Page 1 Product manual Articulated robot IRB 6600 - 225/2.55 type B IRB 6600 - 175/2.8 type B IRB 6650 - 200/2.75 type B IRB 6650 - 125/3.2 type B IRB 6600ID - 185/2.55 IRB 6650ID - 170/2.75 M2000, M2000A, M2004...
Page 3 Product manual IRB 6600 - 225/2.55 type B IRB 6600 - 175/2.8 type B IRB 6650 - 200/2.75 type B IRB 6650 - 125/3.2 type B IRB 6600ID - 185/2.55 IRB 6650ID - 170/2.75 M2000 M2000A M2004 Document ID: 3HAC023082-001...
Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
Table of Contents Overview ................9 Product documentation, M2000/M2000A .
Page 6 Table of Contents 2.6 Restricting the working range ............104 2.6.1 Introduction .
Page 7 Table of Contents 3.7.4 Setting the SIS parameters ............219 3.7.5 Reading the SIS output logs .
Page 8 Table of Contents 5.5 Updating revolution counters ............415 5.6 Checking the calibration position.
Page 9 Table of Contents 11 Circuit Diagram 11.1 Introduction ..............485 11.2 Circuit diagram 3HAC 025744-001.
Page 10 Table of Contents 3HAC023082-001 Revision: E...
Page 11: Overview
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:...
Page 12 Overview Continued References Following documents are referred to throughout the manual: Document name Document ID Note Product specification - IRB 6600/6650/6650S 3HAC023933-001 M2004 M2004 Product specification - IRB 6600/6650/6650S 3HAC14064-1 M2000/M2000A M2000/M2000A Product manual - IRC5 3HAC021313-001 Product manual - S4Cplus M2000 3HAC021333-001 Product manual - S4Cplus M2000A 3HAC022419-001...
Page 13 Overview Continued Revisions Revision Description First edition Chapter Calibration is replaced with new chapter Calibration information. Chapter Safety, Service is replaced with new chapter Safety. Section Document references is completed with article number for calibration manuals. New lubricating oil in the gearboxes, axes 1, 2, 3 and 6. Changes are made in chapter Maintenance and section...
Page 14: Product Documentation, M2000/M2000A
A complete listing of all available software manuals is available from ABB. Controller hardware option manual Each hardware option for the controller is supplied with its own documentation. Each document set contains the types of information specified below: •...
Page 15: Product Documentation, M2004
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.
Page 16 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) •...
Page 17: How To Read The Product Manual
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.
Page 18 How to read the product manual 3HAC023082-001 Revision: E...
Page 19: Safety
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 •...
Page 20: General Safety Information
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...
Page 21: Safety Risks
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 •...
Page 22 1 Safety 1.2.2.1. Safety risks during installation and service work on robot Continued Complete robot Safety risk Description Hot components! CAUTION! Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! Removed parts may result in collapse of robot! WARNING! Take any necessary measures to ensure that the robot...
Page 23: Safety Risks Related To Tools/Workpieces
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).
Page 24: Safety Risks Related To Pneumatic/Hydraulic Systems
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.
Page 25: Safety Risks During Operational Disturbances
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.
Page 26: Risks Associated With Live Electric Parts
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.
Page 27 1 Safety 1.2.2.5. Risks associated with live electric parts Continued Voltage related risks, IRC5 controller A danger of high voltage is associated with for example the following parts: • Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the controller.
Page 28: Safety Actions
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.
Page 29: Fire Extinguishing
1 Safety 1.2.3.2. Fire extinguishing 1.2.3.2. Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot system (manipulator or controller)! 3HAC023082-001 Revision: E...
Page 30: Emergency Release Of The Robot's Arm
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: •...
Page 31: Brake Testing
1 Safety 1.2.3.4. Brake testing 1.2.3.4. Brake testing When to test During operation the holding brake of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function. How to test The function of the holding brake of each axis motor may be checked as detailed below: 1.
Page 32: Risk Of Disabling Function "Reduced Speed 250 Mm/S
1 Safety 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" NOTE! Do not change "Transm gear ratio" or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s". 3HAC023082-001 Revision: E...
Page 33: Safe Use Of The Flexpendant
1 Safety 1.2.3.6. Safe use of the FlexPendant 1.2.3.6. Safe use of the FlexPendant NOTE! The enabling device is a push button located on the side of the FlexPendant which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.
Page 34: Work Inside The Manipulator's Working Range
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.
Page 35: Signal Lamp (Optional)
1 Safety 1.2.3.8. Signal lamp (optional) 1.2.3.8. Signal lamp (optional) Description A signal lamp with an yellow fixed light can be mounted on the manipulator, as a safety device. Function The lamp is active in MOTORS ON mode. Further information Further information about the MOTORS ON/MOTORS OFF mode may be found in the controller documentation.
Page 36: Translate The Information On Safety And Information Labels
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.
Page 37: Safety Related Instructions
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: •...
Page 38 1 Safety 1.3.1. Safety signals, general Continued Symbol Designation Signification ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates DISCHARGE (ESD) electrostatic hazards which could result in severe damage to the product. Electrostatic discharge (ESD) NOTE Note symbols alert you to important facts and conditions.
Page 39: Danger - Moving Manipulators Are Potentially Lethal
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.
Page 40: Danger - First Test Run May Cause Injury Or Damage
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):...
Page 41: Warning - The Brake Release Buttons May Be Jammed After Service Work
1 Safety 1.3.4. WARNING - The brake release buttons may be jammed after service work 1.3.4. WARNING - The brake release buttons may be jammed after service work Description The brake release unit has push buttons for brake release of each axis motor. When service work is performed inside the SMB recess that includes removal and refitting of the brake release unit, the brake release buttons may be jammed after refitting! In case the power is turned on while a brake release button is jammed in depressed position,...
Page 42: Warning - The Unit Is Sensitive To Esd
1 Safety 1.3.5. WARNING - The unit is sensitive to ESD! 1.3.5. 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.
Page 43: Warning - Safety Risks During Work With Gearbox Oil
1 Safety 1.3.6. WARNING - Safety risks during work with gearbox oil 1.3.6. WARNING - Safety risks during work with gearbox oil Description When handling the gearbox oil, there are several dangers to both personal injuries and product damages! Following safety information must be regarded before performing any work with the oil in the gearboxes! Warnings and elimination Warning...
Page 44 1 Safety 1.3.6. WARNING - Safety risks during work with gearbox oil 3HAC023082-001 Revision: E...
Page 45: Installation And Commissioning
2 Installation and commissioning 2.1. Introduction 2 Installation and commissioning 2.1. Introduction General This chapter contains information for installing the robot to the working site. 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. 3HAC023082-001 Revision: E...
Page 46: Robot Transportation Precautions
Transportation in any other way than method 1 or 2 can seriously damage the robot.If the robot is incorrectly transported and the instructions are not followed, the robot is not covered by the warranty and ABB will not accept any compensation claim. Method 1 Transportation according to method 1 is strongly recommended by ABB.
Page 47 2 Installation and commissioning 2.2. Robot transportation precautions Continued Method 2 Transportation according to method 2 is approved by ABB, if use of method 1 is not possible. Always follow these instructions when transporting an ABB robot according to method 2: •...
Page 48 2 Installation and commissioning 2.2. Robot transportation precautions Continued IRB6620 xx0800000036 Transport Support Hexagon socket head cap screw M10x50 Threaded bar M10x280 Nut M10 Continues on next page 3HAC023082-001 Revision: E...
Page 49 2 Installation and commissioning 2.2. Robot transportation precautions Continued Transport position with a transport support All transportation of the robot with tool must follow these instructions. IRB 7600/IRB 66XX xx0800000040 Continues on next page 3HAC023082-001 Revision: E...
Page 50 2 Installation and commissioning 2.2. Robot transportation precautions Continued IRB 6620 xx0800000041 Continues on next page 3HAC023082-001 Revision: E...
Page 51 2 Installation and commissioning 2.2. Robot transportation precautions Continued Recommended transport support Always use the recommended transport support when transporting a robot with tool. IRB 7600/IRB 66XX xx0800000039 Continues on next page 3HAC023082-001 Revision: E...
Page 52 2 Installation and commissioning 2.2. Robot transportation precautions Continued IRB 6620 xx0800000038 3HAC023082-001 Revision: E...
Page 53: Securing The Robot
2 Installation and commissioning 2.3. Securing the robot 2.3. Securing the robot General This section describes how to secure the robot using the transport support. DANGER! Releasing the brakes is a hazardous action that may cause injury and damage property. It must be done with great care and only when absolutely necessary.
Page 54 2 Installation and commissioning 2.3. Securing the robot Continued Action Note 1. Mount the transport support lower end to the Do not tightening the screw. robot using the recommended screw joint, (A) See attachment point for the specific in figure. robot in section Transport position with a transport...
Page 55: Unpacking
2 Installation and commissioning 2.4.1. Pre-installation procedure 2.4 Unpacking 2.4.1. Pre-installation procedure General This section is intended for use when unpacking and installing the robot for the first time. It also contains information useful during later re-installation of the robot. Checking the pre-requisites for installation The checklist below details what must be observed before proceeding with the actual installation of the robot:...
Page 56 0.5 mm Max. tilt 5° The limit for the maximum load on the robot is reduced if the robot is tilted. Contact ABB for further information about acceptable loads. Min. resonance frequency 22 Hz Storage conditions, robot The table below shows the allowed storage conditions for the robot:...
Page 57 2 Installation and commissioning 2.4.1. Pre-installation procedure Continued Protection classes, robot The table below shows the protection class of the robot: Equipment Protection class Robot IP 67 Cooling fans (option) IP 54 3HAC023082-001 Revision: E...
Page 58: Working Range And Type Of Motion
2 Installation and commissioning 2.4.2. Working range and type of motion 2.4.2. Working range and type of motion Working range Following figures show the working ranges of the robot models. The extreme positions of the robot arm are specified at the wrist center (dimensions in mm). IRB 6600 - 225/2.55, IRB 6600ID - 185/2.55 The illustration below shows the unrestricted working range: xx0200000025...
Page 59 2 Installation and commissioning 2.4.2. Working range and type of motion Continued IRB 6600 - 175/2.8 The illustration below shows the unrestricted working range: xx0200000026 Continues on next page 3HAC023082-001 Revision: E...
Page 60 2 Installation and commissioning 2.4.2. Working range and type of motion Continued IRB 6650 - 125/3.2 The illustration below shows the unrestricted working range: xx0200000338 Continues on next page 3HAC023082-001 Revision: E...
Page 61 2 Installation and commissioning 2.4.2. Working range and type of motion Continued IRB 6650 - 200/2.75,IRB 6650ID - 170/2.75 The illustration below shows the unrestricted working range: xx0200000339 Type of motion Axis Type of motion Range of movement Note Rotation motion +180º...
Page 62: Risk Of Tipping / Stability
2 Installation and commissioning 2.4.3. Risk of tipping / stability 2.4.3. Risk of tipping / stability Risk of tipping When the robot is not fastened to the foundation and standing still, the robot is not stable in the whole working area. Moving the arms will displace the center of gravity, which may cause the robot to tip over.
Page 63: On-Site Installation
2 Installation and commissioning 2.5.1. Lifting robot with fork lift 2.5 On-site installation 2.5.1. Lifting robot with fork lift General The robot may be moved using a fork lift, provided that available special aids are used. This section describes how to attach the fork lift equipment to the robot. Attachment points The attachment points for the fork lift equipment are shown in the figure below.
Page 64 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Required equipment Equipment, etc. Art. no. Note Fork lift set, incl. all required 3HAC 0604-1 See the figure Fork lift set, 3HAC 0604-1 hardware on page Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual.
Page 65 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Lifting the robot with fork lift The section below details how to secure the fork lift set to the robot in order to lift and move the robot using the fork lift ONLY! Action Note/Illustration 1.
Page 66 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Action Note/Illustration 6. Make sure the securing screw is removed from the fork lift pocket! It is only used for robot model IRB 6650S. xx0400000977 • A: securing screw 7.
Page 67 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Action Note/Illustration 10. Double-check that the pockets are properly secured to the robot! Insert the fork lift forks into the pockets. xx0200000380 Reposition the harness, if any, before using a fork lift! CAUTION! The robot models weigh: •...
Page 68: Lifting Robot With Roundslings
2 Installation and commissioning 2.5.2. Lifting robot with roundslings 2.5.2. Lifting robot with roundslings General The robot may be lifted with roundslings according to the illustration below. The illustration is identical with the label attached to the robot’s lower arm. Attachment points The figure below shows how to attach the roundslings to the robot.
Page 69 2 Installation and commissioning 2.5.2. Lifting robot with roundslings Continued Sling specification Sling type Lifting capacity Length / Note Chain sling with shortener 3 pcs 4 250 kg 0.47 m 0.54 m 0.76 m Roundsling, robot 3 pcs 2 000 kg Roundsling, upper arm 2 pcs 2 000 kg...
Page 70: Lifting Robot With Lifting Slings
2 Installation and commissioning 2.5.3. Lifting robot with lifting slings 2.5.3. Lifting robot with lifting slings General This section contains a general overview of how to lift the complete robot using special lifting equipment. More detailed instructions are included with the equipment. Illustration, lifting slings The figure below shows how to lift the complete robot with lifting slings.
Page 71 2 Installation and commissioning 2.5.3. Lifting robot with lifting slings Continued Required equipment Equipment Art. no. Note Lifting device, robot 3HAC 15607-1 Includes • user instructions (3HAC 15971-2). Slings attached directly onto robot The section below details how to lift and move the robot using lifting slings when these are attached directly onto the robot frame.
Page 72 2 Installation and commissioning 2.5.3. Lifting robot with lifting slings Continued Action Note/Illustration 6. Raise the overhead crane to lift the robot. Make sure all hooks and attachments maintain their correct positions while lifting the robot! Always move the robot at very low speeds, making sure it does not tip.
Page 73: Manually Releasing The Brakes
2 Installation and commissioning 2.5.4. Manually releasing the brakes 2.5.4. Manually releasing the brakes General This section details how to release the holding brakes of each axis motor. Location of brake release unit The internal brake release unit is located at the frame, as shown in the figure below. xx0300000044 Internal brake release unit with push buttons.
Page 74 2 Installation and commissioning 2.5.4. 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 buttons on the robot. Action Note/Illustration DANGER!
Page 75: Lifting The Base Plate
2 Installation and commissioning 2.5.5. Lifting the base plate 2.5.5. Lifting the base plate Required equipment Equipment Art. no. Note Lifting eye, M16 3HAC 14457-4 3 pcs Lifting slings 3 pcs Length: approx. 2 m Hole configuration xx0200000096 Attachment holes for lifting eyes (x3) Lifting, base plate Action Note...
Page 76: Securing The Base Plate
2 Installation and commissioning 2.5.6. Securing the base plate 2.5.6. Securing the base plate General This section details how to secure the base plate. Base plate, dimensions xx0100000105 Continues on next page 3HAC023082-001 Revision: E...
Page 77 2 Installation and commissioning 2.5.6. Securing the base plate Continued xx0400000715 Note1 Four holes for alternative clamping Continues on next page 3HAC023082-001 Revision: E...
Page 78 A drawing of the base plate itself may be ordered from ABB Robotics! Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual.
Page 79 2 Installation and commissioning 2.5.6. Securing the base plate Continued Recommendations, quality The table specifies any recommendations made by ABB: Variable Recommendation Recommended foundation quality 1 Steel fibre reinforced concrete foundation, 30 kg/m3, class K30, t=250 mm Recommended foundation quality 2 Sturdy concrete foundation, double reinforced by ø10...
Page 80: Orienting And Securing The Robot
2 Installation and commissioning 2.5.7. Orienting and securing the robot 2.5.7. Orienting and securing the robot General This section details how to orient and secure the robot to the base plate in order to run the robot safely. The requirements made on the foundations are shown in the following tables and figures.
Page 81 2 Installation and commissioning 2.5.7. Orienting and securing the robot Continued Securing the robot The procedure below details how to secure the robot to the base plate after fitting the plate to the foundation. Action Note/Illustration 1. Lift the robot. Detailed in section Lifting robot with lifting slings on page...
Page 82 2 Installation and commissioning 2.5.7. Orienting and securing the robot Continued Cross section, guide sleeve hole The illustration below shows the cross section of the guide sleeve holes. xx0600002629 3HAC023082-001 Revision: E...
Page 83: Fitting Equipment On Robot
2 Installation and commissioning 2.5.8. Fitting equipment on robot 2.5.8. Fitting equipment on robot General The robot features mounting holes for additional equipment. Access to any of the following mounting holes may be obstructed by any additional cabling, equipment etc. fitted by the robot user. Make sure the required mounting holes are accessible when planning the robot cell.
Page 84 2 Installation and commissioning 2.5.8. Fitting equipment on robot Continued xx0300000571 Only valid for IRB 6600 and IRB 6650! xx0300000572 Only valid for IRB 6600 and IRB 6650! Continues on next page 3HAC023082-001 Revision: E...
Page 85 2 Installation and commissioning 2.5.8. Fitting equipment on robot Continued Illustration, fitting of extra equipment on upper arm The illustration below shows the mounting holes available for fitting extra equipment on the upper arm. Note! Extra equipment may not be mounted on the upper arm of IRB 6600ID or IRB 6650ID! xx0300000573 Only valid for IRB 6600 and IRB 6650 xx0200000196...
Page 86 2 Installation and commissioning 2.5.8. Fitting equipment on robot Continued Illustration, fitting of extra equipment on frame The illustration below shows the mounting holes available for fitting extra equipment on the frame. xx0500001568 Early version of the frame Later version of the frame Continues on next page 3HAC023082-001 Revision: E...
Page 87 2 Installation and commissioning 2.5.8. Fitting equipment on robot Continued Illustration, fitting on turning disk The illustration below shows the mounting holes available for fitting equipment on the turning disk. xx0200000197 Turning disk for robot version IRB 6600 - 225/2.55 and - 175/2.8, IRB 6650 - 125/3.2 and - 200/2.75 Continues on next page 3HAC023082-001 Revision: E...
Page 88 2 Installation and commissioning 2.5.8. Fitting equipment on robot Continued xx0500001580 Turning disk unit for robot versions IRB 6600ID and IRB 6650ID. Fastener quality When fitting tools on the turning disk (see the figures above), use only screws with quality 12.9.
Page 89: Installation Of Chip And Dust Protection (Option)
2 Installation and commissioning 2.5.9. Installation of chip and dust protection (option) 2.5.9. Installation of chip and dust protection (option) General This section details how to install the optional chip and dust protection. It also details how to remove the proctection, when necessary. Illustration, equipment mounted on robot The illustration below shows the chip and dust protection mounted on the robot.
Page 90 2 Installation and commissioning 2.5.9. Installation of chip and dust protection (option) Continued Equipment Art. no. Note Locking liquid Loctite 577 Used to secure the attachment screws of the rear cover at the end of the balancing device. Standard toolkit 3HAC 15571-1 The contents are defined in section...
Page 91 2 Installation and commissioning 2.5.9. Installation of chip and dust protection (option) Continued Action Note/Illustration 2. Remove the four attachment screws (A) from the cover, axis 2. Use the holes to attach the bearing as described in next step. xx0400001103 3.
Page 92 2 Installation and commissioning 2.5.9. Installation of chip and dust protection (option) Continued Action Note/Illustration 5. Fit the stop to the robot. Use the enclosed attachment screws. xx0400001080 • C: Attachment screws: 2 pcs, M6x25. 6. Remove the rear bracket from the upper shield.
Page 93 2 Installation and commissioning 2.5.9. Installation of chip and dust protection (option) Continued Action Note/Illustration 7. Fit the four shields to the robot with enclosed attachment screws. Begin with the shield at the bottom and continue upwards, correct order is shown in the figure to the right.
Page 94 2 Installation and commissioning 2.5.9. Installation of chip and dust protection (option) Continued Action Note/Illustration 9. Secure the cover, balancing device to the robot with the original attachment screws, earlier removed from the rear cover of the balancing device. Use locking liquid.
Page 95 2 Installation and commissioning 2.5.9. Installation of chip and dust protection (option) Continued Action Note/Illustration 11. Fit the rubber cloth of the sliding cover between the upper shield and the rear bracket (earlier removed from the upper shield). Attach the rear bracket with enclosed attachment screws.
Page 96 2 Installation and commissioning 2.5.9. Installation of chip and dust protection (option) Continued Part to be removed Action Bearing unit, axis 2 motor 1. Remove all the shields. 2. Remove the bearing unit. 3. Refit the original attachment screws to the cover, axis 2.
Page 97: Installation Of Base Spacers (Option)
2 Installation and commissioning 2.5.10. Installation of base spacers (option) 2.5.10. Installation of base spacers (option) Illustration, installation of base spacers xx0500001570 Base spacer (4 pcs) Guide sleeve (4 pcs) Attachment screws and washers (8 pcs) Required equipment Equipment Art. no. Note Base spacers 3HAC 021899-002...
Page 98 2 Installation and commissioning 2.5.10. Installation of base spacers (option) Continued Equipment Art. no. Note Other tools and procedures These procedures include may be required. See references to the tools references to these required. procedures in the step-by- step instructions below. Installation, base spacers The procedure below details how to fit the base spacers between the robot and the base plate.
Page 99: Installation Of Cooling Fan For Motors, Axes 1-3 (Option)
2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) General A cooling fan can be installed on the motors of axes 1, 2 and 3. However, cooling fans for axes 1 and 2 can not be combined! The cabling for the fans is available in different designs: •...
Page 100 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued Cooling fan The details of the cooling fan are shown in the figure below. xx0500002158 Fanbox Attachment screws, fanbox plates (9 pcs) Groove in the connector Tightening screws, fanbox (3 pcs) Required equipment Equipment...
Page 101 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued Equipment Art. no. Note Plate for customer 3HAC025778-001 An additional connection plate must be connections fitted to the robot base, if not already installed. The plate is shown in the figure Plate for customer connections, at base on page Additional cabling to and...
Page 102 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued Installation, fan The procedure below details how to install the cooling fan on any of the motors, axes 1-3. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 103 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued Installation, separate fan cabling axis 1 or 2 The procedure below details how to install the separate cabling for the cooling fan of axis 1 or 2.
Page 104 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued Action Note/Illustration 7. Connect the connector R3.FAN2 to the fan of axis Note! Fans on both axis 1 and 2 1 or 2. can not be used at the same time! 8.
Page 105: Loads
Specification. The loads must also be defined in the software as detailed in User's Guide(RobotWare 4.0)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. 3HAC023082-001 Revision: E...
Page 106: Restricting The Working Range
2 Installation and commissioning 2.6.1. Introduction 2.6 Restricting the working range 2.6.1. 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: •...
Page 107: Mechanically Restricting The Working Range Of Axis 1
2 Installation and commissioning 2.6.2. Mechanically restricting the working range of axis 1 2.6.2. Mechanically restricting the working range of axis 1 General The working range of axis 1 is limited by fixed mechanical stops and can be reduced by adding additional mechanical stops giving 7.5 or 15 graduation, between 22.5°...
Page 108 2 Installation and commissioning 2.6.2. Mechanically restricting the working range of axis 1 Continued Equipment, etc. Art. no. Note User’s guide - S4Cplus (RobotWare Art. no. is specified in section 4.0) References on page Technical reference manual - System parameters (RobotWare 5.0) Installation, mechanical stops axis 1 The procedure below details how to fit the mechanical stops of axis 1 to the robot.
Page 109: Mechanically Restricting The Working Range Of Axis 2
2 Installation and commissioning 2.6.3. Mechanically restricting the working range of axis 2 2.6.3. Mechanically restricting the working range of axis 2 General The working range of axis 2 is limited by fixed mechanical stops and can be reduced by adding up to six additional mechanical stops with 15 graduation in respective direction.
Page 110 2 Installation and commissioning 2.6.3. Mechanically restricting the working range of axis 2 Continued Installation, mechanical stops axis 2 The procedure below details how to fit the mechanical stops for axis 2 to the robot. An assembly drawing is also enclosed with the product. Action Note DANGER!
Page 111: Mechanically Restricting The Working Range Of Axis 3
2 Installation and commissioning 2.6.4. Mechanically restricting the working range of axis 3 2.6.4. Mechanically restricting the working range of axis 3 General The working range of axis 3 is limited by fixed mechanical stops and can be reduced by adding additional mechanical stops with 20 graduation in respective direction.
Page 112 2 Installation and commissioning 2.6.4. Mechanically restricting the working range of axis 3 Continued Installation, mechanical stops axis 3 The procedure below details how to fit the mechanical stops for axis 3 to the robot. An assembly drawing is also enclosed with the product. Action Note DANGER!
Page 113: Installation Of Position Switches (Option)
The position switch kits may be delivered in one of two ways: • Fitted by ABB Robotics on delivery. In this case, the cams must still be fitted and locked by the user. For axis 1, the cover for the cams must also be fitted.
Page 114 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Axis 1 The illustration below shows the position switch for axis 1. There is no extra cabling installed on the robot, as for axes 2 and 3. Instead the switch is connected directly to the connector in the base, R1.SW1.
Page 115 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Axis 2 The illustration below shows the position switch for axis 2. In addition to the shown components, cabling must also be installed from the switch to the robot base. xx0100000159 Position switch, axis 2 Set screw, cam (cam stop)
Page 116 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Axis 3 The illustration below shows the position switch for axis 3. In addition to the shown components, cabling must also be installed from the switch to the robot base. xx0100000160 Position switch, axis 3 Set screw, cam (cam stop)
Page 117 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Connections The position switches are connected to different points on the robot system: • XT8, screw terminal in the controller cabinet when position switch cables are used. • R1.SW1 at the robot base. Customer connection kit is recommended, art. no. is specified in Required equipment on page 111!
Page 118 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Illustration, adjust and secure cams The illustration below show how to adjust and secure the position switch cams and profiles. xx0100000113 Cam stop, M5 nut and M5 x 6 set screw Adjustable cam Profile Illustration, cutting the cam...
Page 119 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Plate for customer connections, at base xx0500002301 Plate for customer connections Attachment screws, 3 pcs, M6x16 Cable harness for position switches and fans, axes 1-3 xx0500002305 Cable bracket, frame Cable bracket, lower arm Cable bracket, upper arm R1.SW2/3...
Page 120 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued R3.FAN3 Connected to the fan of axis 3 R2.SW2 Connected to the position switch of axis 2 R2.SW3 Connected to the position switch of axis 3 Installation of cable harness for position switches and fans The procedure below details how to fit the complete cable harness for position switches and cooling fans to the robot.
Page 121 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Action Note/Illustration 5. Run and secure the cabling inside the frame as detailed below and as shown in the figure to the right: • Secure the cable bracket (A) to the bracket of the robot cabling.
Page 122 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Action Note/Illustration 7. Run the remaining cable harness up through the lower arm and: • secure with the bracket, lower arm, as shown in the figure to the right. •...
Page 123 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Action Note/Illustration 10. Connect the connector R1.SW2/3 to the base of the robot. Make sure that the cabling, run through the base, frame and lower arm, is not twisted and is running free from the robot cabling.
Page 124: Electrical Connections
2 Installation and commissioning 2.7.1. Robot cabling and connection points 2.7 Electrical connections 2.7.1. Robot cabling and connection points General Connect the robot and controller to each other after securing them to the foundation. The lists below specify which cables to use for each respective application. Main cable categories All cables between the robot and controller are divided into the following categories: Cable category...
Page 125 2 Installation and commissioning 2.7.1. Robot cabling and connection points Continued Cable Art. no. Robot cable, power, 15 m 3HAC 11818-2 Robot cable, power, 22 m 3HAC 11818-3 Robot cable, power, 30 m 3HAC 11818-4 Robot cable, signals Cable Art. no. Robot cable, signal, shielded, 7 m 3HAC 7998-1 Robot cable, signal, shielded, 15 m...
Page 126 2 Installation and commissioning 2.7.1. Robot cabling and connection points Continued Cabling between robot base and controller, cooling fans, M2004 The cables specified below are specific for the IRC5 controller and used when the robot is equipped with cooling fans. The cabling for the cooling fans runs all the way from the robot base to the inside of the cabinet.
Page 127: Making Robot Ready For Operation (Foundry Prime)
Environmental conditions Humidity 100% Washing detergent must contain rust inhibitor and be approved by ABB Cleaning bath temperature <60°C, used in a typical waterjet cleaning application at suitable speed. Washing detergent with pH <9.0...
Page 128 2 Installation and commissioning 2.8.1. Additional installation procedure Continued WARNING! If the pressurized air contains oil, it could result in a brake failure in the motors and cause the robot arms to fall down, leding to personal injure or physical damage. WARNING! If the air pressure exceeds the specified, it could result in a brake failure in the motors and cause the robot arms to fall down, leding to personal injure or physical damage.
Page 129 2 Installation and commissioning 2.8.1. Additional installation procedure Continued Protecting from high pressure water WARNING! No part of the robot should be exposed to direct high pressure jet of water. The sealings between the moving parts on the wrist should not be exposed to direct or rebounding high- pressure jet of water.
Page 130 2 Installation and commissioning 2.8.1. Additional installation procedure 3HAC023082-001 Revision: E...
Page 131: Maintenance
3 Maintenance 3.1. Introduction 3 Maintenance 3.1. Introduction Structure of this chapter This chapter details all maintenance activities recommended for the robot and any external units of the robot. It is based on the maintenance schedule, located in the beginning of the chapter. The schedule contains information about required maintenance activities including intervals and refers to procedures for the activities.
Page 132: Maintenance Schedule And Expected Component Life
3 Maintenance 3.2.1. Specification of maintenance intervals 3.2 Maintenance schedule and expected component life 3.2.1. Specification of maintenance intervals Description The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot: •...
Page 133: Maintenance Schedule
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.
Page 134 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Equipment Interval Detailed in section activity Changing Axis 3 gear oil: First change after: Do not mix with other oils! 6 000 h Kyodo Yushi TMO 150 Oil change, gearbox, axis 3 Second change on page 188 after: 24 000 h Changing...
Page 135 3 Maintenance 3.2.2. Maintenance schedule Continued • If the robot is run at ambient temperatures higher than 50°C, the equipment may require maintenance more frequently. • The service time for gearboxes, axes 4 and 5, is not calculated by the SIS, see expected life in section Expected component life on page 136.
Page 136 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Equipment Interval Detailed in section activity Analysis Oil gearbox axis 6 3000h or Inspection, oil level gearbox axis 6 on page 149 6 mths Changing Axis 1 gear, oil: 6000h Oil change, gearbox axis 1 on page 182 Kyodo Yushi TMO 150 Changing...
Page 137 3 Maintenance 3.2.2. Maintenance schedule Continued • 1. If the robot is working in cleanings cells that are not emptied when the robot is switched off, the oil may be replaced more frequently. • 2. Analyse water content in oil in gearbox axis 6 first time after 3000H or 6 mounths. If the working conditions changes, analyse again after 3000h or 6 mounths.
Page 138: Expected Component Life
3 Maintenance 3.2.3. Expected component life 3.2.3. Expected component life General The expected life of a component can vary greatly depending on how hard it is run. Expected life Component Expected life Note Cabling for robot, 7th axis, axis 2/3 4,000,000 cycles axis 1 ±180º...
Page 139: Inspection Activities
3 Maintenance 3.3.1. Inspection, oil level gearbox axis 1 3.3 Inspection activities 3.3.1. Inspection, oil level gearbox axis 1 Location of gearbox The axis 1 gearbox is located between the frame and base. The oil plugs are shown in the figure below.
Page 140 3 Maintenance 3.3.1. Inspection, oil level gearbox axis 1 Continued Equipment Art. no. Note Other tools and procedures may These procedures include be required. See references to references to the tools required. these procedures in the step-by- step instructions below. Inspection, oil level gearbox, axis 1 The procedure below details how to inspect the oil level in gearbox axis 1.
Page 141: Inspection, Oil Level Gearbox Axis 2
3 Maintenance 3.3.2. Inspection, oil level gearbox axis 2 3.3.2. Inspection, oil level gearbox axis 2 Location of gearbox The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment. xx0400001066 Gearbox axis 2 Oil plug, filling Oil plug, draining Vent hole, gearbox axis 2 Required equipment...
Page 142 3 Maintenance 3.3.2. Inspection, oil level gearbox axis 2 Continued Inspection, oil level gearbox 2 The procedure below details how to inspect the oil level in gearbox axis 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...
Page 143: Inspection, Oil Level Gearbox Axis 3
3 Maintenance 3.3.3. Inspection, oil level gearbox axis 3 3.3.3. Inspection, oil level gearbox axis 3 Location of gearbox The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. xx0200000230 Gearbox axis 3 Oil plug, filling Oil plug, draining Required equipment...
Page 144 3 Maintenance 3.3.3. Inspection, oil level gearbox axis 3 Continued Equipment, etc. Art. no. Note Other tools and procedures may These procedures include be required. See references to references to the tools required. these procedures in the step-by- step instructions below. Inspection, oil level gearbox 3 The procedure below details how to inspect the oil level in the gearbox axis 3.
Page 145: Inspection, Oil Level Gearbox Axis 4
3 Maintenance 3.3.4. Inspection, oil level gearbox axis 4 3.3.4. Inspection, oil level gearbox axis 4 Location of gearbox The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure below. xx0200000231 Oil plug, filling Oil plug, draining xx0600002962...
Page 146 3 Maintenance 3.3.4. Inspection, oil level gearbox axis 4 Continued Required equipment Equipment, etc. Art. no. Note Lubricating oil 11712016-604 Mobilgear 600 XP320 This is a common oil that can be replaced with an equivalent oil from another manufacturer! Standard toolkit The contents are defined in section Standard toolkit on page 436.
Page 147 3 Maintenance 3.3.4. Inspection, oil level gearbox axis 4 Continued Action Note WARNING! Do not mix the oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in section WARNING - Mixed oils may cause severe damage to gearbox! on page 3HAC023082-001 Revision: E...
Page 148: Inspection, Oil Level, Gearbox Axis 5
3 Maintenance 3.3.5. Inspection, oil level, gearbox axis 5 3.3.5. Inspection, oil level, gearbox axis 5 Location of gearbox The axis 5 gearbox is located in the wrist unit as shown in the figure below. xx0200000232 The figure above shows the wrist unit of IRB 6600 and IRB 6650 Oil plug, filling Oil plug, draining xx0500002013...
Page 149 3 Maintenance 3.3.5. Inspection, oil level, gearbox axis 5 Continued Required equipment Equipment etc. Art. no. Note Lubricating oil 11712016-604 Mobilgear 600 XP320 This is a common oil that can be replaced with an equivalent oil from another manufacturer! Standard toolkit The contents are defined in section Standard toolkit on page 436.
Page 150 3 Maintenance 3.3.5. Inspection, oil level, gearbox axis 5 Continued Action Note WARNING! Do not mix the oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in section WARNING - Mixed oils may cause severe damage to gearbox! on page 3HAC023082-001 Revision: E...
Page 151: Inspection, Oil Level Gearbox Axis 6
3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 3.3.6. Inspection, oil level gearbox axis 6 Location of gearbox The axis 6 gearbox is located in the wrist unit as shown in the figure below. xx0400001092 The figure above shows the wrist unit of IRB 6600 and IRB 6650 Gearbox, axis 6 Oil plug, filling Oil plug, draining...
Page 152 3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 Continued Required equipment Equipment Art. no. Note Lubricating oil, 3HAC032140-001 Kyodo Yushi TMO 150 IRB 6600/6650 Do not mix with other oils! Check which oil is currently filled in the gearbox, as detailed in section Which type of oil does the gearbox contain? on page 177!
Page 153 3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 Continued Action Note 5. Add oil if required. Art. no. is specified in Required equipment on page 150! Further information about how to fill the oil may be found in section Filling, oil, axis 6 on page 199.
Page 154 3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 Continued Then..2. Less than 2% water in oil, normal replacement interval as specified by SIS or typically 96 months for gearbox axis 6 is required 3000 6000 9000 12000 15000 xx0600003156 •...
Page 155: Inspection, Balancing Device
3 Maintenance 3.3.7. Inspection, balancing device 3.3.7. Inspection, balancing device General Several points are to be checked on the balancing device during the inspection. This section details how to perform the inspection regarding: • dissonance • damage • leakage • contamination / lack of free space.
Page 156 3 Maintenance 3.3.7. Inspection, balancing device Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Maintenance kit, 3HAC 021592-001 Includes: complete • complete kit including the kit with bearings and seals • instructions for mainte- nance. Maintenance kit, 3HAC 021593-001 Includes: bearings and seals...
Page 157 Check for dissonance from... If dissonance is detected... • cylinder (a tapping sound, ...replace the balancing device or consult caused by the springs inside the ABB Robotics. cylinder). How to replace the device is detailed in section Replacement of balancing device on page 322.
Page 158 3 Maintenance 3.3.7. Inspection, balancing device Continued Check for leakage The front ear of the balancing device is lubricated with grease. After filling, excessive grease may normally be forced out between the shaft and the sealing ring in the sealing spacer. This is normal behaviour and must no be confused with incorrect leaks from the ear.
Page 159 3 Maintenance 3.3.7. Inspection, balancing device Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 4. Check the o-rings at the front ear for leakage. The o-rings are included in the Replace the o-rings, if any leaks are detected.
Page 160: Inspection, Cable Harness
3 Maintenance 3.3.8. Inspection, cable harness 3.3.8. Inspection, cable harness Location of cable harness, axes 1-6 The robot cable harness, axes 1-6, is located as shown in the figure below. Note! The cable harness is also available without the division point R2.M5/6. Except for the connectors at the division point, the rest of the inspection points are the same for the harness that runs undivided from axis 1 to axis 6.
Page 161 3 Maintenance 3.3.8. Inspection, cable harness Continued Inspection, cable harness 1-6 The procedure below details how to inspect the cable harness of axes 1-4. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 162 3 Maintenance 3.3.8. Inspection, cable harness Continued Location of cabling axes 5-6 The robot cable harness, axes 5-6, is located as shown in the figure below. Note! The cable harness is also available without the division point R2.M5/6. Except for the connectors at the division point, the rest of the inspection points are the same for the harness that runs undivided from axis 1 to axis 6.
Page 163 3 Maintenance 3.3.8. Inspection, cable harness Continued Inspection, cable harness, axes 5-6 The procedure below details how to inspect the cable harness of axes 5-6. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 164: Inspection, Information Labels
3 Maintenance 3.3.9. Inspection, information labels 3.3.9. Inspection, information labels Location of labels The figures below show the location of the information labels to be inspected. xx0200000236 Warning label "High temperature", 3HAC4431-1 (4 pcs) Warning sign, symbol of a flash (located on motor cover), 3HAC1589-1 (5 pcs) Instruction label "Safety instructions", 3HAC4591-1 Warning label "Brake release", 3HAC9508-1 Warning label, tools are not allowed around the balancing device during operation,...
Page 165 3 Maintenance 3.3.9. Inspection, information labels Continued xx0400000786 Instruction label "Lifting the robot", 3HAC16487-1 Warning label "Robot can tip forward...", 3HAC9191-1 Foundry logotype, 3HAC8256-1 Warning label "Stored energy", 3HAC9526-1 Required equipment Equipment Art. no. Note Labels and plate set 3HAC8711-1 Includes all labels specified in the two previous figures! The labels are in english.
Page 166: Inspection, Mechanical Stop, Axis 1
3 Maintenance 3.3.10. Inspection, mechanical stop, axis 1 3.3.10. Inspection, mechanical stop, axis 1 Location of mechanical stop The mechanical stop axis 1 is located at the base as shown in the figure below. xx0200000151 Mechanical stop (stop pin) Required equipment Equipment, etc.
Page 167 3 Maintenance 3.3.10. Inspection, mechanical stop, axis 1 Continued Inspection, mechanical stop The procedure below details how to inspect the mechanical stop axis 1. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 168: Inspection, Additional Mechanical Stops
3 Maintenance 3.3.11. Inspection, additional mechanical stops 3.3.11. Inspection, additional mechanical stops Location of mechanical stops The figure below shows the location of the additional mechanical stops on axes 1, 2 and 3 (IRB 7600 shown). xx0200000150 Additional stop Fixed stop Continues on next page 3HAC023082-001 Revision: E...
Page 169 3 Maintenance 3.3.11. Inspection, additional mechanical stops Continued xx0200000150 Mechanical stop, axis 1 Required equipment Equipment etc. Art. no. Note Mechanical stop axis 1 3HAC11076-1 Limits the robot working range by 7,5°. Mechanical stop axis 1 3HAC11076-2 Limits the robot working range by 15°. Mechanical stop axis 2 3HAC020885-1 Mechanical stop axis 3...
Page 170 3 Maintenance 3.3.11. Inspection, additional mechanical stops Continued Inspection, mechanical stops The procedure below details how to inspect the additional mechanical stops on axes 1,2 and 3. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 171: Inspection, Damper Axes 2-5
3 Maintenance 3.3.12. Inspection, damper axes 2-5 3.3.12. Inspection, damper axes 2-5 Location of dampers The figure below shows the location of all the dampers to be inspected. xx0300000040 Damper, axis 2 (2 pcs) Damper, axis 3 (2 pcs) Damper, axis 4 (1 pc) Damper, axis 5 (IRB 6600, IRB 6650: 2 pcs, IRB 6600ID, IRB 6650ID: 4 pcs) Required equipment A damper must be replaced if damaged!
Page 172 3 Maintenance 3.3.12. Inspection, damper axes 2-5 Continued Equipment Spare part/ art. no. Note Damper 2, axis 5 (2 pcs) 3HAC021675-001 IRB 6600ID and IRB 6650ID Standard toolkit 3HAC15571-1 The contents are defined in section Standard toolkit on page 436 Inspection, dampers The procedure below details how to inspect the dampers, axes 2-5 Action...
Page 173: Inspection, Position Switch Axes 1, 2 And 3
3 Maintenance 3.3.13. Inspection, position switch axes 1, 2 and 3 3.3.13. Inspection, position switch axes 1, 2 and 3 Position switches, axes 1-3 The position switches are shown, fitted to the robot, in section Installation of position switches (option) on page 111.
Page 174 3 Maintenance 3.3.13. Inspection, position switch axes 1, 2 and 3 Continued Action Note 5. Check the protection sheets on axis 1! • Check that the three sheets are in position and not damaged. Deformation can result in rubbing against the cams! •...
Page 175: Inspection, Signal Lamp
3 Maintenance 3.3.14. Inspection, signal lamp 3.3.14. Inspection, signal lamp Location of signal lamp The signal lamp is located as shown in the figure below. Note that the position can differ depending on how the customer harness for axis 4-6 is mounted. See assembly drawing on the current harness for alternative positioning.
Page 176 3 Maintenance 3.3.14. Inspection, signal lamp Continued xx0600003071 UL signal lamp Clamp Cable strap, outdoor Motor, axis 3 Attachment screw, M6x8 quality 8-A2F(2 pcs) Required equipment Equipment, etc. Art. no. Note Signal lamp 3HAC10830-1 To be replaced in case of detected damage.
Page 177 3 Maintenance 3.3.14. Inspection, signal lamp Continued Inspection, signal lamp The procedure below details how to inspect the function of the signal lamp. Action Note 1. Check that the signal lamp is lit, when the motors are put in operation ("MOTORS ON"). DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Page 178: Inspection Of Air Hoses (Foundry Prime)
3 Maintenance 3.3.15. Inspection of air hoses (Foundry Prime) 3.3.15. Inspection of air hoses (Foundry Prime) General The air hoses on Foundry Prime robots must be inspected for leakage every six month. Required equipment Equipment, etc. Art. no. Note Leak detection spray Pressure gauge Cut off valve Procedure...
Page 179: Replacement/Changing Activities
3 Maintenance 3.4.1. Type of oil in gearboxes 3.4 Replacement/changing activities 3.4.1. Type of oil in gearboxes Location of gearboxes The figure show the location of the gearboxes on the robot. xx0800000247 Axis 1 gearbox Axis 2 gearbox Axis 3 gearbox Axis 4 gearbox Axis 5 gearbox Axis 6 gearbox...
Page 180 3 Maintenance 3.4.1. Type of oil in gearboxes Continued Type of oil - historically used The six gearboxes of the robot have historically been filled with different types of oils. Today only the types of oil specified in the table is recommended. NOTE! When there is a change of oil types in the gearbox, it need to be rinsed.
Page 181 3 Maintenance 3.4.1. Type of oil in gearboxes Continued Labels at robot base Label located at robot base show the types of oil in all gearboxes. Lifting of robot Axis 1 Kyodo Yushi TMO 150 Axis 2 Kyodo Yushi TMO 150 Axis 3 Kyodo Yushi TMO 150 Axis 4 Mobilgear 600 XP320 Axis 5 Mobilgear 600 XP320...
Page 182 3 Maintenance 3.4.1. Type of oil in gearboxes Continued Mixed types of oil may cause may cause severe damage! When refilling or replacing oil in a gearbox it is important to first check which type of oil is recommended to use in the gearbox. See Type of oil - currently used.
Page 183 3 Maintenance 3.4.1. Type of oil in gearboxes Continued Equipment Equipment Art. no. Note Label set See Spare Parts. Includes small labels to each gearbox and the complete label to be fitted at the robot base. NOTE! The correct labels must be fitted to the robot in case of changing of oil types! Oil change equipment 3HAC021745-001...
Page 184: Oil Change, Gearbox Axis 1
3 Maintenance 3.4.2. Oil change, gearbox axis 1 3.4.2. Oil change, gearbox axis 1 Location of oil plugs The axis 1 gearbox is located between the frame and base. The oil plugs for filling and inspection are shown in the figure below. The oil is drained through a hose, available in the rear of the robot base, not shown in the figure.
Page 185 3 Maintenance 3.4.2. Oil change, gearbox axis 1 Continued Equipment, etc. Art. no. Amount Note Standard toolkit The contents are defined in section Standard toolkit on page 436. Draining oil, axis 1 The procedure below details how to drain the oil in gearbox axis 1. When using the oil exchange equipment, follow the instructions enclosed with the kit.
Page 186 3 Maintenance 3.4.2. Oil change, gearbox axis 1 Continued Action Note 8. Close the oil drain hose, and put it back inside the base. 9. Refit the rear cover by securing it with its attachment screws. Filling oil, axis 1 The procedure below details how to fill the oil in gearbox axis 1.
Page 187: Oil Change, Gearbox Axis 2
3 Maintenance 3.4.3. Oil change, gearbox axis 2 3.4.3. Oil change, gearbox axis 2 Location of oil plugs The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment. xx0400001066 Gearbox axis 2 Oil plug, filling Oil plug, draining Vent hole, gearbox axis 2 Required equipment...
Page 188 3 Maintenance 3.4.3. Oil change, gearbox axis 2 Continued Draining, oil The procedure below details how to drain the oil in gearbox axis 2. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 185.
Page 189 3 Maintenance 3.4.3. Oil change, gearbox axis 2 Continued 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 3. Remove the oil plug, filling and the plug from the Shown in the figure Location of oil vent hole.
Page 190: Oil Change, Gearbox, Axis 3
3 Maintenance 3.4.4. Oil change, gearbox, axis 3 3.4.4. Oil change, gearbox, axis 3 Location of gearbox The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. xx0200000230 Gearbox axis 3 Oil plug, filling Oil plug, draining Required equipment Equipment, etc.
Page 191 3 Maintenance 3.4.4. Oil change, gearbox, axis 3 Continued Equipment, etc. Art. no. Amount Note Standard toolkit The contents are defined in section Standard toolkit on page 436. Draining, oil The procedure below details how to drain oil from the gearbox, axis 3. When using the oil exchange equipment, follow the instructions enclosed with the kit.
Page 192 3 Maintenance 3.4.4. Oil change, gearbox, axis 3 Continued Filling, oil The procedure below details how to fill oil to the gearbox, axis 3. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 188.
Page 193: Oil Change, Gearbox, Axis 4
3 Maintenance 3.4.5. Oil change, gearbox, axis 4 3.4.5. Oil change, gearbox, axis 4 Location of gearbox The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure below. xx0200000231 Oil plug, filling Oil plug, draining Required equipment Equipment, etc.
Page 194 3 Maintenance 3.4.5. Oil change, gearbox, axis 4 Continued Draining, oil The procedure below details how to drain the oil in the gearbox, axis 4. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 191.
Page 195 3 Maintenance 3.4.5. Oil change, gearbox, axis 4 Continued 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 3. Refill the gearbox with lubricating oil through the oil Shown in the figure Location of plug, filling.
Page 196: Oil Change, Gearbox, Axis 5
3 Maintenance 3.4.6. Oil change, gearbox, axis 5 3.4.6. Oil change, gearbox, axis 5 Location of gearbox The axis 5 gearbox is located in the wrist unit as shown in the figure below. xx0200000232 Wrist unit of IRB 6600 and IRB 6650 Oil plug, filling Oil plug, draining xx0500002013...
Page 197 3 Maintenance 3.4.6. Oil change, gearbox, axis 5 Continued Required equipment Equipment, etc. Art. no. Amount Note Lubricating oil 11712016-604 IRB 6600/6650: Mobilgear 600 XP320 6,700 ml This is a common oil that can be replaced with an IRB 6600ID/6650ID: equivalent oil from 5,000 ml another manufacturer!
Page 198 3 Maintenance 3.4.6. Oil change, gearbox, axis 5 Continued Filling, oil, axis 5 The procedure below details how to change the oil in gearbox, axis 5. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no.
Page 199: Oil Change, Gearbox Axis 6
3 Maintenance 3.4.7. Oil change, gearbox axis 6 3.4.7. Oil change, gearbox axis 6 Location of gearbox The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. xx0400001092 The figure above shows the wrist unit of IRB 6600 and IRB 6650 Gearbox, axis 6 Oil plug, filling Oil plug, draining...
Page 200 3 Maintenance 3.4.7. Oil change, gearbox axis 6 Continued Required equipment Equipment, etc. Art. no. Amount Note Lubricating oil, 3HAC032140-001 450 ml Kyodo Yushi TMO 150 IRB 6600/6650 Do not mix with other oils! Check which oil is currently filled in the gearbox, as detailed in section Which type of oil does the gearbox...
Page 201 3 Maintenance 3.4.7. Oil change, gearbox axis 6 Continued Action Note 5. Refit the oil plug, draining. Tightening torque: 24 Nm. Filling, oil, axis 6 The procedure below details how to fil oil in the gearbox, axis 6. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no.
Page 202: Replacement Of Smb Battery
Equipment, etc. Spare part no. Note Battery pack 3HAC 16831-1 Battery includes protection circuits. Replace it only with given spare part no. or an ABB approved eqvivalent. Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual.
Page 203 Shown in the figure Location of SMB battery on page 200. Battery includes protection circuits. Replace it only with the specified spare part or with an ABB approved eqvivalent. Refitting, battery The procedure below details how to refit the SMB battery. Action...
Page 204 3 Maintenance 3.4.8. Replacement of SMB battery Continued Action Note 3. Reconnect the battery cable to the SMB battery Art. no. is specified in Required pack and fit it to the frame. equipment on page 200. Shown in the figure Location of SMB battery on page 200.
Page 205: Lubrication Activities
3 Maintenance 3.5.1. Lubrication of spherical roller bearing, balancing device 3.5 Lubrication activities 3.5.1. Lubrication of spherical roller bearing, balancing device Location of bearing The spherical roller bearing is located at the front ear of the balancing device, as shown in the figure below.
Page 206 3 Maintenance 3.5.1. Lubrication of spherical roller bearing, balancing device Continued Lubrication, balancing device bearing The procedure below details how to lubricate the spherical roller bearing. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 207: Rust Preventive, Bearing Axis 1 (Foundry Prime)
3 Maintenance 3.5.2. Rust preventive, bearing axis 1 (Foundry Prime) 3.5.2. Rust preventive, bearing axis 1 (Foundry Prime) Location of bearing axis 1 The bearing axis 1 is located as shown in the illustration. (View from above). xx0600002866 Plastic ring, (bearing cover) Required equipment Equipment Art.
Page 208 3 Maintenance 3.5.2. Rust preventive, bearing axis 1 (Foundry Prime) Continued Procedure The following procedure details how to grese the bearing axis 1. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 209: Rust Preventive, Bearing Axis 4 (Foundry Prime)
3 Maintenance 3.5.3. Rust preventive, bearing axis 4 (Foundry Prime) 3.5.3. Rust preventive, bearing axis 4 (Foundry Prime) Overview The bearing axis 4 is located as shown in the illustration below. xx0500002869 Plastic cover Plastic ring Required equipment Equipment Art. no. Note Brush Rust preventive...
Page 210 3 Maintenance 3.5.3. Rust preventive, bearing axis 4 (Foundry Prime) Continued Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 211 3 Maintenance 3.5.3. Rust preventive, bearing axis 4 (Foundry Prime) Continued Action Note/Illustration 6. Apply the rust preventive on the bearing with the brush. xx0600002868 • A: bearing axis 4 • B plastic ring 7. Refit the plasitc ring and cover 3HAC023082-001 Revision: E...
Page 212: Rust Preventive, Support Bearing In Wrist (Foundry Prime)
3 Maintenance 3.5.4. Rust preventive, support bearing in wrist (Foundry Prime) 3.5.4. Rust preventive, support bearing in wrist (Foundry Prime) Location of bearing The support bearing in the wrist is located as shown in the illustration. xx0500002863 Bearing Cable bracket Cover Required equipment Equipment...
Page 213 3 Maintenance 3.5.4. Rust preventive, support bearing in wrist (Foundry Prime) Continued Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 3.
Page 214: Cleaning Activities
3 Maintenance 3.6.1. Cleaning, robot 3.6 Cleaning activities 3.6.1. Cleaning, robot General The protection class is IP 67, i.e. the robot is watertight. Activities This instruction specifies how to clean the robot. Periodicity The periodicity of cleaning the robot varies a great deal depending on the actual environment and function of the robot.
Page 215 3 Maintenance 3.6.1. Cleaning, robot Continued Required equipment Equipment, etc. Art. no. Note Steam cleaner • Water pressure at nozzle: max. 2,500 kN/m (25 bar) • Type of nozzle: fan jet, min. 45° spread • Flow: max. 100 litres/min. • Water temperature: max.
Page 216: Service Information System, M2000
SIS system parameters production environment. on page 217. Maintenance intervals recommended by ABB are specified in section Maintenance schedule on page 131. 3. Enter these parameters in the system. How to do this is detailed in...
Page 217: Description Of Service Information System (Sis)
3 Maintenance 3.7.2. Description of Service Information System (SIS) 3.7.2. Description of Service Information System (SIS) General Service Information System (SIS) is a software function within the robot controller, which simplifies maintenance of the robot system. It supervises the operating time and mode of the robot, and alerts the operator when a maintenance activity is scheduled.
Page 218 3 Maintenance 3.7.2. Description of Service Information System (SIS) Continued Operation time This is a function within the control system that keeps track of the amount of time the "MOTORS ON" signal is active, i.e. the amount of time the robot is in the operating mode. When the operation time limit for maintenance is reached, a message is displayed on the TPU.
Page 219: Sis System Parameters
Since the counters are to be used for purposes defined by the user, ABB cannot give any recommendations regarding their definitions. The figures below shows the options of parameters to be set.
Page 220 3 Maintenance 3.7.3. SIS system parameters Continued Gearbox warning A percentage of the gearbox service interval as calculated by the system. E.g. by setting the value "90", the SIS will alert the operator after 90% of the expected service interval of each gearbox. The robot system automatically detects and stores all required variables to calculate the expected service interval of each gearbox.
Page 221: Setting The Sis Parameters
3 Maintenance 3.7.4. Setting the SIS parameters 3.7.4. Setting the SIS parameters General If the SIS system is to function properly, a number of parameters must be set. This is detailed below. Procedure M2000 This is an instruction of how to enter SIS parameters to the M2000 robot system. Action Note 1.
Page 222 3 Maintenance 3.7.4. Setting the SIS parameters Continued Action Note 3. Select "0 SIS parameters" and press "Enter". en0200000047 xx0100000200 4. Select the required system The parameter list is displayed. en0200000048 en0200000049 5. Select the required Available parameters are described in section SIS system parameters by stepping up parameters on page...
Page 223: Reading The Sis Output Logs
3 Maintenance 3.7.5. Reading the SIS output logs 3.7.5. Reading the SIS output logs General Whenever a set condition has expired (e.g. max allowed operation time before service), a message to this effect will be shown in the Operational log. Access to logs How to open a log and show its contents is detailed in the User's Guide, chapter Service.
Page 224: Exporting The Sis Data
3 Maintenance 3.7.6. Exporting the SIS data 3.7.6. Exporting the SIS data General This section describes the available variables for entering SIS parameters as well as showing any values of exceeded time limits as detected by the SIS counters. In a M2000 robot system, the values can be read on a PC using "Webware SDK". How to access these variables and how to perform the actual programming sequences are detailed in the robot system User's Guide.
Page 225: Repair
4 Repair 4.1. Introduction 4 Repair 4.1. Introduction Structure of this chapter This chapter details all repair activities recommended for the robot and any external units of the robot. It is made up of separate procedures, each detailing a specific repair activity. Each procedure contains all information required to perform the activity, e.g.
Page 226: General Procedures
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. Required equipment Equipment, etc.
Page 227: Mounting Instructions For Bearings
4 Repair 4.2.2. Mounting instructions for bearings 4.2.2. Mounting instructions for bearings General This section details how to mount and grease different types of bearings on the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB 3537-1 Used to grease the bearings, if not specified otherwise.
Page 228: Mounting Instructions For Seals
4 Repair 4.2.3. Mounting instructions for seals 4.2.3. Mounting instructions for seals General This sections details how to mount different types of seals to the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB 3537-1 Used to lubricate the seals. Rotating seals The procedure below details how to fit rotating seals.
Page 229 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.
Page 230: Complete Robot
4 Repair 4.3.1. Replacement of cable harness, axes 1-6 4.3 Complete robot 4.3.1. Replacement of cable harness, axes 1-6 General This section details how to replace the cable harness that runs undivided from axis 1 to axis 6. In case the cabling has a division point at the upper arm, it should instead be replaced as detailed in sections: •...
Page 231 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Required equipment Equipment Spare part no. Note Cable harness axes 1-6 3HAC 024385-001 (IRB 6600) Cable harness axes 1-6 3HAC 024386-001 (IRB 6650) Brush Rust preventive 3HAC026621-001 Equivalent: • Mercasol 3106 Gasket 3HAC3537-1 motor axes 1-5...
Page 232 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 3.
Page 233 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note/Illustration 12. Gently pull the cable harness out from the upper arm tube. 13. Tie the connectors into bundles, to avoid damaging them during further removal. 14. Continue removing the cable harness as detailed in following procedure.
Page 234 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note/Illustration 8. Remove • the cable gland (A), by removing the four attachment screws from inside the SMB recess (B) • the attachment plate (C), by removing the attachment screws and the velcro strap (D).
Page 235 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note/Illustration 10. Remove the cable gland securing the cables to the arm house. xx0100000143 11. Remove the velcro strap from the harness at the cable fixing bracket at the arm house. 12.
Page 236 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 6. Reconnect all connectors at motor 1 and motor Required equipment on page 229. NOTE! On Foundry Prime robots: When dismantling the cables from the motors, the gasket must be replaced. Continues on next page 3HAC023082-001 Revision: E...
Page 237 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 8. Secure the cable gland (A) with four Locking liquid is specified in Required attachment screws (B) from inside the SMB equipment on page 229. recess. Secure the correct attachment plate (C) to the cable gland with its two attachment screws, using locking liquid.
Page 238 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 9. Reconnect connectors R2.SMB, R1.SMB1-3, R1.SMB4-6 to the SMB unit. Reconnect X8, X9 and X10 to the brake release unit. Reconnect R1.G if it has been disconnected. xx0200000118 10.
Page 239 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 14. Refit the cable gland securing the cables to the arm house. Make sure not to twist the harness! xx0100000143 15. Reconnect all connectors at motor 3 and motor 16.
Page 240 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 20. Fasten the cable bracket, wrist unit with three attachment screws, two of them visible at the rear attachment point and the third located on the bottom of the cable bracket, in the center. xx0200000254 •...
Page 241 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 25. Fit a cable protection to the lower arm, if not already mounted, with two securing screws (A), M6x16. Secure the cable harness with two velcro straps (B), with a distance of approximately 180 mm.
Page 242: Replacement Of Cable Harness, Axes 1-4
4 Repair 4.3.2. Replacement of cable harness, axes 1-4 4.3.2. Replacement of cable harness, axes 1-4 General This section details how to replace the cable harness that runs from axis 1 to axis 4. If the robot is equipped with an undivided cable harness, it is instead replaced as detailed in section Replacement of cable harness, axes 1-6 on page 228.
Page 243 4 Repair 4.3.2. Replacement of cable harness, axes 1-4 Continued Connectors at motor 1: R2.FB1 and R2.MP1 Connectors at motor 2: R2.FB2 and R2.MP2 SMB recess Cable gland, upper arm house Cable fixing bracket + velcro strap Connector R2.M5/6 at the cable division point Connectors at motor 3: R2.FB3 and R2.MP3 (optional signal lamp: R2.H1 and R2.H2) Connectors at motor 4: R2.FB4 and R2.MP4...
Page 244 4 Repair 4.3.2. Replacement of cable harness, axes 1-4 Continued Removal, cable harness, axes 1-4 The procedure below details how to remove the cable harness, axes 1-4. Action Note/Illustration 1. In order to facilitate refitting of cable harness, run the Axes 2 and 3 may be tilted robot to the specified position: slightly to improve access.
Page 245 4 Repair 4.3.2. Replacement of cable harness, axes 1-4 Continued Action Note/Illustration 9. Disconnect connectors R2.SMB, R1.SMB1-3, R1.SMB4-6 from the SMB unit. Disconnect X8, X9 and X10 from the brake release unit. xx0200000118.wmf 10. Remove • the cable gland (A), by removing the four attachment screws from inside the SMB recess (B) •...
Page 246 4 Repair 4.3.2. Replacement of cable harness, axes 1-4 Continued Action Note/Illustration 11. Remove the cable gland securing the cables inside the lower arm. 12. Remove the cable gland securing the cables to the arm house. xx0100000143.wmf 13. Remove the velcro strap from the harness at the Shown in the figure Location of cable fixing bracket at the arm house.
Page 247 4 Repair 4.3.2. Replacement of cable harness, axes 1-4 Continued Action Note/Illustration 3. Pull the cable and connectors down through the Make sure the cables are not cable guide in the center of the frame. twisted with each other or with eventual customer harnesses! Make a note of the correct positions of the connectors!
Page 248 4 Repair 4.3.2. Replacement of cable harness, axes 1-4 Continued Action Note/Illustration 8. Secure the cable gland (A) with four attachment Locking liquid is specified in screws (B) from inside the SMB recess. Required equipment on page 241. Secure the correct attachment plate (C) to the cable gland with its two attachment screws, using locking liquid.
Page 249 4 Repair 4.3.2. Replacement of cable harness, axes 1-4 Continued Action Note/Illustration WARNING! Before continuing any service work, please observe the safety information in section WARNING - The brake release buttons may be jammed after service work on page 12. Pull the cable harness through the lower arm. 13.
Page 250 4 Repair 4.3.2. Replacement of cable harness, axes 1-4 Continued Action Note/Illustration 18. Fit a cable protection to the lower arm, if not Both the protection and the strap already mounted, with two securing screws (A), are included in the spare part no., M6x16.
Page 251: Replacement Of Cable Harness, Axes 5-6
4 Repair 4.3.3. Replacement of cable harness, axes 5-6 4.3.3. Replacement of cable harness, axes 5-6 Location of cable harness ax 5-6 The location of the cable harness, axes 5-6, is shown in the figure below. xx0200000213 Cable bracket, wrist unit Cable bracket, upper arm tube Connectors at motor axis 5;...
Page 252 4 Repair 4.3.3. Replacement of cable harness, axes 5-6 Continued Equipment, etc. Spare part no. Note Other tools and procedures may These procedures include references be required. See references to to the tools required. these procedures in the step-by- step instructions below. Circuit Diagram See chapter Circuit diagram...
Page 253 4 Repair 4.3.3. Replacement of cable harness, axes 5-6 Continued Action Note/Illustration 5. Loosen the cable bracket on top of the wrist Shown in the figure Location of cable unit by undoing the three attachment screws. harness ax 5-6 on page 249! Two of the attachment screws are visibly located at the rear attachment and the third is...
Page 254 4 Repair 4.3.3. Replacement of cable harness, axes 5-6 Continued Action Note/Illustration 4. Place the cabling to motor, axis 6, correctly on the upper arm and gently pull the connectors through the hole on top of wrist unit to motor, axis 6.
Page 255: Replacement Of Cable Harness, Axes 5-6, Irb 6600Id And Irb 6650Id
4 Repair 4.3.4. Replacement of cable harness, axes 5-6, IRB 6600ID and IRB 6650ID 4.3.4. Replacement of cable harness, axes 5-6, IRB 6600ID and IRB 6650ID Location of cable harness, axes 5-6 The cable harness of axes 5-6 is run inside the upper arm, as shown in the figure below. xx0500001896 Cover, upper arm tube Hood, upper arm housing...
Page 256 4 Repair 4.3.4. Replacement of cable harness, axes 5-6, IRB 6600ID and IRB 6650ID Continued Equipment Spare part no. Art. no. Note Standard toolkit The contents are defined in section Standard toolkit on page 436, in part 2 of the Product manual.
Page 257 4 Repair 4.3.4. Replacement of cable harness, axes 5-6, IRB 6600ID and IRB 6650ID Continued Action Note/Illustration 7. Remove the cable bracket from the upper arm housing by removing the three attachment screws (B). Leave the cabling fitted to the bracket. xx0500001905 8.
Page 258 4 Repair 4.3.4. Replacement of cable harness, axes 5-6, IRB 6600ID and IRB 6650ID Continued Cable layout, wrist unit The figure below shows how to run and attach the cabling inside the wrist unit. xx0500002014 Location inside the wrist unit where to strap the cabling, next to the axis 5 motor. Refitting, cable harness axes 5-6 The procedure below details how to refit the cable harness to the upper arm.
Page 259 4 Repair 4.3.4. Replacement of cable harness, axes 5-6, IRB 6600ID and IRB 6650ID Continued Action Note/Illustration 4. Secure the cable clamp (C) inside the upper arm tube. xx0500001904 5. Place the cabling inside the wrist unit according Shown in the figure Location of cable to the cable layout shown in the figure Cable...
Page 260 4 Repair 4.3.4. Replacement of cable harness, axes 5-6, IRB 6600ID and IRB 6650ID Continued Action Note/Illustration 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 3HAC023082-001 Revision: E...
Page 261: Replacement Of Cabling, Axis 5 Motor
4 Repair 4.3.5. Replacement of cabling, axis 5 motor 4.3.5. Replacement of cabling, axis 5 motor Location of cabling The separate cables for the axis 5 motor are located inside the upper arm tube, as shown in the figure below. xx0500002294 Motor axis 5 with connectors R4.FB5 and R4.MP5 Connectors R3.FB5 and R3.MP5...
Page 262 4 Repair 4.3.5. Replacement of cabling, axis 5 motor Continued Action Note 3. Remove the cover of motor, axis 5. 4. Disconnect all connectors at motor, axis 5. 5. Remove the cable gland cover at the cable exit by unscrewing its two attachment screws. 6.
Page 263: Replacement Of Complete Arm System
4 Repair 4.3.6. Replacement of complete arm system 4.3.6. Replacement of complete arm system Location of arm system The complete arm system is defined as the complete robot except for the base and gearbox axis 1. This is shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views on page 477...
Page 264 4 Repair 4.3.6. Replacement of complete arm system Continued Required equipment Equipment, etc. Art. no. Note Lifting device, manipulator 3HAC15607-1 Instruction 3HAC 15971-2 is enclosed! Guide pins M12 x 130 3HAC022637-001 Used to guide the complete arm system when refitting. Always use the guide pins in pairs! In order to make the refitting easier, it is recommended to use two guide pins of...
Page 265 4 Repair 4.3.6. Replacement of complete arm system Continued Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 3.
Page 266 4 Repair 4.3.6. Replacement of complete arm system Continued Refitting, arm system The procedure below details how to lift and refit the complete arm system. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 267 4 Repair 4.3.6. Replacement of complete arm system Continued Action Note/Illustration 6. Look through the empty mounting hole of This is a complex task to be performed motor 1 to assist in aligning the assembly with utmost care in order to avoid injury or during refitting of the arm system.
Page 268 4 Repair 4.3.6. Replacement of complete arm system Continued Action Note/Illustration 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 3HAC023082-001 Revision: E...
Page 269: Replacement Of Air Nipple And Hose (Foundry Prime)
4 Repair 4.3.7. Replacement of air nipple and hose (Foundry Prime) 4.3.7. Replacement of air nipple and hose (Foundry Prime) Location The illustration below shows the routing of the Foundry Prime air hose. xx0500002176 Continues on next page 3HAC023082-001 Revision: E...
Page 270 4 Repair 4.3.7. Replacement of air nipple and hose (Foundry Prime) Continued Hose lenghts xx0600003027 Length in mm. 1520 1090 4020 1605 100 (for option 2,8m/175kg: 350) 149 (for option 2,8m/175kg: 1740) Required equipment Equipment Art. no. Pos. in illustration Elbow fitting Rubber clamp 3HAC026523-001...
Page 271 4 Repair 4.3.7. Replacement of air nipple and hose (Foundry Prime) Continued Procedure The following procedures details how to replace the Foundry Prime air nipples and hose. The pos. no. in following procedures correspond to the illustration in Hose lenghts on page 268 and the table in Required equipment on page 268 Action...
Page 272 4 Repair 4.3.7. Replacement of air nipple and hose (Foundry Prime) Continued Action Note/Illustration Balancing device xx0600003397 Continues on next page 3HAC023082-001 Revision: E...
Page 273 4 Repair 4.3.7. Replacement of air nipple and hose (Foundry Prime) Continued Action Note/Illustration Axis 1-2 xx0600003044 xx0600003162 xx0600003045 Continues on next page 3HAC023082-001 Revision: E...
Page 274 4 Repair 4.3.7. Replacement of air nipple and hose (Foundry Prime) Continued Action Note/Illustration Upper arm housing xx0600003046 xx0600003047 Tube shaft xx0600003163 • 1P: Lay the hose in a spiral in the tube shaft. Continues on next page 3HAC023082-001 Revision: E...
Page 275 4 Repair 4.3.7. Replacement of air nipple and hose (Foundry Prime) Continued Action Note/Illustration Wrist xx0600003097 3HAC023082-001 Revision: E...
Page 276: Upper And Lower Arm
4 Repair 4.4.1. Replacement of turning disk, IRB 6600 and IRB 6650 4.4 Upper and lower arm 4.4.1. Replacement of turning disk, IRB 6600 and IRB 6650 Location of turning disk The turning disk is located in the front of the wrist housing, as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views...
Page 277 4 Repair 4.4.1. Replacement of turning disk, IRB 6600 and IRB 6650 Continued Removal, turning disk The procedure below details how to remove the turning disk. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 278 4 Repair 4.4.1. Replacement of turning disk, IRB 6600 and IRB 6650 Continued Action Note/Illustration 2. Secure the turning disk with its attachment 12 pcs, M12 x 30, 12.9 quality screws. UNBRAKO, tightening torque: 100 Nm. Reused screws may be used, providing they are lubricated as detailed in section Screw joints on page 432...
Page 279: Replacement Of Complete Wrist Unit, Irb 6600 And Irb 6650
4 Repair 4.4.2. Replacement of complete wrist unit, IRB 6600 and IRB 6650 4.4.2. Replacement of complete wrist unit, IRB 6600 and IRB 6650 Wrist unit for robot models IRB 6600 and IRB 6650 This section is valid for robot models IRB 6600 and IRB 6650. How to replace the wrist of the models IRB 6600ID and IRB 6650ID is detailed in section Replacement of complete wrist unit, IRB 6600ID and IRB 6650ID on page...
Page 280 4 Repair 4.4.2. Replacement of complete wrist unit, IRB 6600 and IRB 6650 Continued Required equipment Equipment etc. Spare part no. Art. no. Note Wrist, type 2 3HAC 16626-2 Wrist, type 2, insulated 3HAC 16626-3 turning disk Guide pins M12 x 200 3HAC13056-3 Always use guide pins in pairs!
Page 281 4 Repair 4.4.2. Replacement of complete wrist unit, IRB 6600 and IRB 6650 Continued Action Note/Illustration 7. Loosen the cable bracket on top of the wrist by Shown in the figure Location of wrist undoing the three attachment screws. unit on page 277! Two of the attachment screws are visibly located at the rear of the bracket (B) and the third located...
Page 282 4 Repair 4.4.2. Replacement of complete wrist unit, IRB 6600 and IRB 6650 Continued Action Note/Illustration 3. Fit the lifting tool to the wrist unit. Art. no. is specified Location of wrist unit on page 277! CAUTION! The complete wrist unit weighs 130 kg!All lifting equipment used must be sized accord- ingly! 5.
Page 283 4 Repair 4.4.2. Replacement of complete wrist unit, IRB 6600 and IRB 6650 Continued Action Note/Illustration 12. Fasten the cable bracket at top of the wrist Shown in the figure Location of wrist unit with three attachment screws. Two of unit on page 277! them are visible at the rear attachment point...
Page 284: Replacement Of Complete Wrist Unit, Irb 6600Id And Irb 6650Id
4 Repair 4.4.3. Replacement of complete wrist unit, IRB 6600ID and IRB 6650ID 4.4.3. Replacement of complete wrist unit, IRB 6600ID and IRB 6650ID Wrist unit for robot models IRB 6600ID and IRB 6650ID This section is only valid for robot models IRB 6600ID and IRB 6650ID. How to replace the wrist unit on the models IRB 6600 and IRB 6650 is detailed in section Replacement of complete wrist unit, IRB 6600 and IRB 6650 on page...
Page 285 4 Repair 4.4.3. Replacement of complete wrist unit, IRB 6600ID and IRB 6650ID Continued Equipment Spare part no. Art. no. Note Product manual - Art. no. is specified in SpotPack/DressPack section References on OrangeLine page Removal, wrist unit The procedure below details how to remove the complete wrist unit from the robot. Action Note DANGER!
Page 286 4 Repair 4.4.3. Replacement of complete wrist unit, IRB 6600ID and IRB 6650ID Continued Refitting, wrist unit The procedure below details how to refit the complete wrist unit to the robot. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 287 4 Repair 4.4.3. Replacement of complete wrist unit, IRB 6600ID and IRB 6650ID Continued Action Note 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 3HAC023082-001 Revision: E...
Page 288: Replacement Of Upper Arm
4 Repair 4.4.4. Replacement of upper arm 4.4.4. Replacement of upper arm Location of upper arm The upper arm is located on top of the robot as shown in the following figure. The complete upper arm includes the wrist unit but this section also describes how to remove the upper arm when there is no wrist unit mounted.
Page 289 4 Repair 4.4.4. Replacement of upper arm Continued xx0200000163 Attachment hole for lifting eye, M12 (if wrist unit is mounted) Attachment for lifting device, upper arm (2 pcs if there is no wrist unit mounted) Oil plug, draining, gearbox axis 3 Cable harness division;...
Page 290 4 Repair 4.4.4. Replacement of upper arm Continued Action Note 2. Remove all equipment fitted to turning disk. 3. Move the upper arm to a horizontal position. Shown in the figure Location of upper arm on page 286! Rotate axis 4 so that the attachment hole for lifting eye is faced upwards! 4.
Page 291 4 Repair 4.4.4. Replacement of upper arm Continued Action Note 16. Remove the sealing, axis 2/3 from the lower arm. Shown in the figure Location of upper arm on page 286! Refitting, upper arm The procedure below details how to refit the upper arm. Action Note/Illustration DANGER!
Page 292 4 Repair 4.4.4. Replacement of upper arm Continued Action Note/Illustration 4. Upper arm including wrist unit: Art. no. is specified in Required equipment on page 287! Fit one of the pieces included in the lifting device, upper arm to the front attachment for Attachment points are shown in the the lifting device on the upper arm.
Page 293 4 Repair 4.4.4. Replacement of upper arm Continued Action Note/Illustration 1 1. Insert 31 of the 33 attachment screws, upper Shown in the figure Location of upper arm into the attachment holes in the lower arm. arm on page 286! Do not remove the guide pins until the Removing the plastic mechanical stops attachment screws are tightened as detailed...
Page 294: Replacement Of Complete Lower Arm
4 Repair 4.4.5. Replacement of complete lower arm 4.4.5. Replacement of complete lower arm Location of lower arm The lower arm is located as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
Page 295 4 Repair 4.4.5. Replacement of complete lower arm Continued xx0200000031 Gearbox Lower arm Balancing device piston rod ear Frame Shaft hole Sealing, axis 2/3 Attachment screw Washer Bearing Thrust washer Bushing Retaining ring Shaft, lower arm Protection plug Protection washer Required equipment Equipment, etc.
Page 296 Art. no. Note Puller tool, balancing device 3HAC12475-1 shaft Lifting tool, lower arm 3HAC14691-1 Tool that may be rent from ABB Robotics. Includes: • two guidings, 3HAC 14446-1, must be used for guiding the sealing, axis 2/3. Rotation tool 3HAC 17105-1 Used to rotate the motor pinion and gear if necessary, when brakes are released.
Page 297 4 Repair 4.4.5. Replacement of complete lower arm Continued Action Note/Illustration 4. Apply the shackle to the balancing device and Art. no. is specified in Required raise to unload the weight of the device. equipment on page 293. Attachment is shown in the figure Location of lower arm on page 292.
Page 298 4 Repair 4.4.5. Replacement of complete lower arm Continued Action Note/Illustration 15. Remove the attachment screws and washers that Shown in the figure Internal attach the lower arm to the gearbox axis 2. components, lower arm on page 292! 16. Lift the lower arm and place it on a secure surface.
Page 299 4 Repair 4.4.5. Replacement of complete lower arm Continued Action Note/Illustration CAUTION! The lower arm weighs 160 kg! All lifting equipment used must be sized accordingly! 6. Lift the lower arm and move it to its mounting position. 7. In case the hole pattern of the lower arm and Connect power supply to connector the gearbox axis 2 does not match, use power R2.MP2...
Page 300 4 Repair 4.4.5. Replacement of complete lower arm Continued Action Note/Illustration 16. Refill the gearbox with oil. Detailed in section Oil change, gearbox axis 2 on page 185. 17. Refit and reconnect all cables inside the lower Detailed in section Refitting, cable arm.
Page 301: Replacement Of Lower Arm Shaft
4 Repair 4.4.6. Replacement of lower arm shaft 4.4.6. Replacement of lower arm shaft Prerequisites This section details how to remove and refit the lower arm shaft as a step in the procedure of removing/refitting the complete lower arm. To perform the procedure described in this section, it is required that the preceding instructions in section Replacement of complete lower arm on page 292...
Page 302 4 Repair 4.4.6. Replacement of lower arm shaft Continued Required equipment Equipment Art. no. Note Bearing 3HAC 12441-2 Always use a new bearing when reassembling! Puller device, axis 2 shaft 3HAC021563-001 Press device, axis 2 shaft 3HAC021600-001 Hydraulic pump, 80 MPa 3HAC13086-1 Hydraulic pump, 150 MPa 3HAC021563-012...
Page 303 Nipple for the glycerin pump Indicator Removal, lower arm shaft The procedure below details how to remove the lower arm shaft. If encountering any problems when removing the shaft, contact ABB Robotics! Action Note/Illustration WARNING! This procedure is a step in the complete procedure...
Page 304 4 Repair 4.4.6. Replacement of lower arm shaft Continued Action Note/Illustration 4. Fit the puller device to the shaft as shown in the Art. no. is specified in Required figure to the right. equipment on page 300! xx0300000010 5. Fit both the hydraulic pump and the glycerin pump to Art.
Page 305 4 Repair 4.4.6. Replacement of lower arm shaft Continued Refitting, lower arm shaft The procedure below details how to refit the lower arm shaft. Action Note/Illustration 1. Clean the shaft with isopropanol and lubricate it Art. no. is specified in Required with glycerin.
Page 306 4 Repair 4.4.6. Replacement of lower arm shaft Continued Action Note/Illustration 13. Apply grease to the location of the shaft where the Art. no. is specified in Required bearing is to be mounted. equipment on page 300 14. Press in the new bearing with the press tool, axis 2 Always use a new bearing when bearing.
Page 307: Securing The Lower Arm
4 Repair 4.4.7. Securing the lower arm 4.4.7. Securing the lower arm General This section details how to secure the lower arm with a specific fixture prior to performing certain service activities to the robot. Attachment points, robot The special equipment used to secure the lower arm is fitted to the attachment points shown in the figure below.
Page 308 4 Repair 4.4.7. Securing the lower arm Continued Required equipment Equipment, etc Art. no. Note Fixture lower arm 3HAC020729-001 Includes the locking screw for securing the lower arm. Standard toolkit 3HAC 15571-1 The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual.
Page 309 4 Repair 4.4.7. Securing the lower arm Continued Securing the lower arm The procedure below details how to secure the lower arm by fitting the fixture to the robot. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 310 4 Repair 4.4.7. Securing the lower arm Continued Action Note/Illustration 7. Fit the fixture, lower arm to the frame and the lower Art. no. is specified in Required arm, according to following instruction: equipment on page 306. 1. Fit the both adjusters in the correct holes and Attachment holes on the frame make sure that they are screwed back (C).
Page 311: Frame And Base
4 Repair 4.5.1. Replacement of SMB unit 4.5 Frame and base 4.5.1. Replacement of SMB unit Location of SMB unit The SMB unit (SMB = serial measurement board) is located on the left hand side of the frame as shown in the figure below. xx0200000203 SMB cover SMB unit...
Page 312 4 Repair 4.5.1. Replacement of SMB unit Continued Removal, SMB unit The procedure below details how to remove the SMB unit. Action Note 1. Move the robot to the calibration position. DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 313 4 Repair 4.5.1. Replacement of SMB unit Continued Refitting, SMB unit The procedure below details how to refit the SMB unit. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 314 4 Repair 4.5.1. Replacement of SMB unit Continued Replacement of SMB unit (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level. The repair must be done according to the previous repair procedure with the following additions.
Page 315: Replacement Of Brake Release Unit
4 Repair 4.5.2. Replacement of brake release unit 4.5.2. Replacement of brake release unit Location of brake release unit The brake release unit is located together with the SMB unit on the left hand side of the frame, right next to the gearbox, axis 2, as shown in figure below. xx0200000226 Brake release unit Attachment screws, brake release unit (4 pcs)
Page 316 4 Repair 4.5.2. Replacement of brake release unit Continued Removal, brake release unit The procedure below details how to remove the brake release unit. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 317 4 Repair 4.5.2. Replacement of brake release unit Continued Action Note/Illustration 7. Remove the brake release unit from the bracket by removing the four attachment screws. Refitting, brake release unit The procedure below details how to refit the brake release unit. Action Note/Illustration DANGER!
Page 318 4 Repair 4.5.2. Replacement of brake release unit Continued Action Note/Illustration 5. Refit the complete brake release unit (including brake release unit and bracket) to the SMB recess with the two attachment screws. 6. Refit the SMB cover with its attachment Shown in the figure Location of brake screws.
Page 319: Replacement Of Spherical Roller Bearing, Balancing Device
4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device 4.5.3. Replacement of spherical roller bearing, balancing device Location of bearing The bearing is located at the front ear of the balancing device, as shown in the figure below. xx0500002249 Spherical roller bearing Sealing ring O-ring...
Page 320 4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device Continued Equipment Spare part no. Art. no. Note Toolkit 3HAC Includes: 021984-001 • Threaded bar 3HAC15945-1 • Dolly 3HAC15948-2 • Press tool 3HAC15941-2 • Press tool 3HAC15846-2 • Hexagon nut M12 9ADA267-9 •...
Page 321 4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device Continued Removal, bearing The procedure below details how to remove the bearing from the balancing device front ear. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 322 4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device Continued Action Note/Illustration 3. Insert the threaded bar through the new Spare part no. is specified in bearing and place it at the front ear. Fit also the Required equipment on page 317.
Page 323 4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device Continued Action Note/Illustration 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 3HAC023082-001 Revision: E...
Page 324: Replacement Of Balancing Device
4 Repair 4.5.4. Replacement of balancing device 4.5.4. Replacement of balancing device Location of balancing device The balancing device is located on rear top of the frame as shown in the figure below. xx0200000223 Balancing device Rear cover Support shaft inside Attachment screws, rear cover Balancing device shaft, including securing screw Bearing attachment...
Page 325 4 Repair 4.5.4. Replacement of balancing device Continued Attachment points, balancing device The attachment points for the lifting tools etc. are located as shown in the figure below. xx0300000482 Lifting eye for the lifting equipment Securing screw attachment hole, secures the bearing attachment to the balancing device (remove the protection plug) Hole in the frame to access the balancing device shaft with the puller/press tool Locking screw attachment hole, secures the lower arm to the frame...
Page 326 4 Repair 4.5.4. Replacement of balancing device Continued Equipment Spare part no. Art. no. Note Gasket, end cover 3HAC 17188-1 To be replaced if damaged! Locking screw 3HAA1001-266 M16 x 60 For securing the lower arm. Securing screw 9ADA 183-66 M12 x 35, 2 pcs required For securing the bearing attachments to the...
Page 327 4 Repair 4.5.4. Replacement of balancing device Continued Removal, balancing device The procedure below details how to remove the balancing device. Action Note/Illustration 1. Move the lower arm to a position close to the calibration position. DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 328 4 Repair 4.5.4. Replacement of balancing device Continued Action Note/Illustration 9. Restore the balancing device. Detailed in section Restoring the balancing device on page 334. 10. Secure the two bearing attachments to the Shown in the figure Attachment points, balancing device by replacing the protection balancing device on page 323! plug on the outside of each attachment, with...
Page 329 4 Repair 4.5.4. Replacement of balancing device Continued Action Note 6. Fit the shackle to the balancing device. Art. no. is specified in Required equipment on page 323! Attachments are shown in the figure- Attachment points, balancing device on page 323.
Page 330 4 Repair 4.5.4. Replacement of balancing device Continued Action Note 17. Lubricate the bearing in the ear with grease Art. no. and amount are specified in through the lubricating nipple, with a grease Required equipment on page 323! pump. Lubrication is further detailed in Fill until excessive grease pierces between the section Lubrication of spherical roller...
Page 331 4 Repair 4.5.4. Replacement of balancing device Continued Replacement of balacing device (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level. The repair must be done according to the repair chapter in the Product Manual with the following additions.
Page 332 4 Repair 4.5.4. Replacement of balancing device Continued Action Note/Illustration 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 3HAC023082-001 Revision: E...
Page 333: Unloading The Balancing Device
4 Repair 4.5.5. Unloading the balancing device 4.5.5. Unloading the balancing device Prerequisite This section details how to unload the balancing device with the press tool. The lower arm must be secured before unloading the balancing device! How to secure the lower arm is detailed in the current repair activity, e.g removal of the balancing device.
Page 334 4 Repair 4.5.5. Unloading the balancing device Continued Required equipment Equipment, etc. Art. no. Note Press tool, balancing device 3HAC020902-001 Includes • press device 3HAC 15767-2 • press device 3HAC 18100-1 Choose the correct device, depending on model of balancing device. Hydraulic cylinder 3HAC11731-1 To be used with the press tool.
Page 335 4 Repair 4.5.5. Unloading the balancing device Continued Action Note/Illustration 3. Remove the rear cover of the balancing device, by unscrewing the attachment screws (E). xx0200000175 • E: Rear cover attachment screws, 4 pcs 4. Remove the gasket from the balancing device end.
Page 336: Restoring The Balancing Device
4 Repair 4.5.6. Restoring the balancing device 4.5.6. Restoring the balancing device Overview This section details how to restore the balancing device and how to remove the press tool from the device. Press tool and hydraulic cylinder The figure below shows the hydraulic cylinder mounted on the press tool. The press tool includes two press devices that are used to different models of the balancing device.
Page 337 4 Repair 4.5.6. Restoring the balancing device Continued Equipment, etc. Art. no. Note Locking liquid Loctite 577 Used to secure the attachment screws of the rear cover at the end of the balancing device. Gasket, end cover 3HAC 17188-1 Standard toolkit 3HAC 15571-1 The contents are defined in section Standard toolkit on page 436...
Page 338 4 Repair 4.5.6. Restoring the balancing device Continued Action Note/Illustration DANGER! The rear cover of the balancing device is a safety device for the piston rod during operation! Make sure the cover is properly secured before com- missioning of the robot! 3HAC023082-001 Revision: E...
Page 339: Motors
4 Repair 4.6.1. Replacement of motor, axis 1 4.6 Motors 4.6.1. Replacement of motor, axis 1 Location of motor The motor axis 1 is located on the left hand side of the robotas shown in the figure below. xx0200000200 Motor, axis 1 Motor attachment screws and washers Required equipment Equipment, etc.
Page 340 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Equipment, etc. Spare part no. Art. no. Note Grease 3HAB 3537-1 Used to lubricate the o- ring. Removal tool, motor 3HAC 14631-1 Always use the removal M12x tools in pairs! Lifting tool, motor ax 1, 3HAC 14459-1 4, 5 Power supply...
Page 341 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note/Illustration 3. Remove the cable gland cover at the cable exit by unscrewing its two attachment screws. xx0200000199 • A: Cable gland cover Make sure the gasket is not damaged! 4.
Page 342 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note CAUTION! The motor weighs 25 kg! All lifting equipment used must be sized accordingly! 4. Apply the lifting tool, motor axis 1, 4, 5 to the motor. Art no. is specified in Required equipment on page 337!
Page 343 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Replacement of the motor axis 1 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level. The repair must be done according to the repair chapter in the Product Manual with the following additions.
Page 344 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note/Illustration 5. Fill the four screw recesses on the new motor with Sikaflex. (After hardening, Sikaflex can be formed with a knife) xx0600002875 • A: motor unit • B: Sikaflex in screw recesses 6.
Page 345: Replacement Of Motor Axis 2
4 Repair 4.6.2. Replacement of motor axis 2 4.6.2. Replacement of motor axis 2 Location of motor The motor, axis 2, is located on the left hand side of the robot as shown in the figure below. xx0400001067 Motor, axis 2 Hole for locking screw Cable gland cover (located on the lower side of the motor) Motor attachment holes (4 pcs)
Page 346 4 Repair 4.6.2. Replacement of motor axis 2 Continued Equipment, etc. Spare part no. Art. no. Note Gasket 3HAC3438-1 Option Foundry Prime Must be replaced if the cablling is dismantled from the motor. Grease 3HAB 3537-1 For lubricating the o-ring. Locking screw 3HAA 1001-266 M16 x 60 For securing the lower arm.
Page 347 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 3.
Page 348 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note CAUTION! The motor weighs 32 kg! All lifting equipment used must be sized accordingly! 15. Lift the motor to get the pinion away from the gear. Make sure the motor pinion does not get damaged! 16.
Page 349 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note/Illustration 9. Use the rotation tool in order to rotate the Art. no. is specified in Required motor pinion when mating it to the gear (see equipment on page 343! the figure to the right).
Page 350 4 Repair 4.6.2. Replacement of motor axis 2 Continued Replacement of the motor axis 2 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level. The repair must be done according to the repair chapter in the Product Manual with the following additions.
Page 351 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note/Illustration 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! 9.
Page 352: Replacement Of Motor, Axis 3
4 Repair 4.6.3. Replacement of motor, axis 3 4.6.3. Replacement of motor, axis 3 Location of motor The motor axis 3 is located on the left hand side of the robot as shown in the figure below. xx0200000186 Motor axis 3 Cable gland cover, motor axis 3 Motor attachment holes (4 pcs) xx0600003051...
Page 353 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Motor including 3HAC 15885-2 Includes pinion • motor • pinion • o-ring 2152 2012-430 O-ring 2152 2012-430 Must be replaced when reas- sembling motor! Sikaflex 251FC 3HAC026620-001 Foundry Prime...
Page 354 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Equipment, etc. Spare part no. Art. no. Note Other tools and These procedures include procedures may be references to the tools required. See required. references to these procedures in the step-by-step instructions below.
Page 355 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note/Illustration 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! 9.
Page 356 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note/Illustration 4. Fit the two guide pins in the two lower motor Art no. is specified in Required attachment holes. equipment on page 351! Shown in the figure Location of motor on page 350! CAUTION!
Page 357 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note/Illustration 15. Refit the cover on top of the motor with its four Make sure the cover is tightly attachment screws. sealed! 16. Remove the equipment used to unload the upper arm.
Page 358 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note/Illustration 3. Remove the cover for connector access on top of the motor by unscrewing its four attachment screws. xx0600002874 • A: attachment screw • B: air hose • C: top cover •...
Page 359: Replacement Of Motor, Axis 4
4 Repair 4.6.4. Replacement of motor, axis 4 4.6.4. Replacement of motor, axis 4 Location of motor The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below. xx0200000202 Motor, axis 4 Cable gland cover, motor axis 4 Motor attachment holes (4 pcs) xx0500003050...
Page 360 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Motor including 3HAC 15889-2 Includes pinion • motor • pinion • o-ring 2152 2012-430 O-ring 2152 2012-430 Must be replaced when reas- sembling motor! Sikaflex251FC 3HAC026620-001...
Page 361 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Removal, motor axis 4 The procedure below details how to remove the motor, axis 4. Action Note 1. Move the robot to a position where the upper Draining of oil is described in section arm is pointed straight up.
Page 362 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Refitting, motor axis 4 The procedure below details how to refit motor, axis 4. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 363 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note/Illustration 7. Use the rotation tool in order to rotate the Art. no. is specified in Required motor pinion when mating it to the gear! equipment on page 358! Fit the motor, making sure the motor pinion Make sure the motor pinion does not get is properly mated to the gear, axis 4.
Page 364 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Replacement of the motor axis 4 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level. The repair must be done according to the repair chapter in the Product Manual with the following additions.
Page 365 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note/Illustration 5. Fill the four screw recesses on the new motor with Sikaflex. (After hardening, Sikaflex can be formed with a knife) xx0600002875 • A: motor unit • B: sikaflex in screw recesses 6.
Page 366: Replacement Of Motor, Axis 5, Irb 6600 And Irb 6650
4 Repair 4.6.5. Replacement of motor, axis 5, IRB 6600 and IRB 6650 4.6.5. Replacement of motor, axis 5, IRB 6600 and IRB 6650 Reused pinion The pinion in the motor, axis 5, is matched with the beveral gear for axis 5. When the motor is replaced the pinion must therefore be removed from the dismounted motor and fitted onto the new motor shaft as detailed in this section.
Page 367 4 Repair 4.6.5. Replacement of motor, axis 5, IRB 6600 and IRB 6650 Continued Equipment, etc. Spare part no. Art. no. Note O-ring 2152 2012-430 Must be replaced when reassembling motor! Sikaflex 251FC 3HAC026621-001 Option Foundry Prime Mercasol 3106 3HAC026620-001 Option Foundry Prime Gasket 3HAC3438-1 Option Faundry Prime...
Page 368 4 Repair 4.6.5. Replacement of motor, axis 5, IRB 6600 and IRB 6650 Continued Removal, motor, axis 5 The procedure below details how to remove motor, axis 5. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 369 4 Repair 4.6.5. Replacement of motor, axis 5, IRB 6600 and IRB 6650 Continued Action Note 15. Press out the pinion from the dismounted motor, Replacing the complete wrist unit is with the equipment included in the oil injector kit. detailed in section Replacement of complete wrist unit, IRB 6600 and...
Page 370 4 Repair 4.6.5. Replacement of motor, axis 5, IRB 6600 and IRB 6650 Continued Action Note 8. In order to release the brake, connect the 24 Connect to either: VDC power supply. - connector R4.MP5 (in the motor): • +: pin 2 •...
Page 371 4 Repair 4.6.5. Replacement of motor, axis 5, IRB 6600 and IRB 6650 Continued Replacement of the motor axis 5 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level. The repair must be done according to the previous repair procedures with the following additions.
Page 372 4 Repair 4.6.5. Replacement of motor, axis 5, IRB 6600 and IRB 6650 Continued Action Note/Illustration 6. Continue to remove the motor unit, according to step 8 to 15 in Removal, motor, axis 5 on page 366. 7. Fill the four screw recesses on the new motor with Sikaflex.
Page 373: Replacement Of Motor, Axis 5, Irb 6600Id And Irb 6650Id
4 Repair 4.6.6. Replacement of motor, axis 5, IRB 6600ID and IRB 6650ID 4.6.6. Replacement of motor, axis 5, IRB 6600ID and IRB 6650ID Location of motor, axis 5 The motor of axis 5 is located on the bottom side of the wrist, when axis 4 is placed in calibration position.
Page 374 4 Repair 4.6.6. Replacement of motor, axis 5, IRB 6600ID and IRB 6650ID Continued Removal tools, motor attachment screws The figure below shows the required dimensions of the tools, in order to access the attachment screws of the motor. xx0500002271 Allen key, Ø...
Page 375 4 Repair 4.6.6. Replacement of motor, axis 5, IRB 6600ID and IRB 6650ID Continued Refitting, motor axis 5 The procedure below details how to refit the motor, axis 5. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 376: Replacement Of Motor, Axis 6, Irb 6600 And Irb 6650
4 Repair 4.6.7. Replacement of motor, axis 6, IRB 6600 and IRB 6650 4.6.7. Replacement of motor, axis 6, IRB 6600 and IRB 6650 Location of motor The motor axis 6 is located in the center of the wrist unit as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views...
Page 377 4 Repair 4.6.7. Replacement of motor, axis 6, IRB 6600 and IRB 6650 Continued Equipment, etc. Spare part no. Art. no. Note O-ring 2152 2012-430 Must be replaced when reassembling motor! Merkasol 3106 3HAC026621-001 Option Foundry Prime Sikaflex 3HAC026620-001 Option Foundry Prime Loctite 574 Loctite 480 Gasket...
Page 378 4 Repair 4.6.7. Replacement of motor, axis 6, IRB 6600 and IRB 6650 Continued Action Note 3. Remove the rear motor cover by unscrewing the five attachment screws. 4. Disconnect all connectors beneath the cover. 5. In order to release the brake, connect the 24 VDC Connect to connector R3.MP6 power supply.
Page 379 4 Repair 4.6.7. Replacement of motor, axis 6, IRB 6600 and IRB 6650 Continued Action Note 9. Reconnect all connectors beneath the motor cover. 10. Refit the cover on top of the motor with its five Make sure the cover is tightly sealed! attachment screws.
Page 380 4 Repair 4.6.7. Replacement of motor, axis 6, IRB 6600 and IRB 6650 Continued Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 4.
Page 381 4 Repair 4.6.7. Replacement of motor, axis 6, IRB 6600 and IRB 6650 Continued Action Note/Illustration 8. Fill the four screw recesses on the new motor with Sikaflex. (After hardening, Sikaflex can be formed with a knife) xx0600002884 • A: mercasol •...
Page 382: Replacement Of Motor, Axis 6, Irb 6600Id And Irb 6650Id
4 Repair 4.6.8. Replacement of motor, axis 6, IRB 6600ID and IRB 6650ID 4.6.8. Replacement of motor, axis 6, IRB 6600ID and IRB 6650ID Location of motor, axis 6 The motor of axis 6 is located on top of the wrist, when axis 4 is placed in calibration position. xx0500001574 Motor, axis 6 Motor connectors, R3.MP6 and R3.FB6...
Page 383 4 Repair 4.6.8. Replacement of motor, axis 6, IRB 6600ID and IRB 6650ID Continued Equipment Spare part no. Art. no. Note Circuit diagram See chapter Circuit diagram Product manual, reference information. Removal, motor axis 6 The procedure below details how to remove the motor, axis 6. Action Note 1.
Page 384 4 Repair 4.6.8. Replacement of motor, axis 6, IRB 6600ID and IRB 6650ID Continued Action Note 3. In order to release the brakes, connect the 24 Connect to connector R3.MP6: VDC power supply to the motor. • + : pin C •...
Page 385: Gearboxes
4 Repair 4.7.1. Replacement of gearbox, axis 1 4.7 Gearboxes 4.7.1. Replacement of gearbox, axis 1 Location of gearbox The axis 1 gearbox is located between the frame and base as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
Page 386 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Equipment, etc. Spare part no. Art. no. Note O-ring 3HAB 3772-55 Replace only when damaged! Sealing ring 3HAC 11581-4 Replace only when damaged! Grease 3HAC 3537-1 For lubricating the o-rings. Rust preventive 3HAC026621- Mercasol 3106 (Foundry Prime) Support, base...
Page 387 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note/Illustration 4. Disconnect all cabling in the rear of the robot base and remove the cable support plate inside of the base. 5. Pull the disconnected cabling up through the center of gearbox 1. 6.
Page 388 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note/Illustration 13. Unscrew the 18 attachment screws and remove the 3 washers, shown in the figure to the right. xx0200000227 A view from below: • A: Oil drain hose • B: Attachment screws, gearbox axis 1, 18 pcs •...
Page 389 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note/Illustration 2. Make sure the two o-rings (C, D) on the cir- Art no. is specified in Required cumference of the gearbox are seated equipment on page 383! properly in their grooves respectively. Lubricate them with grease .
Page 390 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note/Illustration 8. Secure the gearbox and the three washers 18 pcs, M16 x 70, 12.9 quality with the 18 attachment screws, gearbox axis UNBRAKO, tightening torque: 300 Nm. Reused screws may be used, providing they are lubricated as detailed in section Screw joints on page 432...
Page 391 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note/Illustration 13. Refit the complete arm system. Detailed in section Refitting, arm system on page 264. This is a complex task to be performed with utmost care in order to avoid injury or damage! 14.
Page 392 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note/Illustration 2. Apply Mercasol 3106 on unpainted areas. xx0600003132 • A: surface on the underside of the frame • B: Radial sealing gear axis 1, against base DANGER! Make sure all safety requirements are met when performing the first test run.
Page 393: Replacement Of Gearbox Axis 2
4 Repair 4.7.2. Replacement of gearbox axis 2 4.7.2. Replacement of gearbox axis 2 TypeA and typeB of robot The gear of axis 2 differs depending on the type of robot. Read more about the difference in section Type A and type B of IRB 6600/6650 on page 427.
Page 394 4 Repair 4.7.2. Replacement of gearbox axis 2 Continued Required equipment Equipment Spare part no. Art. no. Note Gearbox axis 2 3HAC 021541-001 Includes • gearbox • o-ring. Does not include "Sealing, axis 2/3"! O-ring 3HAB 3772-77 O-ring 3HAB 3772-73 O-ring in the cover, axis 2, 1 pc.
Page 395 4 Repair 4.7.2. Replacement of gearbox axis 2 Continued Removal, gearbox axis 2 The procedure below details how to remove the gearbox, axis 2. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 396 4 Repair 4.7.2. Replacement of gearbox axis 2 Continued Action Note/Illustration 11. Fit the lifting tool, gearbox axis 2 to the gearbox. Art. no. is specified in Required equipment on page 392! CAUTION! The gearbox weighs 100 kg! All lifting equipment used must be sized accordingly! 13.
Page 397 4 Repair 4.7.2. Replacement of gearbox axis 2 Continued Action Note/Illustration 4. Fit the guide pins, sealing axis 2/3 to the rear of the gearbox, axis 2. Use the attachment holes shown in the figure to the right! xx0300000552 • A: Rear attachment screws, gearbox (18 pcs) •...
Page 398 4 Repair 4.7.2. Replacement of gearbox axis 2 Continued Action Note/Illustration 12. Insert and secure 30 of the 32 front attachment 32 pcs: M12 x 60, tightening torque: screws, gearbox. 115 Nm. Remove the guide pins, M12 and refit the two remaining screws.
Page 399 4 Repair 4.7.2. Replacement of gearbox axis 2 Continued Refitting, gearbox axis 2 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level. The repair must be done according to the repair chapter in the Product Manual with the following additions.
Page 400 4 Repair 4.7.2. Replacement of gearbox axis 2 Continued Action Note/Illustration 4. Apply Mercasol 3106 on the lower arm according to the illustration to the roght before assembly. xx0600003135 • A: Mercasol 3106 on surfaces DANGER! Make sure all safety requirements are met when performing the first test run.
Page 401: Replacement Of Gearbox, Axis 3
4 Repair 4.7.3. Replacement of gearbox, axis 3 4.7.3. Replacement of gearbox, axis 3 Location of gearbox The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
Page 402 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Equipment, etc. Spare part no. Art. no. Note Grease 3HAB 3537-1 For lubricating the o-rings. Rust preventive 3HAC026621- Only Foundry Prime Equivalent: • Mercasol 3106 Sealing, axis 2/3 3HAC 17212-1 A new sealing must be used on each assembly! Mech stop ax 3 3HAC 12708-1...
Page 403 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note/Illustration 2. Secure the upper arm in a horizontal position Art. no. is specified in Required using a mechanical stop. equipment on page 399. Fit the mechanical stop to the third and final attachment hole (A), below the fixed mechanical stop (B) in the upper arm, shown in the figure to the right.
Page 404 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note/Illustration CAUTION! The gearbox weighs 60 kg! All lifting equipment used must be sized accordingly! 11. Remove the gearbox, with guidance from the guide pins, using an overhead crane or similar. Refitting, gearbox axis 3 The procedure below details how to refit gearbox, axis 3.
Page 405 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note/Illustration 6. Make sure the o-rings are fitted to the gearbox. Art. no. is specified in Required Apply grease to the o-rings to make sure they equipment on page 399! stick in their grooves during assembly.
Page 406 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note/Illustration 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 Refitting, gearbox axis 3 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level.
Page 407: Replacement Of Gearbox, Axis 6
4 Repair 4.7.4. Replacement of gearbox, axis 6 4.7.4. Replacement of gearbox, axis 6 Location of gearbox The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. xx0200000219 Gearbox, axis 6 Attachment screws and washers, gearbox (18 pcs) Oil plug, draining Oil plug, filling...
Page 408 4 Repair 4.7.4. Replacement of gearbox, axis 6 Continued Equipment, etc. Spare part no. Art. no. Note Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual. Calibration 3HAC15716-1 Complete kit that also Pendulum toolkit includes operating manual.
Page 409 4 Repair 4.7.4. Replacement of gearbox, axis 6 Continued Action Note/Illustration 6. Remove the gearbox axis 6 by lifting it out Be careful not to damage the motor carefully. pinion! Refitting, gearbox The procedure below details how to refit gearbox, axis 6. Action Note/Illustration DANGER!
Page 410 4 Repair 4.7.4. Replacement of gearbox, axis 6 Continued Action Note/Illustration 6. If the robot is going to work in a water jet application cell: • apply Mercasol on unpainted surfaces between gea box and turning disk • apply Mercasol on the screw heads in the front of the turning disk.
Page 411: Calibration Information
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 410, and further detailed in separate Calibration manuals.
Page 412: Calibration Methods
5 Calibration information 5.2. Calibration methods 5.2. Calibration methods Overview This section specifies the different types of calibration and the calibration methods that are supplied from ABB. Types of calibration Type of calibra- Description Calibration method tion Standard The calibrated robot is positioned at home...
Page 413 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.
Page 414: Calibration Scales And Correct Axis Position
5 Calibration information 5.3. Calibration scales and correct axis position 5.3. Calibration scales and correct axis position Introduction This section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration scales/marks, IRB 6600, IRB 6650, IRB 6650S, IRB 7600 The illustration below shows the location of the calibration scales on specific plates and the calibration marks directly in the casting at axes 2 and 3.
Page 415 5 Calibration information 5.3. Calibration scales and correct axis position Continued Calibration scales/ marks, IRB 6600ID and IRB 6650ID The illustration below shows the location of the calibration scales on specific plates and the calibration marks directly in the casting at axes 2 and 3. xx0500002016 Calibration scale, axis 1 Calibration mark, axis 2...
Page 416: Calibration Movement Directions For All Axes
5 Calibration information 5.4. Calibration movement directions for all axes 5.4. Calibration movement directions for all axes Overview When calibrating, the axis must consistently be run towards the calibration position in the same direction, in order to avoid position errors caused by backlash in gears etc. Positive directions are shown in the figure below.
Page 417: Updating Revolution Counters
5 Calibration information 5.5. Updating revolution counters 5.5. Updating revolution counters General This section details how to perform a rough calibration of each robot axis, 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;...
Page 418 5 Calibration information 5.5. Updating revolution counters Continued Step 2 - Storing the revolution counter setting with the TPU This section details the second step when updating the revolution counter; storing the revolution counter setting with the TPU (RobotWare 4.0). Action Note 1.
Page 419 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.
Page 420 5 Calibration information 5.5. Updating revolution counters Continued Action 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: •...
Page 421: Checking The Calibration Position
This section describes how to create a program, which runs all the robot axes to their zero position. Action Note 1. On ABB menu tap Program Editor. 2. Create a new program. 3. Use MoveAbsJ in the Motion&Proc menu. 4. Create the following program: MoveAbsJ...
Page 422 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.
Page 423: Additional Calibration Instruction, Irb4400
5 Calibration information 5.7. Additional calibration instruction, IRB4400 5.7. Additional calibration instruction, IRB4400 Instrauction Before updating the revolution counters (coarse calibration) on IRB 4400, the stainless steel metal ring on axis 4 need to be removed. Illustration xx0600003124 Upper arm Stainless steel ring hose clamp 3HAC023082-001 Revision: E...
Page 424 5 Calibration information 5.7. Additional calibration instruction, IRB4400 3HAC023082-001 Revision: E...
Page 425: Decommissioning
6 Decommissioning 6.1. Environmental information 6 Decommissioning 6.1. Environmental information Hazardous material The table specifies some of the materials in the manipulator and their respective use throughout the product. Dispose the components properly to prevent health or environmental hazards. Material Example application Batteries, NiCad or Lithium Serial measurement board...
Page 426: Decommissioning Of Balancing Device
6 Decommissioning 6.2. Decommissioning of balancing device 6.2. Decommissioning of balancing device General There is much energy stored in the balancing device. Therefore a special procedure is required to dismantle it. The coil springs inside the balancing device exert a potentially lethal force unless dismantled properly.
Page 427 6 Decommissioning 6.2. Decommissioning of balancing device Continued Decommissioning at decommissioning company, balancing device The instruction below details how to decommission the balancing device. Contact ABB Robotics for further consultation. Action Note/Illustration DANGER! There is stored energy built up by high...
Page 428 6 Decommissioning 6.2. Decommissioning of balancing device 3HAC023082-001 Revision: E...
Page 429: Robot Description
7 Robot description 7.1. Type A and type B of IRB 6600/6650 7 Robot description 7.1. Type A and type B of IRB 6600/6650 Type B - enlarged gear Type B robots of IRB 6600/6650 have an enlarged gear on axis 2. As a result of this enlargement, following main parts on the robot differ from type A: •...
Page 430 7 Robot description 7.1. Type A and type B of IRB 6600/6650 3HAC023082-001 Revision: E...
Page 431: Reference Information
8 Reference information 8.1. Introduction 8 Reference information 8.1. Introduction General This chapter includes general information, complementing the more specific information in Product manual (part 1 of 2), procedures. 3HAC023082-001 Revision: E...
Page 432: Applicable Safety Standards
8 Reference information 8.2. Applicable Safety Standards 8.2. Applicable Safety Standards Standards, general The robot is designed in accordance with the requirements of: • EN ISO 10218-1:2006 - Robots for industrial environments - Safety requirements - Part 1 Robot. • EN 292-1 - Basic terminology.
Page 433: Unit Conversion
8 Reference information 8.3. Unit conversion 8.3. Unit conversion Converter table Use the table below to convert units used in this manual. Quantity Units Length 3.28 ft 39.37 in Weight 1 kg 2.21 lb Pressure 1 bar 100 kPa 14.5 psi Force 0.738 lbf Moment...
Page 434: Screw Joints
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.
Page 435 8 Reference information 8.4. 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.
Page 436 8 Reference information 8.4. Screw joints Continued The table below specifies the recommended standard tightening torque for oil-lubricated screws with Allen head screws. Tightening torque Tightening torque Tightening torque (Nm) (Nm) (Nm) Dimension Class 8.8, oil-lubri- Class 10.9, oil-lubri- Class 12.9, oil-lubri- cated cated cated...
Page 437: Weight Specifications
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.
Page 438: Standard Toolkit
8 Reference information 8.6. Standard toolkit 8.6. Standard toolkit General All service (repairs, maintenance and installation) procedures contain lists of tools required to perform the specified activity. All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the Standard toolkit and defined in the table below.
Page 439: Special Tools
8 Reference information 8.7. Special tools 8.7. Special tools General All service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in section Standard toolkit on page 436, and of special tools, listed directly in the instructions and also gathered in this section.
Page 440 3HAC021984-001 Tools that may be rented The table below specifies the tools that may be rented from ABB in order to perform certain service procedures as described in the Product manual. The special tools are also listed directly in the instructions.
Page 441 8 Reference information 8.7. Special tools Continued Description Art. no. Note Levelmeter 2000 kit 6369901-347 Includes one sensor. Measuring pin 3HAC 13908-5 Sensor fixture 68080011-GM Sensor plate 3HAC 0392-1 Sync. adapter 3HAC 13908-1 Turn disk fixture 3HAC 68080011-GU Calibration equipment, Calibration Pendulum The table below specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method.
Page 442: Lifting Equipment And Lifting Instructions
8 Reference information 8.8. Lifting equipment and lifting instructions 8.8. 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.
Page 443: Spare Part / Part List
9 Spare part / part list 9.1. Introduction 9 Spare part / part list 9.1. Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot. 3HAC023082-001 Revision: E...
Page 444: Spare Part List
9 Spare part / part list 9.2.1. Introduction 9.2 Spare part list 9.2.1. Introduction Overview This section specifies all articles considered spare parts of the robot. The spare parts are also specified as required equipment directly in the repair instruction of the current spare part. 3HAC023082-001 Revision: E...
Page 445: Spare Part List
9 Spare part / part list 9.2.2. Spare part list 9.2.2. Spare part list Repair instructions Each spare part is replaced as described in corresponding repair instruction in the Product manual, procedures. Location, spare parts, IRB 6600 and IRB 6650 The figure below shows the spare parts of the IRB 6600 and IRB 6650.
Page 446 9 Spare part / part list 9.2.2. Spare part list Continued Location, spare parts, IRB 6600ID and IRB 6650ID The figure below shows the spare parts of the IRB 6600ID and IRB 6650ID. xx0500001796 Continues on next page 3HAC023082-001 Revision: E...
Page 447 9 Spare part / part list 9.2.2. Spare part list Continued Parts The table below specifies all the recommended spare parts for the robot. Item Description Spare part no. Note Motor including pinion 3HAC 15879-2 Axis 1 Motor including pinion 3HAC 15879-3 Foundry Prime Gearbox...
Page 448 9 Spare part / part list 9.2.2. Spare part list Continued Item Description Spare part no. Note Damper 1, axis 5 (2 pcs) 3HAC 021325-001 Axis 5 (IRB 6600ID and IRB 6650ID) Damper 2, axis 5 (2 pcs) 3HAC 021675-001 Axis 5 (IRB 6600ID and IRB 6650ID) Hood...
Page 449 9 Spare part / part list 9.2.2. Spare part list Continued Optional equipment All components required for installation of optional equipment, such as cabling, extra attachment plates etc., are listed in the installation procedure for the equipment. The table below points out the installation procedures for the equipment (in part 1: Procedures, of the Product manual).
Page 450: Part List
9 Spare part / part list 9.3.1. Introduction 9.3 Part list 9.3.1. Introduction Overview This section specifies all the replacement articles of the robot. The parts are shown in exploded views or in foldouts, either in this or in a separate chapter. Specific spare parts are listed separately in a Spare part list.
Page 451: Rebuilding Parts
9 Spare part / part list 9.3.2. Rebuilding parts 9.3.2. Rebuilding parts Overview The robot has some rebuilding parts that differ from eachother, depending on the robot version. This section is a general overview of which parts belong to which versions. The following section, Part list on page 448 also gives further details of the parts specified...
Page 452 9 Spare part / part list 9.3.2. Rebuilding parts Continued Item no Art. no. Part IRB 6600- IRB 6650- IRB 6650S- and type 175/ 225/ 175/ 200/ 125/ 200/ 125/ 2.55 2.55 2.75 3HAA1001-134 Washer 13x19x1,5 24X 111.504 9ABA107-56 Parallel pin 10x20 111.505 9ADA618-56 Screw M6x16...
Page 453: Part List, Overview
9 Spare part / part list 9.3.3. Part list, overview 9.3.3. Part list, overview Part list Item Qty Art. number Description Note / Dimension 3HAC 17358-1 Mechanical stop ax 1, assembly 3HAC 020854-001 Base incl frame ax 1 See section Base incl frame ax 1 on page 453 3HAC 10746-1...
Page 454 9 Spare part / part list 9.3.3. Part list, overview Continued Item Qty Art. number Description Note / Dimension 3HAC 13263-1 Material set manipulator See section Material set, manipulator, 3HAC 13263-1 on page 469 3HAC 13264-1 Material set ax 1-2 See section Material set, axis 1-2, 3HAC 13264-1...
Page 455: Base Incl Frame Ax 1
9 Spare part / part list 9.3.4. Base incl frame ax 1 9.3.4. Base incl frame ax 1 Part list Item Qty Art. number Description Note / Dimension 101.1 3HAC 17224-4 Base, machining See block Base, machining on page 453. 101.1 3HAC026572-001 Base, machining (Foundry...
Page 456: Axis 3-4
9 Spare part / part list 9.3.5. Axis 3-4 9.3.5. Axis 3-4 Overview Item Qty Art. number Description Note 102.1 3HAC 13350-1 Material set ax 4 See block Material set ax 4, 3HAC 13350-1 on page 454 102.2 3HAC 020049-001 Tube shaft 2,55 See block Tube shaft 2.55, 3HAC 020049-001 on page 455...
Page 457 9 Spare part / part list 9.3.5. Axis 3-4 Continued Item Art. number Description Dimension / Note 102.1.23 2 2213 253-5 Ball bearing 170 x 215 x 22 102.1.24 1 2216 261-18 Sealing 170 x 200 x 15 102.1.25 1 2216 0086-4 Sealing (Nilos) 180 x 215 x 4...
Page 458 9 Spare part / part list 9.3.5. Axis 3-4 Continued Item Art. number Description Note 102.2.2 3HAC 1383-2 Protection Cover compl. See sub-block Protection cover compl., 3HAC 1383-2 on page 456 Protection cover compl., 3HAC 1383-2 Item Art. number Description Dimension 102.2.2.1 1 9ADA 624-69...
Page 459 9 Spare part / part list 9.3.5. Axis 3-4 Continued Item Art. number Description Dimension 102.3.5.3 2152 2012-430 O-ring 89.5 x 3 102.3.5.4 9ADA 183-444 Hex socket head cap screw M8 x 130 102.3.5.5 3 ml 3HAB 7116-1 Locking liquid Rot ac motor incl gearbox Item Art.
Page 460: Axis 3-4, Foundry
9 Spare part / part list 9.3.6. Axis 3-4, Foundry 9.3.6. Axis 3-4, Foundry Overview Item Art. number Description Note 102.1 3HAC 13350-1 Material set ax 4 See block Material set ax 4, 3HAC 13350-1 on page 454 102.2 3HAC 020053-001 Tube shaft 2,55 foundry 102.3 3HAC 13351-1 Axis 3...
Page 461: Axis 3-4 Foundry Prime
9 Spare part / part list 9.3.7. Axis 3-4 Foundry Prime 9.3.7. Axis 3-4 Foundry Prime Overview Item Art. number Description Note 102.1 3HAC 13350-1 Material set ax 4 102.2 3HAC 020053-001 Tube shaft 2,55 foundry 102.3 3HAC 13351-1 Axis 3 102.4 3HAC 14753-1 Rot ac motor incl gearbox...
Page 462: Wrist, Type 2, Standard, Irb 6600 And Irb 6650
9 Spare part / part list 9.3.8. Wrist, type 2, standard, IRB 6600 and IRB 6650 9.3.8. Wrist, type 2, standard, IRB 6600 and IRB 6650 Overview Item Art. number Description Dimension / Note 103.1 3HAC 8114-4 Material set See block Material set, 3HAC 8114-4 on page 460 103.2...
Page 463 9 Spare part / part list 9.3.8. Wrist, type 2, standard, IRB 6600 and IRB 6650 Continued Item Art. number Description Dimension / Note 103.1.26 1 3HAC 7941-6 Interm.wheel unit/5 225kg See sub-block Interm. wheel unit/5 225 kg, 3HAC 7941-6 on page 103.1.27 1 3HAC 022695- Screw...
Page 464 9 Spare part / part list 9.3.8. Wrist, type 2, standard, IRB 6600 and IRB 6650 Continued Item Art. number Description Dimension 103.1.28.4 1 ml 3HAB 7116-2 Locking liquid Rot ac motor incl gearbox Item Art. number Description Dimension 103.2.1 3HAC 17484-10 Rotational ac motor M10 103.2.2...
Page 465 9 Spare part / part list 9.3.8. Wrist, type 2, standard, IRB 6600 and IRB 6650 Continued Rot ac motor incl. pinion, 3HAC 14754-1 Item Art. number Description Dimension 103.4.4.1 3HAC 17484-8 Rotational ac motor M8 103.4.4.2 3HAC 11173-3 Pinion RV 70F.125,8 103.4.4.3 2152 2012-430 O-ring...
Page 466: Wrist, Process, Irb 6600Id And 6650Id
9 Spare part / part list 9.3.9. Wrist, process, IRB 6600ID and 6650ID 9.3.9. Wrist, process, IRB 6600ID and 6650ID Overview The items listed below are shown in the exploded view Wrist complete, IRB 6600ID and IRB 6650ID on page 483.
Page 467 9 Spare part / part list 9.3.9. Wrist, process, IRB 6600ID and 6650ID Continued Item Art. no. Description Note/Dimension 103.34 9ADA312-6 Plain washer 6,4x12x1,6 103.35 9ADA183-37 Hex socket head cap screw Steel 8.8-A2F M8x25 103.36 9ADA183-37 Hex socket head cap screw Steel 8.8-A2F M8x25 103.37 9ADA312-7...
Page 468: Wrist, Type 2, Foundry
9 Spare part / part list 9.3.10. Wrist, type 2, Foundry 9.3.10. Wrist, type 2, Foundry Overview Item Art. number Description Dimension 103.1 3HAC 8114-4 Material set See block Material set, 3HAC 8114-4 on page 103.2 3HAC 7941-30 Rot ac motor incl gearbox See block Rot ac motor incl gearbox on page 462...
Page 469: Wrist, Type 2, Insulated
9 Spare part / part list 9.3.11. Wrist, type 2, insulated 9.3.11. Wrist, type 2, insulated Overview Item Qty Art. no. Description Note/Dimension 103.1 3HAC 8114-4 Material set See block Material set, 3HAC 8114-4 on page 460. 103.2 3HAC 7941-30 Rot ac motor incl gearbox See block Rot ac motor incl...
Page 470: Wrist, Type 2, Foundry Prime
9 Spare part / part list 9.3.12. Wrist, type 2, Foundry Prime 9.3.12. Wrist, type 2, Foundry Prime Overview Item Art. number Description Dimension 103.1 3HAC 8114-4 Material set 103.2 3HAC 7941-30 Rot ac motor incl gearbox 103.3 3HAB 3409-89 Hex socket head cap screw 103.4 3HAC 13890-2...
Page 471: Material Set, Manipulator, 3Hac 13263-1
9 Spare part / part list 9.3.13. Material set, manipulator, 3HAC 13263-1 9.3.13. Material set, manipulator, 3HAC 13263-1 Overview Dimension / Item Qty Art. number Description Note 108.201 1 3HAC 020123-001 Sealing axis 2/3 Axis 2 108.201 1 3HAC 17212-1 Sealing axis 2/3 Axis 3 108.202 18...
Page 472: Material Set, Axis 1-2, 3Hac 13264-1
9 Spare part / part list 9.3.14. Material set, axis 1-2, 3HAC 13264-1 9.3.14. Material set, axis 1-2, 3HAC 13264-1 Overview Item Art. number Description Dimension / Note 109.301 3HAC 021541-001 Reduction gear See block Reduction gear on page 471 109.302 3HAC 022812-003 Cover, axis 2...
Page 473 9 Spare part / part list 9.3.14. Material set, axis 1-2, 3HAC 13264-1 Continued Item Art. number Description Dimension / Note 109.332 3HAC 14791-3 Cover battery box See block Cover, battery box, 3HAC 14791-3 on page 472 109.322 3HAC026190-001 Cover battery box (Foundry Prime) 109.334 9ADA 618-53...
Page 474 9 Spare part / part list 9.3.14. Material set, axis 1-2, 3HAC 13264-1 Continued Item Art. number Description Dimension 109.306.3 1 2152 2012-430 O-ring 89.5 x 3 Motor incl pinion, 3HAC 020219-001 Item Art. number Description Dimension 109.307.1 1 3HAC 020208-001 Rotation AC motor, M11 109.307.2 1 3HAC 020131-001 Pinion 109.307.3 1...
Page 475: Material Set, Balancing Device, 3Hac 13265-1
9 Spare part / part list 9.3.15. Material set, balancing device, 3HAC 13265-1 9.3.15. Material set, balancing device, 3HAC 13265-1 Overview Item Art. number Description Dimension 110.401 3HAC 12441-2 Spherical roller bearing 65 x 120 x 38 110.402 3HAC 12481-1 Thrust washer 110.403 3HAC 12627-1...
Page 476: Arm Extension Set, 250 Mm, 3Hac 12311-4
9 Spare part / part list 9.3.16. Arm extension set, 250 mm, 3HAC 12311-4 9.3.16. Arm extension set, 250 mm, 3HAC 12311-4 Overview Item Qty Art. number Description Dimension 111.501 3HAC 9760-3 Arm extender 250mm 111.501 3HAC 15859-2 Arm extender 250mm, Foundry 111.503 3HAB 7700-69 Hex socket head cap screw...
Page 477: Arm Extension Set, 450 Mm, 3Hac 12311-5
9 Spare part / part list 9.3.17. Arm extension set, 450 mm, 3HAC 12311-5 9.3.17. Arm extension set, 450 mm, 3HAC 12311-5 Overview Item Art. number Description Dimension 111.501 3HAC 9760-7 Arm extender, 450mm 111.501 3HAC 15859-3 Arm extender, 450mm, Foundry 111.503 3HAB 7700-69 Hex socket head cap screw...
Page 478 9 Spare part / part list 9.3.17. Arm extension set, 450 mm, 3HAC 12311-5 3HAC023082-001 Revision: E...
Page 479: Exploded Views
10 Exploded views 10.1. Introduction 10 Exploded views 10.1. Introduction Definitions This chapter contains detailed views of the components on the manipulator. The numbered details are specified with item numbers in the Part List. The exploded views are divided into: •...
Page 480: Base Incl. Frame
10 Exploded views 10.2. Base incl. Frame 10.2. Base incl. Frame Exploded view xx0200000329 3HAC023082-001 Revision: E...
Page 481: Frame-Lower Arm 1
10 Exploded views 10.3. Frame-Lower arm 1 10.3. Frame-Lower arm 1 Exploded view xx0500002513 3HAC023082-001 Revision: E...
Page 482: Frame-Lower Arm 2
10 Exploded views 10.4. Frame-Lower arm 2 10.4. Frame-Lower arm 2 Exploded view xx0200000335 3HAC023082-001 Revision: E...
Page 483: Upper Arm
10 Exploded views 10.5. Upper arm 10.5. Upper arm Exploded view xx0200000337 3HAC023082-001 Revision: E...
Page 484: Wrist Complete, Irb 6600 And Irb 6650
10 Exploded views 10.6. Wrist complete, IRB 6600 and IRB 6650 10.6. Wrist complete, IRB 6600 and IRB 6650 Exploded view xx0200000336 3HAC023082-001 Revision: E...
Page 485: Wrist Complete, Irb 6600Id And Irb 6650Id
10 Exploded views 10.7. Wrist complete, IRB 6600ID and IRB 6650ID 10.7. Wrist complete, IRB 6600ID and IRB 6650ID Exploded view xx0500002407 3HAC023082-001 Revision: E...
Page 486 10 Exploded views 10.7. Wrist complete, IRB 6600ID and IRB 6650ID 3HAC023082-001 Revision: E...
Page 487: Circuit Diagram
11 Circuit Diagram 11.1. Introduction 11 Circuit Diagram 11.1. Introduction Overview This chapter includes the circuit diagram for the robot. Use the correct circuit diagram (IRB 6600, IRB 6650 and IRB 6650S) The cable harness of the robot is available in two different designs. Either the cabling is divided between the upper and lower arm, or not.
Page 488: Circuit Diagram 3Hac 025744-001
11 Circuit Diagram 11.2.1. Validity of circuit diagram 3HAC 025744-1 11.2 Circuit diagram 3HAC 025744-001 11.2.1. Validity of circuit diagram 3HAC 025744-1 Is this circuit diagram valid for your robot? The validity of the circuit diagram depends on which cable harness is fitted to the robot. Check the article number of the cable harness fitted to the robot and see page 3 of the circuit diagram in order to determine if the diagram is valid for the harness or not.
Page 489: Circuit Diagram 3Hac 13347-1
ABB for losses, damages to persons or property, fitness for a specific purpose or the like. In no event shall ABB be liable for incidental or consequential damages arising from use of this document. This document and parts thereof must not be reproduced or copied without ABB's written permission, and contents therof must not be imparted to a third party nor be used for any unauthorized purpose.
Page 490 Table of contents ABB Contents1 Page Page description Comment COPYRIGHT page Table of contents: (1 - 150) Valid For Connection point location IRB 6600 / 6640 / 6650 / 7600 Connection point location IRB 6660 Legend IRB 66XX / 7600...
Page 491: Index
Valid For: This circuit diagram is valid for the following cable harness assemblies: 3HAC 024385-001 Manipulator harness axis 1-6 (IRB 6600 / 6640) 3HAC 024386-001 Manipulator harness axis 1-6 (IRB 6640 / 6650 / 6650S) 3HAC14940-1 rev 3 and later. Manipulator harness axis 1-4 (IRB 6600 ID / 6640 ID / 7600) 3HAC16331-1 rev 1 and later.
Page 492 R3.FB5 (IRB 7600, 6600 ID, 6640 ID, 6650 ID) R3.MP5 (IRB 7600, 6600 ID, 6640 ID, 6650 ID) R1.MP R2.M5/6 R3.MP6 R3.MP5 (IRB 6600, 6640, 6650, 6650S) (On IRB7600, 6600 ID, R3.FB6 R3.FB5 (IRB 6600, 6640, 6650, 6650S) 6640 ID, 6650 ID) R4.MP5 (IRB 6600, 6640, 6650, 6650S) R4.FB5 (IRB 6600, 6640, 6650, 6650S) R2.MP4...
Page 493 R3.MP6 R3.FB6 R3.MP5 R3.FB5 R2.CP/CS R2.MP4 R2.FB4 R2.MP3 R2.FB3 R2.H1 R2.H2 R2.MP2 R2.FB2 R2.MP1 R2.FB1 R1.SMB1-3 R1.SMB4-6 R2.SMB R1.MP R1.SMB R1.CP/CS Lab/Office: Latest revision: Status: Plant: IRB6660 Location: Manipulator APPROVED Connection point location Sublocation: Document no. Rev. Ind Page 5 Next 3HAC025744-001 IRB 6660...
Page 494 Motor Protective Earth Brake Twisted wires Temp sensor (PTC- resistor) Screened wires Resolver Any number i.e. 66XX can be 6600, 6640, 6660 or 6650 Battery Pack Brake Release Unit Feedback unit Serial Measurment Board Position switch Keypin Location pin to avoid mismatch Lab/Office: Latest revision: Status:...
Page 495 BU Brake Release (Simplified) -R1.MP Brake Release -X10 -X10 R1.MP -BU M1 / +Axis 1/30;2 Brake PB Brake Bleed Circuit -BU 0V M1 / +Axis 1/30;2 R1.MP -BU M2 / +Axis 2/40;2 -BU 0V M2 / +Axis 2/40;2 -BU 0V M3 / +Axis 3/50;2 Brake Bleed Circuit -BU 0V M4 / +Axis 4/60;2 R1.MP...
Page 496 +Axis 3/50;3 / -0V EXT.LAMP R1.SMB R2.SMB R2.SMB SDI-N WHBK SDO-N WHBN WHRD KEYPIN +Axis 3/50;3 / -24V EXT.LAMP R2.G R1.G(X3) R1.G(X3) Lab/Office: Latest revision: Status: 2005-10-17 Plant: 66XX/7600 Location: APPROVED Serial Measuring Board Sublocation: Document no. Rev. Ind Page 20 Next 3HAC025744-001 IRB 66XX / 7600...
Page 497 R1.MP -R2.MP1 -R2.MP1 R (U) T (W) S (V) GNYE GNYE GNYE GNYE +BU/10;7 / -BU M1 BU M1 BU + Brake +BU/10;2 / -BU 0V M1 BU 0V M1 BU - -PTC1 PTC M +Axis 2/40;2 / -PTC M2 PTC M2 R1.SMB1-3 R1.SMB1-3...
Page 498 R1.MP -R2.MP2 -R2.MP2 R (U) T (W) S (V) GNYE GNYE GNYE GNYE +BU/10;7 / -BU M2 BU M2 BU + Brake +BU/10;2 / -BU 0V M2 BU 0V M2 BU - -PTC2 +Axis 1/30;2 / -PTC M2 PTC M2 +Axis 3/50;2 / -PTC M3 PTC M3 R1.SMB1-3...
Page 499 R1.MP -R2.MP3 -R2.MP3 R (U) T (W) S (V) GNYE GNYE GNYE GNYE +BU/10;7 / -BU M3 BU M3 BU + Brake +BU/10;2 / -BU 0V M3 BU 0V M3 BU - -PTC3 +Axis 2/40;2 / -PTC M3 PTC M3 +Axis 4/60;2 / -PTC M4 PTC M4 KEYPIN...
Page 500 R1.MP -R2.MP4- -R2.MP4- R (U) T (W) S (V) GNYE GNYE +BU/10;7 / -BU M4 BU M4 BU + Brake +BU/10;2 / -BU 0V M4 BU 0V M4 BU - -PTC4 +Axis 3/50;2 / -PTC M4 PTC M4 =7600+Axis 5/70;2 PTC M5 =66XX+Axis 5/80;2 A Keypin...
Page 501 R1.MP R2.M5/6 -R3.MP5 -R3.MP5- R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M5 BU M5 BU M5 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M5 BU 0V M5 BU 0V M5 BU - -PTC5 =66XX/7600+Axis 4/60;2 / -PTC M5 PTC M5 PTC M5 PTC 0V...
Page 502 R1.MP R3.MP5 -R4.MP5- -R4.MP5- R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M5 BU M5 BU M5 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M5 BU 0V M5 BU 0V M5 BU - -PTC5 =66XX/7600+Axis 4/60;2 / -PTC M5 PTC M5 PTC M5 +Axis 6/110;2 / -PTC M6.1...
Page 503 R1.MP R2.M5/6 -R3.MP5 -R3.MP5- R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M5 BU M5 BU M5 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M5 BU 0V M5 BU 0V M5 BU - -PTC5 =66XX/7600+Axis 4/60;2 / -PTC M5 PTC M5 PTC M5 PTC 0V...
Page 504 R1.MP -R2.M5/6- -R3.MP6 -R3.MP6 R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M6 BU M6 BU M6 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M6 BU 0V M6 BU 0V M6 BU - -PTC6 +Axis 5/70;5 / -PTC M6 PTC M6 +Axis 5/70;3 / -PTC 0V PTC 0V...
Page 505 R1.MP -R3.MP6- -R3.MP6- R (U) T (W) S (V) GNYE GNYE =66XX/7600+BU/10;7 / -BU M6 BU M6 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M6 BU 0V M6 BU - -PTC6 +Axis 5/80;2 / -PTC M6.1 PTC M6 PTC 0V R1.SMB4-6 R1.SMB4-6 -R3.FB6...
Page 506 R1.MP -R2.M5/6- -R3.MP6 -R3.MP6 R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M6 BU M6 BU M6 BU + Brake +Axis 5/90;5 / -BU 0V M6.1 BU 0V M6 BU - -PTC6 +Axis 5/90;5 / -PTC M6.2 PTC M6 +Axis 5/90;3 / -PTC 0V.1 PTC 0V...
Page 507 -SW1.1 Power 1.1.1 Location of position switches Power 1.1.2 Signal 1.1.2 Signal 1.1.1 SW1.6 -SW1.2 SW1.5 Power 1.2.1 Power 1.2.2 SW1.4 Signal 1.2.2 SW1.3 Signal 1.2.1 -SW1.3 SW1.2 Power 1.3.1 SW1.1 Power 1.3.2 Signal 1.3.2 Signal 1.3.1 Position switches -SW1.4 Axis 1 Power 1.4.1 Power 1.4.2...
Page 508 Location of position switches -SW2.1 R1.SW2/3 R2.SW2 Power 2.1.1 Power 2.1.1 Power 2.1.2 Power 2.1.2 Signal 2.1.2 Signal 2.1.2 Signal 2.1.1 Signal 2.1.1 -SW2.2 Power 2.2.1 Power 2.2.1 Power 2.2.2 Power 2.2.2 Signal 2.2.2 Signal 2.2.2 Signal 2.2.1 Signal 2.2.1 Position switches -SW2.3 Axis 2...
Page 509 Location of Position switches -SW3.1 R1.SW2/3 R2.SW3 Power 3.1.1 Power 3.1.1 Power 3.1.2 Power 3.1.2 Signal 3.1.2 Signal 3.1.2 Signal 3.1.1 Signal 3.1.1 -SW3.2 Power 3.2.1 Power 3.2.1 Power 3.2.2 Power 3.2.2 Signal 3.2.2 Signal 3.2.2 Signal 3.2.1 Signal 3.2.1 Position switches -SW3.3 Axis 3...
Page 510 11 Circuit Diagram 11.3.1. Validity of circuit diagram 3HAC 13347-1 11.3 Circuit diagram 3HAC 13347-1 11.3.1. Validity of circuit diagram 3HAC 13347-1 Is this circuit diagram valid for your robot? The validity of the circuit diagram depends on which cable harness is fitted to the robot. Check the article number of the cable harness fitted to the robot.
Page 511 Circuit Diagram 3HAC 13347-1 / Rev. 02 CONTENTS S h e e t Contents ........................101 Connection Point Location ...................102 Legend ..........................103 Brake Release Unit .......................104 Serial Measurement Board ...................105 Axis 1..........................106 Axis 2..........................107 Axis 3..........................108 Axis 4..........................109 Axis 5 (IRB 7600) ......................110 Axis 6..........................111 Switches axis 1 ......................113 Switches/Fan axis 2 ......................114...
Page 512 s h e e t R e v i s i o n Contents...
Page 513 s h e e t R e v i s i o n Connection Point Location...
Page 514 s h e e t R e v i s i o n Legend...
Page 515 s h e e t R e v i s i o n Brake Release Unit...
Page 516 s h e e t R e v i s i o n Serial Measurement Board...
Page 517 s h e e t R e v i s i o n Axis 1...
Page 518 s h e e t R e v i s i o n Axis 2...
Page 519 s h e e t R e v i s i o n Axis 3...
Page 520 s h e e t R e v i s i o n Axis 4...
Page 521 s h e e t R e v i s i o n Axis 5 (IRB 7600)
Page 522 s h e e t R e v i s i o n Axis 6...
Page 523 s h e e t R e v i s i o n Switches axis 1...
Page 524 s h e e t R e v i s i o n Switches/Fan axis 2...
Page 525 s h e e t R e v i s i o n Switches/Fan axis 3...
Page 526 s h e e t R e v i s i o n Axis 5 (IRB 6600)
Page 527 s h e e t R e v i s i o n Design changes, note 1.1...
Page 528 s h e e t R e v i s i o n Design changes, note 2.1-2.7...
Page 529 11 Circuit Diagram 11.3.1. Validity of circuit diagram 3HAC 13347-1 3HAC023082-001 Revision: E...
Page 530 Index requirements 54 Absolute Accuracy, calibration 411 gearbox axis 1, replacement 383 gearbox axis 2, replacement 391 balancing device bearing, replacement 317 gearbox axis 3, replacement 399 balancing device, replacement 322 gearbox axis 6, replacement 405 brake release unit, replacement 313 brakes testing function 29 identification 427...
Page 531 Index storage conditions, robot 54 symbols, safety 35 range of movement 59 sync marks 412 replacement balancing device 322 bearing, balancing device 317 testing, brakes 29 brake release unit 313 tightening torque cable harness axes 1-4 240 mechanical stop axis 1 106 cable harness axes 1-6 228 mechanical stop axis 2 108 cabling axis 5 259...
Page 533 ABB AB Robotics Products S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...

This manual is also suitable for:

Irb 6600 - 175/2.8 type b Irb 6650id - 170/2.75 Irb 6650 - 200/2.75 type b Irb 6650 - 125/3.2 type b Irb 6600id - 185/2.55

ABB IRB 6600 - 225/2.55 type B Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration Information

6 Decommissioning

7 Robot Description

8 Reference Information

9 Spare Part / Part List

10 Exploded Views

11 Circuit Diagram

Index

Quick Links

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Summary of Contents for ABB IRB 6600 - 225/2.55 type B