ABB IRB 6620 - 150/2.2 Product Manual
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ABB IRB 6620 - 150/2.2 Product Manual

Articulated robot
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Articulated robot
IRB 6620 - 150/2.2
M2004

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Summary of Contents for ABB IRB 6620 - 150/2.2

  • Page 1 Product manual Articulated robot IRB 6620 - 150/2.2 M2004...
  • Page 3 Product manual IRB 6620 - 150/2.2 M2004 Document ID: 3HAC027151-001 Revision: B...
  • 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 ................7 Product documentation, M2004 .
  • Page 6 Table of Contents 2.7 Electrical connections ............. . 89 2.7.1 Robot cabling and connection points .
  • Page 7 Table of Contents 4.6 Motors ................199 4.6.1 Replacement of motor, axis 1 .
  • Page 8 Table of Contents 3HAC027151-001 Revision: B...

  • Page 9: 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 10 Overview Continued References Reference Document Id Note Product specification - IRB 6620 3HAC025861-001 Product manual - IRC5 3HAC021313-001 Operating manual - IRC5 with Flexpendant 3HAC16590-1 Operating manual - Calibration pendulum 3HAC16578-1 Operating manual - Service Information System 3HAC025709-001 Application manual - Additional axes and stand 3HAC021395-001 alone controller Technical reference manual - System parameter...

  • Page 11: 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 12 Product documentation, M2004 Continued Operating manuals This group of manuals is aimed at those having first hand operational contact with the robot, that is production cell operators, programmers and trouble shooters. The group of manuals includes: • Emergency safety information •...

  • Page 13: 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 14 How to read the product manual 3HAC027151-001 Revision: B...

  • Page 15: 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.

  • Page 16: 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 17: 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 18 1 Safety 1.2.2.1. Safety risks during installation and service work on robot Continued Complete robot Safety risk Description Hot components! CAUTION! Motors and gears are HOT after running the robot! Touching motors and gears may result in burns! With higher environment temperature more surfaces on the robot are getting HOT and may result in burns too! Removed parts may result in collapse of robot!

  • Page 19: 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 20: 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 21: 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 22: 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, need to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.

  • Page 23: 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 24: 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 (robot or controller)! 3HAC027151-001 Revision: B...

  • Page 25: 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 26: 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 27: 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". 3HAC027151-001 Revision: B...

  • Page 28: 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 29: Work Inside The Robot's Working Range

    1 Safety 1.2.3.7. Work inside the robot's working range 1.2.3.7. Work inside the robot's working range WARNING! If work must be carried out within the robot’s work envelope, the following points must be observed: • The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel.

  • Page 30: 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 robot, 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 31: 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 32: 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 33 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 34: Danger - Moving Robots Are Potentially Lethal

    1 Safety 1.3.2. DANGER - Moving robots are potentially lethal! 1.3.2. DANGER - Moving robots are potentially lethal! Description Any moving robot is a potentially lethal machine. When running the robot, it may perform unexpected and sometimes irrational movements. Moreover, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the working range of the robot.

  • Page 35: 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 36: 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.

  • Page 37: 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 (electrostatic discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges.

  • Page 38: 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 39: 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), can be found in the Product specification for the robot. 3HAC027151-001 Revision: B...

  • Page 40: 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 41 Always read and follow the instructions in section Pre-installation procedure on page 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 42 2 Installation and commissioning 2.2. Robot transportation precautions Continued IRB7600/IRB66XX xx0800000037 Transport Support Hexagon socket head cap screw M16x140 Threaded bar M10x200 Nut M10 Continues on next page 3HAC027151-001 Revision: B...
  • Page 43 2 Installation and commissioning 2.2. Robot transportation precautions Continued IRB6620/Foundry Plus xx0800000036 Transport Support Hexagon socket head cap screw M10x50 Threaded bar M10x280 Nut M10 Continues on next page 3HAC027151-001 Revision: B...
  • Page 44 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 6620/Foundy Plus xx0800000041 Continues on next page 3HAC027151-001 Revision: B...
  • Page 45 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 3HAC027151-001 Revision: B...
  • Page 46 2 Installation and commissioning 2.2. Robot transportation precautions Continued IRB 6620 xx0800000038 3HAC027151-001 Revision: B...

  • Page 47: 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 48 2 Installation and commissioning 2.3. Securing the robot Continued Action Note 2. Jog the robot into a position as near above as possible to the recommended transport position for the specific robot. specified in section Transport position with a transport CAUTION! support on page Do not try to jog the robot to the exact...

  • Page 49: Unpacking

    Weight, robot The table below shows the weights of the different models: Robot model Weight IRB 6620 - 150/2.2 900 kg * * Weight of robot excluding DressPack. Loads on foundation, robot The table below shows the various forces and torques working on the foundation during different kinds of operation, in relation to the base coordinate system.
  • Page 50 0.5 mm Max. tilt 15° 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 51: 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 The following figures show the working ranges of the robot model mounted in different ways. The extreme positions of the robot arm are specified at the wrist center (dimensions in mm). Floor mounted The illustration below shows the unrestricted working range when the robot is floor mounted: xx0600002906...
  • Page 52 2 Installation and commissioning 2.4.2. Working range and type of motion Continued Suspended mounted The illustration below shows the unrestricted working range when the robot is mounted suspended: xx0600002907 Continues on next page 3HAC027151-001 Revision: B...
  • Page 53 2 Installation and commissioning 2.4.2. Working range and type of motion Continued Floor mounted in 15° angle The illustration below shows the unrestricted working range when the robot is floor mounted in 15° angle: xx0600002908 Note! Maximum tilt angle is 15° Intersection between base and axis 1 center Continues on next page 3HAC027151-001 Revision: B...
  • Page 54 2 Installation and commissioning 2.4.2. Working range and type of motion Continued Turning radius - floor mounted The turning radius for the robot when floor mounted, is shown in the figure below. xx0600002909 Type of motion Axis Type of motion Range of movement Note Rotation motion + 170°...

  • Page 55: 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 56: On-Site Installation

    2 Installation and commissioning 2.5.1. Lifting the robot with fork lift 2.5 On-site installation 2.5.1. Lifting the 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. Fork lift device set The fork lift device set, is fitted to the robot as shown in the figure below.
  • Page 57 2 Installation and commissioning 2.5.1. Lifting the robot with fork lift Continued Lifting the robot with fork lift The procedure below details how to secure the fork lift set in order to lift the robot and move it using fork lift ONLY! The illustration below shows the position of the robot when lifting it with fork lift.
  • Page 58 2 Installation and commissioning 2.5.1. Lifting the robot with fork lift Continued Action Note 3. Fit the four fork lift pockets on the base of Make sure the original screws are always the robot with its attachment screws. used (or replacements of equivalent quality: M20x50, quality 8.8)! Attachment points on the robot are shown in the figure below.
  • Page 59 2 Installation and commissioning 2.5.1. Lifting the robot with fork lift Continued Action Note 5. Insert the fork lift forks into the pockets. CAUTION! The robot weighs 900 kg! All lifting equipment used must be sized accordingly! 7. Carefully lift the robot and move it to its installation site.

  • Page 60: 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 61 2 Installation and commissioning 2.5.2. Lifting robot with roundslings Continued Sling type Lifting capacity Length / Note Roundsling, upper arm 2 pcs 1 000 kg Note! Do not stretch! Secures against rotation. Roundsling, upper arm 1 pc 1 000 kg Note! Do not stretch! Secures against rotation.
  • Page 62 2 Installation and commissioning 2.5.2. Lifting robot with roundslings Continued Action Note WARNING! Personnel must not, under any circumstances, be present under the suspended load! 3HAC027151-001 Revision: B...

  • Page 63: Manually Releasing The Brakes

    2 Installation and commissioning 2.5.3. Manually releasing the brakes 2.5.3. 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. xx0600002936 Internal brake release unit with push buttons.
  • Page 64 2 Installation and commissioning 2.5.3. 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 DANGER!

  • Page 65: Lifting The Base Plate

    2 Installation and commissioning 2.5.4. Lifting the base plate 2.5.4. Lifting the base plate Required equipment Equipment Art. no. Note Lifting eye, M16 3HAC14457-4 3 pcs Lifting slings 3 pcs Length: approx. 2 m Hole configuration xx0200000096 Attachment holes for lifting eyes (x3) Lifting, base plate Action Note...

  • Page 66: Securing The Base Plate

    2 Installation and commissioning 2.5.5. Securing the base plate 2.5.5. Securing the base plate General This section details how to secure the base plate. Base plate, dimensions xx0100000105 Continues on next page 3HAC027151-001 Revision: B...
  • Page 67 2 Installation and commissioning 2.5.5. Securing the base plate Continued xx0400000715 Four holes for alternative clamping, 4x Ø18 Continues on next page 3HAC027151-001 Revision: B...
  • Page 68 • attachment screws and washers for securing the robot to the base plate. A drawing of the base plate itself may be ordered from ABB Robotics! Standard toolkit The content is defined in section Standard toolkit on page 265. Other tools and procedures may These procedures include references be required.
  • Page 69 2 Installation and commissioning 2.5.5. 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 70: Orienting And Securing The Robot

    2 Installation and commissioning 2.5.6. Orienting and securing the robot 2.5.6. 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 71 2 Installation and commissioning 2.5.6. 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 1. Lift the robot. Detailed in section Lifting robot with roundslings on page...
  • Page 72 2 Installation and commissioning 2.5.6. Orienting and securing the robot Continued Hole configuration, base The illustration below shows the hole configuration used when securing the robot. xx0600002932 Cross section, guide sleeve hole The illustration below shows the cross section of the guide sleeve holes. xx0600002934 3HAC027151-001 Revision: B...

  • Page 73: Suspended Mounting

    2 Installation and commissioning 2.5.7. Suspended mounting 2.5.7. Suspended mounting General Initially the system is configured for mounting on the floor, without leaning. The method for mounting the robot in a suspended position is basically the same as for floor mounting. NOTE! With suspended installation, make sure that the gantry or corresponding structure is rigid enough to prevent unacceptable vibrations and deflections, so that optimum performance can...
  • Page 74 2 Installation and commissioning 2.5.7. Suspended mounting Continued Mounting angles and values The parameter “gravity beta” specifies the robot’s mounting angle in radians. It is calculated in the following way for a mounting angle of 15°. Gravity beta = 15° x 3.141593/180 = 0.261799 radians. Example of position Mounting angle Gravity beta...
  • Page 75 2 Installation and commissioning 2.5.7. Suspended mounting Continued Defining the parameter The value of the system parameter Gravity beta must be redefined when changing the mounting angle of the robot. The parameter belongs to the type Robot, in the topic Motion. How to calculate a new value is detailed in Mounting angles and values on page The parameter is further detailed in the Technical reference manual - System parameters.

  • Page 76: 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 77 2 Installation and commissioning 2.5.8. Fitting equipment on robot Continued xx0600002944 Continues on next page 3HAC027151-001 Revision: B...
  • Page 78 2 Installation and commissioning 2.5.8. Fitting equipment on robot Continued Illustration, fitting of extra equipment on upper arm The illustrations below shows the mounting holes available for fitting extra equipment on the upper arm. xx0600002941 Continues on next page 3HAC027151-001 Revision: B...
  • Page 79 2 Installation and commissioning 2.5.8. Fitting equipment on robot Continued xx0600002945 Continues on next page 3HAC027151-001 Revision: B...
  • Page 80 2 Installation and commissioning 2.5.8. Fitting equipment on robot Continued Illustration, fitting of extra equipment on frame The illustrations below shows the mounting holes available for fitting extra equipment on the frame. xx0600002947 Continues on next page 3HAC027151-001 Revision: B...
  • Page 81 2 Installation and commissioning 2.5.8. Fitting equipment on robot Continued xx0600002950 Continues on next page 3HAC027151-001 Revision: B...
  • Page 82 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. xx0200000397 Turning disk for robot version IRB6620 - 150/2.2. Use every other of the bolt holes for six attachment bolts, as numbered in the figure.
  • Page 83 2 Installation and commissioning 2.5.8. Fitting equipment on robot Continued xx0200000197 Fastener quality When fitting tools on the turning disk (see the figures above), only use screws with quality 12.9. When fitting other equipment standard screws with quality 8.8 may be used. 3HAC027151-001 Revision: B...

  • Page 84: Loads

    Specification. The loads must also be defined in the software as detailed in Operating manual IRC5 with FlexPendant. Stop time and braking distances Robot motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB. 3HAC027151-001 Revision: B...

  • Page 85: 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 86: 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 87 2 Installation and commissioning 2.6.2. Mechanically restricting the working range of axis 1 Continued Required equipment Equipment, etc. Art. no. Note Movable mechanical stop set, axis 1 3HAC025204-003 Includes: (+15°/-7.5°) • two stops (+15°/ -7.5°), 3HAC025366-001 • two stops (+7.5°/ -15°), 3HAC025367-001 •...
  • Page 88 2 Installation and commissioning 2.6.2. Mechanically restricting the working range of axis 1 Continued Action Note The system parameters that must be changed in RobotWare 5.0 (Upper joint bound and Lower joint bound) are further NOTE! detailed in Technical reference manual - System parameters.

  • Page 89: Mechanically Restricting The Working Range Of Axis 3

    2 Installation and commissioning 2.6.3. Mechanically restricting the working range of axis 3 2.6.3. Mechanically restricting the working range of axis 3 General The working range of axis 3 is limited by a fixed mechanical stop. This stop limits the backwards movement of the upper arm to -90°, which secures the robot arm from tipping over.
  • Page 90 2 Installation and commissioning 2.6.3. 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 91: 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 92 2 Installation and commissioning 2.7.1. Robot cabling and connection points Continued Robot cable, signals Cable Art. no. Robot cable, signal, shielded, 7 m 3HAC7998-1 Robot cable, signal, shielded, 15 m 3HAC7998-2 Robot cable, signal, shielded, 22 m 3HAC7998-3 Robot cable, signal, shielded, 30 m 3HAC7998-4 3HAC027151-001 Revision: B...

  • Page 93: 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 94: 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 is specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot: •...

  • Page 95: 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 96 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Equipment Interval Detailed in section activity Changing Axis 3 gear oil: First change after: 6 Do not mix with other oils! 000 h Kyodo Yushi TMO Oil change, gearbox, axis 3 Second change after: on page 132 24 000 h Changing...

  • Page 97: 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 4,000,000 cycles axis 1 ±180º See note 2,000,000 cycles axis 1 ±220º...

  • Page 98: 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 99 3 Maintenance 3.3.1. Inspection, oil level gearbox axis 1 Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 3. Open the oil plug, inspection. Shown in the figure Location of gearbox on page 4.

  • Page 100: 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, floor mounted The axis 2 gearbox is located in the lower arm rotational center, underneath the motor attachment. The figure below shows the robot floormounted. xx0600002959 Oil plug, filling Oil plug, inspection...
  • Page 101 3 Maintenance 3.3.2. Inspection, oil level gearbox axis 2 Continued Required equipment Equipment etc. Art. no. Note Lubricating oil 3HAC032140-001 Kyodo Yushi TMO 150 Note! Do not mix with other oil types! Standard toolkit The content is defined in section Standard toolkit on page 265.

  • Page 102: 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. xx0600002961 Oil plug, filling Oil plug, inspection Oil plug, draining Required equipment...
  • Page 103 3 Maintenance 3.3.3. Inspection, oil level gearbox axis 3 Continued Inspection, oil level gearbox 3 The procedure below details how to inspect the oil level in the gearbox axis 3. 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 104: 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. xx0600002962 Oil plug, filling / inspection Oil plug, draining Required equipment...
  • Page 105 3 Maintenance 3.3.4. Inspection, oil level gearbox axis 4 Continued Action Note 2. Move the robot to the calibration position. Shown in section Calibration scales and correct axis position on page 252. DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 4.

  • Page 106: 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. xx0600002963 Oil plug, filling / inspection Oil plug, draining Required equipment Equipment etc.
  • Page 107 3 Maintenance 3.3.5. Inspection, oil level, gearbox axis 5 Continued Action Note 4. Open the oil plug, filling. Shown in the figure Location of gearbox on page 104. 5. Measure the oil level. Required oil level to the upper edge of the oil plug hole (a): 10mm.

  • Page 108: 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. xx0200000233 Gearbox axis 6 Oil plug, filling Oil plug, draining Required equipment Equipment...
  • Page 109 3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 3. Open the oil plug, filling. Shown in the figure Location of gearbox on page 106.

  • Page 110: Inspection, Cable Harness

    3 Maintenance 3.3.7. Inspection, cable harness 3.3.7. Inspection, cable harness Location of cable harness, axes 1-6 The robot cable harness, axes 1-6, is located as shown in the figures below. xx0600002970 The figure shows the lower routing of the cable harness. SMB/BU box Top cover, connection box Connection plate, base...
  • Page 111 3 Maintenance 3.3.7. Inspection, cable harness Continued xx0600003078 The figure shows the upper routing of the cable harness. Cable harness Metal clamp, at gearbox axis 3 Attachment screws, metal clamp at gearbox axis 3, M6x16 quality 8.8 (2 pcs) Metal clamp, lower arm (2 pcs) Attachment screws, metal clamp lower arm, M6x16 quality 8.8 (2+2 pcs) Metal clamp, armhouse Attachment screws, metal clamp armhouse, M6x16 quality 8.8 (2 pcs)
  • Page 112 3 Maintenance 3.3.7. Inspection, cable harness Continued Inspection cable harness, axes 1-6 The procedure below details how to inspect the cable harness of axes 1-6. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.

  • Page 113: Inspection, Information Labels

    3 Maintenance 3.3.8. Inspection, information labels 3.3.8. Inspection, information labels Location of labels The figures below show the location of the information labels to be inspected. xx0600002980 Warning label "High temperature", 3HAC4431-1 (4 pcs) Warning sign, symbol of a flash (located on motor cover), 3HAC1589-1 (5 pcs) Warning label "Brake release", 3HAC15335-1 Instruction label "Lifting", 3HAC025472-001 Serial no.
  • Page 114 3 Maintenance 3.3.8. Inspection, information labels Continued xx0600002981 Warning label "Robot can tip forward...", 3HAC9191-1 Label Calibration, 3HAC024307-001 Serial no. from rating label UL-label, 3HAC2763-1 AbsAcc information sign, 3HAC14257-1 Required equipment Equipment Art. no. Note Labels and plate set 3HAC025471-001 Includes all labels specified in the two previous figures! The labels are in english.

  • Page 115: Inspection, Mechanical Stop, Axis 1

    3 Maintenance 3.3.9. Inspection, mechanical stop, axis 1 3.3.9. 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. xx0600002972 Mechanical stop pin, axis 1 Fixed stop pin Required equipment Equipment, etc.
  • Page 116 3 Maintenance 3.3.9. Inspection, mechanical stop, axis 1 Continued Action Note 3. If the stop pin is bent or damaged, it must be Art. no. is specified in Required replaced! equipment on page 113. NOTE! The expected life of gearboxes can be reduced as a result of collissions with the mechanical stop.

  • Page 117: Inspection, Additional Mechanical Stops

    3 Maintenance 3.3.10. Inspection, additional mechanical stops 3.3.10. Inspection, additional mechanical stops Location of mechanical stops The figure below shows the location of the additional mechanical stops on axes 1 and 3 . Additional mechanical stops are not available for axis 2. xx0600002938 Additional stop, axis 1 Attachment screws and washers (2 pcs)
  • Page 118 3 Maintenance 3.3.10. Inspection, additional mechanical stops Continued xx0600002973 Mechanical stop pin, axis 3 Attachment screw and washer Required equipment Equipment etc. Art. no. Note Mechanical stop set, axis 1 3HAC025204-003 Includes: • Stop +15°/-7.5° • Stop +7.5°/-15° • Attachment screws plus washers •...
  • Page 119 3 Maintenance 3.3.10. Inspection, additional mechanical stops Continued Inspection, mechanical stops The procedure below details how to inspect the additional mechanical stops on axes 1and 3. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.

  • Page 120: Inspection, Damper Axes 2-5

    3 Maintenance 3.3.11. Inspection, damper axes 2-5 3.3.11. Inspection, damper axes 2-5 Location of dampers The figure below shows the location of all the dampers to be inspected. xx0600002976 Damper axis 2 Damper axis 3 Damper axis 5 Required equipment A damper must be replaced if damaged! Equipment Spare part/ art.
  • Page 121 3 Maintenance 3.3.11. Inspection, damper axes 2-5 Continued Action Note 2. Check all dampers for damage, and for cracks or Shown in the figure Location of existing impressions larger than 1 mm. dampers on page 118. 3. Check attachment screws for deformation. 4.

  • Page 122: Inspection, Signal Lamp

    3 Maintenance 3.3.12. Inspection, signal lamp 3.3.12. Inspection, signal lamp Location of signal lamp The signal lamp is located as shown in the figure below. xx0600003071 UL signal lamp Clamp Cable strap, outdoor Motor, axis 3 Attachment screw, M6x8 quality 8-A2F(2 pcs) Required equipment Equipment, etc.
  • Page 123 3 Maintenance 3.3.12. Inspection, signal lamp Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 3. If the lamp is not lit, trace the fault by: Art. no. is specified in Required equipment on page 120.

  • Page 124: 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. xx0600002977 Gearbox, axis 1 Gearbox, axis 2 Gearbox, axis 3 Gearbox, axis 4 Gearbox, axis 5...
  • Page 125 3 Maintenance 3.4.1. Type of oil in gearboxes Continued Type of oil - historically used The gearboxes of the robot have historically been filled with different types of oils. Today only the types of oil specified in the table is recommended. NOTE! When there is a change of oil types in the gearbox, it need to be rinsed.
  • Page 126 3 Maintenance 3.4.1. Type of oil in gearboxes Continued Mixed types of oil may cause may cause severe damage! When refilling or replacing oil in a gearbox it is important to first check which type of oil is recommended to use in the gearbox. See Type of oil - currently used on page 123.
  • Page 127 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 128: 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. xx0600002958 Oil plug, filling Oil plug, inspection...
  • Page 129 3 Maintenance 3.4.2. Oil change, gearbox axis 1 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. Collect the drained oil in an oil vessel. Vessel capacity is specified in Required equipment on page 126.
  • Page 130 3 Maintenance 3.4.2. Oil change, gearbox axis 1 Continued Action Note Detailed in section Type of oil in gearboxes on page 122. NOTE! Don´t mix Kyodo Yushi TMO 150 with other oil types! 6. Refit the oil plug, filling. Tightening torque: 24 Nm. 3HAC027151-001 Revision: B...

  • Page 131: 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. xx0600002983 The figure shows both floor and suspended mounted robot. Note that the holes are used differently depending on how the robot is mounted! Oil plug, filling Oil plug, inspection...
  • Page 132 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, draining, and drain the Shown in the figure Location of oil plugs gearbox oil using a hose with nipple and an...
  • Page 133 3 Maintenance 3.4.3. Oil change, gearbox axis 2 Continued Action Note Detailed in section Type of oil in gearboxes on page 122. NOTE! Don´t mix Kyodo Yushi TMO 150 with other oil types! 6. Refit the oil plug. Tightening torque: 24 Nm. 3HAC027151-001 Revision: B...

  • Page 134: 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. xx0600002961 Oil plug, filling Oil plug, inspection Oil plug, draining Required equipment Equipment, etc.
  • Page 135 3 Maintenance 3.4.4. Oil change, gearbox, axis 3 Continued 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. Art. no. for the kit is specified in Required equipment on page 132.
  • Page 136 3 Maintenance 3.4.4. Oil change, gearbox, axis 3 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. Shown in the figure Location of gearbox on page...

  • Page 137: 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. xx0600002962 Oil plug, filling / inspection Oil plug, draining Required equipment Equipment, etc.
  • Page 138 3 Maintenance 3.4.5. Oil change, gearbox, axis 4 Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 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 4.

  • Page 139: 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. xx0600002963 Oil plug, filling / inspection Oil plug, draining Required equipment Equipment, etc.
  • Page 140 3 Maintenance 3.4.6. Oil change, gearbox, axis 5 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 4. Drain the oil from the gearbox by opening the oil Shown in the figure Location of plug, draining.

  • Page 141: 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. The figure shows gearbox axis 6 for IRB 6620 Foundry Plus. xx0200000233 Gearbox axis 6 Oil plug, filling...
  • Page 142 3 Maintenance 3.4.7. Oil change, gearbox axis 6 Continued Draining, oil, axis 6 The procedure below details how to drain oil from the gearbox, axis 6. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no.
  • Page 143 3 Maintenance 3.4.7. Oil change, gearbox axis 6 Continued Action Note 4. Refill the gearbox with lubricating oil. Art. no. and the total amount are specified in Required equipment The amount of oil to be refilled depends on the on page 139.

  • Page 144: Replacement Of Smb Battery

    Required equipment Equipment, etc. Spare part no. Note Battery pack 3HAC16831-1 Battery includes protection circuits. Replace it only with given spare part no. or an ABB approved equivalent. Standard toolkit The content is defined in section Standard toolkit on page 265.
  • Page 145 Shown in the figure Location of SMB battery on page 142. Battery includes protection circuits. Replace it only with the specified spare part or with an ABB approved equivalent. Refitting, battery The procedure below details how to refit the SMB battery. Action...
  • Page 146 3 Maintenance 3.4.8. Replacement of SMB battery Continued Action Note WARNING! The unit is sensitive to ESD, before handling the unit please observe the safety information in section WARNING - The unit is sensitive to ESD! on page 35 3. Reconnect the battery cable to the SMB battery Art.

  • Page 147: Cleaning Activities

    3 Maintenance 3.5.1. Cleaning, robot 3.5 Cleaning activities 3.5.1. Cleaning, robot General The protection class of the robot is IP 54 except the upper arm and wrist unit which are protection class IP 67. 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 148 3 Maintenance 3.5.1. Cleaning, robot Continued Required equipment Equipment, etc. Art. no. Note Vacuum cleaner Cloth with mild detergent Do's and don'ts! The section below specifies some special considerations when cleaning the robot. Always! • Always use cleaning equipment as specified above! Any other cleaning equipment may shorten the life of paintwork, rust inhibitors, signs, or labels! •...

  • Page 149: 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, for example spare parts numbers, required special tools and materials.

  • Page 150: 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 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 151: 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 3HAB3537-1 Used to grease the bearings, if not specified otherwise.
  • Page 152 4 Repair 4.2.2. Mounting instructions for bearings Continued Greasing of bearings The bearings must be greased after assembly, according to instructions below: • The bearings must not be completely filled with grease. However, if space is available beside the bearing fitting, the bearing may be totally filled with grease when mounted, as excessive grease will be pressed out from the bearing when the robot is started.

  • Page 153: 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 3HAB3537-1 Used to lubricate the seals. Rotating seals The procedure below details how to fit rotating seals.
  • Page 154 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 155: Complete Robot

    4 Repair 4.3.1. Replacement of cable harness, lower end (axes 1-2) 4.3 Complete robot 4.3.1. Replacement of cable harness, lower end (axes 1-2) General The cable harness 1-6 is undivided. Replacement of the cable harness is detailed in two steps - lower end and upper end. The procedure below details replacement of lower end of the cable harness.
  • Page 156 4 Repair 4.3.1. Replacement of cable harness, lower end (axes 1-2) Continued Connector R1.MP Metal clamps Cable harness Cable guide (cut away view) Required equipment Equipment, etc. Spare part no. Art. no. Note Cable harness 3HAC 025054-001 Standard toolkit The content is defined in section Standard toolkit on page...
  • Page 157 4 Repair 4.3.1. Replacement of cable harness, lower end (axes 1-2) Continued Action Note 4. Disconnect the earth cable. xx0600003028 • A: Earth (placed beneath the top cover) • B: Top cover, connection box 5. Disconnect connectors R1.MP and R1.SMB on Shown in the figure Location of cable the connection plate, base.
  • Page 158 4 Repair 4.3.1. Replacement of cable harness, lower end (axes 1-2) Continued Action Note 4. Disconnect the earth cable. xx0600003028 • A: Earth (placed beneath the top cover) • B: Top cover, connection box 5. Disconnect connectors R1.MP and R1.SMB on Shown in the figure Location of cable the connection plate, base.
  • Page 159 4 Repair 4.3.1. Replacement of cable harness, lower end (axes 1-2) Continued Action Note 10. Pull the cable harness and its connectors Shown in the figure Location of cable carefully up through the cable guide in the harness, axes 1-2 on page 153.
  • Page 160 4 Repair 4.3.1. Replacement of cable harness, lower end (axes 1-2) Continued Action Note 4. Put the SMB/BU unit carefully back into its box and refit its attachment screws. xx0600003026 • A : Attachment screws, M5x12 quality 8.8 (7 pcs) •...

  • Page 161: Replacement Of Cable Harness, Upper End

    4 Repair 4.3.2. Replacement of cable harness, upper end 4.3.2. Replacement of cable harness, upper end General The cable harness 1-6 is undivided. Replacement of the cable harness is detailed in two steps - lower end (axes 1-2) and upper end (axes 3-6).This procedure details how to replace the cable harness that runs from axis 3 to 6.
  • Page 162 4 Repair 4.3.2. Replacement of cable harness, upper end Continued Equipment, etc. Spare part no. Art. no. Note Gasket 3HAC12877-1 Motor axis 6 Standard toolkit The content is defined in section Standard toolkit on page 265. Other tools and These procedures procedures may be include references to required.
  • Page 163 4 Repair 4.3.2. Replacement of cable harness, upper end Continued Action Note 5. Remove the metal clamp securing the cable harness at axis 5 by removing its attachment screws. xx0600003030 • A : Cable harness • B : Motor, axis 5 •...
  • Page 164 4 Repair 4.3.2. Replacement of cable harness, upper end Continued Action Note 8. Remove the back cover motor, axis 6 by removing its attachment screws. 9. Pull out the cabling R2.MP6 and R2.FB6 Shown in the figure Location of cable from motor, axis 6 .
  • Page 165 4 Repair 4.3.2. Replacement of cable harness, upper end Continued Action Note 4. Reconnect all connectors at motors axes 3 (R2.MP3, R2.FB3) and 4 (R2.MP4, R2.FB4). 5. Refit covers motor axes 3 and 4. 6. Refit the cable holder wrist unit, with the three attachment screws.
  • Page 166 4 Repair 4.3.2. Replacement of cable harness, upper end Continued Action Note 11. Refit the metal clamp securing the cable harness at axis 5. xx0600003030 • A : Cable harness • B : Motor, axis 5 • C : Attachment crews M6x16, 8.8 (2 pcs) •...
  • Page 167 4 Repair 4.3.2. Replacement of cable harness, upper end Continued Action Note 13. Refit the cover, wrist unit. xx0600003024 xx0700000140 • A : Cover, wrist unit 14. Recalibrate the robot. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.

  • Page 168: Replacement Of Complete Arm System

    4 Repair 4.3.3. Replacement of complete arm system 4.3.3. Replacement of complete arm system Location of arm system The complete arm system is defined as the complete robot except for the base, motor 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 .
  • Page 169 4 Repair 4.3.3. Replacement of complete arm system Continued Equipment, etc. Art. no. Note Hoisting block Used to adjust the length of the lifting chain. Lifting chain Used together with the hoisting block. Standard toolkit The content is defined in section Standard toolkit on page 265.
  • Page 170 4 Repair 4.3.3. Replacement of complete arm system Continued Action Note 7. Fit the lifting device and adjust it as Art. no. is specified in Required equipment on detailed in the enclosed instructions. page 166. Also fit a hoisting block to the front, used Make sure the lift is done completely level! to adjust the balance of the arm system in How to adjust the lift is described in the...
  • Page 171 4 Repair 4.3.3. Replacement of complete arm system Continued Action Note 8. Alternate method of lifting: Art. no. is specified in Required equipment on page 166. Fit the lifting device and a roundsling on the upper arm and a roundsling with a Make sure the lift is done completely level! hoisting block, to the wrist unit.
  • Page 172 4 Repair 4.3.3. Replacement of complete arm system Continued Refitting, arm system The procedure below details how to lift and refit the complete arm system. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 173 4 Repair 4.3.3. Replacement of complete arm system Continued Action Note 3. Alternate method of lifting: Art. no. is specified in Required equipment on page 166. Fit the lifting device and a roundsling on the upper arm and a roundsling with a hoisting Make sure the lift is done completely block, to the wrist unit.
  • Page 174 4 Repair 4.3.3. Replacement of complete arm system Continued Action Note 6. Fit the two guide pins to the holes in gearbox Dimension is specified in Required axis 1, as shown in the figure to the right. equipment on page 166.
  • Page 175 4 Repair 4.3.3. Replacement of complete arm system Continued Action Note 7. 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 176 4 Repair 4.3.3. Replacement of complete arm system Continued Action Note 10. Refit the cabling in the base. Detailed in section Replacement of cable harness, lower end (axes 1-2) on page 153. 11. Perform a leak-down test of the gearbox axis Detailed in section Performing a leak- down test on page...

  • Page 177: Upper And Lower Arm

    4 Repair 4.4.1. Replacement of turning disk 4.4 Upper and lower arm 4.4.1. Replacement of turning disk Location of turning disk The turning disk is located in the front of the wrist housing, as shown in the figure below. The figure shows turning disk on IRB 6620 Foundry Plus. A more detailed view of the component and its position may be found in chapter .
  • Page 178 4 Repair 4.4.1. Replacement of turning disk Continued Equipment, etc. Spare part no. Art. no. Note Other tools and These procedures include procedures may be references to the tools required. See references required. to these procedures in the step-by-step instruc- tions below.
  • Page 179 4 Repair 4.4.1. Replacement of turning disk Continued Refitting, turning disk The procedure below details how to refit the turning disk. Action Note 1. Lubricate the turning disk o-ring with grease. Art. no. is specified in Required equipment on page 175.

  • Page 180: Replacement Of Wrist Unit

    4 Repair 4.4.2. Replacement of wrist unit 4.4.2. Replacement of wrist unit Location of wrist unit The wrist unit is located in the foremost part of the upper arm as shown in the figure below. xx0600003055 Wrist unit Turning disk Cover, wrist unit Cable holder Cover, cable gland...
  • Page 181 4 Repair 4.4.2. Replacement of wrist unit Continued Equipment, etc. Spare part no. Art. no. Note Other tools and These procedures include procedures may be references to the tools required. See references required. to these procedures in the step-by-step instruc- tions below.
  • Page 182 4 Repair 4.4.2. Replacement of wrist unit Continued Action Note 3. Put some grease on the surface of the fit. 4. Check the cylidrical pin. If the pin is damaged - replace! 5. Fit the wrist with its 8 attachment screws and M12x50 12.9 gleitmo (8 pcs) washers.

  • Page 183: Replacement Of The Upper Arm

    4 Repair 4.4.3. Replacement of the upper arm 4.4.3. Replacement of the upper arm Location of the upper arm The upper arm is located on top of the robot as shown in the figure below. xx0600003057 Motor, axis 3 Gearbox, axis 3 Attachment screws, M12x50 quality 12.9 Gleitmo (20 pcs) Attachment screws, M16x50 quality 12.9 Gleitmo (16 pcs) Hole in the lower arm...
  • Page 184 4 Repair 4.4.3. Replacement of the upper arm 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 instruc- tions below.
  • Page 185 4 Repair 4.4.3. Replacement of the upper arm Continued Action Note 5. Fit the lifting tool on the upper arm as Art. no. is specified in Required detailed in the enclosed instructions. equipment on page 181. Also fit a hoisting block to the front, used to adjust the balance of the upper arm in order to lift it completely level.
  • Page 186 4 Repair 4.4.3. Replacement of the upper arm Continued Refitting The procedure below details how to refit the upper arm. Action Note 1. Make sure the o-ring is fitted to the gearbox. Lightly lubricate the o-ring with grease. CAUTION! The complete upper arm (incl. gearbox axis 3) weighs 282 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel!
  • Page 187 4 Repair 4.4.3. Replacement of the upper arm Continued Action Note 8. Refit the metal clamps securing the cable harness on the lower arm and armhouse. xx0600003083 • A: Metal clamp, lower arm (2 pcs) • B: Metal clamp, gearbox axis 3 •...

  • Page 188: Replacement Of Lower Arm

    4 Repair 4.4.4. Replacement of lower arm 4.4.4. Replacement of lower arm Location of lower arm The location of the lower arm is shown in the figures below. xx0600003058 Upper arm Gearbox, axis 3 Lower arm Hole in lower arm Attachment screws, M16x50 quality 12.9 Gleitmo (16 pcs) xx0600003059 Lower arm...
  • Page 189 4 Repair 4.4.4. Replacement of lower arm Continued Equipment, etc. Spare part no. Art no. Note Grease 3HAB 3537-1 Used to lubricate o-rings. Lifting tool 3HAC 026597-001 Instruction 3HAC 026600- 002 is enclosed. Lifting chain Hoisting block Roundslings Guiding pins Always use in pairs.
  • Page 190 4 Repair 4.4.4. Replacement of lower arm Continued Action Note 5. Remove the upper arm. Detailed in section Replacement of the upper arm on page 181. 6. Secure the lower arm with a roundsling in an overhead crane. CAUTION! The lower arm weighs 75 kg (gearboxes axes 2-3 excluded)! All lifting equipment used must be sized accordingly! 8.
  • Page 191 4 Repair 4.4.4. Replacement of lower arm Continued Action Note 11. Recalibrate the robot. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration infor- mation. DANGER! Make sure all safety requirements are met when performing the first test run.

  • Page 192: 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/BU unit (SMB = serial measurement board, BU = brakerelease unit) is located on the left hand side of the frame as shown in the figure below. The SMB unit and the BU unit are both located inside the SMB/BU box.
  • Page 193 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! WARNING! The unit is sensitive to ESD, before handling the unit please observe the safety information in...
  • Page 194 4 Repair 4.5.1. Replacement of SMB unit Continued Action Note 7. Unscrew the hexagon nuts securing the SMB unit, not more than it is possible to pull the SMB unit out. xx0600003053 • A: Hexagon nut, M5 • B: Tooth lock washer, 6.4 fzb •...
  • Page 195 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 1. Push the SMB unit into its tracks and secure it with its hexagon nuts. xx0600003053 • A : Hexagon nut, M5 •...
  • Page 196 4 Repair 4.5.1. Replacement of SMB unit 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 3HAC027151-001 Revision: B...

  • Page 197: 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 SMB/BU unit (SMB = serial measurement board, BU = brakerelease unit) is located on the left hand side of the frame as shown in the figure below. The SMB unit and the BU unit are both located inside the SMB/BU box.
  • Page 198 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 DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! WARNING! The unit is sensitive to ESD, before handling the unit please observe the safety information...
  • Page 199 4 Repair 4.5.2. Replacement of brake release unit Continued Refitting, brake release unit The procedure below details how to refit the brake release unit. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! WARNING! The unit is sensitive to ESD, before handling the unit please observe the safety information...
  • Page 200 4 Repair 4.5.2. Replacement of brake release unit Continued Action Note 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 7. Refit the push button guardand thecover, push Shown in the figure Location of brake button guard to the SMB cover.

  • Page 201: 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 as shown in the figure below. xx0600003037 Motor, axis 1 Motor attachment screws and washers Cable gland Cover Required equipment...
  • Page 202 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Equipment, etc. Spare part no. Art. no. Note Power supply 24 VDC, max. 1,5 A For releasing the brakes. Standard toolkit The content is defined in section Standard toolkit on page 265.
  • Page 203 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 8. If required, press the motor out of position by fitting Art. no. is specified in Required removal tool, motor to the motor attachment screw equipment on page 199. holes.
  • Page 204 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 11. Refit the motor cover with its four attachment Make sure the cover is tightly screws. sealed! 12. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.

  • Page 205: 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. xx0600003940 Motor, axis 2 Motor attachment holes (4 pcs) Cable gland Required equipment...
  • Page 206 4 Repair 4.6.2. Replacement of motor axis 2 Continued Equipment, etc. Spare part no. Art. no. Note Rotation tool 3HAC17105-1 Used to rotate the motor pinion when mating it to the gear, when brakes are released with 24VDC power supply. Standard toolkit The content is defined in section...
  • Page 207 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note Use the lock screw to lock the lower arm, as detailed above! DANGER! Secure the weight of the lower arm properly before releasing the brakes of motor, axis 2! When releasing the holding brakes of the motor, the lower arm will be movable and may fall down! 8.
  • Page 208 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note 3. In order to release the brake, remove the Connect to connector R2.MP2 cover on top of the motor and connect the 24 • +: pin 2 VDC power supply. •...
  • Page 209 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note 15. Refit the cover on top of the motor with its four Make sure the cover is tightly sealed! attachment screws. 16. Perform a leak down test. Detailed in Performing a leak-down test on page 148.

  • Page 210: 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. xx0600003051 Cable gland cover, motor axis 3 Motor attachment holes (4 pcs) Motor, axis 3 Required equipment...
  • Page 211 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Equipment, etc. Spare part no. Art. no. Note Calibration 3HAC15716-1 Complete kit that also Pendulum toolkit includes operating manual. Other tools and These procedures include procedures may be references to the tools required.
  • Page 212 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note 6. Remove the cover on top of the motor by unscrewing its four attachment screws. 7. Remove the cable gland cover at the cable exit by Shown in the figure Location of unscrewing its two securing screws.
  • Page 213 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note 2. Make sure the o-ring on the circumference of the Art no. is specified in Required motor is seated properly. Lightly lubricate it with equipment on page 208. grease. 3.
  • Page 214 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note 14. Refit the cable gland cover at the cable exit with Make sure the cover is tightly its two attachment screws. sealed! Shown in the figure Location of motor on page 208.

  • Page 215: 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. xx0500003050 Cable gland cover, motor axis 4 Motor, axis 4 Motor attachment holes (4 pcs) Required equipment...
  • Page 216 4 Repair 4.6.4. Replacement of motor, axis 4 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 217 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 DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Make sure the o-ring on the circumference Art.
  • Page 218 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note 12. Refit the cover on top of the motor with its Make sure the cover is tightly sealed! four attachment screws. 13. Refit the cable gland cover at the cable exit Shown in the figure Location of motor on with its two attachment screws.

  • Page 219: Replacement Of Motor, Axis 5

    4 Repair 4.6.5. Replacement of motor, axis 5 4.6.5. Replacement of motor, axis 5 Location of motor The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown in the figure below. A more detailed view of the component and its position may be found in chapter .
  • Page 220 4 Repair 4.6.5. Replacement of motor, axis 5 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 instruc- tions below.
  • Page 221 4 Repair 4.6.5. Replacement of motor, axis 5 Continued Action Note 14. Remove the motor by gently lifting it straight out. Keep track of the shims between the motor flange and the wrist housing. Refitting, motor, axis 5 The procedure below details how to refit motor, axis 5. Action Note DANGER!
  • Page 222 4 Repair 4.6.5. Replacement of motor, axis 5 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 3HAC027151-001 Revision: B...

  • Page 223: Replacement Of Motor, Axis 6, Irb 6620/Foundry Plus

    4 Repair 4.6.6. Replacement of motor, axis 6, IRB 6620/Foundry Plus 4.6.6. Replacement of motor, axis 6, IRB 6620/Foundry Plus 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 .
  • Page 224 4 Repair 4.6.6. Replacement of motor, axis 6, IRB 6620/Foundry Plus Continued Equipment, etc. Spare part no. Art. no. Note Extension bar 300 mm 3HAC12342-1 for bits 1/2" Guide pins M8 x 100 3HAC15520-1 For guiding the motor. Guide pins M8 x 150 3HAC15520-2 For guiding the motor.
  • Page 225 4 Repair 4.6.6. Replacement of motor, axis 6, IRB 6620/Foundry Plus Continued Action Note 6. Remove the motor by unscrewing its four attachment screws and plain washers. xx0600003038 • A: Tilthouse • B: Motor, axis 6 • C: Attachment screws (4 pcs) 7.
  • Page 226 4 Repair 4.6.6. Replacement of motor, axis 6, IRB 6620/Foundry Plus Continued Action Note 4. Fit the motor, with guidance from the pins, Make sure the pinion on the motor making sure the motor pinion is properly mated shaft is not damaged! to the gear of gearbox, axis 6.

  • Page 227: Gearboxes

    4 Repair 4.7.1. Replacement gearbox axis 1 4.7 Gearboxes 4.7.1. Replacement gearbox axis 1 Location of gearbox axis 1 xx0600003068 Gearbox, axis 1 RV 320C-191.35 Attachment screw, M12x80 quality 12.9 gleitmo (16 pcs) Attachment screw, M16x60 quality 12.9 gleitmo (12 pcs) Base Frame Cable guide...
  • Page 228 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Equipment, etc. Spare part no. Art. no. Note Lifting tool 3HAC026597-001 Instruction 3HAC026600- 002 is enclosed. Lifting tool 3HAC15556-1 Used to lift gearbox axis 1 and frame. Lifting eye (2 pcs) 3HAC025333-005 Used together with lifting tool 3HAC15556-1.
  • Page 229 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 5. Remove the cable harness, axes 1-2. Detailed in section Replacement of cable harness, lower end (axes 1-2) on page Secure the cable harness to the robot in a 153. safe way, that it will not be damaged in the continued removal procedure.
  • Page 230 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 9. Alternate method of lifting: Art. no. is specified in Required equipment on page 225. Fit the lifting tool and a roundsling on the upper arm and a roundsling with a hoisting Make sure the lift is done completely level! block, to the wrist unit.
  • Page 231 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 13. Fit two lifting eyes on each side of the Art. no. is specified in Required gearbox and secure it with a roundsling. equipment on page 225. 14. Attach the lifting tool to the gearbox. Art.
  • Page 232 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 2. Make sure the o-ring is fitted to the gearbox Art. no. is specified in Required as shown in the figure to the right. equipment on page 225. Lightly lubricate the o-ring with grease. xx0200000055 •...
  • Page 233 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 8. Refit the gearbox to the base with its Shown in the figure Location of gearbox attachment screws and washers. axis 1 on page 225. M16x60 quality 12.9 (12 pcs) Tightening torque: 300 Nm.
  • Page 234 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 13. Fit the lifting tool and adjust as detailed in Art. no. is specified in Required the enclosed instructions. equipment on page 225. Also fit a hoisting block to the front, used to Make sure the lift is done completely adjust the balance of the armsystem in order level!
  • Page 235 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 14. Alternate method of lifting: Art. no. is specified in Required equipment on page 225. Fit the lifting tool and a roundsling on the upper arm and a roundsling with a hoisting Make sure the lift is done completely block, to the wrist unit.
  • Page 236 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 17. Refit motor, axis 1. Detailed in section Replacement of motor, axis 1 on page 199. 18. Fill oil in gearbox axis 1. Detailed in section Oil change, gearbox axis 1 on page 126.

  • Page 237: Replacement Gearbox Axis 2

    4 Repair 4.7.2. Replacement gearbox axis 2 4.7.2. Replacement gearbox axis 2 Location of gearbox axis 2 The gearbox axis 2 is located in the lower arm rotational center. xx0600003056 Attachment screws, M12x60 quality 12.9 Gleitmo (24 pcs) Attachment screws, M16x50 quality 12.9 Gleitmo (16 pcs) Motor, axis 2 Gearbox, axis 2 Required equipment...
  • Page 238 4 Repair 4.7.2. Replacement gearbox axis 2 Continued Spare part Equipment, etc 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 239 4 Repair 4.7.2. Replacement gearbox axis 2 Continued Action Note 5. Fit the lifting tool on the upper arm and secure Art. no. is specified in Required the robot in an overhead crane. equipment on page 235. xx0600003102 • A : Lifting tool •...
  • Page 240 4 Repair 4.7.2. Replacement gearbox axis 2 Continued Refitting The procedure below details how to refit gearbox axis 2. Action Note 1. Make sure the o-ring is fitted to the gearbox. Lightly lubricate it with grease. xx0600003128 • A : O-ring 3HAB3772-91 CAUTION! The gearbox weighs 98 kg! All lifting equipment used must be sized accordingly!
  • Page 241 4 Repair 4.7.2. Replacement gearbox axis 2 Continued Action Note 8. Fit the lifting tool on the upper arm and secure Art. no. is specified in Required the robot in an overhead crane and lift it equipment on page 235. carefully up to its mounting position.

  • Page 242: 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 axis 3 The gearbox axis 3 is located in the upper arm rotational center. xx0600003057 Motor, axis 3 Gearbox, axis 3 Attachment screw, M12x50 quality 12.9 gleitmo (20 pcs) Attachment screw, M16x50 quality 12.9 gleitmo (16 pcs) Hole in lower arm Required equipment...
  • Page 243 4 Repair 4.7.3. Replacement of gearbox axis 3 Continued Spare part Equipment, etc. 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 244 4 Repair 4.7.3. Replacement of gearbox axis 3 Continued Action Note 8. Remove the attachment screws securing the Shown in the figure Location of gearbox to the upper arm. gearbox axis 3 on page 240. 9. Remove the gearbox and put it in a safe place. Refitting The procedure below details how to refit gearbox axis 3.
  • Page 245 4 Repair 4.7.3. Replacement of gearbox axis 3 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 3HAC027151-001 Revision: B...

  • Page 246: 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 247 4 Repair 4.7.4. Replacement of gearbox, axis 6 Continued Turning disk Attachment screws, turning disk xx0200000219 Gearbox, axis 6 (IRB 6620 Foundry Plus) Attachment screws and washers Oil plug, draining Oil plug, filling Required equipment Equipment, etc. Spare part no. Art.
  • Page 248 4 Repair 4.7.4. Replacement of gearbox, axis 6 Continued Removal, gearbox The procedure below details how to remove gearbox, axis 6. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Drain the oil from gearbox, axis 6. Detailed in section Oil change, gearbox axis 6 on page...
  • Page 249 4 Repair 4.7.4. Replacement of gearbox, axis 6 Continued Action Note 2. Make sure the o-ring is fitted to the rear of Art. no. is specified in Required equipment the gearbox. Lubricate the o-ring with on page 245. grease. xx0100000132 •...
  • Page 250 4 Repair 4.7.4. Replacement of gearbox, axis 6 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 3HAC027151-001 Revision: B...

  • Page 251: 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 250, and further detailed in separate Calibration manuals.

  • Page 252: 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 253 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 254: 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, IRB 6620 The illustration below shows the positions of the calibration marks on all axes of the robot. xx0600003096 Calibration scale, axis 1 Calibration scale, axis 2...

  • Page 255: 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 256: Updating Revolution Counters

    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 257 5 Calibration information 5.5. Updating revolution counters Continued Action 2. Tap the mechanical unit in question. A screen is displayed: tap Rev. Counters. en0400000771 3. Tap Update Revolution Counters..A dialog box is displayed, warning that updating the revolution counters may change programmed robot positions: •...

  • Page 258: 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 259: Decommissioning

    6 Decommissioning 6.1. Environmental information 6 Decommissioning 6.1. Environmental information Hazardous material The table specifies some of the materials in the robot 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 260 6 Decommissioning 6.1. Environmental information 3HAC027151-001 Revision: B...

  • Page 261: Reference Information

    7 Reference information 7.1. Applicable Safety Standards 7 Reference information 7.1. 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. •...

  • Page 262: Unit Conversion

    7 Reference information 7.2. Unit conversion 7.2. 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 263: 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 264 7 Reference information 7.3. Screw joints Continued Tightening torque Before tightening any screw, note the following: • Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure descriptions.
  • Page 265 7 Reference information 7.3. Screw joints Continued Tightening torque (Nm) Tightening torque (Nm) Dimension Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass. Tightening torque Tightening torque Tightening torque...

  • Page 266: 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 267: Standard Toolkit

    7 Reference information 7.5. Standard toolkit 7.5. 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 268: Special Tools

    7 Reference information 7.6. Special tools 7.6. 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 265, and of special tools, listed directly in the instructions and also gathered in this section.
  • Page 269 7 Reference information 7.6. Special tools Continued Description Art. no. Lifting tool, gearbox axis 1 3HAC15556-1 Lifting eye (used together with lifting tool 3HAC025333-005 3HAC 15556-1) Lifting tool, gearbox 3HAC025214-001 Guide pins, M12x130 3HAC022637-001 Guide pins, M16x Lifting eye, M16 3HAC14457-1 Lifting eye, M20 Crank...

  • Page 270: Lifting Equipment And Lifting Instructions

    7 Reference information 7.7. Lifting equipment and lifting instructions 7.7. 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 271: Spare Parts And Exploded Views

    8 Spare parts and exploded views 8.1. Introduction 8 Spare parts and exploded views 8.1. Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot. 3HAC027151-001 Revision: B...

  • Page 272: Spare Parts - Cable Harness

    8 Spare parts and exploded views 8.2. Spare parts - cable harness 8.2. Spare parts - cable harness Part list Description Item. Qty. SparePart number Material set, Cable harness Manipulator harness IRB 6620 3HAC025054-001 Connection plate 3HAC025079-001 Frame bracket, conn.plate 3HAC025080-001 Top cover, conn.box 3HAC025081-001...
  • Page 273 8 Spare parts and exploded views 8.2. Spare parts - cable harness Continued Illustration 1 xx0600003066 Continues on next page 3HAC027151-001 Revision: B...
  • Page 274 8 Spare parts and exploded views 8.2. Spare parts - cable harness Continued Illustration 2 xx0600003067 3HAC027151-001 Revision: B...

  • Page 275: Spare Parts - Frame And Base

    8 Spare parts and exploded views 8.3. Spare parts - frame and base 8.3. Spare parts - frame and base Parts list Description Item. Qty. Part number Base incl. frame, axis 1 RV 320C-191,35 3HAC026114-001 Frame 3HAC026178-001 Base 3HAC026117-001 Screw 9ADA205-75 Stop pin 3HAC024014-001...
  • Page 276 8 Spare parts and exploded views 8.3. Spare parts - frame and base Continued Illustration xx0600003061 3HAC027151-001 Revision: B...

  • Page 277: Spare Parts - Wrist

    8 Spare parts and exploded views 8.4. Spare parts - wrist 8.4. Spare parts - wrist Parts list Description Item. Qty. SparePart number Wrist 3HAC028475-001 Wrist insulated 3HAC031470-001 Rotational AC motor incl. Pinion 1.301 3HAC024782-004 Gear unit Z2-3/5 1.302 3HAC024746-003 Middle gear unit Z4-5/5 1.303 3HAC024715-003...
  • Page 278 8 Spare parts and exploded views 8.4. Spare parts - wrist Continued Description Item. Qty. SparePart number Screw M4x8 350.8 9ADA618-32 Protection cover 350.9 3HAC14263-1 Continues on next page 3HAC027151-001 Revision: B...
  • Page 279 8 Spare parts and exploded views 8.4. Spare parts - wrist Continued Illustration xx0600003062 3HAC027151-001 Revision: B...

  • Page 280: Spare Parts - Upper Arm

    8 Spare parts and exploded views 8.5. Spare parts - Upper arm 8.5. Spare parts - Upper arm Parts list Description Item. Qty. SparePart number Axis 3-4 3HAC025576-001 Reduction gear RV-320E i=201 201.1 3HAC023619-001 Screw 201.3 3HAB3409-69 Washer 201.4 3HAA1001-134 Rot AC motor incl.
  • Page 281 8 Spare parts and exploded views 8.5. Spare parts - Upper arm Continued Illustration xx0600003063 3HAC027151-001 Revision: B...

  • Page 282: Spare Parts - Complete Robot

    8 Spare parts and exploded views 8.6. Spare parts - complete robot 8.6. Spare parts - complete robot Parts list Description Item. Qty. SparePart number Revolution indicator ax. 4 3HAC026087-001 Rotational AC motor incl. pinion 3HAC024512-003 Rotational AC motor incl. pinion 3HAC024518-004 Screw 3HAB3409-50...
  • Page 283 8 Spare parts and exploded views 8.6. Spare parts - complete robot Continued Illustration xx0600003064 3HAC027151-001 Revision: B...
  • Page 284 8 Spare parts and exploded views 8.6. Spare parts - complete robot 3HAC027151-001 Revision: B...

  • Page 285: Circuit Diagram

    9 Circuit diagram 9.1. Introduction 9 Circuit diagram 9.1. Introduction Overview This chapter includes the circuit diagram for the robot. 3HAC027151-001 Revision: B...
  • Page 299 9 Circuit diagram 9.1. Introduction 3HAC027151-001 Revision: B...
  • Page 300 Index mechanical stop axis 1 84 mechanical stop axis 3 87 Absolute Accuracy, calibration 251 inverted mounting 71 brake release unit, replacement 195 Levelmeter calibration 251 brakes lifting equipment 264 testing function 24 loads on foundation 47 cabling between robot and controller 89 mechanical stop cabling, robot 89 axis 1 84...
  • Page 301 Index safety equipment mechanical stop 84 mechanical stop axis 3 87 signal lamp 120 Safety, service 14 safety, symbols 30 scales on robot 252 securing the robot to foundation, attachment screws 68 securing, base plate 64 securing, robot 68 special tools 266 stability 53 storage conditions, robot 48 suspended mounting 71...
  • Page 303 ABB AB Robotics Products S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...

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