedure below details how to fit the mechanical stop to the robot.

Note

1.

Action

-

Danger!


2. Fit the mechanical stop to the parallel bar with the three attachment screws. Use locking liquid.


How to define the range of movement in

RobotWare 5.0 is detailed in the

Technical reference manual - System parameters- chapter Motion .

4.

Shown in the figure

Location of mechanical stop on page 69

.

3 pcs; M6x16. Tightening torque: 11 Nm.

Locking liquid is specified in

Required equipment on page 69 .

-

Warning!




2.5.1. Connectors on robot

2.5 Electrical connections

2.5.1. Connectors on robot

Connectors on the robot

The figure below shows all connections of the robot cabling, including the customer connections.

xx0500002434



2.5.2. Robot cabling and connection points

2.5.2. Robot cabling and connection points

General

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

Main cable categories

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

Cable category Description

Robot cables

Position switch cables

(option)

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

Specified in the table Robot cables on page 72

.

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

Specified in the table Position switch cables, robot base to control cabinet (option) on page 73

.

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

See the product manual for the controller 1) .

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

See the product manual for external axes

1)

.

1) Art. no. is specified in section


.

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

Robot cables

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

Cable sub-category Description

Robot cable, power

Robot cable, signals

Connection point, cabinet

Connection point, robot

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

XS1

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

XS2 R1.SMB

Robot cable, power

Cable

Robot cable, power, 7 m




Art. no.

3HAC 9038-1

3HAC 9038-2

3HAC 9038-3

3HAC 9038-4

72





Continued

Robot cable, signals

Cable

Robot cable, signal, shielded, 7 m




Art. no.

3HAC 7998-1

3HAC 7998-2

3HAC 7998-3

3HAC 7998-4

Position switch cables, robot base to control cabinet (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 between robot base and control cabinet

Cable

Position switch cable, axis 1, 7 m




Art. no.

3HAC 7997-1

3HAC 7997-2

3HAC 7997-3

3HAC 7997-4


R1.SW

R1.SW

R1.SW

R1.SW

Connection point, cabinet

XS8

XS8

XS8

XS8

Customer cables (option)

The customer cables specified below are connected between robot and controller.

Customer cables

Cable

Customer cable, power-signal, 7 m




Art. no.

3HAC 8183-1

3HAC 8183-2

3HAC 8183-3

3HAC 8183-4


R1.CP/CS

R1.CP/CS

R1.CP/CS

R1.CP/CS





3 Maintenance

3.1. Introduction

3 Maintenance


Structure of this chapter

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

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

Each procedure contains all information required to perform the activity, e.g. required tools and materials.

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


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

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

Safety on page 13 before performing any service work.


3 Maintenance

3.2.1. Specification of maintenance intervals

3.2 Maintenace schedule

3.2.1. Specification of maintenance intervals

Description

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

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

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


3 Maintenance

3.2.2. Maintenance schedule

3.2.2. Maintenance schedule

General

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

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

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

Activities and intervals, standard equipment

The table below specifies the required maintenance activities and intervals and also refers to the section where performing the activity is detailed.

Maintenance activity Interval Note Detailed in section:

Oil change in gearboxes, axes 1,2, 3

Oil change in wrist unit -

40,000 h

Replacement of back-up battery for SMB unit

Inspection of all signal cabling in lower and upper arm

Replacement of mechanical stop axis 1

12-36 mths 1

36 mths

60 mths

Lubricated for life.

Maintenance free units.

No preventive maintenance in terms of changing the gear oil is needed when gearbox is lubricated with Shell Tivela S 150.

Oil change, gearbox axis 6 (wrist unit) on page 81

.

Replacement of SMB battery on page 83 .

Replace if required.

Replace if bent.

1. The battery is used as a back-up when the robot system is switched off. Therefore, the life of a lithium battery depends on how frequently the power to the system is switched off and also if the environment temperature is higher than recommended operating temperature. The life varies from 12 - 36 mths, depending on current conditions. An alert is given on the TPU or the FlexPendant when the battery is nearly discharged and it must then be replaced within a month.


3 Maintenance

3.3.1. Inspection of information labels

3.3 Inspection activities

3.3.1. Inspection of information labels

Location of labels

The labels are located on the robot as shown in the figure below.

List of labels

78 xx0600002622

F

G

H

D

E

A, B

C

Instruction plate. Specified further in the following table.

Rating label (silver coloured)

Calibration label. Specified further in the following table.

Label with maximum air pressure.

Warning sign. Specified further in the following table.

UL label

Instruction plate. Specified further in the following table.

Equipment

Instruction plate

Instruction plate

Calibration label

Instruction plate

Warning sign

Spare part no.

3HAC2814-2

2945 4489-16

3HAC024307-001

3HAC025469-001

3HAC1589-1

Note

Item A in the figure.

Warning of brake release.

Item B in the figure.

Item D in the figure.

Item H in the figure.

Lifting of robot.

Item F in the figure.

Lightning flash.



3 Maintenance

3.3.1. Inspection of information labels

Continued

Inspection, labels

1.

Action Note

-

Danger!


2. Inspect that all labels are fitted to the robot. Replace them if damaged or missing.

Shown in the figure Location of labels on page 78 .


3 Maintenance

3.4.1. Oil in gearboxes

3.4 Changing activites

3.4.1. Oil in gearboxes

Location of gearboxes

The figure below shows the location of all the gearboxes.

xx0500001950

A

B

C

D

Gearbox, axis 1

Gearbox, axis 2

Gearbox, axis 3

Gearbox, axis 6

Type and amount of oil in the gearboxes

Gearbox

Axis 1

Axis 2

Axis 3

Axis 6

Type of oil Art. no.

Mobilgear 600 XP320 11712016-604

Mobilgear 600 XP320 11712016-604

Mobilgear 600 XP320 11712016-604

Shell Tivela S 150 3HAC 021469-001

Amount

6,400 ml

4,500 ml

3,800 ml

70 ml


3 Maintenance

3.4.2. Oil change, gearbox axis 6 (wrist unit)

3.4.2. Oil change, gearbox axis 6 (wrist unit)

Location of oil plugs, gearbox

The gearbox is located in the frontmost part of the upper arm. Oil plugs are located as shown in the figure below.

xx0500001949

A

B

Oil plug, draining

Oil plug, filling



Volume Note

Lubricating oil

Oil collecting vessel -

Standard toolkit -

3HAC 021469-001 70 ml Shell Tivela S 150

Capacity: 150 ml.


Standard toolkit on page 190

, in part 2 of the Product manual.

Draining oil, gearbox axis 6

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

Note

1.

Action

-

Danger!




81

3 Maintenance

3.4.2. Oil change, gearbox axis 6 (wrist unit)

Continued

2.

Action Note

-

Warning!

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

WARNING - Safety risks during work with gearbox oil on page 34

.

3. Place the oil collecting vessel underneath the gearbox of axis 6.

4. Remove the both oil plugs to drain the gearbox.

Shown in the figure Location of oil plugs, gearbox on page 81 .

5. Refit the oil plug, draining.

Filling oil, gearbox axis 6

The procedure below details how to refill the gearbox, axis 6, with lubricating oil.

Note

1.

Action

2.

-

Danger!


-

Warning!

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

WARNING -

Safety risks during work with gearbox oil on page 34 .

3. Fill lubricating oil to the wrist unit until the oil reaches to the hole for the oil plug, filling.

Art. no. and volume are specified in

Required equipment on page 81

.

Oil plugs are shown in the figure Location of oil plugs, gearbox on page 81 .

4. Refit the oil plug.


3 Maintenance

3.4.3. Replacement of SMB battery

3.4.3. Replacement of SMB battery

Location of SMB battery

The SMB battery is located inside the robot base, as shown in the figure below. xx0300000067

A

B

SMB battery

SMB battery cable


Equipment

Battery pack

Gasket, cover

Standard toolkit

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

Spare part no.

3HAC16831-1

3HAC3200-1

Note

Lithium battery.

Always replace with a new one!


Standard toolkit on page 190 , in part

2 of the Product manual.

These procedures include references to the tools required.



83

3 Maintenance

3.4.3. Replacement of SMB battery

Continued

Replacement, SMB battery

The procedure below details how to replace the SMB battery.

Note

1.

Action

2.

-

Danger!


Warning!

WARNING!

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

WARNING - The unit is sensitive to

ESD! on page 33

3. Remove the rear cover plate (A) on the robot by unscrewing its attachment screws (B).

4. Remove the battery terminals from the serial measuring board and cut the clasp that keeps the battery unit in place.

5. Fit the new battery with a clasp and connect the terminals to the serial measuring board.

xx0200000399

Shown in the figure Location of SMB battery on page 83

.

6. Refit the cover to the robot base, together with a new gasket.

Always replace a removed gasket with a new!

Spare part no. is specified in Required equipment on page 83

.

7. Update the revolution counters!

Detailed in section Updating revolution counters on page 180 .


4 Repair

4.1. Introduction

4 Repair


Structure of this chapter

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

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

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


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

The equipment is also gathered in different lists in the Product manual, reference information .


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

There are general safety aspects that must be read through, as well as more specific safety information that describe danger and safety risks when performing specific steps in a procedure. Make sure to read through the chapter

Safety on page 13 before commencing any

service work.


4 Repair

4.2.1. Performing a leak-down test

4.2 General procedures

4.2.1. Performing a leak-down test

General

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


Equipment, etc.

Leakdown tester

Leak detection spray

Art. no.

3HAC 0207-1

-

Note

Procedure

Action Note

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

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

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

Art. no. is specified above!

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

Recommended value:

0.2 - 0.25 bar (20 - 25 kPa)

4. Disconnect the compressed air supply.

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

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

6. Was any pressure drop evident?

Localize the leak as detailed below.

Remove the leakdown tester, and refit the oil plug.

The test is complete.

7. Spray suspected leak areas with leak detection spray.

Bubbles indicate a leak.

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


4 Repair

4.2.2. Mounting instructions for bearings

4.2.2. Mounting instructions for bearings

General

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

Equipment

Equipment, etc.

Grease

Art. no.

3HAB 3537-1

Note

Used to grease the bearings, if not specified otherwise.

Assembly of all bearings

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

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

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

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

Assembly of tapered bearings

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

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

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

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 lifespan of the bearing.

Greasing of bearings

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

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

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

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

Grease the different types of bearings as detailed below:

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

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


4 Repair

4.2.3. Mounting instructions for seals

4.2.3. Mounting instructions for seals

General

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

Equipment

Equipment, etc.

Grease

Art. no.

3HAB 3537-1

Note

Used to lubricate the seals.

Rotating seals

The procedure below details how to fit rotating seals.

CAUTION!

Please observe the following before commencing any assembly of seals:

• Protect the sealing surfaces during transport and mounting.

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

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

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

Action Note

1. Check the seal to ensure that:

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

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

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

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

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

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

Art. no. is specified in

Equipment on page 88

.

4. Mount the seal correctly with a mounting tool.

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

Flange seals and static seals

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

88

Action

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

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

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



O-rings

4 Repair

4.2.3. Mounting instructions for seals

Continued

Action

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

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

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

The procedure below details how to fit o-rings.

Action Note

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

2. Check the o-ring for surface defects, burrs, shape accuracy, etc. Defective o-rings may not be used.

3. Check the o-ring grooves.

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

Defective o-rings may not be used.

4. Lubricate the o-ring with grease.

5. Tighten the screws evenly when assembling.


4 Repair

4.3.1. Replacement of cable unit, axes 1-3

4.3 Complete robot

4.3.1. Replacement of cable unit, axes 1-3

Location of cabling

The cable unit of axes 1-3 is run from the base of the robot to the motors, axes 1, 2 and 3, as shown in the figure below.

A more detailed view of the component and its position may be found in section

Axes 1-3, spare part view 3 on page 213 .

xx0200000396

A Connectors behind the cover plate at the robot base; R1.MP1-3 and R2.BU1-3. At the serial measurement board; R2.G (battery), R2.FB1-3.

B Connectors at motor 2; R3.MP2 and R3.FB2

C Connectors at motor 3; R3.MP3, R3.FB3,R3.LS1 and R3.LS2

D Connectors at motor 1; R3.MP1, R3.FB1

E

F

Upper bracket

Cable guide in the middle of the frame


Equipment, etc.

Cable unit, axes 1-3

90

Sealing

Spare part no. Art. no.

3HAC025725-001

3HAC4113-1

Note

Includes:

• cabling

• motor covers

• attachment screws

• gaskets, motor 1-3

Sealing in the base for the cables. Always use a new sealing.



4 Repair


Continued

Equipment, etc.

Gasket, cover

Cable straps, outdoor

Flange sealing

Circuit diagram

Standard toolkit

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


3HAC3200-1

Note

2166 2055-3

1234 0011-116 Loctite 574

See chapter Circuit diagram in the Product manual, reference information .



, in part 2 of the

Product manual.


Removal, cable unit, axes 1-3

The procedure below details how to remove the cabling of axes 1-3.

Action

1. In order to facilitate refitting of the cable harness, move the robot to the specified position:

• Axis 1: 0°

• Axis 2: 0°

• Axis 3: 0°

• Axis 6: no significance

2.


Axes 2 and 3 may be tilted slightly to improve access.

-

Danger!


3. Remove the rear cover plate (A) on the robot by unscrewing its attachment screws

(B).

4. Disconnect the connectors R1.MP1-3 and

R2.BU1-3 inside the base.

5. Disconnect all the earth cables on the

R1.M1-3 cable from the back of the cover.

xx0200000399



91

4 Repair


Continued

Action

6. Loosen the nuts (D) and remove the SMB unit carefully from the bracket.

The cable (A) between the battery (B) and the SMB unit (C) may stay connected, in order to avoid recalibration of the robot. Be careful not to let the weight of the SMB unit strain the cable!

In order to remove the SMB unit completely, the connector R2.G must be disconnected! This causes a necessary recalibration of the robot!


7. Disconnect the connector R2.FB 1-3 from the connection R2.SMB1-4 (C) on the SMB unit.

xx0200000398

92

8. Unscrew the four screws securing the cable gland.

9. Remove the cable guide in the middle of the frame by removing the attachment screws of the holder (A).

Remove the cables from the guide. xx0200000400

A. R2.SMB

B. R2.SMB3-6

C. R2.SMB1-4

This releases the cable harness from the frame.

xx0200000404

Note! Different robot versions are fitted with different versions of the holder. Make sure the correct one is used to avoid cable failure.

10. Remove the upper bracket securing the cables to the arm house by unscrewing its two attachment screws.

Note! Do not remove or loosen any of the cable brackets from the new harness, the angle of the brackets is factory optimized.

11. Remove the cover of the motors 1-3.



4 Repair


Continued

Action

12. Disconnect all the connectors at the motors of axes 1, 2 and 3.


13. Remove the three screws of the connection box for the motors of axes 1, 2 and 3.

14. Gently pull the cable harness out. xx0200000401

A. R3.MP1-3

B. R3.FB1-3

C. Connection box

Refitting, cable unit, axes 1-3

The procedure below details how to refit the cabling of axes 1-3 to the robot.


1.

Action

-

Danger!


2. Gently pull down the cable harness through the center hole of axis 1.

3. Fit a new gasket and fit the connection box on motor 1, 2 and 3, using the three attachment screws.

The gasket is included in the spare part of the cable unit, spare part no. is

specified in Required equipment on page 90 .

4. Reconnect all the connectors at motors 1, 2 and 3.

5. Refit the cover of the motors, axes 1, 2 and 3, with the five attachment screws.

xx0200000401

A. R3.MP1-3

B. R3.FB1-3

C. Connection box



93

4 Repair


Continued

Action

6. Refit the upper bracket securing the cables to the arm house, using the two attachment screws.

7. Fit the cable guide to the harness and secure the holder to the frame with its two attachment screws (A).


8. Secure the cabling inside the base.

Insert the cables in the sealing:

A. Power cable

B. Power cable

C. Power cable

D. Customer cable

E. Signal cable

F. Signal cable

Note! Make sure that each cable is fitted in the same position as the old one, otherwise the conduit entry will not be watertight. Use six cable straps.

Note! Always use a new sealing, combined with a flange sealing (Loctite 574).

xx0200000404

Note! Different robot versions are fitted with different versions of the holder.

Make sure the correct one is used to avoid cable failure.

9. Connect the connectors R2.FB 1-3 to the connection R2.SMB1-4 (C) on the SMB unit.

xx0200000402

Art. numbers are specified in Required equipment on page 90 .

94 xx0200000400

A. R2.SMB

B. R2.SMB3-6

C. R2.SMB1-4



4 Repair


Continued

Action

10. Refit the SMB unit to the bracket with the nuts

(D). Be careful not to let the weight of the

SMB-unit strain the cable! (A).


11. Connect all the earth cables on the R1.M1-3 cable to the back of the cover.

xx0200000398

Note! The cable (A) between the battery

(B) and the SMB-unit (C) may stay connected, in order to avoid recalibration of the robot.

12. Connect the connectors R1.MP1-3 and

R2.BU1-3 inside the base.

13. Refit the rear cover plate (A) on the robot with its attachment screws (B), together with a new gasket. xx0200000403 xx0200000399


.

14. If the battery has been disconnected from the

SMB unit, the revolution counters must be updated!

Detailed in section

Updating revolution counters on page 180

.

15.

-

Danger!

Make sure all safety requirements are met when performing the first test run. These are

further detailed in section DANGER - First test run may cause injury or damage! on page 32 .


4 Repair

4.3.2. Replacement of cable unit, axis 6

4.3.2. Replacement of cable unit, axis 6

Location of cable unit, axis 6

The cabling of axis 6 is run throughout the robot, from the base to the wrist unit. Besides the power and signal cable, the cable unit also includes a customer cable, an UL lamp cable and an air hose.

96 xx0500002540

A Cable bracket inside the base

B Cable attachment inside the frame (view from above)

C Cable bracket inside the lower arm (view from above)

D Cable bracket inside the upper arm

E Cable guide in the middle of the frame (view from above)

F Connectors at the base: Power cable: R1.MP4-6, signal cable: R2.FB4-6, brake release:

R2.BU4-6, UL-lamp: R1.H1, Customer cable: R1.CP and R1.CS, air hose: R1.CAIR

G Connector at motor axis 6: R3.FB6 (signal)

H Connector at motor axis 6: R3.MP6 (power)

K Connector at UL lamp: R3.H1 and R3.H2.

L Customer connectors / air hose are located on the opposite side of the wrist unit: R2.CS,

R2.CP and R2.CAIR

1 Power cable

2 Signal cable

3 Customer cable

4 Air hose



4 Repair


Continued


Equipment

Cable unit axis 6

Standard toolkit

Circuit diagram -

Spare part no.

-

3HAC024115-001

Note

The contents are defined in section Standard toolkit on page 190



Removal, cable unit axis 6

The procedure below details how to remove the cable unit of axis 6 from the robot.

Action

1. In order to facilitate removal of the cable unit, move the robot to positions:

• Axis 1: 0º

• Axis 2: 45º

• Axis 3 (upper arm): horizontal

• Axis 6: no significance

2.


-

Danger!


3. Remove the rear cover plate (A) from the base of the robot by unscrewing the attachment screws (B).

xx0200000399

4. Disconnect the connectors R1.MP4-6 and

R2.BU4-6 from the base. Also disconnect the customer cables and the air hose.

Specified in the figure

Location of cable unit, axis 6 on page 96

.

5. Disconnect all earth cables.



97

4 Repair


Continued

Action

6. Loosen the nuts (D) and remove the SMBunit from the bracket carefully.

Leaving the cable (A) between the battery

(B) and the SMB-unit (C) connected avoids recalibration of the robot. But be careful not to let the weight of the SMB-unit strain the cable!

In order to remove the SMB-unit completely, the connector R2.G must be disconnected, which causes a necessary recalibration of the robot!


7. Disconnect the connector R2.FB4-6 from the SMB-unit, connector R2.SMB3-6 (B).

xx0200000398

98 xx0200000400

A. R2.SMB

B. R2.SMB3-6

C. R2.SMB1-4

Shown in the figure Location of cable unit, axis 6 on page 96 .

8. Loosen the cable brackets by removing their attachment screws:

• inside the base

• inside the frame

• inside the lower arm

• inside the upper arm.

9. Loosen the cables from the cable guide in

the middle of the frame, by unscrewing the holder and assembling the guide.


10. Gently pull up the cable harness from inside the base.

11. Disconnect the connectors at the upper arm:

• at the UL lamp

• at motor, axis 6 (R3.MP6 and

R3.FB6)

• at customer connections (R2.CS,

R2.CP and R2.CAIR).



4 Repair


Continued

Action

12. Gently pull down the cable harness through the lower arm and remove it from the robot.


Refitting, cable unit axis 6

The procedure below details how to refit the cable unit of axis 6 to the robot.


1.

Action

-

Danger!


2. Insert the lower part of the cable unit through the frame, into the base.

3. Connect the connectors R1.MP4-6 and

R2.BU4-6 to the base. Also connect the customer cables and the air hose.

4. Connect the earth cables.

5. Connect the connector R2.FB4-6 to the

SMB-unit, connector R2.SMB3-6 (B).

xx0200000400

A. R2.SMB

B. R2.SMB3-6

C. R2.SMB1-4



99

4 Repair


Continued

Action

6. Refit the SMB unit to the bracket by tightening the nuts (D).

Reconnect the battery cable (A), if disconnected.


100 xx0200000398

7. Secure the cable bracket inside the base.


8. Insert the cabling through the cable guide in

the middle of the frame and secure the guide with the holder and its attachment screws.


9. Secure the cable attachment inside the

frame with its attachment screws.


10. Pull the cabling up through the lower arm and secure the cable bracket inside the

lower arm with its attachment screws.

Note! Run the cabling in front of the upper arm attachment, as shown in the figure!


11. Run the cabling through the upper arm and secure the cable bracket inside the upper

arm.

12. Connect all the connectors at the upper arm:

• at the UL lamp

• at motor, axis 6 (R3.MP6 and

R3.FB6)

• at customer connections (R2.CS,

R2.CP and R2.CAIR).

13. Refit the rear cover plate (A) to the base with its attachment screws (B).


14. If the battery has been disconnected from the SMB unit, the revolution counters must be updated!

xx0200000399

Detailed in section Updating revolution counters on page 180 .



15.

Action

-

Danger!



4 Repair


Continued



4 Repair

4.4.1. Replacement of shaft and bearings, tilthouse

4.4 Upper arm

4.4.1. Replacement of shaft and bearings, tilthouse

Location of shaft and bearings

The tilthouse is located in the front part of the upper arm, linked to the upper arm with a shaft, as shown in the figure below.

A more detailed view of the component and its position may be found in section Upper arm, exploded view on page 217 in part 2 of the Product manual.

102 xx0500002583

F

G

D

E

I

H

A

B

C

Shaft, tilthouse

Tilthouse

Sealing ring

Taper roller bearing (2 pcs)

Sealing ring with dust lip

Lock nut (2 pcs)

Protection hood (2 pcs)

VK cover (2 pcs)

M6 screws, including washers (4 pcs)



4 Repair


Continued


Equipment

Shaft 3HAC024867-001

Taper roller bearing 3HAA2103-14

Sealing ring with dust lip 3HAB3701-25

Sealing ring

VK-cover

Washer

Protection hood

Bearing grease

Locking liquid

Toolkit for service

Hydraulic pump, 80 Mpa

Standard toolkit

Calibration Pendulum toolkit


Spare part no.

Art. no.

3HAC7877-2

3HAA2166-15

3HAC020537-001

Note

-

25222101-17

3HAB3537-1

3HAC023963-

026

2 pcs.



2 pcs. Always replace with a new one!

4 pcs. To the lubrication holes for the bearings.

2 pcs. Must be replaced if damaged!

To fill the bearings at the shaft (2 x 25 ml).

Also for lubricating the mounting surfaces in the upper arm.

Loctite 243

Required tools for removal/refitting are assembled from the loose parts in the kit.

The contents are defined

in section Content, toolkit for service, 3HAC023963-

026 on page 191 in part 2

of the Product manual.

-

3HAC13086-1


in section Standard toolkit on page 190


3HAC15716-1 Complete kit that also includes operating manual.




103

4 Repair


Continued

Dismounting tool, tilthouse shaft

The tool for removing the tilthouse shaft from the tilthouse is assembled with the parts shown in the figure below (included in the toolkit for service).

Note! The parts cannot be ordered separately, but are included in the complete toolkit! The article numbers are only given for identification.

xx0600002589

G

J

E

F

C

D

A

B

Hydraulic cylinder, 3HAC11731-1

Press washer, 3HAC023963-007

Hex socket head cap screw, 9ADA183-25, 2 pcs, M6 x 25

Connection rod, M16, length= 400 mm

Nut, 3HAC5507-1

Sleeve, 3HAC023963-027

Nut, 3HAC023963-028

Pad, 3HAC023963-029

104



4 Repair


Continued

Dismounting tool, bearing race, upper arm

The tool for removing the bearing race from the upper arm is assembled with the parts shown in the figure below (included in the toolkit for service).

Note! The parts cannot be ordered separately, but are included in the complete toolkit! The article numbers are given only for identification.

xx0600002656

I

H

F

G

C

E

A

B




Nut, 3HAC5507-1


Nut, 3HAC023963-028

Press sleeve, 3HAC023963-038

Connection rod, 3HAC025192-006

Dismounting tool, bearing race, tilthouse shaft

The tool for removing the bearing race from the tilthouse shaft is assembled with the parts shown in the figure below (included in the toolkit for service).


xx0600002657

A Hydraulic cylinder, 3HAC11731-1



105

4 Repair


Continued

D

E

B

C

G

M




Nut, 3HAC5507-1

Nut, 3HAC023963-028


Mounting tool, tilthouse shaft

The tool for fitting the tilthouse shaft to the tilthouse is assembled with the parts shown in the figure below (included in the toolkit for service).


106 xx0500002581

E

J

K

C

D

A

B





Nut, 3HAC5507-1

Pad, 3HAC023963-029




4 Repair


Continued

Mounting tool, bearing race and sealing, upper arm

The tool for fitting the bearing race and sealing to the upper arm is assembled with the parts shown in the figure below (included in the toolkit for service).


xx0500002582

I

L

N

C

E

A

B




Nut, 3HAC5507-1


Press head, 3HAC023963-039


Mounting tool, bearing race, tilthouse shaft

The tool for fitting a bearing race to the tilthouse shaft is assembled with the parts shown in the figure below (included in the toolkit for service).


xx0600002658

A Hydraulic cylinder, 3HAC11731-1



107

4 Repair


Continued

D

E

B

C

G

H




Nut, 3HAC5507-1

Nut, 3HAC023963-028


Removal, shaft and bearings

The procedure below details how to remove the shaft and bearings.


1.

Action

-

Danger!


2. Remove the upper parallel rod.

Detailed in section Removal, upper rod on page 124

.

3. Remove the both VK covers by making a hole in the middle and bending them off.

Shown in the figure Location of shaft and bearings on page 102

.

4. Remove the both protection hoods and lock nuts. Shown in the figure Location of shaft and bearings on page 102

.

5. Gather the required parts to assemble a dismounting tool for the tilthouse shaft from the

toolkit for service.

The assembly is shown in the fig-

ure Dismounting tool, tilthouse shaft on page 104

.

Art. no. for the toolkit is specified in


.

6. Insert the dismounting tool, tilthouse shaft through the shaft. Fit the nut (A) to the end of the bar and use the pad (B) when pulling out the shaft.

108

7. Connect the hydraulic pump to the cylinder and pull out the shaft.

8. Rebuild the dismounting tool into a dismounting

tool, bearing race, upper arm.

xx0600002590

Art. no. is specified in Required equipment on page 103 .

The assembly is shown in the figure

Dismounting tool, bearing race, upper arm on page 105

.

9. Remove the bearing races and sealings from the seating, using the dismounting tool.



4 Repair


Continued

Action

10. If removing the remaining bearing race from the shaft, rebuild the tool to a dismounting tool,

bearing race, tilthouse shaft.



Dismounting tool, bearing race, tilthouse shaft on page 105 .

Refitting, shaft and bearings

The procedure below details how to refit the shaft, bearings and the tilthouse.


1.

Action

-

Danger!


2. Lubricate the seating (A) of the bearings and sealing rings in the upper arm with bearing

grease.



3. Gather the required parts to assemble a mounting tool for the bearing race and sealings from the toolkit for service.

Following steps detail the fitting of the bearing, additional information is also found in section

Mounting instructions for bearings on page 87 .

xx0500002580



.

The assembly of the tool is shown in the figure

Mounting tool, bearing race and sealing, upper arm on page 107 .



109

4 Repair


Continued

Action

4. Fit a new sealing ring to the press washer (A) and place it on the inner side of the seating, as shown in the figure to the right.

Fasten the bar (B) to the press washer.


5. If not already fitted, fit the press washer to the

hydraulic cylinder, using the two M6 bolts.

xx0500002582

Spare part no. for the sealing ring is specified in


and it is shown in the figure

Location of shaft and bearings on page 102 .

Shown in the figure Mounting tool, bearing race and sealing, upper arm on page 107 .

Spare part no. for the bearing is specified in


6. Thread the bearing race on to the press washer/hydraulic cylinder and fit the complete assembly to the bar.

7. Fit the nut to the end of the bar.

Shown in the figure Mounting tool, bearing race and sealing, upper arm on page 107 .

8. Press both the sealing ring and the bearing race into the seating.

9. Repeat the procedure to fit the other bearing race and the new sealing ring with dust lip to the opposite side.


.

10. Press the inner bearing race on to the shaft, by using a mounting tool, assembled of the parts in the toolkit for service.

The assembly of the mounting tool is shown in the figure

Mounting tool, bearing race, tilthouse shaft on page

107

.



.

11. Lubricate the shaft and the mounting surfaces in the upper arm and in the tilthouse with

bearing grease.

12. Gather the required parts to assemble a mounting tool for the tilthouse shaft from the toolkit for service.

The assembly of the mounting tool is shown in the figure

Mounting tool, tilthouse shaft on page 106

.

13. Place the tilthouse in mounting position and insert the shaft through the upper arm and tilthouse.

110



4 Repair


Continued

Action

14. Insert the bar (A) through the shaft and secure with press washer (B).


15. If not already fitted, fit the press washer to the hydraulic cylinder with the two M6 bolts.

16. Thread the remaining bearing race on to the bar and fit also the hydraulic cylinder and the nut.

xx0500002584

Shown in the figure Mounting tool, tilthouse shaft on page 106 .

17. Press the both bearings into the upper arm, on either ends of the shaft, with a hydraulic pump.

Use the pad (G).

Press until the both bearings reaches bottom.

18. Lubricate the both bearings with bearing

grease.

xx0500002585

25 ml in each bearing. Art. no. is

specified in Required equipment on page 103

.

19. Apply locking liquid to the both lock nuts and fit the nuts on each side of the shaft, facing the flat surface outwards.

Tighten one of them with 30 Nm. Tighten the other with 35 Nm, untighten it and retighten with

30 Nm.

Shown in the figure Location of shaft and bearings on page 102 .

Locking liquid is specified in Required equipment on page 103 .

20. Fit the protection hoods on each side of the shaft. Replace them if damaged!

21. Fit new VK covers on each side of the upper arm.

22. Fit four M6 screws, including washers, to the lubrication holes.

23. Refit the upper parallel rod.

Shown in the figure Location of shaft and bearings on page 102

equipment on page 103 .

.

Spare part no. is specified in Required



Spare part no. for washer is specified

in Required equipment on page 103

.

Detailed in section Refitting, upper rod on page 125

.



111

4 Repair


Continued

Action

24. Recalibrate the robot.

25.

-

Danger!


further detailed in section DANGER - First test run may cause injury or damage! on page 32

.


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

General calibration information is included in section

Calibration information on page 175 .


4 Repair

4.4.2. Replacement of turning disk

4.4.2. Replacement of turning disk

Location of turning disk

The turning disk is located at the frontmost part of the robot, as shown in the figure below.


Tilthouse, exploded view on page 219

in part 2 of the Product manual.

xx0500001938

A

B

Turning disk

Attachment screws and o-rings, turning disk (6 pcs)


Equipment

Turning disk

O-ring

O-ring

Locking liquid

Standard toolkit


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

-

-

Spare part no.

Art. no.

3HAC023881-001

3HAB3772-16

3HAB3772-89

Note

Replace if damaged.

6 pcs; one o-ring at each attachment screw. Replace if damaged.

Loctite 243



, in part 2 of the

Product manual.





113

4 Repair


Continued

Removal, turning disk

The procedure below details how to remove the turning disk from the robot.

Note

1.

Action

-

Danger!


2. Drain the oil from the axis 6 gearbox.

3. Remove the turning disk by removing its six

attachment screws and washers.

Detailed in section

Draining oil, gearbox axis 6 on page 81 .

Shown in the figure Location of turning disk on page 113 .

Refitting, turning disk

The procedure below details how to refit the turning disk to the robot.

Note

1.

Action

-

Danger!


2. Make sure that the o-ring is fitted properly to the turning disk. Replace it if damaged!

Spare part no. is specified in


.

3. Lubricate and fit the six o-rings to the holes of the attachment screws. Replace if damaged!



.

4. Fit the turning disk to the axis 6 gearbox with the six attachment screws and o-rings, using locking liquid.

6 pcs; M8x20.

Tightening torque: 30 Nm.



.

Shown in the figure Location of turning disk on page 113 .

5. Perform a leak-down test.

6. Refill the gearbox with oil.

Detailed in section

Performing a leak-down test on page 86

.

Detailed in section

Filling oil, gearbox axis 6 on page 82 .



General calibration information is

included in section Calibration information on page 175 .

114



8.

Action

-

Danger!

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

detailed in section DANGER - First test run may cause injury or damage! on page 32 .

4 Repair


Continued

Note


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 as shown in the figure below.


Robot IRB

260, exploded view 1 of 2 on page 206 in part 2 of the Product manual.

116 xx0600002601

A

B

C

Upper arm

Linkage (upper parallel rod, link and lower parallel rod)

Parallel bar


Equipment

Sealing ring

Shaft end

VK-cover

Grease

Locking liquid


3HAC7877-2

3HAC025034-

001

3HAC12165-2

-

3HAB3537-1

Note

2 pcs. Always replace with new.

2 pcs.

For lubrication of mounting surfaces.

Loctite 243



4 Repair


Continued

Equipment

Lifting straps

Guide pins

Toolkit for service

Hydraulic pump, 80

Mpa

Extended KM nut (KM7)

Standard toolkit


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


-

3HAC024097-

006

3HAC023963-

026

Note

For lifting the upper arm.

3 pcs required. Length: 62 mm. Diameter: 6 mm. Thread:

M6x12. Used for guiding the shaft end of the upper arm into place.

If additional aid is required for pulling out the shaft from the upper arm, a tool can be assembled from the loose parts in the kit.


Press tool, link on page

130 .

3HAC13086-1

3HAC023963-

040

Length: 135 mm.



, in part 2 of the

Product manual.



Removal, upper arm

The procedure below details how to remove the upper arm from the robot.


1.

Action

-

Danger!


2. Disconnect all the connectors at the tilthouse

(motor and customer connections) and unfasten the cabling from the upper arm by removing all brackets available.

Shown in the figure

Location of cable unit, axis 6 on page 96 .



117

4 Repair


Continued

Action

3. Remove the linkage.

4. Remove the parallel bar.

5.

-

Caution!

The complete upper arm weighs 23 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel!

6. Fit the lifting equipment to the upper arm according to the figure to the right.


Detailed in sections:

•

Removal, upper rod on page

124

•

Removal, lower rod on page

127

•

Removal, link on page 131

Detailed in section

Removal, parallel bar on page 139

.

7. Remove the distance and the radial sealing from the end shaft.

xx0500002549

118

8. Untighten and remove the lock nut with the

extended KM nut.

9. Remove the bearing.

10. Unfasten the shaft end by removing the flanged bolts from inside the lower arm.

xx0600002607





4 Repair


Continued


11. Remove the VK cover from the opposite side by making a hole in the middle.

Be careful not to damage the parts underneath!

12. Untighten and remove the lock nut and the bearing also from this side of the upper arm.

13. Unscrew the attachment screw and washer and remove the end shaft from both sides.

14. Make sure the cabling lies freely inside the upper arm. Then lift the upper arm while feeding the cabling from inside the arm.

If necessary, use the press tool, link as a puller tool (fit the auxiliary shaft to the upper arm shaft). Assembly of the

tool is shown in the figure Press tool, link on page 130

.

Note! The tilthouse is movable, be careful not to damage it!

Refitting, upper arm

The procedure below details how to refit the upper arm to the robot.


1.

Action

2.

-

Danger!


-

Caution!


3. Make sure that the sealing rings are fitted properly in the upper arm, facing the flat surface outwards! Replace them if any damage is detected!

Spare part no. is specified in Required equipment on page 116 .

3HAC026048-001 Revision: A xx0600002602

A. Sealing rings


119

4 Repair


Continued

Action

4. Fit the lifting equipment to the upper arm according to the figure to the right.

Note! The tilthouse is movable, be careful not to damage it!

Note/Illustration xx0500002549

5. Lubricate the mounting holes of the upper arm with grease.


6. Insert the cabling into the upper arm while placing the arm into mounting position.

7. Secure the upper arm to the lower arm by fastening the shaft end (A) with the attachment screw and washer (B), as shown in the figure to the right.

120

8. Fit three guide pins to the other shaft end.

xx0600002603

A. Shaft end

B. 1 pc, M12 x 60, (UNBRAKO

12.9) and washer. Tightening torque: 90 Nm.

Reused screws may be used, providing they are lubricated as detailed in section

Screw joints on page 186

before fitting.

The guide pins and the spare part no. for the shaft end are specified in




4 Repair


Continued

Action

9. Secure the other side of the upper arm to the lower arm by fitting the shaft end with guidance from the guide pins.

Note/Illustration xx0600002605

A. Shaft end

B. Guide pins, 3 pcs

C. Attachment screw and washer

10. Remove the guide pins and secure the shaft end with three flanged bolts from the inside of the lower arm, using locking liquid. Do not tighten yet.

Specified in Required equipment on page 116

.

11. Fit the one attachment screw and washer (C in the previous figure) to the shaft end.

1 pc, M12 x 60, UNBRAKO 12.9.


Reused screws may be used, providing they are lubricated as detailed in section

Screw joints on page 186

before fitting.

12. Tighten the flanged bolts.


13. Return to the other side of the upper arm and prepare the lock nut by lubricating it with

locking liquid.


.

14. Fit the tapered roller bearing and the lock nut

(flat side outwards) to the shaft end.

15. Fit a new VK cover to the upper arm.

xx0600002606

A. Tapered roller bearing

B. Lock nut, tightening torque: 35

Nm.



121

4 Repair


Continued


16. Fit the other tapered roller bearing and lubricated lock nut to the opposite side of the upper arm.

Use the extended KM nut and tighten the lock nut with 55 Nm, then untighten and retighten with 35 Nm.


17. Fit the distance and the radial sealing to the shaft end by hand.

Note! Make sure to fit the radial sealing with the flat side outwards!

122

18. Refit the parallel bar.

19. Refit the linkage.

20. Run the cable unit inside the upper arm.

Reconnect all connectors and refit all brackets.


xx0600002607

A. Radial sealing

B. Distance

Detailed in section

Refitting, parallel bar on page 140

.


•

Refitting, link on page 132

•

Refitting, upper rod on page

125

•

Refitting, lower rod on page 127

Cable run, connectors and brackets

are shown in the figure Location of cable unit, axis 6 on page 96 .

The refitting is further detailed in section

Refitting, cable unit axis 6 on page 99 .



Calibration information on page 175

.

22.

-

Danger!

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

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

.


4 Repair

4.4.4. Replacement of linkage - upper rod

4.4.4. Replacement of linkage - upper rod

Overview

The link system consists of three basic parts - upper rod, lower rod and link. The procedures below details how to remove and refit the upper rod.

Location of upper rod

The upper rod is located as shown in the figure below.

xx0600002615

C

D

A

B

E

Upper rod

Sealing ring (2 pcs)

Support washer (4 pcs)

Lock nut (2 pcs)

Link


Equipment

Parallel rod upper

Needle bearing

Spare part no.

Art no.

3HAC024575-001

3HAB6432-1


Note

Replace if damaged.


123

4 Repair


Continued

Equipment

Support washer

Bearing grease

Locking liquid

Press sleeve

Standard toolkit


Spare part no.

Art no.

3HAB6279-1

Note

3HAB3537-1

Replace if damaged.

Used to lubricate the bearings.

3HAB7116-1 Loctite 243

3HAC023963-013 Used for pressing new bearings into the rod, if replaced.



, in part 2 of the

Product manual.


Removal, upper rod

The procedure below details how to remove the upper rod of the linkage.

Note

1.

Action

-

Danger!


2. Put the robot in a position where it is possible to reach all parts that shall be removed.

Check especially that the lock nut at the link is possible to be removed.

3. Remove the lock nuts holding the upper rod at each end.

4. Remove the support washers from the upper rod.

5. Remove the upper rod.

Note! The support washers on the inside of the rod can stick to the grease of the bearings when the rod is being removed.

Remove them from the rod!

6. Remove the support washers and the sealing rings.

Remove residual grease.

124



4 Repair


Continued

Refitting, upper rod

The procedure below details how to refit the upper rod of the linkage.

Action Note

1. If needed, replace the bearings in the rod.

Use the press sleeve.

Note! The bearings are sensitive for pushes. Make sure they are not damaged!



2. Lubricate the bearings properly with bearing grease. Specified in


3. Refit the sealing rings on the shaft ends of the link and tilthouse.

4. Refit the support washers on the shaft ends.

Shown in the figure upper rod on page 123

Shown in the figure

Location of

Location of upper rod on page 123

.

.

5. Refit the upper rod to its place on the shafts.

Check that the rod is pushed in completely.

6. Refit the support washers on the outside of the upper rod, on the shaft ends.

7. Refit the lock nuts on the link and tilthouse, using locking liquid.

8.


-

Danger!



.


4 Repair

4.4.5. Replacement of linkage - lower rod

4.4.5. Replacement of linkage - lower rod

Overview

The linkage consists of three basic parts - upper rod, lower rod and link. The procedures below details how to remove and refit the lower rod.

Location of lower rod

The lower rod is located as shown in the figure below.

xx0600002617

C

D

A

B

E

Lower rod

Sealing ring (2 pcs)

Support washer (4 pcs)

Lock nut (2 pcs)

Link


Equipment

Needle bearing

Support washer

Bearing grease

Locking liquid

Press sleeve

Spare part no.

3HAC3311-1

3HAC7253-1

126

Art no.

Note

Replace if damaged.

Replace if damaged.

3HAB3537-1


3HAC023963-013 Used for pressing new bearings into the rod.



4 Repair


Continued

Equipment

Standard toolkit

Spare part no.

Art no.


Removal, lower rod

The procedure below details how to remove the lower rod of the linkage.

Note

1.

Action

Note


in section Standard toolkit on page 190 , in part 2 of

the Product manual.


-

Danger!


2. If the upper rod is removed, secure the link with a roundsling in a crane. Use the hole in the middle of the link.

This is done in order to prevent the link from moving if the upper rod also is being removed.

3. Remove the lock nuts holding the lower rod at each end.

Shown in the figure

Location of lower rod on page 126

.

4. Remove the support washers.

5. Remove the lower rod.

These can stick to the grease and can easy be forgotten and lost when removing the lock nuts.

Shown in the figure


.

Note! The support washers on the inside of the rod can stick to the grease of the bearings when the rod is being removed.

Remove them from the rod!

6. Remove the support washers and the sealing rings and remove residual grease.

Refitting, lower rod

The procedure below details how to refit the lower rod of the linkage.

Action

1. If needed, replace the bearings.

Use a press sleeve.

Note! The bearings are sensitive for pushes.

Make sure they are not damaged!

Note



.

Art. no. for the press sleeve is also specified in




127

4 Repair


Continued

Action Note

2. Lubricate the bearings properly with bearing

grease.

3. Refit the sealing rings to the shaft ends on the link and frame.

4. Refit the support washers to the shaft ends.


.

Shown in the figure


.

Tip! Putting some grease on the support washers will keep them in position.

Shown in the figure


.

Check that the lower rod is pushed completely in.

5. Refit the lower rod on the shaft ends of the link and frame.

6. Refit the support washers on the outside of the lower rod, on the link and frame shafts.

7. Refit the lock nuts on the shaft ends, using

locking liquid.




.

8.

-

Danger!


detailed in section DANGER - First test run may cause injury or damage! on page 32 .


4 Repair

4.4.6. Replacement of linkage - link

4.4.6. Replacement of linkage - link

Overview

The link system consists of three basic parts - upper rod, lower rod and link. The procedures below details how to remove and refit the link.

Location of link

The link is located at the upper arm as shown in the figure below. It is fitted to the same shaft that holds the upper arm to the lower am.

C

D

E

F xx0600002619

A

B

Link

Bearing (shown as complete bearing, but the outer race should already be mounted inside the seating prior to refitting of link)

Lock nut

Protection hood

VK cover

Screws and washers for lubrication and venting holes (3 pcs)



129

4 Repair


Continued


Equipment

Protection hood

VK-cover

Toolkit for service

Bearing grease

Locking liquid

Standard toolkit



2522 2101-17

3HAC12165-2

3HAC023963-

026

Note

Replace if damaged!

Replace if damaged!

A tool for pressing the bearing and the link to the upper arm shaft is assembled from the loose parts in the kit.

The assembly is shown in the

figure Press tool, link on page

130 .

-

-

3HAB3537-1

Loctite 243



, in part 2 of the

Product manual.


Press tool, link

The tool for fitting the bearing and the link to the upper arm shaft includes the parts shown in the figure below (included in the toolkit for service).

Note! The parts cannot be ordered separately, but are included in the complete toolkit! The article numbers are only given for identification!

130 xx0600002618

A

E

O

P


Nut, 3HAC5507-1

Connecting rod, 3HAC023081-003

Press housing, 3HAC024097-002



Removal, link

4 Repair


Continued

R

S

T

Auxiliary shaft, 3HAC024097-005

Screw, M6x12, 9ADA183-24 (2 pcs)

Distance, 3HAC023062-001

The procedure below details how to remove the link from the robot.


1.

Action

-

Danger!


2. Secure the link with a roundsling in a crane.

Use the hole in the middle of the link.

3. Remove the upper and lower rods.


•

Removal, upper rod on page

124 .

•

Removal, lower rod on page

127 .

4. Remove the center screw and washer in the hole for filling grease.

5. Use compressed air to remove the VK cover.

Blow with a very low air pressure into the hole for filling grease.

Note! A very low air pressure is needed!

Shown in the figure Location of link on page 129 .

Put one hand with some paper on top of the VK cover in order to catch it when released.

6. Remove the protection hood.

7. Remove the lock nut.

Shown in the figure Location of link on page 129 .

8. Fit the auxiliary shaft on the shaft in order to let the weight of the link rest on it.

Included in the toolkit for service. Art.

no. is specified in Required equipment on page 130

.

9. Loosen the roundsling and turn the link up side down in order to find room to knock on it from the inside as close to its center as possible.

Note! Loosen the roundsling some before knocking! Otherwise the link may be locked by the lifting power.

10. Use a pair of levers, to bend the link loose.

11. Remove the link.

12. Wipe off residual grease.



131

4 Repair


Continued

Refitting, link

The procedure below details how to refit the link to the robot.


1.

Action

-

Danger!


2. Check that the bearings and the radial sealing inside the link seating are undamaged.

3. Make sure that the radial sealing and the distance are fitted to the shaft end in the upper arm.

132 xx0600002607

A. Radial sealing

B. Distance

The fitting is further detailed in

section Refitting, upper arm on page 119 .

4. Lubricate the shaft end with bearing grease.

5. Gather the required parts to assemble a press tool for the link and bearing from the toolkit for service.

The assembly is shown in the Press tool, link on page 130 .



.

6. Fit the auxiliary shaft to the shaft end.

Specified in


7. Thread the link and the bearing onto the auxiliary shaft.

8. Fit the remaining parts of the press tool and press the link and the bearing onto the shaft end.

9. Apply locking liquid to the lock nut and fit it to the shaft end, facing the flat surface outwards.

Fit it first with a tightening torque of 55 Nm, then unscrew it and fit it once again. This time with a tightening torque of 35 Nm.

Specified in




4 Repair


Continued


10. Fit a protection hood to the lock nut. It must be replaced if damaged!

11. Fit the VK cover. Replace if damaged!

12. Fill the link with grease, and refit the three screws and washers.

Note! Fill through the center hole. The two holes at the sides are meant for venting while filling.

13. Refit the upper and lower rods.


•

Refitting, upper rod on page

125 .

•

Refitting, lower rod on page

127 .

14.



Shown in the figure

Location of link on page 129 .



-

Danger!



.


4 Repair

4.5.1. Replacement of complete lower arm

4.5 Lower arm

4.5.1. Replacement of complete lower arm

Location of lower arm

The lower arm is located as shown in the figure below.


Axes 1-3, spare part view 2 on page 211

in part 2 of the Product manual.

xx0500002548

A

B

C

D

Lower arm

Sealing ring

Attachment screw (12 pcs)

Spring tension plate


Equipment, etc.

Lower arm

Sealing ring (V-ring)

Spare part no.

3HAC025729-001

3HAB3732-13

Art. no.

Note

Replace if damaged.

134



4 Repair


Continued

Equipment, etc.

Bearing grease

Hoisting equipment

Standard toolkit


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

-

3HAB 3537-1 Used to lubricate the sealing ring.

3HAC15716-

1



, in part 2 of the

Product manual.

Complete kit that also includes operating manual.


Removal, lower arm

The procedure below details how to remove the complete lower arm.


1.

Action

-

Danger!


2. Remove the upper arm. Detailed in section

Removal, upper arm on page 117 .

3.

-

Caution!

The lower arm weighs 27 kg! Use a suitable lifting device to avoid injury to personnel!



135

4 Repair


Continued

Action

4. Fit the lifting equipment to the lower arm to secure its weight.


5. Remove the parallel bar. xx0200000439

Detailed in section

Removal, parallel bar on page 139 .

6. Remove the parallel arm.

7. Pull down the cabling from inside the lower arm and remove any cable attachments.

8. Remove the attachment screws and the

spring tension plate.

Detailed in section Removal, parallel arm on page 148

.

Shown in the figure

Location of lower arm on page 134

.

9. Remove the lower arm.

Refitting, lower arm

The procedure below details how to refit the complete lower arm.

Note

1.

Action

-

Danger!


2. Move the damper and calibration marking to the new lower arm.

3. Make sure that the sealing ring is fitted properly to the gearbox, undamaged and properly lubricated with grease. If damaged, replace with a new one.


.

Shown in the figure

Location of lower arm on page 134

.

136



4 Repair


Continued

Note

4.

Action

-

Caution!

The lower arm weighs 27 kg! Use a suitable lifting device to avoid injury to personnel!

5. Lift the lower arm into position.

6. Fit the spring tension plate to the lower arm and secure the arm to the gearbox with the 12

attachment screws.

12 pcs; M10 x 40. Tightening torque:

72 Nm.

7. Refit the parallel arm.


Detailed in section

Refitting, parallel arm on page 149 .

Detailed in section

Refitting, parallel bar on page 140 .

9. Refit the upper arm.

10. Refit the cabling.

11. Recalibrate the robot!

Detailed in section

Refitting, upper arm on page 119 .

Detailed in section Refitting, cable unit axis 6 on page 99

.




.

12.

-

Danger!


further detailed in section DANGER - First test run may cause injury or damage! on page 32

.


4 Repair

4.5.2. Replacement of parallel bar

4.5.2. Replacement of parallel bar

Location of parallel bar

The parallel bar is located as shown in the figure below.


Axes 1-3, spare part view 1 on page 210 in part 2 of the Product manual.

xx0500002552

F

G

D

E

A

B

C

Parallel bar

Attachment screw (2 pcs)

Locking washer (2 pcs)

Bearing sealing (2 pcs)

Bearing sealing (2 pcs)

Parallel arm

Spherical roller bearing (2 pcs)


Equipment, etc.

Parallel bar complete


3HAC025714-

001

Spherical roller bearing 3HAA2167-12

Note

Includes:

• spherical roller bearings

• bearing sealings

2 pcs

138



4 Repair


Continued

Equipment, etc.

Bearing sealing

Bearing sealing

Locking liquid

Bearing grease

Press tool, parallel bar bearing

Mounting tool, parallel bar

Standard toolkit




3HAC10088-4

3HAC10089-2

Note

One at each end of the bar.

(Item D in the figure

Location of parallel bar on page 138 .)

One at each end of the bar.

(Item E in the figure

Location of parallel bar on page 138 .)


3HAB3537-1

3HAB6324-1

-

3HAB6331-1

3HAC15716-

1

The contents are defined in

section Standard toolkit on page 190 , in part 2 of the

Product manual.



Removal, parallel bar

The procedure below details how to remove the parallel bar from the robot.

Note

1.

Action

2.

-

Danger!


-

Caution!




139

4 Repair


Continued

Action

3. Use a crane to secure the weight of the upper arm.

Note

If the upper arm is also to be removed, secure the weight as shown in the figure below.

4. Remove the attachment screw from the upper and lower end.

5. Remove the locking washer from both ends.

6. Insert a screw in the center of each end, to be used as support.

7. Use a puller to pull out the parallel bar.

8. Remove the bearings and seals.

xx0500002549

Shown in the figure Location of parallel bar on page 138

.


.

M8


.

Refitting, parallel bar

The procedure below details how to refit the parallel bar to the robot.

Note

1.

Action

140

-

Danger!


2. Make sure the weight of the upper arm is properly secured.

Use a crane!

3. Fit the new spherical roller bearings to the parallel bar using the press tool, parallel bar

bearing. Lubricate the bearings with bearing grease.

Shown in the figure

Location of parallel bar on page 138 .



.

4. Fit new bearing sealings to the shaft ends and lubricate the shaft ends with grease.

5. Refit the parallel bar, using the mounting

tool, parallel bar.

Note! Press by hand!

6. Fit new bearing sealings to the bearings.

Shown in the figure

Location of parallel bar on page 138 .



.



.



4 Repair


Continued

Action Note

7. Refit the locking washer.

8. Refit the attachment screw at both ends of the bar, using locking liquid.



.

M8 x 16.

Loctite 243


.




.

10.

-

Danger!




4 Repair

4.6.1. Replacement of SMB unit

4.6 Frame and base

4.6.1. Replacement of SMB unit

Location of SMB unit

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



Note that the robot is shown with the SMB cover already removed! xx0200000451

C

D

A

B

Cable, battery/SMB board

Battery

Serial measurement board

Lock nuts


Equipment Spare part no. Art. no.

Gasket, cover 3HAC3200-1

Serial measurement unit 3HAC 17396-1

Note

Must always be replaced!

142



SMB unit, layout

Equipment

Standard toolkit

Circuit Diagram



-

4 Repair


Continued

Note


section Standard toolkit on page 190

, in part 2 of the

Product manual.


These procedures include references to the tools required. xx0600002645

A

B

C

D

E

Connector R2.SMB4-6

Connector R2.SMB1-3

Connector R2.SMB1-2 (external axis)

Connector R2.SMB

Connector R2.G (battery unit)



143

4 Repair


Continued

Replacement, SMB unit

The procedure below details how to replace the SMB unit.

Note

1.

Action

-

Danger!


2. Remove the rear cover plate (A) from the base by unscrewing the attachment screws (B).

3. Remove the SMB battery. xx0200000399

Detailed in section Replacement, SMB battery on page 84

.

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

Pull the battery cable through the hole in the

SMB cover.

5. Remove the two locknuts and washers from the pins securing the board.

6. Gently disconnect the connectors from the

SMB unit when pulling the board out. Also disconnect the battery cable from the SMB unit.

7. Gently connect the connectors to the new

SMB unit and push the board in.

All connectors are shown in the figure

SMB unit, layout on page 143 .

All connectors are shown in the figure

SMB unit, layout on page 143 .

8. Refit the SMB cover using the attachment lock nuts.

Pull the battery cable through the hole in the

SMB cover.

9. Reassemble the two locknuts and washers to the pins securing the board.

10. Refit the SMB battery.

11. Fit a new gasket to the cover and refit the cover with the attachment screws.

12. Update the revolution counters!

Always replace a removed gasket with a new!



Detailed in section Updating revolution counters on page 180

.


4 Repair

4.6.2. Replacement of brake release unit

4.6.2. Replacement of brake release unit

Location of brake release unit

The brake release unit is located behind the flange plate at the robot base, as shown below.

xx0200000459

A Brake release unit with buttons


Equipment, etc.

BU w. buttons DSQC 563

Standard toolkit

Spare part no.

3HAC16035-1

-

Note



Standard toolkit on page 190 , in

part 2 of the Product manual.


Replacement, brake release unit

The procedure below details how to replace the brake release unit from the robot base.

1.

Action

-

Danger!


2. Remove the cover at the rear of the base.

3. Unscrew the six attachment screws of the brake release unit on the outside of the base.

4. Disconnect the cable from the brake release unit and remove the unit from the base.

5. Reconnect the cable to the new brake release unit and fit it to the base.

6. Secure the unit with its six attachment screws on the outside of the base.



145

4 Repair

4.6.2. Replacement of brake release unit

Continued

Action

7. Refit the cover to the rear of the base.

8.

-

Danger!



.


4 Repair

4.6.3. Replacement of parallel arm

4.6.3. Replacement of parallel arm

Location of parallel arm

The parallel arm is located at the frame, as shown in the figure below. xx0600002591

A

B

Parallel arm

Parallel bar


Equipment

Parallel arm complete

Bearing grease

Standard toolkit


Spare part no.

Art. no.

3HAC025727-001

Note

Includes:

• groove ball bearing

• sealing ring

3HAB 3537-1


in section Standard toolkit on page 190


3HAC15716-

1




147

4 Repair


Continued

Equipment


Spare part no.

Art. no.

Removal, parallel arm

The procedure below details how to remove the parallel arm.

Note

1.

Action

Note


-

Danger!


2. Remove the parallel bar.

Detailed in section

Removal, parallel bar on page 139

.

3. Remove the parallel arm by removing its eight attachment screws and washers.

148



4 Repair


Continued

Assembly, parallel arm

The figure below shows the assembly of the parallel arm.

xx0200000450

C

D

A

B

Parallel arm

Sealing V- ring (2 pcs)

Groove ball bearing

Attachment screws and washers (8 pcs)

Refitting, parallel arm

The procedure below details how to refit the complete parallel arm to the robot.

Note

1.

Action

-

Danger!


2. Fit the complete parallel arm to the robot with the eight attachment screws and washers.

8 pcs; M10x60.



Detailed in section

Refitting, parallel bar on page 140

.



149

4 Repair


Continued

Action


5.

-

Danger!



.

Note




.


4 Repair

4.7.1. Replacement of motor, axis 1

4.7 Motors

4.7.1. Replacement of motor, axis 1

Location of motor, axis 1

The motor, axis 1, is located on the left hand side of the robot as shown in the figure below:


Axes 1-3, spare part view 1 on page 210 .

xx0200000465

A

B

C

D

E

Cover

Connection box

Attachment screws and washers, motor (4 pcs)

Motor axis 1

Correct orientation of holes



151

4 Repair


Continued


Equipment

Motor unit, axes 1 and 3

O-ring

Gasket

Measuring tool, motor

Power supply

Standard toolkit



Circuit Diagram


3HAC025712-001

Note

3HAB 3772-1 Always fit a new one!

3HAB 3676-1

-

3HAB7887-1

3HAC15716-

1

24 VDC, max. 1.5 A. For releasing the brakes.


Standard toolkit on page 190 , in part 2 of

the Product manual.




Removal, motor axis 1

The procedure below details how to remove the motor, axis 1.


1.

Action

-

Danger!


2. Remove the cover of the connection box.

3. Disconnect the connectors R3.MP1 and

R3.FB1.

Shown in the figure Location of motor, axis 1 on page 151

152 xx0200000401

• A: R3.MP1

• B: R3.FB1

• C: Connection box



4 Repair


Continued


4. Remove the connection box by unscrewing its three attachment screws and plain washers.

5. Use a marker pen to mark the position of the motor (A).

Shown in the figure

Location of motor, axis 1 on page 151

.

6. Unscrew the four attachment screws and

washers of the motor.

7. Gently lift the motor straight up, making sure not to damage the motor pinion.

xx0600002646

Shown in the figure


.

Refitting, motor axis 1

The procedure below details how to refit the motor, axis 1.


1.

Action

-

Danger!


2. Check that the assembly surfaces are clean and the motor is unscratched.

3. Fit the new o-ring.

Always fit a new one, see art. no. in


4. Fit the motor by gently lowering it straight down.

Note the position of the motor! Use the mark , made on the motor base before removal. See also orientation of the holes on top of the motor, shown in the figure

Location of motor, axis 1 on page 151 .

5. Tighten the four attachment screws and washers. 4 pcs. TIghtening torque: 2 Nm.

6. In order to release the brakes, connect the 24

VDC power supply to the motor.

Connect power supply to connector

R3.MP1:

• + : pin 7

• - : pin 8



153

4 Repair


Continued


7. Fit the measuring tool to the rear of the motor.


Shown in the figure below.

8. Rotate the motor shaft several turns, using the measuring tool.

There must always be some backlash, meaning that the shaft should go easy to rotate!

9. Place the tip of a dial indicator against the scribed mark on the measuring tool.

The tip of the dial indicator must measure on a 50 mm radius from the center of the motor shaft.

154 xx0200000473

A. Measuring tool

10. Set the gear play to 0.02 mm, which corresponds to a reading on the dial indicator of 0.13 mm.

11. Pull gently in one direction. Note the reading.

(The gear must not turn.)

12. Then gently knock on the tool in the other direction and note the reading. The difference in reading = gear play. The gear play should be 0.02 mm which corresponds to a reading on the dial indicator of 0.13 mm.

13. Tighten the motor attachment screws.

4 pcs. Tightening torque: 23 Nm.

14. Refit the connection box with the three attachment screws and plain washers.

Make sure the gasket is fitted properly!

15. Reconnect the connectors R3.MP1 and R3.FB1.

Shown in the figure


.

xx0200000406

• A: R3.MP1

• B: R3.FB1




Action

16. Refit the cover of the connection box.


18.

-

Danger!



.

4 Repair


Continued


Shown in the figure






4 Repair




The motor, axis 2, is located on the left hand side of the robot as shown in the figure below:

156 xx0200000470

G

H

E

F

C

D

A

B

Attachment screws, cover (5 pcs)

Cover

Connection box

Gasket

Motor, axis 2

Attachment screws, motor (4 pcs)

O-ring

Correct orientation of holes on top of motor



4 Repair


Continued


Equipment, etc.

Motor unit, axis 2

O-ring

Gasket


Power supply

Standard toolkit



Circuit Diagram

Spare part no.

Art. no.

3HAC025713-001

Note

3HAB 3772-1 Always fit a new one!

3HAB 3676-1

3HAB7887-1

3HAC15716-

1




, in part 2 of the

Product manual.







1.

Action

-

Danger!



Shown in the figure Location of motor, axis 2 on page 156

.

3. Disconnect the motor connectors R3.MP2 and

R3.FB2.

3HAC026048-001 Revision: A xx0200000401

• A: R3.MP2

• B: R3.FB2



157

4 Repair


Continued

Action

4. Remove the connection box by unscrewing its three attachment screws and plain washers.

5. Use a marker pen to mark out the position of the motor.

6.


Secure the robot arms before unscrewing any of the attachment screws of the axis 2 motor.

-

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! xx0300000107

7.

-

Warning!

Oil will be running out of the motor attachment hole when removing the motor! It may also be hot! Take any necessary measures to collect the oil.

8. Unscrew the four attachment screws and washers of the motor.

Shown in the figure Location of motor, axis 2 on page 156 .

9. Remove the motor by gently lifting it straight out.




1.

Action

-

Danger!


158



4 Repair


Continued



3. Fit the o-ring.

Always fit a new one, see art. no. in


4. Fit the motor by gently lifting it straight on.

Note the position of the motor! Use the mark on the motor base, made before removing the motor. Also see the orientation holes on the motor cover, shown in the figure


5. Fit the four attachment screws and tighten them slightly. Make the adjustments described below before tightening the screws properly.




Connect to connector R3.MP2:

• +: pin 7

• -: pin 8

7. Fit the measuring tool to the rear of the motor.

See the figure below.



.





xx0200000473

A. Measuring tool



(The gear must not turn.)

See the figure above.

12. Then gently knock on the tool in the other direction and note the reading. The difference in reading = gear play. The gear play should be

0.02 mm which corresponds to a reading on the dial indicator of 0.13 mm.




159

4 Repair


Continued

Action

13. Tighten the four attachment screws.


15. Fill the gearbox with oil.

16. Refit the connection box and secure with the three attachment screws and plain washers.

Make sure that the gasket is fitted properly!

17. Reconnect connectors R3.MP2 and R3.FB2.



Detailed in section Performing a leak-down test on page 86 .

Type and amount of oil is specified in

section Oil in gearboxes on page 80

.

Shown in the figure




20.

-

Danger!


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

xx0200000401

• A: R3.MP2

• B: R3.FB2


Shown in the figure






4 Repair




The motor, axis 3, is located on the right hand side of the robot, as shown in the figure below:



xx0200000471

F

G

D

E

H

A

B

C

Attachment screws, cover

Cover

Connection box

Gasket

Motor, axis 2

Attachment screws, motor (4 pcs)

O-ring

Correct orientation of holes on top of motor



161

4 Repair


Continued


Equipment

Motor unit, axes 1 and 3 3HAC025712-001

Gasket

O-ring


Power supply

Standard toolkit



Circuit Diagram


-

Note

-

3HAB 3676-1

3HAB 3772-1 Always fit a new one.

-

3HAB7887-1

3HAC15716-

1




Product manual.







1.

Action

-

Danger!




R3.FB3.

Shown in the figure


.

162 xx0200000401

• A: R3.MP3

• B: R3.FB3




4 Repair


Continued


4. Remove the connection box by unscrewing its three attachment screws and plain washers.

5. Use a marker pen to mark out the position of the motor.

6.

Shown in the figure


Secure the upper arm before loosening any of the screws on the motor!

-

Danger!

Secure the weight of the upper arm properly before releasing the brakes of motor, axis 3.

When releasing the holding brakes of the motor, the upper arm will be movable and may fall down!

xx0300000107

7.

-

Warning!

Oil will be running out of the motor attachment hole when removing the motor! It may also be hot! Take any necessary measures to collect the oil.

8. Unscrew the four attachment screws and plain washers of the motor.

9. Remove the motor by gently lifting it straight out.

Shown in the figure





1.

Action

-

Danger!





163

4 Repair


Continued


3. Fit a new o-ring to the motor.

Always mount a new one, see art. no. in section

Required equipment on page

162

.

4. Fit the motor, by gently lifting it straight on.

Note the position of the motor! Use the mark on the motor base, made before removal. Also see the orientation holes on the motor cover, shown in the figure


.


5. Tighten the four screws lightly.




• +: pin 7

• -: pin 8

7. Fit the measuring tool to the rear of the motor. See the figure below.



.



See the figure below.



164 xx0200000473

A. Measuring tool



(The gear must not turn.)


12. Then gently knock on the tool in the other direction and note the reading. The difference in reading = gear play. The gear play should be

0.02 mm which corresponds to a reading on the dial indicator of 0.13 mm.


13. Tighten the four motor attachment screws.




4 Repair


Continued




16. Refit the connection box with the three attachment screws and plain washers.

Make sure that the gasket is fitted properly!

17. Reconnect the motor connectors R3.MP3 and

R3.FB3.

Detailed in section

Performing a leakdown test on page 86 .

Type and amount of oil is specified in

section Oil in gearboxes on page 80 .




20.

-

Danger!



.

xx0200000401

• A: R3.MP3

• B: R3.FB3






.


4 Repair




The motor, axis 6 is located in the tilthouse, as shown in the figure below.


Tilthouse, exploded view on page 219 in part 2 of the Product manual.

xx0500001940

A

B

C

Motor, axis 6

Attachment screws and washers, axis 6 motor (4 pcs)

Motor connectors, R3.MP6 and R3.FB6


Equipment

Rot. ac motor incl. pinion

Power supply

Locking liquid

Standard toolkit


Circuit diagram -

-

-

-

Spare part no.

Art. no.

3HAC025734-001

Note


Loctite 243



, in part 2 of the

Product manual.



166



4 Repair


Continued

Removal, motor, axis 6

The procedure below details how to remove the motor, axis 6 from the robot.

Note

1.

Action

-

Danger!



R2.FB6.

3. In order to release the brakes, connect the 24 VDC power supply to the motor.


• +: pin 4

• -: pin 5

4. Unscrew the four attachment screws and washers. Shown in the figure Location of motor, axis 6 on page 166 .

5. Remove the motor by gently lifting it straight up.

Be careful not to damage the motor pinion!

Refitting, motor, axis 6

The procedure below details how to refit the motor, axis 6 to the robot.

Note

1.

Action

-

Danger!


2. In order to release the brakes, connect the 24 VDC power supply to the motor.


• +: pin 4

• -: pin 5

3. Gently fit the motor to the tilthouse. Be careful not to damage the motor pinion when mating it to the gearbox!

4. Secure the motor with its four attachment screws

and washers, using locking liquid.


4 pcs; M6x20.




.

5. Disconnect the brake release voltage.


Detailed in section

Performing a leak-down test on page 86 .

7. Reconnect the motor connectors R3.MP6 and

R3.FB6.



167

4 Repair


Continued

Action


9.

-

Danger!



.

Note





4 Repair

4.8.1. Replacement of gearbox, axis 1-3

4.8 Gearboxes

4.8.1. Replacement of gearbox, axis 1-3

Location of gearbox, axis 1-3

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

Axis 1 gearbox is of the conventional type, manufactured with high precision. Together with the gearboxes for axes 2 and 3, it forms a complete unit.



Note! The gearbox is not normally serviced or adjusted.

xx0300000007

A

B

Attachment screws, gearbox unit

Bottom plate


Equipment

Gearbox, axes 1-3

Standard toolkit


Spare part no.

Art. no.

Note

-

3HAC025711-001







169

4 Repair


Continued

Equipment


Spare part no.

Art. no.

Removal, gearbox axis 1-3

The procedure below details how to remove the gearbox, axis 1-3.

Note

1.

Action

Note


-

Danger!


2. Remove the cable unit, axes 1-3.

3. Remove the complete lower arm.

Detailed in section Removal, cable unit, axes 1-3 on page 91

.

Detailed in section Removal, lower arm on page 135

.

4. Remove the motor, axis 1.



Detailed in section

Removal, motor axis 1 on page 152

.

Detailed in section


.

Detailed in section


.

7.

-

Caution!

The complete gearbox unit weighs 200 kg (without the base)! All lifting equipment used must be sized accordingly!

8. Place the remaining parts of the robot upside-down on a table or similar surface and remove the bottom plate.

9. Undo the 12 attachment screws.

10. Lift away the base from the gearbox unit.

170



4 Repair


Continued

Refitting, gearbox axis 1-3

The procedure below details how to refit the gearbox, axis 1-3.

Note

1.

Action

2.

-

Danger!


-

Caution!

The complete gearbox unit weighs 200 kg

(without the base)! All lifting equipment used must be sized accordingly!

3. Place the gearbox unit upside-down on a table or similar surface.

4. Fit the base to the gearbox unit and secure with the 12 screws and washers.

12 pcs; M12x50. Tightening torque:

54 Nm.

5. Refit the bottom plate to the base.

6. Turn the base and gearbox unit around and secure to the installation site.

7. Refit the motor, axis 1.



10. Refit the complete lower arm.

11. Refit the cable unit, axes 1-3.

12. Calibrate the robot.

Further detailed in section Orienting and securing the robot on page 47 .

Detailed in section Refitting, motor axis 1 on page 153

.


.


.

Detailed in section Refitting, lower arm on page 136

.

Detailed in section Refitting, gearbox axis 1-3 on page 171 .




13.

-

Danger!


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

.


4 Repair

4.8.2. Replacement of gearbox, axis 6

4.8.2. Replacement of gearbox, axis 6

Location of gearbox, axis 6

The gearbox, axis 6, is located at the frontmost part of the robot, as shown in the figure below.

xx0500001939

A

B

Gearbox, axis 6

Attachment screws, gearbox (8 pcs)


Equipment Spare part no.

Art. no.

Note

RV-6E, i=79

O-ring

Locking liquid

Bearing grease

Standard toolkit



-

3HAC025110-001

-

3HAB3772-88

3HAB3537-1

Replace if damaged!

Loctite 243

Used to lubricate o-rings and contact surfaces.



Product manual.



172



4 Repair


Continued

Removal, gearbox, axis 6

The procedure below details how to remove the gearbox, axis 6 from the robot.

Note

1.

Action

-

Danger!


2. Drain the oil from the gearbox.

3. Remove the turning disk.

Detailed in section

Draining oil, gearbox axis 6 on page 81 .

Detailed in section

Removal, turning disk on page 114 .

4. Remove the gearbox from the robot by removing its attachment screws and washers.

Shown in the figure Location of gearbox, axis 6 on page 172

.

5. If necessary, press out the gearbox by inserting screws into the two M5 holes on the gearbox.

Press out holes: 2 x M5.

Refitting, gearbox, axis 6

The procedure below details how to refit the gearbox, axis 6 to the robot.

Note

1.

Action

-

Danger!


2. Lubricate the contact surfaces inside the housing with grease.

3. Make sure the o-ring is lubricated and fitted properly to the upper side of the gearbox.

Replace if damaged!

4. Refit the gearbox with the attachment screws and washers, using locking liquid.



8 pcs; M5x25.

Tightening torque: 8 Nm. Locking liquid is specified in


.

5. Refit the turning disk.



Detailed in section Refitting, turning disk on page 114

.

Detailed in section

Performing a leak-down test on page 86 .

Detailed in section

Filling oil, gearbox axis 6 on page 82

.



173

4 Repair


Continued

Action


9.

-

Danger!



.

Note





5 Calibration information

5.1. Introduction



General

This chapter includes general information about different calibration methods and also details procedures that do not require specific calibration equipment.

When the robot system must be recalibrated, it is done according to documentation enclosed with the calibration tools.

When to calibrate

The system must be calibrated if any of the below occurs.

The resolver values are changed

If resolver values are changed, the robot must be recalibrated using the calibration methods supplied from ABB. Calibrate the robot carefully with standard calibration. The different

methods are briefly described in section Calibration methods on page 176 , and further

detailed in separate Calibration manuals.

If the robot has Absolute Accuracy calibration, it is also recommended but not always needed to be calibrated for new Absolute Accuracy.

The resolver values will change when parts affecting the calibration position are replaced on the robot, e.g. motors, wrist or part of transmission.

Contents of the revolution counter memory are lost

If the contents of the revolution counter memory are lost, the counters must be updated as detailed in section


. This will occur when:

• the battery is discharged

• a resolver error occurs

• the signal between a resolver and measurement board is interrupted

• a robot axis is moved with the control system disconnected

The revolution counters must also be updated after the robot and controller are connected at the first installation.

The robot is rebuilt

If the robot has been rebuilt, e.g. after a crash or when the robot has been changed for other reachability, 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.



5.2. Calibration methods

5.2. Calibration methods

Overview

This section specifies the different types of calibration and the calibration methods that are supplied from ABB.

Types of calibration

Type of calibration

Description Calibration method

Standard calibration

Absolute Accuracy calibration

(optional)

The calibrated robot is positioned at home position, i.e. the axes positions (angles) are set to 0º.

Standard calibration data is found in the file calib.cfg, supplied with the robot at delivery.

The file identifies the correct resolver/motor position corresponding to the robot home position.

From deliveries together with RobotWare 5.0.5 and higher, the data will instead be found on the SMB (serial measurement board) in the robot, and not in a separate file.


(standard method)

Based on standard calibration, and besides positioning the robot at home position, the

Absolute Accuracy calibration also compensates for:

• mechanical tolerances in the robot structure

• deflection due to load.

Absolute Accuracy calibration focuses on positioning accuracy in the Cartesian coordinate system for the robot.

Absolute Accuracy data is found in the file absacc.cfg, supplied with the robot at delivery.

The file replaces the calib.cfg file and identifies motor positions as well as absacc-compensation parameters.

From deliveries together with RobotWare 5.0.6 and higher, the data will instead be found on the SMB (serial measurement board) in the robot, and not in a separate file.

A robot calibrated with AbsAcc has a sticker next to the identification plate of the robot.

To regain 100% Absolute Accuracy performance, the robot must be recalibrated for

Absolute Accuracy!

CalibWare xx0400001197

176




5.2. Calibration methods

Continued

Calibration methods

Each calibration method is detailed in a separate manual. Below is a brief description of the methods available.

Calibration Pendulum - standard method

Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB

6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the standard type of calibration. It is the recommended method in order to achieve proper performance.

Two different routines are available for the Calibration Pendulum method:

• Calibration Pendulum II

• Reference Calibration.

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the operating manual for Calibration Pendulum, which describes the method and the different routines further.

CalibWare - Absolute Accuracy calibration

In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy is used as a TCP calibration. The tool CalibWare guides through the calibration process and calculates new compensation parameters. This is detailed further in the manual CalibWare 2.0

Users Guide (M2000).

If a service operation is done to a robot with Absolute Accuracy, a new absolute accuracy calibration is required in order to establish full performance. For most cases after motor and transmission replacements that do not include taking apart the robot structure, standard calibration is sufficient. Standard calibration also supports wrist exchange.

References

Article numbers for the calibration tools are listed in section

Special tools on page 191 in part

2 of the Product manual. A calibration manual is enclosed with the calibration tools.

The article numbers for the operating manuals for calibration are also listed in section

References on page 8 .



5.3. Calibration scales and correct axis position

5.3. Calibration scales and correct axis position

Introduction

This section specifies the calibration scale positions and/or correct axis position for all robot models.

Calibration scales, IRB 260

When axis 3 is put in calibration position, the mark on the calibration plate is visible above the mechanical stop, as shown in the figure below.

178 xx0500002485

C

D

A

B

E

Mechanical stop of axis 3

Calibration mark on calibration plate, axis 3

Calibration plate and marking, axis 6

Punch, axis 1, 3HAB8223-1

Punch, axis 2, 3HAB8223-1 (1 marking)



5.4. Calibration movement directions for all axes

5.4. Calibration movement directions for all axes

Overview

When calibrating, the axis must consistently be run towards the calibration position in the same direction, in order to avoid position errors caused by backlash in gears etc. Positive directions are shown in the figure below.

This is normally handled by the robot calibration software.

Calibration movement directions, 4 axes

Note! The figure shows an IRB 260, but the positive direction is the same for all 4-axis robots xx0500001927



5.5. Updating revolution counters

5.5. Updating revolution counters

General

This section details how to perform a rough calibration of each robot axis, i.e. updating the revolution counter value for each axis, using the pendant.

Step 1 - Manually running the robot to the calibration position

This procedure details the first step when updating the revolution counter; manually running the robot to the calibration position.

Action Note

1. Select axis-by-axis motion mode.

3. When all axes are positioned, store the revolution counter settings.

2. Jog the robot to place the calibration marks within the tolerance zone.

Shown in section Calibration scales and correct axis position on page 178

.


Step 2 - Storing the revolution counter setting with the FlexPendant on page 180

(RobotWare 5.0).

Step 2 - Storing the revolution counter setting with the FlexPendant

This procedure details the second step when updating the revolution counter; storing the revolution counter setting with the FlexPendant (RobotWare 5.0).

Action

1. On the ABB menu, tap Calibration.

All mechanical units connected to the system are shown along with their calibration status.

180



Action

2. Tap the mechanical unit in question.

A screen is displayed: tap Rev. Counters.


5.5. Updating revolution counters

Continued en0400000771

3. Tap Update Revolution Counters....

A dialog box is displayed, warning that updating the revolution counters may change programmed robot positions:

• Tap Yes to update the revolution counters.

• Tap No to cancel updating the revolution counters.

Tapping Yes displays the axis selection window.

4. Select the axis to have its revolution counter updated by:

• Ticking in the box to the left

• Tapping Select all to update all axes.

Then tap Update.

5. A dialog box is displayed, warning that the updating operation cannot be undone:

• Tap Update to proceed with updating the revolution counters.

• Tap Cancel to cancel updating the revolution counters.

Tapping Update updates the ticked revolution counters and removes the tick from the list of axes.

6.

-

Caution!

If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury!

Check the calibration position very carefully after each update.

See section Checking the calibration position on page 182 .



5.6. Checking the calibration position

5.6. Checking the calibration position

General

Check the calibration position before beginning any programming of the robot system. This may be done in one of two ways:

• Using a MoveAbsJ instruction with argument zero on all axes

• Using the Jogging window on the teach pendant

Using a MoveAbsJ instruction on the FlexPendant, IRC5

This section describes how to create a program, which runs all the robot axes to their zero position.

Action

1. On ABB menu tap Program Editor.

2. Create a new program.

3. Use MoveAbsJ in the Motion&Proc menu.

4. Create the following program: MoveAbsJ

[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E

9]]\NoEOffs, v1000, z50, Tool0

5. Run the program in manual mode.

6. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!

Note

The calibration marks are shown

in section Calibration scales and correct axis position on page

178 .

How to update the revolution counters is detailed in section


.

Using the Jogging window on the FlexPendant, IRC5

This section describes how to jog the robot to all axes zero position.

Action Note

1. Tap Jogging in the ABB menu.

2. Tap Motion mode to choose group of axes to jog.

3. Tap axes 1-3 to jog axes 1, 2 or 3.

4. Manually run the robots axes to a position where the axis position value read on the FlexPendant, is equal to zero.

5. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!

The calibration marks are

shown in section Calibration scales and correct axis position on page 178

.

How to update the counters is detailed in section


.


6 Reference information

6.1. Introduction



General

This chapter includes general information, complementing the more specific information in the Product manual (part 1 of 2), procedures .

3HAC 026048-001 Revision: - 183


6.2. Applicable safety standards

6.2. Applicable safety standards

Overview

The robot conforms to the standards specified below.

Standards, EN

Standard Description

EN ISO 12100-1

EN ISO 12100-2

EN 954-1

Safety of machinery, terminology

Safety of machinery, technical specifications

Safety of machinery, safety related parts of control systems

EN 60204

EN 775

Electrical equipment of industrial machines


EN 61000-6-4 (option) EMC, Generic emission

EN 61000-6-2 EMC, Generic immunity

Standards, IEC

Standard

IEC 60204-1

IEC 60529-1

Description


Degrees of protection provided by enclosures

Standards, ISO

Standard

ISO 10218

ISO 9787

Description

Manipulating industrial robots, safety

Manipulating industrial robots, coordinate systems and motions

Additional standards

Standard Description

ANSI/RIA 15.06/1999 Safety requirements for industrial robots and robot systems

ANSI/UL 1740-1998 (option) Safety standard for robots and robotic equipment

CAN/CSA Z 424-03 (option) Industrial robots and robot systems - general safety requirements

184 3HAC 026048-001 Revision: -


6.3. Unit conversion

6.3. Unit conversion

Converter table

Use the table below to convert units used in this manual.

Quantity

Length

Weight

Pressure

Force

Moment

Volume

Units

1 m

1 kg

1 bar

1 N

1 Nm

1 L

3.28 ft

2.21 lb

100 kPa

0.738 lbf

0.738 lbf-tn

0.264 US gal

39.37 in

14.5 psi

3HAC 026048-001 Revision: - 185


6.4. Screw joints

6.4. Screw joints

General

This section details how to tighten the various types of screw joints on the robot and the controller.

The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.

UNBRAKO screws

UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue.

Whenever used, this is specified in the instructions, and in such cases, no other type of

replacement screw is allowed! Using other types of screws will void any warranty and may potentially cause serious damage or injury!

Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.

Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this the screw must be discarded and replaced with a new one.

When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used.

Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the repair, maintenance or installation procedure descriptions.

In such cases, proceed as follows:

1. Apply lubricant to the screw thread.

2. Apply lubricant between the plain washer and screw head.

3. Tighten to the torque specified in section Tightening torque below. Screw dimensions of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or smaller may be tightened without a torque wrench if this is done by trained and qualified personnel.

Lubricant Art. no.

Molycote 1000 (molybdenum disulphide grease) 1171 2016-618

186


3HAC 026048-001 Revision: -


6.4. Screw joints

Continued

Tightening torque

Before tightening any screw, note the following:

• Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description. Any special torque specified overrides the standard value.

• Use the correct tightening torque for each type of screw joint.

• Only use correctly calibrated torque keys.

• Always tighten the joint by hand, and never use pneumatical tools.

• Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow, flowing motion.

• Maximum allowed total deviation from the specified value is 10%!

The table below specifies the recommended standard tightening torque for oil-lubricated

screws with slotted or cross-recess head screws.

Dimension

M2.5

M3

M4

M5

M6

Tightening torque (Nm)

Class 4.8, oil-lubricated

0.25

0.5

1.2

2.5

5.0

The table below specifies the recommended standard tightening torque for oil-lubricated

screws with Allen head screws.

M5

M6

M8

M10

M12

M16

Dimension


(Nm)


6

10

24

47

82

200


(Nm)



(Nm)


-

-

34

67

115

290

-

-

40

80

140

340

The table below specifies the recommended standard tightening torque for Molycote-

lubricated screws with Allen head screws.

Dimension


Class 10.9, Molycote-lubricated


Class 12.9, Molycote-lubricated

M8

M10

M12

M16

28

55

96

235

34

66

115

280



187


6.4. Screw joints

Continued

The table below specifies the recommended standard tightening torque for water and air

connectors when one or both connectors are made of brass.

Dimension


Nm - Nominal

1/8

1/4

3/8

1/2

3/4

12

15

20

40

70


Nm - Min.

8

10

15

30

55


Nm - Max.

15

20

25

50

90

188 3HAC 026048-001 Revision: -


6.5. Weight specifications

6.5. Weight specifications

Definition

In all repair and maintenance procedures, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.

To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each manipulator model.

Example

Below is an example of how a weight specification is presented, inside a procedure table:

Action Note

-

Caution!

The motor weighs 32 kg! All lifting equipment used must be sized accordingly!

3HAC 026048-001 Revision: - 189


6.6. Standard toolkit

6.6. Standard toolkit

General

Contents, standard toolkit

Qty

1

1

1

1

1

1

1

1

1

1

1

1

All service (repairs, maintenance and installation) procedures contain lists of tools required to perform the specified activity.

All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the Standard toolkit and defined in the table below.

This way, the tools required are the sum of the Standard Toolkit and any tools listed in the instruction.

Tool

Ring-open-end spanner 8-19mm

Socket head cap 2,5-17mm

Torx socket no:20-60

Torque wrench 8-100Nm

Small screwdriver

Plastic mallet

Ratchet head for torque wrench 1/2

KM nut (KM7)

Socket head cap no:5, socket 1/2"" bit L 20mm



Small cutting plier

190 3HAC 026048-001 Revision: -


6.7. Special tools

6.7. Special tools

General

All service instructions contain lists of tools required to perform the specified activity. The

required tools are a sum of standard tools, defined in section Standard toolkit on page 190

, and of special tools, listed directly in the instructions and also gathered in this section.

Special tools

The table below specifies the special tools required during service procedures. The tools are also specified directly in concerned procedures for repair.

-

-

-

-

-

-

-

Item Description

H

Art. no.

Note

Guide pins 3HAC024097-006 3 pcs required. Length: 62 mm.

Diameter: 6 mm. Thread: M6x12.

Used for guiding the shaft end of the upper arm into place.

Hydraulic pump, 80 Mpa 3HAC13086-1

Press tool, parallel bar bearing

3HAB6324-1

Mounting tool, parallel bar 3HAB6331-1

Measuring tool, motor 3HAB7887-1

Extended KM nut (KM7) 3HAC023963-040 Length: 135 mm.

Toolkit for service 3HAC023963-026 The kit contains loose parts that are assembled into different tools for different service occasions.

The content is specified in the following table (

Content, toolkit for service, 3HAC023963-026 on page

191 ).

The different assemblies are shown in the figures on the following pages, as in the service procedures that require the tool assembly.

Press sleeve 3HAC023963-013

Used when refitting motor axes 1, 2 and 3.

Content, toolkit for service, 3HAC023963-026

The table below specifies the loose parts in the toolkit for service. The item numbers refer to the items shown in the figures for each assembly of the complete tools, on following pages.

Note Item

F

G

D

E

A

B

C

Description Art. no.

Hydraulic cylinder 3HAC11731-1

Press washer 3HAC023963-007

Hex socket head cap screw 9ADA183-25

Connection rod

Nut

Sleeve

Nut

-

3HAC5507-1

3HAC023963-027

3HAC023963-028

2 pcs, M6 x 25

M16, length= 400 mm

D= 70 mm

D= 28 mm



191


6.7. Special tools

Continued

Item

N

O

P

R

S

T

H

I

J

K

L

M


Press sleeve

Connection rod

Pad

Press washer

Press head

Sleeve

3HAC023963-038

3HAC025192-006

3HAC023963-029

3HAC023963-014

3HAC023963-039

3HAC023963-037

Press sleeve

Connecting rod

Press housing

3HAC023963-015

3HAC023081-003

3HAC024097-002

Auxiliary shaft 3HAC024097-005


Distance 3HAC023062-001

Note

D= 48.8 mm

M16, length= 280 mm

D= 70 mm

D= 55 mm

D= 55 mm

D= 70 mm

Mxx, length= xx mm

2 pcs, M6 x 12

Special tools, location of usage

The toolkit for service includes loose parts that are assembled into different tools, depending on usage. The figure below shows some of the assembled tools and where to use them on the robot. The detailed assemblies are shown in separate figures, referred to in the item list.

192 xx0600002588

A Dismounting tool, tilthouse shaft. Assembly is shown in the figure

Dismounting tool, tilthouse shaft on page 193

.




6.7. Special tools

Continued

D

E

F

B

C

Mounting tool, tilthouse shaft. Assembly is shown in the figure Mounting tool, tilthouse shaft on page 194

.

Mounting tool, bearing race and sealing, upper arm. Assembly is shown in the figure

Mounting tool, bearing race and sealing, upper arm on page 195 .

Dismounting tool, bearing race, upper arm. Assembly is shown in the figure

Dismounting tool, bearing race, upper arm on page 195

.

Press tool, link. Assembly is shown in the figure

Press tool, link on page 198 .

Press sleeve, art. no. specified in the table

Special tools on page 191 .

Dismounting tool, tilthouse shaft

The tool for removing the tilthouse shaft from the tilthouse is assembled with the parts shown in the figure below (included in the toolkit for service).

Note! The parts cannot be ordered separately, but are included in the complete toolkit! The article numbers are only given for identification.

xx0600002589

G

J

E

F

C

D

A

B





Nut, 3HAC5507-1


Nut, 3HAC023963-028

Pad, 3HAC023963-029



193


6.7. Special tools

Continued

Mounting tool, tilthouse shaft

The tool for fitting the tilthouse shaft to the tilthouse is assembled with the parts shown in the figure below (included in the toolkit for service).


xx0500002581

E

J

K

C

D

A

B





Nut, 3HAC5507-1

Pad, 3HAC023963-029


194




6.7. Special tools

Continued

Mounting tool, bearing race and sealing, upper arm

The tool for fitting the bearing race and sealing to the upper arm is assembled with the parts shown in the figure below (included in the toolkit for service).


xx0500002582

I

L

N

C

E

A

B




Nut, 3HAC5507-1


Press head, 3HAC023963-039


Dismounting tool, bearing race, upper arm

The tool for removing the bearing race from the upper arm is assembled with the parts shown in the figure below (included in the toolkit for service).


xx0600002656

A

B





195


6.7. Special tools

Continued

F

G

C

E

I

H


Nut, 3HAC5507-1


Nut, 3HAC023963-028



Dismounting tool, bearing race, tilthouse shaft

The tool for removing the bearing race from the tilthouse shaft is assembled with the parts shown in the figure below (included in the toolkit for service).


xx0600002657

E

G

M

C

D

A

B





Nut, 3HAC5507-1

Nut, 3HAC023963-028


196




6.7. Special tools

Continued

Mounting tool, bearing race, tilthouse shaft

The tool for fitting a bearing race to the tilthouse shaft is assembled with the parts shown in the figure below (included in the toolkit for service).


xx0600002658

G

H

D

E

A

B

C





Nut, 3HAC5507-1

Nut, 3HAC023963-028




197


6.7. Special tools

Continued

Press tool, link

The tool for fitting the bearing and the link to the upper arm shaft includes the parts shown in the figure below (included in the toolkit for service).

Note! The parts cannot be ordered separately, but are included in the complete toolkit! The article numbers are only given for identification!

xx0600002618

R

S

T

O

P

A

E


Nut, 3HAC5507-1

Connecting rod, 3HAC023081-003

Press housing, 3HAC024097-002

Auxiliary shaft, 3HAC024097-005

Screw, M6x12, 9ADA183-24 (2 pcs)

Distance, 3HAC023062-001

Calibration equipment, Calibration Pendulum

The table below specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method.


Note

Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating manual.

198 3HAC 026048-001 Revision: -


6.8. Lifting equipment and lifting instructions

6.8. Lifting equipment and lifting instructions

General

Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure.

The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment.

This implies that the instructions delivered with the lifting equipment should be stored for later reference.

3HAC 026048-001 Revision: - 199


6.8. Lifting equipment and lifting instructions

200 3HAC 026048-001 Revision: -

7 Spare part lists and exploded views

7.1. Introduction



Definitions

This chapter specifies all spare parts and replacement articles of the robot.

3HAC 026048-001 Revision: - 201


7.2. Spare parts - overview

7.2. Spare parts - overview

Overview - spare parts

The location of the different plates, labels and signs are shown in section

Inspection of information labels on page 78

.

Item

1

2

3

4

5

6

7

10

14

14

14

15

11

12

13

-

16

Qty

1

1

1

1

1

-

1

1

2

3

3

1

5

1

1

1

1

Description

Cover Foundry

Instruction plate

Robot IRB 260

Instruction plate

Rating label

Warning sign

Instruction plate

Conn.set R1.CP/CS,

Foundry

CP/CS Conn .set

ABB Logotype

Calibration label




Stop axis 1

Signal lamp

Material set

Spare part no.

Note/ specified in section:

-

Spare parts - cover on page 203

-

3HAC2814-2 Warning of brake release.

Spare parts - robot IRB

260 on page 205

2945 4489-16

3HAB9549-1

3HAC1589-1 Lightning flash.

3HAC025469-001 Lifting of robot.

3HAC12558-2

3HAC025223-001

3HAC0453-2

3HAC024307-001

3HAC12062-1

3HAC12062-2

3HAC12062-3

3HAB 7298-1

3HAC025254-001

3HAC24116-001

Includes one switch.

Includes two switches.

Includes three switches.

Spare parts - material set cabling axis 6 on page 221

202 3HAC 026048-001 Revision: -


7.3. Spare parts - cover

7.3. Spare parts - cover

Cover, spare part list

The items specified below are shown in the figure Cover, spare part view on page 204

.

Item Qty Description

63 9

104 1

105 1

121 1

Torx pan head roll. screw

Cover 2400 machined

Gasket, cover

BU w. buttons DSQC 563

122 4

123 1

129 1

157 1

158 1

170 1

Distance bolt

Push button guard

Signal cable SMB

Adaptor customer cabling

Adaptor power cabling

Cover pushbuttons

Spare part no.

Dimension/Note

9ADA629-43

3HAC8722-1

3HAC3200-1

3HAC16035-1

3HAC7819-1

3HAB7328-1

Recommended spare part.

Replacement is detailed in section

Replacement of brake release unit on page

145 .

2125 2052-198 M5X15

3HAC2744-1 Recommended spare part.


3HAC2809-1

3HAC3197-1



203


7.3. Spare parts - cover

Continued

Cover, spare part view

204 xx0500002436



7.4. Spare parts - robot IRB 260

7.4. Spare parts - robot IRB 260

Robot IRB 260, spare part list

The items specified below are shown in the figures Robot IRB 260, exploded view 1 of 2 on page 206 and Robot IRB 260, exploded view 2 of 2 on page 206

.

2

3

3

6

3

3

1

3

3

4

8

2

2

1

2

2

1

1

1

4

1

2

2

1

1

1

1

1

27

28

29

30

31

32

23

24

25

26

19

20

21

22

15

16

17

18

11

12

13

14

7

8

9

10

4

5

6


1

2

3

1

1

1

Spare part no.

Note

Axis 1-3

Upper arm -

Spare parts are shown in

section Spare parts - axes 1-

3 on page 208

.

Spare parts are shown in section

Spare parts - upper arm on page 216 .

Linkage Spare parts are shown in

section Spare parts - linkage on page 220 .


Shaft end

Shaft end

Spacer, axis 2

Spacer, axis 2

Shaft end

Lock nut

Taper roller bearing

Radial sealing

Lock nut

-


3HAC025740-001

3HAC025741-001

3HAB5527-1

2126 2851-107

3HAA2103-15

2126 2851-106

Distance -

Hex socket head cap screw 3HAB7700-71 M12x60, UNBRAKO 12.9

VK-cover

Washer

Ring

Support washer

3HAC12165-2

3HAA1001-134

-

3HAB6279-1

13x19x1,5

Lock nut

Bearing sealing

Locking washer

Hex socket counters, head

-

3HAC10088-4

3HAB5523-1

2121 2852-449

D=34; T=4

M8x16 Steel 8,8 Fe/Zn 5c

Loctite 243 Locking liquid

Mechanical stop, axis 3

Torx counters. head screw

Torx pan head screw

-

3HAC024253-001

9ADA624-56

9ADA618-53

M6x16 Steel 8.8-A2F

M6x8 Steel 8.8-A2F

Washer 3HAC020537-001 D=6,4/12 T=1,6

Hex socket head cap screw 3HAB3402-37 M8x25 Steel 8.8 Gleitmo 610

Damper axis 2

Plain washer

3HAB8284-1

9ADA312-6

Flanged bolt -

Hex socket head cap screw 3HAB3409-25 M6x20 Steel 12.9 Gleitmo

610



205



Continued


33

35

37

38

1

1

1

1

Protection hood

Lifting eye

Plain washer

Bearing sealing

Robot IRB 260, exploded view 1 of 2 xx0500001936

Robot IRB 260, exploded view 2 of 2

Spare part no.

Note

2522 2101-17

2179 090-25

9ADA312-9

3HAC10089-2

13x24x2,5

206 xx0500001937




3HAC 026048-001 Revision: - 207


7.5. Spare parts - axes 1-3

7.5. Spare parts - axes 1-3

Axes 1-3, spare part list

The items specified below are shown in the figures Axes 1-3, spare part view 1 on page 210

and Axes 1-3, spare part view 2 on page 211

.

208

4

5

6

7

8

42

43

46

34

35

36

17

19

32

33

13

14

15

16

9

11

12


1

2

3

41

Spare part no.

Dimension

1

1

12

Base Foundry

Gearbox, axes 1-3




Replacement of gearbox, axis 1-3 on page

169 .

Hex socket head cap screw M12x50 Steel 8.8 Gleitmo

610

3

12

4

12

2

Plain washer

Motor unit, axes 1 and 3

9ADA312-9 13x24x2.5



Replacement of motor, axis 1 on page 151

and

Replacement of motor, axis 3 on page 161 .

21522012-434 Recommended spare part.

O-ring

Spring washer 21542033-9

Hex socket head cap screw -

Hex socket head cap screw 3HAB3409-37

8.4x18x2

M8x65 Steel 12.9 Gleitmo

610

M8x25 8

8

12

1

4

1

1

1

1

8

2

1

1

1

Spring washer 21542033-10


Spring tension plate

Damper standard, axis 2

Sealing ring (V-ring)

3HAC2205-1

3HAC2180-1

Damper, axis 3 3HAB5512-1

Torx pan head roll. screw 9ADA629-56


3HAB3732-13

10.5x23x2.5

M10x40

M6x16

M10x60


14,700 ml

Bearing sealing

Locking washer

Hex socket counters, head 21212852-449

Bearing sealing 3HAC10089-2

Motor unit, axis 2

3HAC10088-4

3HAB5523-1

Lubricating oil


D=34; T=4

M8x16




Replacement of motor, axis 2 on page 156 .

11712016-604

165g

1 ml

1

Bearing grease

Locking liquid

Stop, axis 1

-

3HAB3537-1

3HAB6687-1

Shell Alvania WR2

Loctite 243





Continued


48

49

50

-

51

134 15

172 1

173 1

6

1

1

1

2

Spare part no.

Dimension

Washer

Friction washer

Calibration mark, axis 2

Parallel bar complete

Spherical roller bearing

21512082-150

3HAC0447-1

3HAB5522-1

6.1x20x2

3HAC025714-001

3HAA2167-12 Included in the complete parallel bar.

Torx pan head tapp. screw 21212477-331

Parallel arm complete

Lower arm

3HAC025727-001

3HAC025729-001



209



Continued

Axes 1-3, spare part view 1

210 xx0500002047









211



Continued

Axes 1-3, spare part list

The items specified below are shown in the figures Axes 1-3, spare part view 3 on page 213

,

Axes 1-3, spare part view 4 on page 214

and Axes 1-3, spare part view 5 on page 215

.

Item Qty Description Spare part no.

Dimension/Note

-

100 1

102 1

103 1

106 1

107 1

108 2

109 1

110 1

112 3

115 1

1

116 1

118 12

119 1

135 63

137 6

138 1

139 1

156 1

161 1

171 120 mm

Cable unit, axes 1-3

Bottom plate

Gasket

Sealing

Bracket

Holder for cableguide

Cable guide

Spring

Cover

Serial measurement unit

Battery pack

Torx pan head screw

Hexagon nut with flange

Cable straps, outdoors

-


Replacement is detailed in

section Replacement of cable unit, axes 1-3 on page 90

.

3HAC2828-1

3HAC4554-1

3HAC4113-1

3HAB5923-1

3HAB3299-1


3HAB5924-1

3HAB3662-1

3HAC025749-1

3HAC17396-1

3HAC16831-1

9ADA290-1

21662055-3


Torx pan head roll. screw

Cable straps, outdoors

Coupling

140 2 ml Locking liquid

141 1 Protective hood

147 3

149 1

Gasket

Gasket

150 1 ml Flange sealing

151 300 mm

Adhesive tape

152 1 Bracket

Parallel pin, hardened

Sealing

Profile

-

9ADA629-44

21662055-1

3HAB3333-20

25222101-8

3HAC4419-1

3HAB7160-1

12340011-116

11699198-301

3HAB5921-1

3HAC3785-3

3HAC5479-4

18661903-1



section Replacement of

SMB unit on page 142

.

Lithium battery.

Included in the serial measurement unit kit.


section Replacement, SMB battery on page 84

.

M5x16 Steel 8.8 Fe/ZN 5c

M5

M8x12

M5x12

Loctite 542

212









213



Continued


214 xx0500002085

C

D

A

B

The housing must be removed from the cabling for foundry option

Conductors from R2.BU, R2.BU1-3, R2.BU4-6 and PE conductors under strap

Option: internal connectors

Option: external connectors







3HAC 026048-001 Revision: - 215


7.6. Spare parts - upper arm

7.6. Spare parts - upper arm

Upper arm, spare part list

The items specified below are shown in the figure Upper arm, exploded view on page 217

.

3

4

5

6

9

10

11

12

13


1

2

7

8

14

15

Spare part no.

Dimension

2

1

2

3

2

2

1

1

1

1

1

Tilthouse Spare parts are specified in

section Spare parts - tilthouse on page 218 .


Sealing ring with dust lip

Protection hood

3HAB3701-25

Sealing ring

Lock nut


25222101-17

3HAC7877-2

21262851-106

3HAA2103-14


VK-cover 3HAA2166-15



section Replacement of shaft and bearings, tilthouse on page 102 .


Shaft 3HAC024867-001 Recommended spare part.


section Replacement of shaft and bearings, tilthouse on page 102 .

Upper arm machining 3HAC025737-001

Ballplug

Protection cap



4

4

Torx pan head screw 9ADA618-53

Washer 3HAC020537-001

M6x8

D=6,4/12 T=1,6


Locking liquid -

60 g Bearing grease 3HAB3537-1 Shell Alvania WR2

216



Upper arm, exploded view


7.6. Spare parts - upper arm


3HAC 026048-001 Revision: - 217


7.7. Spare parts - tilthouse

7.7. Spare parts - tilthouse

Tilthouse, spare part list

The items specified below are shown in the figure Tilthouse, exploded view on page 219 .

13

14

15

17

18

10

11

12

7

8

9


3

4

5

6

1

2

19

20

Spare part no.

Dimension

1

1

6

1

2

2

1

1

1

8

8

1

Tilthouse, machining

Rot. ac motor incl. pinion

RV-6E, i=79

3HAC025733-001



section Replacement of motor, axis 6 on page 166 .



section Replacement of gearbox, axis 6 on page

172

.


Plain washer

Turning disk

Sync. plate

Torx pan head screw

Magnetic plug

9ADA618-32

2522122-1


610

9ADA312-5 5,3x10x1



section Replacement of turning disk on page 113

.

3HAC024689-001

M4x8

Plug

Protection cover


25291920-2

3HAC025212-001

R 1/8"


610


4

1

6

4

O-ring 3HAB3772-89


Plain washer

O-ring

9ADA312-6

3HAB3772-16

1

1

70 ml Lubricating oil, Shell Tivela

S150

3HAC021469-001

Torx counters.head screw 9ADA624-69

Washer 21524411-1


M8x20

13,5x18x1,5

218



Tilthouse, exploded view


7.7. Spare parts - tilthouse


3HAC 026048-001 Revision: - 219


7.8. Spare parts - linkage

7.8. Spare parts - linkage

Linkage, spare part list

Item Qty

4

5

6

1

2

3

1

2

4

1

1

1

Description

Parallel rod, lower

Parallel rod upper

Radial Seal 35x62x7

Link machining


Needle bearing

Linkage, exploded view

Spare part no.

3HAC024576-001

-

3HAC024575-001

-

-

3HAB6432-1

Dimension

220 xx0500001933



7.9. Spare parts - material set cabling axis 6

7.9. Spare parts - material set cabling axis 6

Material set cabling axis 6, spare part list

The items specified below are shown in the figure Material set cabling axis 6, spare part view on page 222

.

8

9

6

7

10

2

3

5

2

1

6

2

4

1

1

1


1 1

Spare part no.

Dimension/Note

Cable unit axis 6 3HAC024115-001 Recommended spare part.


Replacement of cable unit, axis 6 on page

96 .

Connection box CP/CS/AIR 3HAC024194-001 Recommended spare part.

Dust cap

Coupling

Torx pan head screw

Square washer -

3HEA800897-002

3HAB3333-20

9ADA618-57 M6x20 Steel 8.8-A2F

Torx pan head screw

Cable bracket tilt house

Torx pan head screw

M5x16 Steel 8.8 Fe/ZN 5c


9ADA618-23 M3x8 Steel 8.8-A2F



221


7.9. Spare parts - material set cabling axis 6

Continued

Material set cabling axis 6, spare part view

222 xx0500002438


8 Circuit diagram


Overview

This chapter includes the circuit diagram for the robot.


8.1. Introduction

3HAC 026048-001 Revision: - 223


8.1. Introduction

224 3HAC 026048-001 Revision: -

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Symbols

¶restricting working range axis 1

63

A

Absolute Accuracy, calibration

177

application manual article number

8

attachment screws securing robot

47

B brake release unit, replacing

145

brakes releasing manually

45

testing function

24

C cabling axes 1-3, replacing

90

cabling axis 6, replacing

96

cabling, position switch

73

cabling, robot

72

calibrating roughly

180

calibration

Absolute Accuracy type

176


177

marks/scales

178

rough

180

standard method

177

standard type

176

when to calibrate

175

calibration manuals

177


177

calibration position

180

checking

182

jogging to, FlexPendant

182

scales

178

calibration, Absolute Accuracy

177

CalibWare

176

chains lifting of robot

42

chains, lifting of robot

43

conditions operating

39

storage

39

Connection of external safety devices

14

connectors on robot, figure

71

customer connections

71

D dimensions

49

direction of axes

179

document references

8

documentation article numbers, other manuals

8

references

8

drilling pattern, mechanical stop axis 1

60


Index

E endurance load

38

ESD damage elimination

33

sensitive equipment

33

explanation, safety symbols

29

F figures connectors on robot

71

where to use special tools

192

fitting equipment on robot

49

FlexPendant jogging to calibration position

182

MoveAbsJ instruction

182

updating revolution counters

180

forces and torques on robot

38

foundation

38

attachment screws

47

orienting and securing robot

47

requirements

39

G gearbox axes 1-3, replacing

169

gearbox axis 6, replacing

172

guide sleeves securing robot

48

H hole configuration robot base

47

hydraulic pump

103

,

117

,

191

I illustrations connectors on robot

71

inspection labels

78

installation loads on foundation

38

mechanical stop axis 1

58


66


69

position switch axis 1

63

prior to

38

signal lamp

55

interval maintenance

77

L labels, location

78

lifting robot

42

upper arm

118

lifting of robot chains

43

slings

42

linkage replacing link

129

replacing lower rod

126

replacing upper rod

123

225

Index load diagram

54

loads

38

loads on foundation

38

location of connectors

71

lower arm replacing

134

securing

136

M maintenance intervals

77

maintenance schedule

77

manually releasing the brakes

45

manuals reference documentation

8


58

axis 2

66

axis 3

69

motion of axes

40

motor axis 1, replacing

151


156


161


166

motor connectors

71

MoveAbsJ instruction

FlexPendant

182

N negative directions, axes

179

O oil change gearbox axis 6 (wrist unit)

81

safety risks

34

oil in gearboxes, type and amount

80

operating conditions

39

operating manual article number

8

option signal lamp

55

orienting and securing robot

47

P parallel arm, replacing

147

parallel bar, replacing

138


63

position switch axis 1 article number

64

position, robot

178

positive directions, axes

179

product manual, controller article number

8

product specification article number

8

protection class

39

R

R1.MP connector, supplying power to

46

references, other manuals

8

releasing brakes

45

226 replacing brake release unit

145

cable unit axes 1-3

90

cabling axis 6

96

gearbox axes 1-3

169

gearbox axis 6

172

link, linkage

129

lower arm

134

,

136

lower rod, linkage

126

motor axis 1

151

motor axis 2

156

motor axis 3

161

motor axis 6

166

parallel arm

147

parallel bar

138

shaft and bearings at tilthouse

102

SMB battery

83

SMB unit

142

tie rod

138

turning disk

113

upper arm

116

upper rod, linkage

123

requirements foundation

39

restricting working range axis 1

58

working range axis 2

66

working range axis 3

69

revolution counters storing on FlexPendant

180

updating

180

robot connectors

71

dimensions

49

fitting equipment

49

orienting and securing

47

spare parts

205

robot position

178

S safety equipment mechanical stop axis 1

58


66


69


63

Safety, service

14

safety, symbols

29

scales on robot

178

schedule for maintenance

77

signal connectors

71

signal lamp

55

slings, lifting of robot

42

SMB battery, replacing

83

SMB unit, replacing

142

spare parts axes 1-3

208

cabling axis 6

221

cover

203

linkage

220

overview

202


Index robot

205

tilthouse

218

upper arm

216

special tools

191

storage conditions

39

symbols, safety

29

sync marks. See calibration - marks.

T technical reference manual article number

8

testing, brakes

24

tie rod, replacing

138

tightening torque gearbox axes 1-3

171

gearbox axis 6

173

lower arm

137

motor, axis 1

154

motor, axis 2

160

motor, axis 3

164

motor, axis 6

167

parallel arm

149

turning disk

114

upper arm

120

tilthouse shaft, replacing

102

tools

Calibration Pendulum equipment

198

dismounting tilthouse shaft

193

for service

191

hydraulic pump

103

,

117

,

191

mounting shaft and bearings at link

193

,

198

mounting tilthouse bearing race and sealing

193

,

195

mounting tilthouse shaft

193

,

194

turning disk attachment holes

52

dimensions

52

replacing

113

turning radius axis 2

51

U updating revolution counters

180

upper arm, replacing

116

V

Validity and responsibility

14

W weight gearbox unit

170

,

171

lower arm

135

,

137

robot

38

,

44

upper arm

118

,

119

,

139

working range

40

restricting axis 1

58

,

63

restricting axis 2

66

restricting axis 3

69


Index


ABB AB

Robotics Products

S-721 68 VÄSTERÅS

SWEDEN

Telephone: +46 (0) 21 344000

Telefax: +46 (0) 21 132592

ABB IRB 260 Product Manual

Product manual

Articulated robot

Product manual

IRB 260

1 Safety

2 Installation and commissioning

3 Maintenance

4 Repair

5 Calibration information

6 Reference information

7 Spare part lists and exploded views

8 Circuit diagram

Related manuals

Table of contents

ABB IRB 260 Product Manual

Product manual

Articulated robot

Product manual

IRB 260

1 Safety

2 Installation and commissioning

3 Maintenance

4 Repair

5 Calibration information

6 Reference information

7 Spare part lists and exploded views

8 Circuit diagram

Related manuals

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XL-5700

Brother

PR-620/620C/600II/600IIC

ABB

IRB 260

ABB

IRB 6660 - 130/3.1

ABB

IRB 140T type C

ABB

IRB 760 Series

ABB

IRB1410

ABB

IRB 140T-6/0.8

ABB

IRB 460-110/2.4

ABB

MTD 500

ABB

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ABB

IRB 14000

Table of contents