ABB IRB 6650S - 200/3.0 Product Manual
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ABB IRB 6650S - 200/3.0 Product Manual

Articulated robot
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Product manual
Articulated robot
IRB 6650S - 200/3.0
IRB 6650S - 125/3.5
IRB 6650S - 90/3.9
M2000, M2000A, M2004

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Summary of Contents for ABB IRB 6650S - 200/3.0

  • Page 1 Product manual Articulated robot IRB 6650S - 200/3.0 IRB 6650S - 125/3.5 IRB 6650S - 90/3.9 M2000, M2000A, M2004...
  • Page 3 Product manual IRB 6650S - 200/3.0 IRB 6650S - 125/3.5 IRB 6650S - 90/3.9 M2000 M2000A M2004 Document ID: 3HAC020993-001 Revision: G...
  • Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Table of Contents Overview ................9 Product documentation, M2000/M2000A .
  • Page 6 Table of Contents 2.4.3 Mechanically restricting the working range of axis 2 ........88 2.4.4 Mechanically restricting the working range of axis 3 .
  • Page 7 Table of Contents 3.7.6 Exporting the SIS data ............198 4 Repair 4.1 Introduction .
  • Page 8 Table of Contents 6.2 Decommissioning of balancing device ..........378 7 Reference information 7.1 Introduction .
  • Page 9 Table of Contents 3HAC020993-001 Revision: G...
  • Page 10 Table of Contents 3HAC020993-001 Revision: G...

  • Page 11: Overview

    Prerequisites A maintenance/repair/ installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters:...
  • Page 12 Overview Continued References Document name Document ID Note Product specification - IRB 6600/6650/6650S M2004 3HAC023933-001 Product specification - IRB 6600/6650/6650S M2000/ 3HAC14064-1 M2000A Product manual - IRC5 3HAC021313-001 Product manual - S4Cplus M2000 3HAC021333-001 Product manual - S4Cplus M2000A 3HAC022419-001 Operating manual - IRC5 with FlexPendant 3HAC16590-1 User’s guide - S4Cplus...
  • Page 13 Overview Continued Revision Description • Article number for mechanical stop set added to section Mechanically restricting the working range of axis 2 on page • New section added to the manual: Installation of cooling fan for motors, axes 1-3 (option) on page •...

  • Page 14: Product Documentation, M2000/M2000A

    A complete listing of all available software manuals is available from ABB. Controller hardware option manual Each hardware option for the controller is supplied with its own documentation. Each document set contains the types of information specified below: •...

  • Page 15: Product Documentation, M2004

    This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems.
  • Page 16 Product documentation, M2004 Continued Application manuals Specific applications (e.g. software or hardware options) are described in Application manuals. An application manual can describe one or several applications. An application manual generally contains information about: • The purpose of the application (what it does and when it is useful) •...

  • Page 17: How To Read The Product Manual

    How to read the product manual How to read the product manual Reading the procedures The procedures contain references to figures, tools, material etc. The references are read as described below. References to figures The procedures often include references to components or attachment points located on the robot/controller.
  • Page 18 How to read the product manual 3HAC020993-001 Revision: G...

  • Page 19: Safety

    1 Safety 1.1. Introduction 1 Safety 1.1. Introduction Overview The safety information in this manual is divided in two categories: • general safety aspects, important to attend to before performing any service work on the robot. These are applicable for all service work and are found in section General safety information on page •...

  • Page 20: General Safety Information

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

  • Page 21: Safety Risks

    Nation/region specific regulations To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Non-voltage related risks •...
  • Page 22 1 Safety 1.2.2.1. Safety risks during installation and service work on robot Continued Complete robot Safety risk Description Hot components! CAUTION! Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! Removed parts may result in collapse of robot! WARNING! Take any necessary measures to ensure that the robot...

  • Page 23: Safety Risks Related To Tools/Workpieces

    1 Safety 1.2.2.2. Safety risks related to tools/workpieces 1.2.2.2. Safety risks related to tools/workpieces Safe handling It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating. It should be possible to release parts by manual operation (valves).

  • Page 24: Safety Risks Related To Pneumatic/Hydraulic Systems

    1 Safety 1.2.2.3. Safety risks related to pneumatic/hydraulic systems 1.2.2.3. Safety risks related to pneumatic/hydraulic systems General Special safety regulations apply to pneumatic and hydraulic systems. Residual energy • Residual energy may be present in these systems. After shutdown, particular care must be taken.

  • Page 25: Safety Risks During Operational Disturbances

    1 Safety 1.2.2.4. Safety risks during operational disturbances 1.2.2.4. Safety risks during operational disturbances General • The industrial robot is a flexible tool which can be used in many different industrial applications. • All work must be carried out professionally and in accordance with the applicable safety regulations.

  • Page 26: Risks Associated With Live Electric Parts

    1 Safety 1.2.2.5. Risks associated with live electric parts 1.2.2.5. Risks associated with live electric parts Voltage related risks, general • Although troubleshooting may, on occasion, have to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.
  • Page 27 1 Safety 1.2.2.5. Risks associated with live electric parts Continued Voltage related risks, IRC5 controller A danger of high voltage is associated with for example the following parts: • Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the controller.

  • Page 28: Safety Actions

    1 Safety 1.2.3.1. Safety fence dimensions 1.2.3. Safety actions 1.2.3.1. Safety fence dimensions General Install a safety cell around the robot to ensure safe robot installation and operation. Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed.

  • Page 29: Fire Extinguishing

    1 Safety 1.2.3.2. Fire extinguishing 1.2.3.2. Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot system (manipulator or controller)! 3HAC020993-001 Revision: G...

  • Page 30: Emergency Release Of The Robot's Arm

    1 Safety 1.2.3.3. Emergency release of the robot’s arm 1.2.3.3. Emergency release of the robot’s arm Description In an emergency situation, any of the robot's axes may be released manually by pushing the brake release buttons on the robot. How to release the brakes is detailed in section: •...

  • Page 31: Brake Testing

    1 Safety 1.2.3.4. Brake testing 1.2.3.4. Brake testing When to test During operation the holding brake of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function. How to test The function of the holding brake of each axis motor may be checked as detailed below: 1.

  • Page 32: Risk Of Disabling Function "Reduced Speed 250 Mm/S

    1 Safety 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" NOTE! Do not change "Transm gear ratio" or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s". 3HAC020993-001 Revision: G...

  • Page 33: Safe Use Of The Flexpendant

    1 Safety 1.2.3.6. Safe use of the FlexPendant 1.2.3.6. Safe use of the FlexPendant NOTE! The enabling device is a push button located on the side of the FlexPendant which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.

  • Page 34: Work Inside The Manipulator's Working Range

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

  • Page 35: Signal Lamp (Optional)

    1 Safety 1.2.3.8. Signal lamp (optional) 1.2.3.8. Signal lamp (optional) Description A signal lamp with an yellow fixed light can be mounted on the manipulator, as a safety device. Function The lamp is active in MOTORS ON mode. Further information Further information about the MOTORS ON/MOTORS OFF mode may be found in the controller documentation.

  • Page 36: Translate The Information On Safety And Information Labels

    Using a transparent sticker over the standard label with text added in a fourth language. Drawings detailing the design (text, figure, dimensions) of the standard labels can be ordered from ABB. Notice that each label is identified according to the article number located in the lower corner of the label.

  • Page 37: Safety Related Instructions

    1 Safety 1.3.1. Safety signals, general 1.3 Safety related instructions 1.3.1. Safety signals, general General This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of: •...
  • Page 38 1 Safety 1.3.1. Safety signals, general Continued Symbol Designation Signification ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates DISCHARGE (ESD) electrostatic hazards which could result in severe damage to the product. Electrostatic discharge (ESD) NOTE Note symbols alert you to important facts and conditions.

  • Page 39: Danger - Moving Manipulators Are Potentially Lethal

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

  • Page 40: Danger - First Test Run May Cause Injury Or Damage

    1 Safety 1.3.3. DANGER - First test run may cause injury or damage! 1.3.3. DANGER - First test run may cause injury or damage! Description Since performing a service activity often requires disassembly of the robot there are several safety risks to take into consideration before the first test run. Elimination Follow the procedure below when performing the first test run after a service activity (repair, installation or maintenance):...

  • Page 41: Warning - The Brake Release Buttons May Be Jammed After Service Work

    1 Safety 1.3.4. WARNING - The brake release buttons may be jammed after service work 1.3.4. WARNING - The brake release buttons may be jammed after service work Description The brake release unit has push buttons for brake release of each axis motor. When service work is performed inside the SMB recess that includes removal and refitting of the brake release unit, the brake release buttons may be jammed after refitting! In case the power is turned on while a brake release button is jammed in depressed position,...

  • Page 42: Warning - The Unit Is Sensitive To Esd

    1 Safety 1.3.5. WARNING - The unit is sensitive to ESD! 1.3.5. WARNING - The unit is sensitive to ESD! Description ESD (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 43: Warning - Safety Risks During Work With Gearbox Oil

    1 Safety 1.3.6. WARNING - Safety risks during work with gearbox oil 1.3.6. WARNING - Safety risks during work with gearbox oil Description When handling the gearbox oil, there are several dangers to both personal injuries and product damages! Following safety information must be regarded before performing any work with the oil in the gearboxes! Warnings and elimination Warning...
  • Page 44 1 Safety 1.3.6. WARNING - Safety risks during work with gearbox oil 3HAC020993-001 Revision: G...

  • Page 45: Installation And Commissioning

    2 Installation and commissioning 2.1. Introduction 2 Installation and commissioning 2.1. Introduction General This chapter contains information for installing the robot to the working site. More detailed technical data, such as load diagram, permitted extra loads (equipment) and location of extra loads (equipment), may be found in the Product Specification for the robot. 3HAC020993-001 Revision: G...

  • Page 46: Unpacking

    On-site installation on page Weight, robot The table below shows the weights of the different models: Robot model Weight IRB 6650S - 200/3.0 2225 kg * IRB 6650S - 125/3.5 2250 kg * IRB 6650S - 90/3.9 2275 kg * * Weight of robot excluding DressPack.
  • Page 47 0.5 mm Max. tilt 5° The limit for the maximum load on the robot is reduced if the robot is tilted. Contact ABB for further information about acceptable loads. Min. resonance frequency 22 Hz Storage conditions, robot The table below shows the allowed storage conditions for the robot:...
  • Page 48 2 Installation and commissioning 2.2.1. Pre-installation procedure Continued Protection classes, robot The table below shows the protection class of the robot: Equipment Protection class Robot IP 67 Cooling fans (option) IP 54 3HAC020993-001 Revision: G...

  • Page 49: Working Range And Type Of Motion

    Following figures show the working ranges of the robot models. The extreme positions of the robot arm are specified at the wrist center (dimensions in mm). IRB 6650S - 200/3.0 The illustration below shows the unrestricted working range of IRB 6650S - 200/3.0: xx0300000562 Continues on next page...
  • Page 50 2 Installation and commissioning 2.2.2. Working range and type of motion Continued IRB 6650S - 125/3.5 The illustration below shows the unrestricted working range of IRB 6650S - 125/3.5: xx0300000563 Continues on next page 3HAC020993-001 Revision: G...
  • Page 51 2 Installation and commissioning 2.2.2. Working range and type of motion Continued IRB 6650S - 90/3.9 The illustration below shows the unrestricted working range of IRB 6650S - 90/3.9: xx0600002739 Marked area: max. payload 50 kg Continues on next page 3HAC020993-001 Revision: G...
  • Page 52 Continued Turning radius The turning radius, shown as A in the figure below, is specified for the different robot models below the figure. xx0600002740 IRB 6650S - 200/3.0 3039 mm IRB 6650S - 125/3.5 3485 mm IRB 6650S - 90/3.9...

  • Page 53: Risk Of Tipping / Stability

    2 Installation and commissioning 2.2.3. Risk of tipping / stability 2.2.3. 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 54: On-Site Installation

    2 Installation and commissioning 2.3.1. Lifting robot with fork lift 2.3 On-site installation 2.3.1. Lifting robot with fork lift General The robot may be moved using a fork lift, provided that available special aids are used. This section describes how to attach the fork lift equipment to the robot. Attachment points The attachment points for the fork lift equipment are shown in the figure below.
  • Page 55 2 Installation and commissioning 2.3.1. Lifting robot with fork lift Continued Required equipment Equipment, etc. Art. no. Note Fork lift set, incl. all required 3HAC 0604-1 See the figure Fork lift set, 3HAC 0604-1 hardware on page Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual.
  • Page 56 2 Installation and commissioning 2.3.1. Lifting robot with fork lift Continued Lifting the robot with fork lift The section below details how to secure the fork lift set to the robot in order to lift and move the robot using the fork lift ONLY! Action Note/Illustration 1.
  • Page 57 2 Installation and commissioning 2.3.1. Lifting robot with fork lift Continued Action Note/Illustration 6. Make sure the securing screw is fitted to the longer fork lift pocket. It prevents the fork of the fork lift to be inserted too far into the pocket and thereby damaging the motor of axis 2.
  • Page 58 2 Installation and commissioning 2.3.1. Lifting robot with fork lift Continued Action Note/Illustration 10. Double-check that the pockets are properly secured to the robot! Insert the fork lift forks into the pockets. xx0200000380 Reposition the harness, if any, before using a fork lift! CAUTION! The robot weighs 2275 kg! All lifting equipment must be sized accordingly!

  • Page 59: Lifting Robot With Roundslings

    2 Installation and commissioning 2.3.2. Lifting robot with roundslings 2.3.2. 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 60 2 Installation and commissioning 2.3.2. Lifting robot with roundslings Continued Sling specification Sling type Lifting capacity Length / Note Chain sling with shortener 4 pcs 4 250 kg 0.43 m 0.605 m 0.75 m 0.785 m Roundsling, robot 4 pcs 2 000 kg 2.5 m Lifting with roundslings...

  • Page 61: Lifting Robot With Lifting Slings

    2 Installation and commissioning 2.3.3. Lifting robot with lifting slings 2.3.3. Lifting robot with lifting slings General This section contains a general overview of how to lift the complete robot using special lifting equipment. More detailed instructions are included with the equipment. Illustration, lifting slings The figure below shows how to lift the complete robot with lifting slings.
  • Page 62 2 Installation and commissioning 2.3.3. Lifting robot with lifting slings Continued Action Note/Illustration 2. Make sure the robot is positioned as shown in Release the brakes if required as the figure on the right. If it is not, position it that detailed in section Manually releasing way.

  • Page 63: Manually Releasing The Brakes

    2 Installation and commissioning 2.3.4. Manually releasing the brakes 2.3.4. Manually releasing the brakes General This section details how to release the holding brakes of each axis motor. Location of brake release unit The internal brake release unit is located at the frame, as shown in the figure below. xx0300000564 Internal brake release unit with push buttons Releasing the brakes...
  • Page 64 2 Installation and commissioning 2.3.4. Manually releasing the brakes Continued Supplying power to connector R1.MP If the robot is not connected to the controller, power must be supplied to connector R1.MP in the robot base in order to enable the brake release buttons on the robot. Action Note/Illustration DANGER!

  • Page 65: Lifting The Base Plate

    2 Installation and commissioning 2.3.5. Lifting the base plate 2.3.5. Lifting the base plate Required equipment Equipment Art. no. Note Lifting eye, M16 3HAC 14457-4 3 pcs Lifting slings 3 pcs Length: approx. 2 m Hole configuration xx0200000096 Attachment holes for lifting eyes (x3) Lifting, base plate Action Note...

  • Page 66: Securing The Base Plate

    2 Installation and commissioning 2.3.6. Securing the base plate 2.3.6. Securing the base plate General This section details how to secure the base plate. Base plate, dimensions xx0100000105 Continues on next page 3HAC020993-001 Revision: G...
  • Page 67 2 Installation and commissioning 2.3.6. Securing the base plate Continued xx0400000715 Note1 Four holes for alternative clamping Continues on next page 3HAC020993-001 Revision: G...
  • Page 68 A drawing of the base plate itself may be ordered from ABB Robotics! Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual.
  • Page 69 2 Installation and commissioning 2.3.6. Securing the base plate Continued Recommendations, quality The table specifies any recommendations made by ABB: Variable Recommendation Recommended foundation quality 1 Steel fibre reinforced concrete foundation, 30 kg/m3, class K30, t=250 mm Recommended foundation quality 2 Sturdy concrete foundation, double reinforced by ø10...

  • Page 70: Orienting And Securing The Robot

    2 Installation and commissioning 2.3.7. Orienting and securing the robot 2.3.7. Orienting and securing the robot General This section details how to orient and secure the robot to the base plate in order to run the robot safely. The requirements made on the foundations are shown in the following tables and figures.
  • Page 71 2 Installation and commissioning 2.3.7. Orienting and securing the robot Continued Securing the robot The procedure below details how to secure the robot to the base plate after fitting the plate to the foundation. Action Note/Illustration 1. Lift the robot. Detailed in section Lifting robot with lifting slings on page...
  • Page 72 2 Installation and commissioning 2.3.7. Orienting and securing the robot Continued Cross section, guide sleeve hole The illustration below shows the cross section of the guide sleeve holes. xx0600002629 3HAC020993-001 Revision: G...

  • Page 73: Fitting Equipment On Robot

    2 Installation and commissioning 2.3.8. Fitting equipment on robot 2.3.8. 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 74 2 Installation and commissioning 2.3.8. Fitting equipment on robot Continued xx0300000569 xx0300000570 Continues on next page 3HAC020993-001 Revision: G...
  • Page 75 2 Installation and commissioning 2.3.8. Fitting equipment on robot Continued xx0600003407 Illustration, fitting of extra equipment on upper arm The illustration below shows the mounting holes available for fitting extra equipment on the upper arm. xx0300000574 Continues on next page 3HAC020993-001 Revision: G...
  • Page 76 2 Installation and commissioning 2.3.8. Fitting equipment on robot Continued xx0200000196 Illustration, fitting of extra equipment on frame The illustration below shows the mounting holes available for fitting extra equipment on the frame. xx0300000575 Continues on next page 3HAC020993-001 Revision: G...
  • Page 77 2 Installation and commissioning 2.3.8. Fitting equipment on robot Continued Illustration, fitting on turning disk The illustration below shows the mounting holes available for fitting equipment on the turning disk. xx0200000197 Fastener quality When fitting tools on the turning disk (see the figures above), use only screws with quality 12.9.

  • Page 78: Installation Of Base Spacers (Option)

    2 Installation and commissioning 2.3.9. Installation of base spacers (option) 2.3.9. Installation of base spacers (option) Illustration, installation of base spacers xx0500001570 Base spacer (4 pcs) Guide sleeve (4 pcs) Attachment screws and washers (8 pcs) Required equipment Equipment Art. no. Note Base spacers 3HAC 021899-002...
  • Page 79 2 Installation and commissioning 2.3.9. Installation of base spacers (option) Continued Equipment Art. no. Note Other tools and procedures These procedures include may be required. See references to the tools references to these required. procedures in the step-by- step instructions below. Installation, base spacers The procedure below details how to fit the base spacers between the robot and the base plate.

  • Page 80: Installation Of Cooling Fan For Motors, Axes 1-3 (Option)

    2 Installation and commissioning 2.3.10. Installation of cooling fan for motors, axes 1-3 (option) 2.3.10. Installation of cooling fan for motors, axes 1-3 (option) General A cooling fan can be installed on the motors of axes 1, 2 and 3. However, cooling fans for axes 1 and 2 can not be combined! The cabling for the fans is available in different designs: •...
  • Page 81 2 Installation and commissioning 2.3.10. Installation of cooling fan for motors, axes 1-3 (option) Continued Cooling fan The details of the cooling fan are shown in the figure below. xx0500002158 Fanbox Attachment screws, fanbox plates (9 pcs) Groove in the connector Tightening screws, fanbox (3 pcs) Required equipment Equipment...
  • Page 82 2 Installation and commissioning 2.3.10. Installation of cooling fan for motors, axes 1-3 (option) Continued Equipment Art. no. Note Additional cabling to and Specified in section Position switch and inside the controller fan cables, robot base to controller (option) on page 102.
  • Page 83 2 Installation and commissioning 2.3.10. Installation of cooling fan for motors, axes 1-3 (option) Continued Installation, fan The procedure below details how to install the cooling fan on any of the motors, axes 1-3. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 84 2 Installation and commissioning 2.3.10. Installation of cooling fan for motors, axes 1-3 (option) Continued Installation, separate fan cabling axis 1 or 2 The procedure below details how to install the separate cabling for the cooling fan of axis 1 or 2.
  • Page 85 2 Installation and commissioning 2.3.10. Installation of cooling fan for motors, axes 1-3 (option) Continued Action Note/Illustration 7. Connect the connector R3.FAN2 to the fan of axis Note! Fans on both axis 1 and 2 1 or 2. can not be used at the same time! 8.

  • Page 86: Loads

    Specification. The loads must also be defined in the software as detailed in User's Guide(RobotWare 4.0)Operating manual(RobotWare 5.0). Stop time and braking distances Robot motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB. 3HAC020993-001 Revision: G...

  • Page 87: Restricting The Working Range

    2 Installation and commissioning 2.4.1. Introduction 2.4 Restricting the working range 2.4.1. Introduction General When installing the robot, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited. The working range of the following axes may be restricted: •...

  • Page 88: Mechanically Restricting The Working Range Of Axis 1

    2 Installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 2.4.2. 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 89 2 Installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 Continued Equipment, etc. Art. no. Note User’s guide - S4Cplus (RobotWare Art. no. is specified in section 4.0) References on page Technical reference manual - System parameters (RobotWare 5.0) Installation, mechanical stops axis 1 The procedure below details how to fit the mechanical stops of axis 1 to the robot.

  • Page 90: Mechanically Restricting The Working Range Of Axis 2

    2 Installation and commissioning 2.4.3. Mechanically restricting the working range of axis 2 2.4.3. Mechanically restricting the working range of axis 2 General The working range of axis 2 is limited by fixed mechanical stops and can be reduced by adding up to six additional mechanical stops with 15 graduation in respective direction.
  • Page 91 2 Installation and commissioning 2.4.3. Mechanically restricting the working range of axis 2 Continued Installation, mechanical stops axis 2 The procedure below details how to fit the mechanical stops for axis 2 to the robot. An assembly drawing is also enclosed with the product. Action Note DANGER!

  • Page 92: Mechanically Restricting The Working Range Of Axis 3

    2 Installation and commissioning 2.4.4. Mechanically restricting the working range of axis 3 2.4.4. Mechanically restricting the working range of axis 3 General The working range of axis 3 is limited by fixed mechanical stops and can be reduced by adding additional mechanical stops with 20 graduation in respective direction.
  • Page 93 2 Installation and commissioning 2.4.4. Mechanically restricting the working range of axis 3 Continued Installation, mechanical stops axis 3 The procedure below details how to fit the mechanical stops for axis 3 to the robot. An assembly drawing is also enclosed with the product. Action Note DANGER!

  • Page 94: Installation Of Position Switches (Option)

    The position switch kits may be delivered in one of two ways: • Fitted by ABB Robotics on delivery. In this case, the cams must still be fitted and locked by the user. For axis 1, the cover for the cams must also be fitted.
  • Page 95 2 Installation and commissioning 2.4.5. Installation of position switches (option) Continued Axis 1 The illustration below shows the position switch for axis 1. There is no extra cabling installed on the robot, as for axes 2 and 3. Instead the switch is connected directly to the connector in the base, R1.SW1.
  • Page 96 2 Installation and commissioning 2.4.5. Installation of position switches (option) Continued Installation of position switch, axis 2 In equipped with a cable protection at the lower arm that must be removed before fitting the positions switch for axis 2: Action 1.
  • Page 97 2 Installation and commissioning 2.4.5. Installation of position switches (option) Continued Illustration, adjust and secure cams The illustration below show how to adjust and secure the position switch cams and profiles. xx0100000113 Cam stop, M5 nut and M5 x 6 set screw Adjustable cam Profile Illustration, cutting the cam...
  • Page 98 2 Installation and commissioning 2.4.5. Installation of position switches (option) Continued Plate for customer connections, at base xx0500002301 Plate for customer connections Attachment screws, 3 pcs, M6x16 Cable harness for position switches and fans, axes 1-3 xx0500002305 Cable bracket, frame Cable bracket, lower arm Cable bracket, upper arm R1.SW2/3...
  • Page 99 2 Installation and commissioning 2.4.5. Installation of position switches (option) Continued R3.FAN3 Connected to the fan of axis 3 R2.SW2 Connected to the position switch of axis 2 R2.SW3 Connected to the position switch of axis 3 Installation of cable harness for position switches and fans The procedure below details how to fit the complete cable harness for position switches and cooling fans to the robot.
  • Page 100 2 Installation and commissioning 2.4.5. Installation of position switches (option) Continued Action Note/Illustration 5. Run and secure the cabling inside the frame as detailed below and as shown in the figure to the right: • Secure the cable bracket (A) to the bracket of the robot cabling.
  • Page 101 2 Installation and commissioning 2.4.5. Installation of position switches (option) Continued Action Note/Illustration 7. Run the remaining cable harness up through the lower arm and: • secure with the bracket, lower arm, as shown in the figure to the right. •...
  • Page 102 2 Installation and commissioning 2.4.5. Installation of position switches (option) Continued Action Note/Illustration 10. Connect the connector R1.SW2/3 to the base of the robot. Make sure that the cabling, run through the base, frame and lower arm, is not twisted and is running free from the robot cabling.

  • Page 103: Electrical Connections

    2 Installation and commissioning 2.5.1. Robot cabling and connection points 2.5 Electrical connections 2.5.1. 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 104 2 Installation and commissioning 2.5.1. Robot cabling and connection points Continued Robot cable, power Cable Art. no. Robot cable, power, 7 m 3HAC 11818-1 Robot cable, power, 15 m 3HAC 11818-2 Robot cable, power, 22 m 3HAC 11818-3 Robot cable, power, 30 m 3HAC 11818-4 Robot cable, signals Cable...
  • Page 105 2 Installation and commissioning 2.5.1. Robot cabling and connection points Continued Cabling between robot base and controller, cooling fans, M2004 The cables specified below are specific for the IRC5 controller and used when the robot is equipped with cooling fans. The cabling for the cooling fans runs all the way from the robot base to the inside of the cabinet.

  • Page 106: Making Robot Ready For Operation (Foundry Prime)

    Environmental conditions Humidity 100% Washing detergent with pH <9.0 Washing detergent must contain rust inhibitor and be approved by ABB Cleaning bath temperature <60°C, used in a typical waterjet cleaning application at suitable speed. Air specification for pressurizing of robot The air must be dry and clean, such as instrument air.
  • Page 107 2 Installation and commissioning 2.6.1. Additional installation procedure Continued WARNING! If the pressurized air contains oil, it could result in a brake failure in the motors and cause the robot arms to fall down, leding to personal injure or physical damage. WARNING! If the air pressure exceeds the specified, it could result in a brake failure in the motors and cause the robot arms to fall down, leding to personal injure or physical damage.
  • Page 108 2 Installation and commissioning 2.6.1. Additional installation procedure Continued Protecting from high pressure water WARNING! No part of the robot should be exposed to direct high pressure jet of water. The sealings between the moving parts on the wrist should not be exposed to direct or rebounding high- pressure jet of water.

  • Page 109: Commissioning (Foundry Prime)

    2 Installation and commissioning 2.6.2. Commissioning (Foundry Prime) 2.6.2. Commissioning (Foundry Prime) General The following should be taken in consideration when running a robot in a water jet application cell. CAUTION! Never switch off the overpressure in motors and serial measurement compartment during cooling down of robot after it has been switched off.
  • Page 110 2 Installation and commissioning 2.6.2. Commissioning (Foundry Prime) 3HAC020993-001 Revision: G...

  • Page 111: 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 112: Maintenance Schedule And Expected Component Life

    3 Maintenance 3.2.1. Specification of maintenance intervals 3.2 Maintenance schedule and expected component life 3.2.1. Specification of maintenance intervals Description The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot: •...

  • Page 113: 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 114 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Equipment Interval Detailed in section activity Changing Axis 3 gear oil: First change after: Do not mix with other oils! 6 000 h Kyodo Yushi TMO 150 Oil change, gearbox, axis 3 Second change on page 163 after: 24 000 h Changing...
  • Page 115 3 Maintenance 3.2.2. Maintenance schedule Continued • If the robot is run at ambient temperatures higher than 50°C, the equipment may require maintenance more frequently. • The service time for gearboxes, axes 4 and 5, is not calculated by the SIS, see expected life in section Expected component life on page 116.
  • Page 116 3 Maintenance 3.2.2. Maintenance schedule Continued Activities and intervals, optional equipment The table below specifies the required maintenance activities and intervals for common optional equipment. Maintenance of other external equipment for the robot is detailed in separate documentation. Maintenance Equipment Interval Detailed in section activity...
  • Page 117 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Equipment Interval Detailed in section activity Replacement Cable harness If required Replacement of cable harness, axes 1-6 on page 204 Replacement SMB Battery pack 36 mths Replacement of SMB battery on page 175 Replacement Axis 1 gearbox Replacement of gearbox, axis 1...

  • Page 118: 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, axes 2/3 4,000,000 cycles axis 1 ±180º...

  • Page 119: 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 120 3 Maintenance 3.3.1. Inspection, oil level gearbox axis 1 Continued Equipment Art. no. Note Other tools and procedures may These procedures include be required. See references to references to the tools required. these procedures in the step-by- step instructions below. Inspection, oil level gearbox, axis 1 The procedure below details how to inspect the oil level in gearbox axis 1.

  • Page 121: Inspection, Oil Level Gearbox Axis 2

    3 Maintenance 3.3.2. Inspection, oil level gearbox axis 2 3.3.2. Inspection, oil level gearbox axis 2 Location of gearbox The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment. xx0300000631 Oil plug, filling and inspection Oil plug, draining Vent hole, gearbox axis 2 Required equipment...
  • Page 122 3 Maintenance 3.3.2. Inspection, oil level gearbox axis 2 Continued Inspection, oil level gearbox 2 The procedure below details how to inspect the oil level in gearbox axis 2. Action Note WARNING! Handling gearbox oil involves several safety risks. Before proceeding, please observe the safety information in section WARNING - Safety risks during work with gearbox oil on page...

  • Page 123: Inspection, Oil Level Gearbox Axis 3

    3 Maintenance 3.3.3. Inspection, oil level gearbox axis 3 3.3.3. Inspection, oil level gearbox axis 3 Location of gearbox The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. xx0200000230 Gearbox axis 3 Oil plug, filling Oil plug, draining Required equipment...
  • Page 124 3 Maintenance 3.3.3. Inspection, oil level gearbox axis 3 Continued Equipment, etc. Art. no. Note Other tools and procedures may These procedures include be required. See references to references to the tools required. these procedures in the step-by- step instructions below. Inspection, oil level gearbox 3 The procedure below details how to inspect the oil level in the gearbox axis 3.

  • Page 125: Inspection, Oil Level Gearbox Axis 4

    3 Maintenance 3.3.4. Inspection, oil level gearbox axis 4 3.3.4. Inspection, oil level gearbox axis 4 Location of gearbox The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure below. xx0200000231 Oil plug, filling Oil plug, draining Required equipment...
  • Page 126 3 Maintenance 3.3.4. Inspection, oil level gearbox axis 4 Continued Inspection, oil level gearbox 4 The procedure below details how to inspect the oil level in gearbox axis 4. 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 127: Inspection, Oil Level, Gearbox Axis 5

    3 Maintenance 3.3.5. Inspection, oil level, gearbox axis 5 3.3.5. Inspection, oil level, gearbox axis 5 Location of gearbox The axis 5 gearbox is located in the wrist unit as shown in the figure below. xx0200000232 Oil plug, filling Oil plug, draining Required equipment Equipment etc.
  • Page 128 3 Maintenance 3.3.5. Inspection, oil level, gearbox axis 5 Continued Inspection, oil level gearbox 5 The procedure below details how to inspect the oil level in gearbox axis 5. 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 129: Inspection, Oil Level Gearbox Axis 6

    3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 3.3.6. Inspection, oil level gearbox axis 6 Location of gearbox The axis 6 gearbox is located in the wrist unit as shown in the figure below. xx0400001092 Gearbox, axis 6 Oil plug, filling Oil plug, draining Required equipment Equipment...
  • Page 130 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! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 3.
  • Page 131 3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 Continued Analysis of water content in oil, gearbox axis 6 (Foundry Prime) When changing oil, check for water content in oil an analysis can be ordered from the oil manufacturer Shell. Then..

  • Page 132: Inspection, Balancing Device

    3 Maintenance 3.3.7. Inspection, balancing device 3.3.7. Inspection, balancing device General Several points are to be checked on the balancing device during the inspection. This section details how to perform the inspection regarding: • dissonance • damage • leakage • contamination / lack of free space.
  • Page 133 3 Maintenance 3.3.7. Inspection, balancing device Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Maintenance kit, Includes: complete • complete kit including the kit with bearings and seals • instructions for mainte- nance. Maintenance kit, Includes: bearings and seals •...
  • Page 134 131. • cylinder (a tapping sound, ...replace the balancing device or consult caused by the springs inside the ABB Robotics. cylinder). How to replace the device is detailed in section Replacement of balancing device on page 286. This section also specifies the spare part number! •...
  • Page 135 3 Maintenance 3.3.7. Inspection, balancing device Continued Check for leakage The front ear of the balancing device is lubricated with grease. After filling, excessive grease may normally be forced out between the shaft and the sealing ring in the sealing spacer. This is normal behaviour and must no be confused with incorrect leaks from the ear.
  • Page 136 3 Maintenance 3.3.7. Inspection, balancing device Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 4. Check the o-rings at the front ear for leakage. The o-rings are included in the Replace the o-rings, if any leaks are detected.

  • Page 137: Inspection, Cable Harness

    3 Maintenance 3.3.8. Inspection, cable harness 3.3.8. Inspection, cable harness Location of cable harness, axes 1-4 The robot cable harness, axes 1-4, is located as shown in the figure below. Note! The cable harness is also available without the division point R2.M5/6. Except for the connectors at the division point, the rest of the inspection points are the same for the harness that runs undivided from axis 1 to axis 6.
  • Page 138 3 Maintenance 3.3.8. Inspection, cable harness Continued Inspection, cable harness 1-4 The procedure below details how to inspect the cable harness of axes 1-4. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 139 3 Maintenance 3.3.8. Inspection, cable harness Continued Location of cabling axes 5-6 The robot cable harness, axes 5-6, is located as shown in the figure below. Note! The cable harness is also available without the division point R2.M5/6. Except for the connectors at the division point, the rest of the inspection points are the same for the harness that runs undivided from axis 1 to axis 6.
  • Page 140 3 Maintenance 3.3.8. Inspection, cable harness Continued Action Note 2. Make an overall visual inspection of the cable harness, in order to detect wear and damage. 3. Check the attachments at the rear of the Shown in the figure Location of cabling upper arm and in the upper arm tube.

  • Page 141: Inspection, Information Labels

    3 Maintenance 3.3.9. Inspection, information labels 3.3.9. Inspection, information labels Location of labels The figures below show the location of the information labels to be inspected. xx0200000236 Warning label "High temperature", 3HAC4431-1 (4 pcs) Warning sign, symbol of a flash (located on motor cover), 3HAC1589-1 (5 pcs) Instruction label "Safety instructions", 3HAC4591-1 Warning label "Brake release", 3HAC9508-1 Warning label, tools are not allowed around the balancing device during operation,...
  • Page 142 3 Maintenance 3.3.9. Inspection, information labels Continued xx0400000786 Instruction label "Lifting the robot", 3HAC16487-1 Warning label "Robot can tip forward...", 3HAC9191-1 Foundry logotype, 3HAC8256-1 Warning label "Stored energy", 3HAC9526-1 Required equipment Equipment Art. no. Note Labels and plate set 3HAC8711-1 Includes all labels specified in the two previous figures! The labels are in english.

  • Page 143: Inspection, Mechanical Stop, Axis 1

    3 Maintenance 3.3.10. Inspection, mechanical stop, axis 1 3.3.10. Inspection, mechanical stop, axis 1 Location of mechanical stop The mechanical stop axis 1 is located at the base as shown in the figure below. xx0200000151 Mechanical stop (stop pin) Required equipment Equipment, etc.
  • Page 144 3 Maintenance 3.3.10. Inspection, mechanical stop, axis 1 Continued Action Note 4. If the stop pin is bent or damaged, it must be Art. no. is specified in Required replaced! equipment on page 141! Note! The expected life of gearboxes can be reduced as a result of collissions with the mechanical stop.

  • Page 145: Inspection, Additional Mechanical Stops

    3 Maintenance 3.3.11. Inspection, additional mechanical stops 3.3.11. Inspection, additional mechanical stops Location of mechanical stops The figure below shows the location of the additional mechanical stops on axes 1, 2 and 3 (IRB 7600 shown). xx0200000150 Additional stop Fixed stop Continues on next page 3HAC020993-001 Revision: G...
  • Page 146 3 Maintenance 3.3.11. Inspection, additional mechanical stops Continued xx0200000150 Mechanical stop, axis 1 Required equipment Equipment etc. Art. no. Note Mechanical stop axis 1 3HAC11076-1 Limits the robot working range by 7,5°. Mechanical stop axis 1 3HAC11076-2 Limits the robot working range by 15°. Mechanical stop axis 2 3HAC020885-001 Includes:...
  • Page 147 3 Maintenance 3.3.11. Inspection, additional mechanical stops Continued Action Note 3. Make sure the stops are properly attached. Correct tightening torque, mechanical stop axis 1: 120 Nm. 4. If any damage is detected, the mechanical stops Art. no. is specified in Required must be replaced! equipment on page...

  • Page 148: Inspection, Damper Axes 2-5

    3 Maintenance 3.3.12. Inspection, damper axes 2-5 3.3.12. Inspection, damper axes 2-5 Location of dampers The figure below shows the location of all the dampers to be inspected. xx0400001024 Damper, axis 2 (2 pcs) Damper, axis 3 (2 pcs) Damper, axis 4 (1 pc) Damper, axis 5 (2 pcs) Required equipment A damper must be replaced if damaged!
  • Page 149 3 Maintenance 3.3.12. Inspection, damper axes 2-5 Continued Inspection, dampers The procedure below details how to inspect the dampers, axes 2-5 Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.

  • Page 150: Inspection, Position Switch Axes 1, 2 And 3

    3 Maintenance 3.3.13. Inspection, position switch axes 1, 2 and 3 3.3.13. Inspection, position switch axes 1, 2 and 3 Position switches, axes 1-3 The position switches are shown, fitted to the robot, in section Installation of position switches (option) on page Required equipment Equipment, etc.
  • Page 151 3 Maintenance 3.3.13. Inspection, position switch axes 1, 2 and 3 Continued Action Note 5. Check the protection sheets on axis 1! • Check that the three sheets are in position and not damaged. Deformation can result in rubbing against the cams! •...

  • Page 152: Inspection, Signal Lamp

    3 Maintenance 3.3.14. Inspection, signal lamp 3.3.14. Inspection, signal lamp Location of signal lamp The signal lamp is located as shown in the figure below. Note that the position can differ depending on how the customer harness for axis 4-6 is mounted. See assembly drawing on the current harness for alternative positioning.
  • Page 153 3 Maintenance 3.3.14. Inspection, signal lamp Continued Inspection, signal lamp The procedure below details how to inspect the function of the signal lamp. Action Note 1. Check that the signal lamp is lit, when the motors are put in operation ("MOTORS ON"). DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

  • Page 154: Inspection Of Air Hoses (Foundry Prime)

    3 Maintenance 3.3.15. Inspection of air hoses (Foundry Prime) 3.3.15. Inspection of air hoses (Foundry Prime) General The air hoses on Foundry Prime robots must be inspected for leakage every six month. Required equipment Equipment, etc. Art. no. Note Leak detection spray Pressure gauge Cut off valve Procedure...

  • Page 155: Replacement/Changing Activities

    3 Maintenance 3.4.1. Type of oil in gearboxes 3.4 Replacement/changing activities 3.4.1. Type of oil in gearboxes Location of gearboxes The figure show the location of the gearboxes on the robot. xx0800000247 Gearbox, axis 1 Gearbox, axis 2 Gearbox, axis 3 Gearbox, axis 4 Gearbox, axis 5 Gearbox, axis 6...
  • Page 156 3 Maintenance 3.4.1. Type of oil in gearboxes Continued Type of oil - historically used The six gearboxes of the robot have historically been filled with different types of oils. Today only the types of oil specified in the table is recommended. NOTE! When there is a change of oil types in the gearbox, it need to be rinsed.
  • Page 157 3 Maintenance 3.4.1. Type of oil in gearboxes Continued Mixed types of oil may cause may cause severe damage! When refilling or replacing oil in a gearbox it is important to first check which type of oil is recommended to use in the gearbox. See Type of oil - currently used.
  • Page 158 3 Maintenance 3.4.1. Type of oil in gearboxes Continued Equipment Art. no. Note Oil change equipment 3HAC021745-001 Includes pump with outlet pipe. 3HAC020993-001 Revision: G...

  • Page 159: Oil Change, Gearbox Axis 1

    3 Maintenance 3.4.2. Oil change, gearbox axis 1 3.4.2. Oil change, gearbox axis 1 Location of oil plugs The axis 1 gearbox is located between the frame and base. The oil plugs for filling and inspection are shown in the figure below. The oil is drained through a hose, available in the rear of the robot base, not shown in the figure.
  • Page 160 3 Maintenance 3.4.2. Oil change, gearbox axis 1 Continued Equipment, etc. Art. no. Amount Note Standard toolkit The contents are defined in section Standard toolkit on page Draining oil, axis 1 The procedure below details how to drain the oil in gearbox axis 1. When using the oil exchange equipment, follow the instructions enclosed with the kit.
  • Page 161 3 Maintenance 3.4.2. Oil change, gearbox axis 1 Continued Action Note 8. Close the oil drain hose, and put it back inside the base. 9. Refit the rear cover by securing it with its attachment screws. Filling oil, axis 1 The procedure below details how to fill the oil in gearbox axis 1.

  • Page 162: 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. xx0300000631 Oil plug, filling Oil plug, draining Vent hole Required equipment Equipment, etc.
  • Page 163 3 Maintenance 3.4.3. Oil change, gearbox axis 2 Continued Draining, oil The procedure below details how to drain the oil in gearbox axis 2. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 160.
  • Page 164 3 Maintenance 3.4.3. Oil change, gearbox axis 2 Continued Filling, oil The procedure below details how to fill oil into the gearbox, axis 2. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 160.

  • Page 165: Oil Change, Gearbox, Axis 3

    3 Maintenance 3.4.4. Oil change, gearbox, axis 3 3.4.4. Oil change, gearbox, axis 3 Location of gearbox The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. xx0200000230 Gearbox axis 3 Oil plug, filling Oil plug, draining Required equipment Equipment, etc.
  • Page 166 3 Maintenance 3.4.4. Oil change, gearbox, axis 3 Continued Equipment, etc. Art. no. Amount Note Standard toolkit The contents are defined in section Standard toolkit on page Draining, oil The procedure below details how to drain oil from the gearbox, axis 3. When using the oil exchange equipment, follow the instructions enclosed with the kit.
  • Page 167 3 Maintenance 3.4.4. Oil change, gearbox, axis 3 Continued Filling, oil The procedure below details how to fill oil to the gearbox, axis 3. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 163.

  • Page 168: Oil Change, Gearbox, Axis 4

    3 Maintenance 3.4.5. Oil change, gearbox, axis 4 3.4.5. Oil change, gearbox, axis 4 Location of gearbox The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure below. xx0200000231 Oil plug, filling Oil plug, draining Required equipment Equipment, etc.
  • Page 169 3 Maintenance 3.4.5. Oil change, gearbox, axis 4 Continued Draining, oil The procedure below details how to drain the oil in the gearbox, axis 4. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 166.
  • Page 170 3 Maintenance 3.4.5. Oil change, gearbox, axis 4 Continued Filling, oil The procedure below details how to fill the oil in the gearbox, axis 4. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 166.

  • Page 171: Oil Change, Gearbox, Axis 5

    3 Maintenance 3.4.6. Oil change, gearbox, axis 5 3.4.6. Oil change, gearbox, axis 5 Location of gearbox The axis 5 gearbox is located in the wrist unit as shown in the figure below. xx0200000232 Oil plug, filling Oil plug, draining Required equipment Equipment, etc.
  • Page 172 3 Maintenance 3.4.6. Oil change, gearbox, axis 5 Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. WARNING! Handling gearbox oil involves several safety risks.
  • Page 173 3 Maintenance 3.4.6. Oil change, gearbox, axis 5 Continued Action Note 4. Refill the gearbox with lubricating oil through the Shown in the figure Location of oil plug, filling. gearbox on page 169! The amount of oil to be refilled depends on the Art.

  • Page 174: Oil Change, Gearbox Axis 6

    3 Maintenance 3.4.7. Oil change, gearbox axis 6 3.4.7. Oil change, gearbox axis 6 Location of gearbox The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. xx0400001092 Gearbox, axis 6 Oil plug, filling Oil plug, draining Required equipment...
  • Page 175 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 176 3 Maintenance 3.4.7. Oil change, gearbox axis 6 Continued Action Note 3. Remove the oil plug, filling. Shown in the figure Location of gearbox on page 172! 4. Refill the gearbox with lubricating oil. Art. no. and the total amount are specified in Required The amount of oil to be refilled depends on the...

  • Page 177: Replacement Of Smb Battery

    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 eqvivalent. Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual.
  • Page 178 6. Remove the SMB battery. Shown in the figure Location of SMB battery on page 175. Battery includes protection circuits. Replace it only with the specified spare part or with an ABB approved eqvivalent. Continues on next page 3HAC020993-001 Revision: G...
  • Page 179 3 Maintenance 3.4.8. Replacement of SMB battery Continued Refitting, battery The procedure below details how to refit the SMB battery. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.

  • Page 180: Lubrication Activities

    3 Maintenance 3.5.1. Lubrication of spherical roller bearing, balancing device 3.5 Lubrication activities 3.5.1. Lubrication of spherical roller bearing, balancing device Location of bearing The spherical roller bearing is located at the front ear of the balancing device, as shown in the figure below.
  • Page 181 3 Maintenance 3.5.1. Lubrication of spherical roller bearing, balancing device Continued Lubrication, balancing device bearing The procedure below details how to lubricate the spherical roller bearing. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.

  • Page 182: Rust Preventive, Bearing Axis 1 (Foundry Prime)

    3 Maintenance 3.5.2. Rust preventive, bearing axis 1 (Foundry Prime) 3.5.2. Rust preventive, bearing axis 1 (Foundry Prime) Location of bearing axis 1 The bearing axis 1 is located as shown in the illustration. (View from above). xx0600002866 Plastic ring, (bearing cover) Required equipment Equipment Art.
  • Page 183 3 Maintenance 3.5.2. Rust preventive, bearing axis 1 (Foundry Prime) Continued Procedure The following procedure details how to grese the bearing axis 1. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.

  • Page 184: Rust Preventive, Bearing Axis 4 (Foundry Prime)

    3 Maintenance 3.5.3. Rust preventive, bearing axis 4 (Foundry Prime) 3.5.3. Rust preventive, bearing axis 4 (Foundry Prime) Overview The bearing axis 4 is located as shown in the illustration below. xx0500002869 Plastic cover Plastic ring Required equipment Equipment Art. no. Note Brush Rust preventive...
  • Page 185 3 Maintenance 3.5.3. Rust preventive, bearing axis 4 (Foundry Prime) Continued Procedure The following procedure details how to grease the bearing axis 1. Action Note/Illustration 1. Put the manipulator in a suitable position. DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn...
  • Page 186 3 Maintenance 3.5.3. Rust preventive, bearing axis 4 (Foundry Prime) Continued Action Note/Illustration 6. Apply the rust preventive on the bearing with the brush. xx0600002868 • A: bearing axis 4 • B plastic ring 7. Refit the plasitc ring and cover 3HAC020993-001 Revision: G...

  • Page 187: Rust Preventive, Support Bearing In Wrist (Foundry Prime)

    3 Maintenance 3.5.4. Rust preventive, support bearing in wrist (Foundry Prime) 3.5.4. Rust preventive, support bearing in wrist (Foundry Prime) Location of bearing The support bearing in the wrist is located as shown in the illustration. xx0500002863 Bearing Cable bracket Cover Required equipment Equipment...
  • Page 188 3 Maintenance 3.5.4. Rust preventive, support bearing in wrist (Foundry Prime) Continued Greasing, bearings The procedure below details how to grease the bearing in the wrist. Action Note/Illustration 1. Place the robot and the upper arm in a suitable position. DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

  • Page 189: Cleaning Activities

    3 Maintenance 3.6.1. Cleaning, robot 3.6 Cleaning activities 3.6.1. Cleaning, robot General The protection class is IP 67, that is the robot is watertight. Activities This instruction specifies how to clean the robot. Periodicity The periodicity of cleaning the robot varies a great deal depending on the actual environment and function of the robot.
  • Page 190 3 Maintenance 3.6.1. Cleaning, robot Continued Required equipment Equipment, etc. Art. no. Note Steam cleaner • Water pressure at nozzle: max. 2,500 kN/m (25 bar) • Type of nozzle: fan jet, min. 45° spread • Flow: max. 100 litres/min. • Water temperature: max.

  • Page 191: Service Information System, M2000

    Defining the SIS input production environment. parametersSIS system parameters on page 192. Maintenance intervals recommended by ABB are specified in section Maintenance ScheduleMaintenance schedule on page 111. 3. Enter these parameters in the system. How to do this is detailed in...

  • Page 192: Description Of Service Information System (Sis)

    3 Maintenance 3.7.2. Description of Service Information System (SIS) 3.7.2. Description of Service Information System (SIS) General Service Information System (SIS) is a software function within the robot controller, which simplifies maintenance of the robot system. It supervises the operating time and mode of the robot, and alerts the operator when a maintenance activity is scheduled.
  • Page 193 3 Maintenance 3.7.2. Description of Service Information System (SIS) Continued Operation time This is a function within the control system that keeps track of the amount of time the "MOTORS ON" signal is active, i.e. the amount of time the robot is in the operating mode. When the operation time limit for maintenance is reached, a message is displayed on the TPU.

  • Page 194: Sis System Parameters

    Since the counters are to be used for purposes defined by the user, ABB cannot give any recommendations regarding their definitions. The figures below shows the options of parameters to be set.
  • Page 195 3 Maintenance 3.7.3. SIS system parameters Continued Gearbox warning A percentage of the gearbox service interval as calculated by the system. E.g. by setting the value "90", the SIS will alert the operator after 90% of the expected service interval of each gearbox. The robot system automatically detects and stores all required variables to calculate the expected service interval of each gearbox.

  • Page 196: Setting The Sis Parameters

    3 Maintenance 3.7.4. Setting the SIS parameters 3.7.4. Setting the SIS parameters General If the SIS system is to function properly, a number of parameters must be set. This is detailed below. Procedure M2000 This is an instruction of how to enter SIS parameters to the M2000 robot system. Action Note 1.
  • Page 197 3 Maintenance 3.7.4. Setting the SIS parameters Continued Action Note 3. Select "0 SIS parameters" and press "Enter". en0200000047 xx0100000200 4. Select the required system The parameter list is displayed. en0200000048 en0200000049 5. Select the required Available parameters are described in section Defining the parameters by stepping up SIS input parametersSIS system parameters on page...

  • Page 198: Reading The Sis Output Logs

    3 Maintenance 3.7.5. Reading the SIS output logs 3.7.5. Reading the SIS output logs General Whenever a set condition has expired (e.g. max allowed operation time before service), a message to this effect will be shown in the Operational log. Access to logs How to open a log and show its contents is detailed in the User's Guide, chapter Service.
  • Page 199 3 Maintenance 3.7.5. Reading the SIS output logs Continued SIS message in Available in: Meaning: the log: Gearbox time Service Message X percent of gearbox hours remain until the auto- matically calculated gearbox time limit expires. X% of the service interval has expired How to set the value determining when the for gearbox x!

  • Page 200: Exporting The Sis Data

    3 Maintenance 3.7.6. Exporting the SIS data 3.7.6. Exporting the SIS data General This section describes the available variables for entering SIS parameters as well as showing any values of exceeded time limits as detected by the SIS counters. In a M2000 robot system, the values can be read on a PC using "Webware SDK". How to access these variables and how to perform the actual programming sequences are detailed in the robot system User's Guide.

  • Page 201: Repair

    4 Repair 4.1. Introduction 4 Repair 4.1. Introduction Structure of this chapter This chapter details all repair activities recommended for the robot and any external units of the robot. It is made up of separate procedures, each detailing a specific repair activity. Each procedure contains all information required to perform the activity, e.g.

  • Page 202: General Procedures

    4 Repair 4.2.1. Performing a leak-down test 4.2 General procedures 4.2.1. Performing a leak-down test General After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equipment Equipment, etc.

  • Page 203: Mounting Instructions For Bearings

    4 Repair 4.2.2. Mounting instructions for bearings 4.2.2. Mounting instructions for bearings General This section details how to mount and grease different types of bearings on the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB 3537-1 Used to grease the bearings, if not specified otherwise.

  • Page 204: Mounting Instructions For Seals

    4 Repair 4.2.3. Mounting instructions for seals 4.2.3. Mounting instructions for seals General This sections details how to mount different types of seals to the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB 3537-1 Used to lubricate the seals. Rotating seals The procedure below details how to fit rotating seals.
  • Page 205 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 206: Complete Robot

    4 Repair 4.3.1. Replacement of cable harness, axes 1-6 4.3 Complete robot 4.3.1. Replacement of cable harness, axes 1-6 General This section details how to replace the cable harness that runs undivided from axis 1 to axis 6. In case the cabling has a division point at the upper arm, it should instead be replaced as detailed in sections: •...
  • Page 207 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Required equipment Equipment Spare part no. Note Cable harness axes 1-6 3HAC024386-001 Brush Rust preventive 3HAC026621-001 Equivalent: • Mercasol 3106 Gasket 3HAC3537-1 motor axes 1-5 Gasket 3HAC12877-1 motor axis 6 Standard toolkit The contents are defined in section Standard toolkit on page...
  • Page 208 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 3.
  • Page 209 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note/Illustration 12. Gently pull the cable harness out from the upper arm tube. 13. Tie the connectors into bundles, to avoid damaging them during further removal. 14. Continue removing the cable harness as detailed in following procedure.
  • Page 210 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note/Illustration 8. Remove • the cable gland (A), by removing the four attachment screws from inside the SMB recess (B) • the attachment plate (C), by removing the attachment screws and the velcro strap (D).
  • Page 211 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note/Illustration 10. Remove the cable gland securing the cables to the arm house. xx0100000143 11. Remove the velcro strap from the harness at the cable fixing bracket at the arm house. 12.
  • Page 212 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Refitting, cable harness axes 1-6 The procedure below details how to refit the cable harness to the robot. Action Note Required equipment on page 205. NOTE! On Foundry Prime robots: Apply rust preventive around all dismantled covers and attachment screws with a brush.
  • Page 213 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 8. Secure the cable gland (A) with four Locking liquid is specified in Required attachment screws (B) from inside the SMB equipment on page 205. recess. Secure the correct attachment plate (C) to the cable gland with its two attachment screws, using locking liquid.
  • Page 214 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 9. Reconnect connectors R2.SMB, R1.SMB1-3, R1.SMB4-6 to the SMB unit. Reconnect X8, X9 and X10 to the brake release unit. Reconnect R1.G if it has been disconnected. xx0200000118 10.
  • Page 215 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 14. Refit the cable gland securing the cables to the arm house. Make sure not to twist the harness! xx0100000143 15. Reconnect all connectors at motor 3 and motor 16.
  • Page 216 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 20. Fasten the cable bracket, wrist unit with three attachment screws, two of them visible at the rear attachment point and the third located on the bottom of the cable bracket, in the center. xx0200000254 •...
  • Page 217 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 25. Fit a cable protection to the lower arm, if not already mounted, with two securing screws (A), M6x16. Secure the cable harness with two velcro straps (B), with a distance of approximately 180 mm.

  • Page 218: Replacement Of Cable Harness, Axes 1-4

    4 Repair 4.3.2. Replacement of cable harness, axes 1-4 4.3.2. Replacement of cable harness, axes 1-4 General This section details how to replace the cable harness that runs from axis 1 to axis 4. If the robot is equipped with an undivided cable harness, it is instead replaced as detailed in section Replacement of cable harness, axes 1-6 on page 204.
  • Page 219 4 Repair 4.3.2. Replacement of cable harness, axes 1-4 Continued Cable guide in the center of the frame Connectors at motor 1: R2.FB1 and R2.MP1 Connectors at motor 2: R2.FB2 and R2.MP2 SMB recess Cable gland, upper arm house Cable fixing bracket + velcro strap Connector R2.M5/6 at the cable division point Connectors at motor 3: R2.FB3 and R2.MP3 (optional signal lamp: R2.H1 and R2.H2) Connectors at motor 4: R2.FB4 and R2.MP4...
  • Page 220 4 Repair 4.3.2. Replacement of cable harness, axes 1-4 Continued Removal, cable harness, axes 1-4 The procedure below details how to remove the cable harness, axes 1-4. Action Note/Illustration 1. In order to facilitate refitting of cable harness, run the Axes 2 and 3 may be tilted robot to the specified position: slightly to improve access.
  • Page 221 4 Repair 4.3.2. Replacement of cable harness, axes 1-4 Continued Action Note/Illustration 9. Disconnect connectors R2.SMB, R1.SMB1-3, R1.SMB4-6 from the SMB unit. Disconnect X8, X9 and X10 from the brake release unit. xx0200000118.wmf 10. Remove • the cable gland (A), by removing the four attachment screws from inside the SMB recess (B) •...
  • Page 222 4 Repair 4.3.2. Replacement of cable harness, axes 1-4 Continued Action Note/Illustration 11. Remove the cable gland securing the cables inside the lower arm. 12. Remove the cable gland securing the cables to the arm house. xx0100000143.wmf 13. Remove the velcro strap from the harness at the Shown in the figure Location of cable fixing bracket at the arm house.
  • Page 223 4 Repair 4.3.2. Replacement of cable harness, axes 1-4 Continued Refitting, cable harness, axes 1-4 The procedure below details how to refit the cable harness, axes 1-4. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 224 4 Repair 4.3.2. Replacement of cable harness, axes 1-4 Continued Action Note/Illustration 8. Secure the cable gland (A) with four attachment Locking liquid is specified in screws (B) from inside the SMB recess. Required equipment on page 217. Secure the correct attachment plate (C) to the cable gland with its two attachment screws, using locking liquid.
  • Page 225 4 Repair 4.3.2. Replacement of cable harness, axes 1-4 Continued Action Note/Illustration WARNING! Before continuing any service work, please observe the safety information in section WARNING - The brake release buttons may be jammed after service work on page 12. Pull the cable harness through the lower arm. 13.
  • Page 226 4 Repair 4.3.2. Replacement of cable harness, axes 1-4 Continued Action Note/Illustration 18. Fit a cable protection to the lower arm, if not Both the protection and the strap already mounted, with two securing screws (A), are included in the spare part no., M6x16.

  • Page 227: Replacement Of Cable Harness, Axes 5-6

    4 Repair 4.3.3. Replacement of cable harness, axes 5-6 4.3.3. Replacement of cable harness, axes 5-6 General This cable is not applicable for robot model IRB 6650S - 90/3.9. Location of cable harness ax 5-6 The location of the cable harness, axes 5-6, is shown in the figure below. xx0200000213 Cable bracket, wrist unit Cable bracket, upper arm tube...
  • Page 228 4 Repair 4.3.3. Replacement of cable harness, axes 5-6 Continued Equipment, etc. Spare part no. Note Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual. Other tools and procedures may These procedures include references be required.
  • Page 229 4 Repair 4.3.3. Replacement of cable harness, axes 5-6 Continued Action Note/Illustration 5. Loosen the cable bracket on top of the wrist Shown in the figure Location of cable unit by undoing the three attachment screws. harness ax 5-6 on page 225! Two of the attachment screws are visibly located at the rear attachment and the third is...
  • Page 230 4 Repair 4.3.3. Replacement of cable harness, axes 5-6 Continued Action Note/Illustration 4. Place the cabling to motor, axis 6, correctly on the upper arm and gently pull the connectors through the hole on top of wrist unit to motor, axis 6.

  • Page 231: Replacement Of Cabling, Axis 5 Motor

    4 Repair 4.3.4. Replacement of cabling, axis 5 motor 4.3.4. Replacement of cabling, axis 5 motor Location of cabling The separate cables for the axis 5 motor are located inside the upper arm tube, as shown in the figure below. xx0500002294 Motor axis 5 with connectors R4.FB5 and R4.MP5 Connectors R3.FB5 and R3.MP5...
  • Page 232 4 Repair 4.3.4. Replacement of cabling, axis 5 motor Continued Action Note 4. Disconnect all connectors at motor, axis 5. 5. Remove the cable gland cover at the cable exit by unscrewing its two attachment screws. 6. Remove the cable, axis 5. Refitting, cabling axis 5 motor The procedure below details how to refit the cabling to the motor of axis 5.

  • Page 233: Replacement Of Complete Arm System

    4 Repair 4.3.5. Replacement of complete arm system 4.3.5. Replacement of complete arm system Location of arm system The complete arm system is defined as the complete robot except for the base and gearbox axis 1. This is shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views on page 423...
  • Page 234 4 Repair 4.3.5. Replacement of complete arm system Continued Required equipment Equipment, etc. Art. no. Note Lifting device, manipulator 3HAC15607-1 Instruction 3HAC 15971-2 is enclosed! Guide pins M12 x 130 3HAC022637-001 Used to guide the complete arm system when refitting. Always use the guide pins in pairs! In order to make the refitting easier, it is recommended to use two guide pins of...
  • Page 235 4 Repair 4.3.5. Replacement of complete arm system Continued Action Note/Illustration 3. Drain the oil from gearbox axis 1. Detailed in section Oil change, gearbox axis 1 on page 157. 4. Loosen the cable connectors from the base and pull up the cabling from the base, through the hole in the center of the frame.
  • Page 236 4 Repair 4.3.5. Replacement of complete arm system Continued Action Note/Illustration 2. Fit the lifting device as detailed in enclosed Art. no. is specified in Required instruction. equipment on page 232! Also fit a hoisting block to the frontchain, used to adjust the balance of the arm system in order to lift it completely level! CAUTION! The complete arm system weighs 1250 kg!
  • Page 237 4 Repair 4.3.5. Replacement of complete arm system Continued Action Note/Illustration 8. Remove the guide pins and secure the arm Shown in the figure Location of arm system to the base with its 24attachment system on page 231! screws and washers. M12 x 110, 12.9 quality UNBRAKO.

  • Page 238: Replacement Of Air Nipple And Hose (Foundry Prime)

    4 Repair 4.3.6. Replacement of air nipple and hose (Foundry Prime) 4.3.6. Replacement of air nipple and hose (Foundry Prime) Location The illustration below shows the routing of the Foundry Prime air hose. xx0500002176 Hose lengths xx0600003395 Length in mm. 2080 1130 Continues on next page...
  • Page 239 4 Repair 4.3.6. Replacement of air nipple and hose (Foundry Prime) Continued Length in mm. 4290 1605 1490 Required equipment Equipment Art. no. Pos. in illustration Velcro strap 3HAC12625-1 Cable straps 21662055-3 Elbow fitting Rubber clamp 3HAC026523-001 T-plug connector 3HAC026515-001 Y-plug connector 3HAC026514-001 Bulkhead plug connector...
  • Page 240 4 Repair 4.3.6. Replacement of air nipple and hose (Foundry Prime) Continued Action Note/Illustration Connection at base. xx0600003042 Axis 1 xx0600003043 Balancing cylinder xx0600003398 Continues on next page 3HAC020993-001 Revision: G...
  • Page 241 4 Repair 4.3.6. Replacement of air nipple and hose (Foundry Prime) Continued Action Note/Illustration Axis 1-2 xx0600003417 xx0600003419 xx0600003045 Continues on next page 3HAC020993-001 Revision: G...
  • Page 242 4 Repair 4.3.6. Replacement of air nipple and hose (Foundry Prime) Continued Action Note/Illustration Upper arm housing xx0600003046 xx0600003047 Tube shaft xx0600003163 • 1K: Lay the hose in a spiral in the tube shaft. Continues on next page 3HAC020993-001 Revision: G...
  • Page 243 4 Repair 4.3.6. Replacement of air nipple and hose (Foundry Prime) Continued Action Note/Illustration Wrist NOTE! Make sure the cable length from 5a to the nipple of axis 6 = S, see Hose lengths on page 236. xx0600003097 3HAC020993-001 Revision: G...

  • Page 244: 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. A more detailed view of the component and its position may be found in chapter Exploded views in the...
  • Page 245 4 Repair 4.4.1. Replacement of turning disk Continued Removal, turning disk The procedure below details how to remove the turning disk. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 246 4 Repair 4.4.1. Replacement of turning disk Continued Action Note/Illustration 2. Secure the turning disk with its attachment 12 pcs, M12 x 30, 12.9 quality screws. UNBRAKO, tightening torque: 100 Nm. Reused screws may be used, providing they are lubricated as detailed in section Screw joints on page 384 before fitting.

  • Page 247: Replacement Of Complete Wrist Unit

    4 Repair 4.4.2. Replacement of complete wrist unit 4.4.2. Replacement of complete wrist unit Location of wrist unit The wrist unit is located in the frontmost part of the upper arm as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
  • Page 248 4 Repair 4.4.2. Replacement of complete wrist unit Continued Equipment etc. Spare part no. Art. no. Note Guide pins M12 x 200 3HAC13056-3 Always use guide pins in pairs! Lifting tool, wrist unit 3HAC 13605-1 Standard toolkit The contents are defined in section Standard toolkit on page 388...
  • Page 249 4 Repair 4.4.2. Replacement of complete wrist unit Continued Action Note/Illustration 7. Loosen the cable bracket on top of the wrist by Shown in the figure Location of wrist undoing the three attachment screws. unit on page 245! Two of the attachment screws are visibly located at the rear of the bracket (B) and the third located at the bottom of the cable bracket, in the center (C), shown in the figure to the right.
  • Page 250 4 Repair 4.4.2. Replacement of complete wrist unit Continued Action Note/Illustration 3. Fit the lifting tool to the wrist unit. Art. no. is specified Location of wrist unit on page 245! CAUTION! The complete wrist unit weighs 130 kg!All lifting equipment used must be sized accord- ingly! 5.
  • Page 251 4 Repair 4.4.2. Replacement of complete wrist unit Continued Action Note/Illustration 12. Fasten the cable bracket at top of the wrist Shown in the figure Location of wrist unit with three attachment screws. Two of unit on page 245! them are visible at the rear attachment point (B) and the third is located on the bottom of the cable bracket, in the center (C), shown in the figure to the right.

  • Page 252: Replacement Of Upper Arm

    4 Repair 4.4.3. Replacement of upper arm 4.4.3. Replacement of upper arm Location of upper arm The upper arm is located on top of the robot as shown in the following figure. The complete upper arm includes the wrist unit but this section also describes how to remove the upper arm when there is no wrist unit mounted.
  • Page 253 4 Repair 4.4.3. Replacement of upper arm Continued xx0200000163 Attachment hole for lifting eye, M12 (if wrist unit is mounted) Attachment for lifting device, upper arm (2 pcs if there is no wrist unit mounted) Oil plug, draining, gearbox axis 3 Cable harness division;...
  • Page 254 4 Repair 4.4.3. Replacement of upper arm Continued Action Note 2. Remove all equipment fitted to turning disk. 3. Move the upper arm to a horizontal position. Shown in the figure Location of upper arm on page 250! Rotate axis 4 so that the attachment hole for lifting eye is faced upwards! 4.
  • Page 255 4 Repair 4.4.3. Replacement of upper arm Continued Refitting, upper arm The procedure below details how to refit the upper arm. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 256 4 Repair 4.4.3. Replacement of upper arm Continued Action Note/Illustration 5. In order to release the brake of the axis 3 motor, Connect to connector R2.MP3 connect the 24 VDC power supply, after • +: pin 2 removing the motor cover. •...
  • Page 257 4 Repair 4.4.3. Replacement of upper arm Continued Action Note/Illustration 14. Disconnect the brake release voltage and remove the rotation tool from the motor. 15. Remove the lifting devices. 16. Refit any cabling removed during the removal process. 17. Reconnect all connectors inside motors, axis 3 and 4.

  • Page 258: Replacement Of Complete Lower Arm

    4 Repair 4.4.4. Replacement of complete lower arm 4.4.4. Replacement of complete lower arm Location of lower arm The lower arm is located as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
  • Page 259 4 Repair 4.4.4. Replacement of complete lower arm Continued xx0300000475 Gearbox Cover axis 2 O-ring Bearing Thrust washer Bushing Retaining ring, shaft Shaft, lower arm Protection washer Shaft, balancing device Grease Securing screw and washer, balancing device shaft Protection plug Attachment screws and washers Continues on next page 3HAC020993-001 Revision: G...
  • Page 260 Shackle, balancing device 3HAC 020997-1 Puller tool, balancing device 3HAC12475-1 shaft Lifting tool, lower arm 3HAC14691-1 Tool that may be rent from ABB Robotics. Includes: • two guidings, 3HAC 14445-1, must be used for guiding the sealing, axis 2/3. Rotation tool...
  • Page 261 4 Repair 4.4.4. Replacement of complete lower arm Continued Removal, lower arm The procedure below details how to remove the complete lower arm. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 262 4 Repair 4.4.4. Replacement of complete lower arm Continued Action Note/Illustration 9. Move the lower arm backwards to the lowest position possible. xx0400001028 10. Apply the lifting tool to the lower arm. Art. no. is specified in Required equipment on page 258! 11.
  • Page 263 4 Repair 4.4.4. Replacement of complete lower arm Continued Action Note/Illustration 3. Fit two guidings in the attachment holes of the Art. no. is specified in Required lower arm. equipment on page 258! xx0300000548 A: Attachment holes for the two guidings 4.
  • Page 264 4 Repair 4.4.4. Replacement of complete lower arm Continued Action Note/Illustration 9. Disconnect the power supply, if used. 10. Secure the lower arm with 16 of the 18 pcs: M16 x 50, tightening torque: 18attachment screws and washers in gearbox, 300 Nm.

  • Page 265: Replacement Of Lower Arm Shaft

    4 Repair 4.4.5. Replacement of lower arm shaft 4.4.5. Replacement of lower arm shaft Prerequisites This section details how to remove and refit the lower arm shaft as a step in the procedure of removing/refitting the complete lower arm. To perform the procedure described in this section, it is required that the preceding instructions in section Replacement of complete lower arm on page 256...
  • Page 266 4 Repair 4.4.5. Replacement of lower arm shaft Continued Required equipment Equipment Art. no. Note Bearing 3HAC 12441-2 Always use a new bearing when reassembling! Puller device, axis 2 shaft 3HAC021563-001 Press device, axis 2 shaft 3HAC021600-001 Hydraulic pump, 80 MPa 3HAC13086-1 Hydraulic pump, 150 MPa 3HAC021563-012...
  • Page 267 Nipple for the glycerin pump Indicator Removal, lower arm shaft The procedure below details how to remove the lower arm shaft. If encountering any problems when removing the shaft, contact ABB Robotics! Action Note/Illustration WARNING! This procedure is a step in the complete procedure...
  • Page 268 4 Repair 4.4.5. Replacement of lower arm shaft Continued Action Note/Illustration 4. Fit the puller device to the shaft as shown in the Art. no. is specified in Required figure to the right. equipment on page 264! xx0300000010 5. Fit both the hydraulic pump and the glycerin pump to Art.
  • Page 269 4 Repair 4.4.5. Replacement of lower arm shaft Continued Refitting, lower arm shaft The procedure below details how to refit the lower arm shaft. Action Note/Illustration 1. Clean the shaft with isopropanol and lubricate it Art. no. is specified in Required with glycerin.
  • Page 270 4 Repair 4.4.5. Replacement of lower arm shaft Continued Action Note/Illustration 13. Apply grease to the location of the shaft where the Art. no. is specified in Required bearing is to be mounted. equipment on page 264 14. Press in the new bearing with the press tool, axis 2 Always use a new bearing when bearing.

  • Page 271: Securing The Lower Arm

    4 Repair 4.4.6. Securing the lower arm 4.4.6. Securing the lower arm General This section details how to secure the lower arm with a specific fixture prior to performing certain service activities to the robot. Attachment points, robot The special equipment used to secure the lower arm is fitted to the attachment points shown in the figure below.
  • Page 272 4 Repair 4.4.6. Securing the lower arm Continued Fixture, lower arm The attachment bolts, locking screw, adjusters and ring nuts are attached to the fixture tool as shown in the figure below. Move them to the attachment points shown in the instruction. Placeholder Locking screw Adjusters, 2 pcs...
  • Page 273 4 Repair 4.4.6. Securing the lower arm Continued Action Note/Illustration 3. Move the robot to the calibration position. The upper arm can be directed in three different ways, shown in the figure to the right. The lowered position, as in figure A, is recommended as it gives the least load on the tool.
  • Page 274 4 Repair 4.4.6. Securing the lower arm Continued Action Note/Illustration 7. Fit the fixture, lower arm to the frame and the lower Art. no. is specified in Required arm, according to following instruction: equipment on page 269. 1. Fit the both adjusters in the correct holes and Attachment holes on the frame make sure that they are screwed back (C).

  • Page 275: Frame And Base

    4 Repair 4.5.1. Replacement of SMB unit 4.5 Frame and base 4.5.1. Replacement of SMB unit Location of SMB unit The SMB unit (SMB = serial measurement board) is located on the left hand side of the frame as shown in the figure below. xx0300000557 SMB cover SMB unit...
  • Page 276 4 Repair 4.5.1. Replacement of SMB unit Continued Removal, SMB unit The procedure below details how to remove the SMB unit. Action Note 1. Move the robot to the calibration position. DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 277 4 Repair 4.5.1. Replacement of SMB unit 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 40 3. Connect the battery cable to the SMB unit. Shown in the figure Location of SMB unit on page...
  • Page 278 4 Repair 4.5.1. Replacement of SMB unit Continued Action Note/Illustration 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 3. Remove the SMB unit according to step 4 - 8 in Removal, SMB unit on page 274 4.

  • Page 279: Replacement Of Brake Release Unit

    4 Repair 4.5.2. Replacement of brake release unit 4.5.2. Replacement of brake release unit Location of brake release unit The brake release unit is located together with the SMB unit on the left hand side of the frame, right next to the gearbox, axis 2, as shown in figure below. xx0300000558 Brake release unit SMB cover...
  • Page 280 4 Repair 4.5.2. Replacement of brake release unit Continued Removal, brake release unit The procedure below details how to remove the brake release unit. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 281 4 Repair 4.5.2. Replacement of brake release unit Continued Action Note/Illustration 7. Remove the brake release unit from the bracket by removing the four attachment screws. Refitting, brake release unit The procedure below details how to refit the brake release unit. Action Note/Illustration DANGER!
  • Page 282 4 Repair 4.5.2. Replacement of brake release unit Continued Action Note/Illustration 5. Refit the complete brake release unit (including brake release unit and bracket) to the SMB recess with the two attachment screws. 6. Refit the SMB cover with its attachment Shown in the figure Location of brake screws.

  • Page 283: Replacement Of Spherical Roller Bearing, Balancing Device

    4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device 4.5.3. Replacement of spherical roller bearing, balancing device Location of bearing The bearing is located at the front ear of the balancing device, as shown in the figure below. xx0500002249 Spherical roller bearing Sealing ring O-ring...
  • Page 284 4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device Continued Equipment Spare part no. Art. no. Note Toolkit 3HAC15943-1 Includes: • Threaded bar 3HAC15945-1 • Dolly 3HAC15948-1 • Press tool 3HAC15941-1 • Press tool 3HAC15846-1 • Hexagon nut M12 9ADA267-9 •...
  • Page 285 4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device Continued Removal, bearing The procedure below details how to remove the bearing from the balancing device front ear. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 286 4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device Continued Action Note/Illustration 3. Insert the threaded bar through the new Spare part no. is specified in bearing and place it at the front ear. Fit also the Required equipment on page 281.
  • Page 287 4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device Continued Action Note/Illustration DANGER! Make sure all safety requirements are met when performing the first test run. These are further detailed in section DANGER - First test run may cause injury or damage! on page 3HAC020993-001 Revision: G...

  • Page 288: Replacement Of Balancing Device

    4 Repair 4.5.4. Replacement of balancing device 4.5.4. Replacement of balancing device Location of balancing device The balancing device is located on rear top of the frame as shown in the figure below. xx0300000533 Balancing device Rear cover Support shaft inside Attachment screws, rear cover Balancing device shaft, including securing screw Bearing attachment...
  • Page 289 4 Repair 4.5.4. Replacement of balancing device Continued Attachment points, balancing device The attachment points for the lifting tools etc. are located as shown in the figure below. xx0300000481 Lifting eye for the lifting equipment Securing screw attachment hole, secures the bearing attachment to the balancing device (remove the protection plug) Hole in the frame to access the balancing device shaft with the puller/press tool Locking screw attachment hole, secures the lower arm to the frame...
  • Page 290 4 Repair 4.5.4. Replacement of balancing device Continued Equipment Spare part no. Art. no. Note Locking screw 3HAA1001-266 M16 x 60 For securing the lower arm. Securing screw 9ADA 183-66 M12 x 35, 2 pcs required For securing the bearing attachments to the balancing device when lifting.
  • Page 291 4 Repair 4.5.4. Replacement of balancing device Continued Removal, balancing device The procedure below details how to remove the balancing device. Action Note/Illustration 1. Move the lower arm to a position close to the calibration position. DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 292 4 Repair 4.5.4. Replacement of balancing device Continued Action Note/Illustration 9. Restore the balancing device. Detailed in section Restoring the balancing device on page 298. 10. Secure the two bearing attachments to the Shown in the figure Attachment points, balancing device by replacing the protection balancing device on page 287! plug on the outside of each attachment, with...
  • Page 293 4 Repair 4.5.4. Replacement of balancing device Continued Action Note 6. Fit the lifting eye and the shackle to the Art. no. is specified in Required attachment points on the balancing device. equipment on page 287! Attachments are shown in the figure- Attachment points, balancing device on page...
  • Page 294 4 Repair 4.5.4. Replacement of balancing device Continued Action Note 17. Lubricate the bearing in the ear with grease Art. no. and amount are specified in through the lubricating nipple, with a grease Required equipment on page 287! pump. Lubrication is further detailed in Fill until excessive grease pierces between the section Lubrication of spherical roller...
  • Page 295 4 Repair 4.5.4. Replacement of balancing device Continued Replacement of balacing device (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level. The repair must be done according to the repair chapter in the Product Manual with the following additions.
  • Page 296 4 Repair 4.5.4. Replacement of balancing device Continued Action Note/Illustration DANGER! Make sure all safety requirements are met when performing the first test run. These are further detailed in section DANGER - First test run may cause injury or damage! on page 3HAC020993-001 Revision: G...

  • Page 297: Unloading The Balancing Device

    4 Repair 4.5.5. Unloading the balancing device 4.5.5. Unloading the balancing device Prerequisite This section details how to unload the balancing device with the press tool. The lower arm must be secured before unloading the balancing device! How to secure the lower arm is detailed in the current repair activity, e.g removal of the balancing device.
  • Page 298 4 Repair 4.5.5. Unloading the balancing device Continued Required equipment Equipment, etc. Art. no. Note Press tool, balancing device 3HAC020902-001 Includes • press device 3HAC 15767-2 • press device 3HAC 18100-1 Choose the correct device, depending on model of balancing device. Hydraulic cylinder 3HAC11731-1 To be used with the press tool.
  • Page 299 4 Repair 4.5.5. Unloading the balancing device Continued Action Note/Illustration 2. Fit the correct press device and moving pin to Shown in the figure Press tool and the press tool. Secure with the bolt, press hydraulic cylinder on page 295. device.

  • Page 300: Restoring The Balancing Device

    4 Repair 4.5.6. Restoring the balancing device 4.5.6. Restoring the balancing device Overview This section details how to restore the balancing device and how to remove the press tool from the device. Press tool and hydraulic cylinder The figure below shows the hydraulic cylinder mounted on the press tool. The press tool includes two press devices that are used to different models of the balancing device.
  • Page 301 4 Repair 4.5.6. Restoring the balancing device Continued Equipment, etc. Art. no. Note Locking liquid Loctite 577 Used to secure the attachment screws of the rear cover at the end of the balancing device. Standard toolkit 3HAC 15571-1 The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual.

  • Page 302: Motors

    4 Repair 4.6.1. Replacement of motor, axis 1 4.6 Motors 4.6.1. Replacement of motor, axis 1 Location of motor The motor axis 1 is located on the left hand side of the robotas shown in the figure below. xx0300000499 Motor, axis 1 Motor attachment screws and washers Required equipment Equipment, etc.
  • Page 303 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Equipment, etc. Spare part no. Art. no. Note Lifting tool, motor ax 1, 3HAC 14459-1 4, 5 Power supply 24 VDC, max. 1,5 A For releasing the brakes. Standard toolkit The contents are defined in section Standard toolkit on page 388...
  • Page 304 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note/Illustration 5. Apply lifting tool, motor axis 1, 4, 5 to the motor. Art. no. is specified in Required equipment on page 300! 6. In order to release the brakes, connect the 24 VDC Connect to connector R2.MP1 power supply.
  • Page 305 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 6. Fit the motor, making sure the motor pinion is Make sure the motor is turned the properly mated to gearbox of axis 1. correct way, i.e. connection of motorcableforwards..
  • Page 306 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note/Illustration 2. Remove the cover for connector access on top of the motor by unscrewing its four attachment screws. xx0600002874 • A: attachment screw • B: air hose • C: top cover •...
  • Page 307 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note/Illustration 7. After mounting the motor on the manipulator, the surface between the motor and the base frame must be protected with Mercasol 3106. xx0600002877 • A: base frame • B: motor unit 8.

  • Page 308: 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. xx0300000500 Motor axis 2 Hole for lock screw Cable gland cover (located on the lower side of the motor) Motor attachment holes (4 pcs)
  • Page 309 4 Repair 4.6.2. Replacement of motor axis 2 Continued Equipment, etc. Spare part no. Art. no. Note Guide pins M10 x 150 3HAC 15521-2 For guiding the motor. Guides are to be used in pairs! Lifting tool, motor ax 2, 3, 3HAC 15534-1 Extension bar, 300 mm 3HAC 12342-1...
  • Page 310 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note 5. Remove the cover on top of the motor by unscrewing its four attachment screws. 6. Remove the cable gland cover at the cable exit by Shown in the figure Location of unscrewing its two attachment screws.
  • Page 311 4 Repair 4.6.2. Replacement of motor axis 2 Continued Refitting, motor The procedure below details how to refit the motor axis 2. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 312 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note/Illustration 9. Use the rotation tool in order to rotate the Art. no. is specified in Required motor pinion when mating it to the gear (see equipment on page 306! the figure to the right).
  • Page 313 4 Repair 4.6.2. Replacement of motor axis 2 Continued Replacement of the motor axis 2 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level. The repair must be done according to the repair chapter in the Product Manual with the following additions.
  • Page 314 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note/Illustration DANGER! Secure the weight of the lower arm properly before releasing the brakes of motor, axis 2! When releasing the holding brakes of the motor, the lower arm will be movable and may fall down! 9.

  • Page 315: Replacement Of Motor, Axis 3

    4 Repair 4.6.3. Replacement of motor, axis 3 4.6.3. Replacement of motor, axis 3 Location of motor The motor axis 3 is located on the left hand side of the robot as shown in the figure below. xx0200000186 Motor axis 3 Cable gland cover, motor axis 3 Motor attachment holes (4 pcs) xx0600003051...
  • Page 316 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Motor including 3HAC15885-2 Includes pinion • motor • pinion • o-ring 2152 2012-430 O-ring 2152 2012-430 Must be replaced when reas- sembling motor! Sikaflex 251FC 3HAC026620-001 Foundry Prime...
  • Page 317 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Equipment, etc. Spare part no. Art. no. Note Other tools and These procedures include procedures may be references to the tools required. See required. references to these procedures in the step-by-step instructions below.
  • Page 318 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note/Illustration DANGER! Secure the weight of the upper arm properly before releasing the brakes of motor, axis 3. When releasing the holding brakes of the motor, the upper arm will be movable and may fall down! 9.
  • Page 319 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note/Illustration 4. Fit the two guide pins in the two lower motor Art no. is specified in Required attachment holes. equipment on page 314! Shown in the figure Location of motor on page 313! CAUTION!
  • Page 320 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note/Illustration 15. Refit the cover on top of the motor with its four Make sure the cover is tightly attachment screws. sealed! 16. Remove the equipment used to unload the upper arm.
  • Page 321 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note/Illustration 3. Remove the cover for connector access on top of the motor by unscrewing its four attachment screws. xx0600002874 • A: attachment screw • B: air hose • C: top cover •...

  • Page 322: Replacement Of Motor, Axis 4

    4 Repair 4.6.4. Replacement of motor, axis 4 4.6.4. Replacement of motor, axis 4 Location of motor The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below. xx0200000202 Motor, axis 4 Cable gland cover, motor axis 4 Motor attachment holes (4 pcs) xx0500003050...
  • Page 323 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Motor including 3HAC15889-2 Includes pinion • motor • pinion • o-ring 2152 2012-430 O-ring 2152 2012-430 Must be replaced when reas- sembling motor! Sikaflex251FC 3HAC026620-001...
  • Page 324 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Removal, motor axis 4 The procedure below details how to remove the motor, axis 4. Action Note 1. Move the robot to a position where the upper Draining of oil is described in section arm is pointed straight up.
  • Page 325 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Refitting, motor axis 4 The procedure below details how to refit motor, axis 4. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 326 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note/Illustration 8. Remove the guide pins. 9. Secure the motor with four attachment 4 pcs: M8 x 25, tightening torque: 24 Nm. screws and plain washers. 10. Disconnect the brake release voltage. 11.
  • Page 327 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note/Illustration 2. Remove the cover for connector access on top of the motor by unscrewing its four attachment screws. xx0600002874 • A: attachment screw • B: air hose • C: top cover •...

  • Page 328: Replacement Of Motor, Axis 5

    4 Repair 4.6.5. Replacement of motor, axis 5 4.6.5. Replacement of motor, axis 5 Reused pinion The pinion in the motor, axis 5, is matched with the beveral gear for axis 5. When the motor is replaced the pinion must therefore be removed from the dismounted motor and fitted onto the new motor shaft as detailed in this section.
  • Page 329 4 Repair 4.6.5. Replacement of motor, axis 5 Continued Equipment, etc. Spare part no. Art. no. Note O-ring 2152 2012-430 Must be replaced when reassembling motor! Sikaflex 251FC 3HAC026621-001 Option Foundry Prime Mercasol 3106 3HAC026620-001 Option Foundry Prime Gasket 3HAC3438-1 Option Faundry Prime Must be replaced if the cabling is dismantled from...
  • Page 330 4 Repair 4.6.5. Replacement of motor, axis 5 Continued Removal, motor, axis 5 The procedure below details how to remove motor, axis 5. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 331 4 Repair 4.6.5. Replacement of motor, axis 5 Continued Action Note 15. Press out the pinion from the dismounted motor, Replacing the complete wrist unit is with the equipment included in the oil injector kit. detailed in section Replacement of complete wrist unit on page 245.
  • Page 332 4 Repair 4.6.5. Replacement of motor, axis 5 Continued Action Note 9. Fit the two guide pins in two of the motor Art. no. is specified in Required attachment holes. equipment on page 326! 10. Fit the motor, with guidance from the pins, Make sure the motor pinion does not making sure the motor pinion is properly mated get damaged!
  • Page 333 4 Repair 4.6.5. Replacement of motor, axis 5 Continued Replacement of the motor axis 5 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level. The repair must be done according to the previous repair procedures with the following additions.
  • Page 334 4 Repair 4.6.5. Replacement of motor, axis 5 Continued Action Note/Illustration 6. Continue to remove the motor unit, according to step 8 to 15 in Removal, motor, axis 5 on page 328. 7. Fill the four screw recesses on the new motor with Sikaflex.

  • Page 335: Replacement Of Motor, Axis 6

    4 Repair 4.6.6. Replacement of motor, axis 6 4.6.6. Replacement of motor, axis 6 Location of motor The motor axis 6 is located in the center of the wrist unit as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
  • Page 336 4 Repair 4.6.6. Replacement of motor, axis 6 Continued Equipment, etc. Spare part no. Art. no. Note O-ring 2152 2012-430 Must be replaced when reassembling motor! Merkasol 3106 3HAC026621-001 Option Foundry Prime Sikaflex 3HAC026620-001 Option Foundry Prime Loctite 574 Loctite 480 Gasket 3HAC12877-1 Must be replaced when...
  • Page 337 4 Repair 4.6.6. Replacement of motor, axis 6 Continued Action Note 3. Remove the rear motor cover by unscrewing the five attachment screws. 4. Disconnect all connectors beneath the cover. 5. In order to release the brake, connect the 24 VDC Connect to connector R3.MP6 power supply.
  • Page 338 4 Repair 4.6.6. Replacement of motor, axis 6 Continued Action Note 9. Reconnect all connectors beneath the motor cover. 10. Refit the cover on top of the motor with its five Make sure the cover is tightly sealed! attachment screws. NOTE! On Foundry Prime robots: When changing motor, keep the cover from the...
  • Page 339 4 Repair 4.6.6. Replacement of motor, axis 6 Continued Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 4.
  • Page 340 4 Repair 4.6.6. Replacement of motor, axis 6 Continued Action Note/Illustration 8. Fill the four screw recesses on the new motor with Sikaflex. (After hardening, Sikaflex can be formed with a knife) xx0600002884 • A: mercasol • B: motor unit •...

  • Page 341: Gearboxes

    4 Repair 4.7.1. Replacement of gearbox, axis 1 4.7 Gearboxes 4.7.1. Replacement of gearbox, axis 1 Location of gearbox The axis 1 gearbox is located between the frame and base as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
  • Page 342 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Equipment, etc. Spare part no. Art. no. Note Rust preventive 3HAC026621- Mercasol 3106 (Foundry Prime) Support, base 3HAC15535-1 Lifting device, base 3HAC15560-1 Lifting tool (chain) 3HAC15556-1 Standard toolkit The contents are defined in section Standard toolkit on page in part 2 of the Product...
  • Page 343 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note/Illustration 7. Remove the robot's attachment screws to unfasten the base from the foundation. 8. Attach the lifting device, base and gear 1 Art. no. is specified in Required and the lifting tool (chain), to the gearbox. equipment on page 339! CAUTION!
  • Page 344 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note/Illustration 14. Remove the cable guide in the center of gearbox 1 by unscrewing its attachment screws. xx0200000256 • A: Location for attachment screws, cable guide (cable guide removed in the figure) CAUTION! The gearbox weighs 200 kg! All lifting equipment used must be sized accordingly!
  • Page 345 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note/Illustration 3. Refit the cable guide in the center of gearbox 1 with its attachment screws. xx0200000256 • A: Location for attachment screws, cable guide (cable guide removed in figure) 4.
  • Page 346 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note/Illustration 9. Refit the bottom plate underneath the robot 1 screw: M6 x 8. base by pushing it into the groove and fitting the attachment screw. Note! Direct the bends on the plate downwards! If removed, also refit the rear connector plate.
  • Page 347 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note/Illustration DANGER! Make sure all safety requirements are met when performing the first test run. These are further detailed in section DANGER - First test run may cause injury or damage! on page Refitting, gearbox axis 1 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level.

  • Page 348: Replacement Of Gearbox Axis 2

    4 Repair 4.7.2. Replacement of gearbox axis 2 4.7.2. Replacement of gearbox axis 2 Location of gearbox The gearbox for axis 2 is located in the lower arm rotational center, underneath the cover. A more detailed view of the component and its position may be found in chapter Exploded views in the...
  • Page 349 4 Repair 4.7.2. Replacement of gearbox axis 2 Continued Equipment Spare part no. Art. no. Note O-ring 3HAB 3772-77 O-ring in gearbox, 1 pc. O-ring 3HAB 3772-73 O-ring in the cover, axis 2, 1 pc. Should be replaced if damaged! Rust preventive 3HAC026621-001 Only Foundry Prime...
  • Page 350 4 Repair 4.7.2. Replacement of gearbox axis 2 Continued Removal, gearbox axis 2 The procedure below details how to remove the gearbox, axis 2. Action Note/Illustration DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 351 4 Repair 4.7.2. Replacement of gearbox axis 2 Continued Action Note/Illustration 11. Fit the lifting tool, gearbox axis 2 to the gearbox. Art. no. is specified in Required equipment on page 346! CAUTION! The gearbox weighs 100 kg! All lifting equipment used must be sized accordingly! 13.
  • Page 352 4 Repair 4.7.2. Replacement of gearbox axis 2 Continued Action Note/Illustration 4. Fit the guide pins, sealing axis 2/3 to the rear of the gearbox, axis 2. Use the attachment holes shown in the figure to the right! xx0300000552 • A: Rear attachment screws, gearbox (18 pcs) •...
  • Page 353 4 Repair 4.7.2. Replacement of gearbox axis 2 Continued Action Note/Illustration 8. Lift the gearbox to its mounting position and slide it onto the guiding pins attached in the frame, through the front attachment screw holes. 9. Align the gearbox attachment screw holes to Art.
  • Page 354 4 Repair 4.7.2. Replacement of gearbox axis 2 Continued Action Note/Illustration 25. Recalibrate the robot. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information on page 365. DANGER! Make sure all safety requirements are met when performing the first test run.
  • Page 355 4 Repair 4.7.2. Replacement of gearbox axis 2 Continued Action Note/Illustration 3. Apply Mercasol 3106 on the gear according to the illustration to the right before assembly. xx0600003134 • A: Mercasol 3106 on surfaces 4. Apply Mercasol 3106 on the lower arm according to the illustration to the roght before assembly.

  • Page 356: Replacement Of Gearbox, Axis 3

    4 Repair 4.7.3. Replacement of gearbox, axis 3 4.7.3. Replacement of gearbox, axis 3 Location of gearbox The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
  • Page 357 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Equipment, etc. Spare part no. Art. no. Note Grease 3HAB 3537-1 For lubricating the o-rings. Rust preventive 3HAC026621- Only Foundry Prime Equivalent: • Mercasol 3106 Sealing, axis 2/3 3HAC 17212-1 A new sealing must be used on each assembly! Mech stop ax 3 3HAC 12708-1...
  • Page 358 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note/Illustration 2. Secure the upper arm in a horizontal position Art. no. is specified in Required using a mechanical stop. equipment on page 354. Fit the mechanical stop to the third and final attachment hole (A), below the fixed mechanical stop (B) in the upper arm, shown in the figure to the right.
  • Page 359 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note/Illustration CAUTION! The gearbox weighs 60 kg! All lifting equipment used must be sized accordingly! 11. Remove the gearbox, with guidance from the guide pins, using an overhead crane or similar. Refitting, gearbox axis 3 The procedure below details how to refit gearbox, axis 3.
  • Page 360 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note/Illustration 6. Make sure the o-rings are fitted to the gearbox. Art. no. is specified in Required Apply grease to the o-rings to make sure they equipment on page 354! stick in their grooves during assembly.
  • Page 361 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note/Illustration DANGER! Make sure all safety requirements are met when performing the first test run. These are further detailed in section DANGER - First test run may cause injury or damage! on page Refitting, gearbox axis 2 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level.

  • Page 362: 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 363 4 Repair 4.7.4. Replacement of gearbox, axis 6 Continued Equipment, etc. Spare part no. Art. no. Note Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual. Calibration 3HAC15716-1 Complete kit that also Pendulum toolkit includes operating manual.
  • Page 364 4 Repair 4.7.4. Replacement of gearbox, axis 6 Continued Action Note/Illustration 6. Remove the gearbox axis 6 by lifting it out Be careful not to damage the motor carefully. pinion! Refitting, gearbox The procedure below details how to refit gearbox, axis 6. Action Note/Illustration DANGER!
  • Page 365 4 Repair 4.7.4. Replacement of gearbox, axis 6 Continued Action Note/Illustration 6. If the robot is going to work in a water jet application cell: • apply Mercasol on unpainted surfaces between gea box and turning disk • apply Mercasol on the screw heads in the front of the turning disk.
  • Page 366 4 Repair 4.7.4. Replacement of gearbox, axis 6 3HAC020993-001 Revision: G...

  • Page 367: 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 366, and further detailed in separate Calibration manuals.

  • Page 368: 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 369 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 370: Calibration Scales And Correct Axis Position

    5 Calibration information 5.3. Calibration scales and correct axis position 5.3. Calibration scales and correct axis position Introduction This section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration scales/marks, IRB 6600, IRB 6650, IRB 6650S, IRB 7600 The illustration below shows the location of the calibration scales on specific plates and the calibration marks directly in the casting at axes 2 and 3.

  • Page 371: 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 372: Updating Revolution Counters

    5 Calibration information 5.5. Updating revolution counters 5.5. Updating revolution counters General This section details how to perform a rough calibration of each robot axis, i.e. updating the revolution counter value for each axis, using the pendant. Step 1 - Manually running the robot to the calibration position This procedure details the first step when updating the revolution counter;...
  • Page 373 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 374 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 375: 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 376 This section describes how to jog the robot to all axes zero position. Action Note 1. Tap Jogging in the ABB menu. 2. Tap Motion mode to choose group of axes to jog. 3. Tap axes 1-3 to jog axes 1, 2 or 3.

  • Page 377: Additional Calibration Instruction, Irb4400

    5 Calibration information 5.7. Additional calibration instruction, IRB4400 5.7. Additional calibration instruction, IRB4400 Instrauction Before updating the revolution counters (coarse calibration) on IRB 4400, the stainless steel metal ring on axis 4 need to be removed. Illustration xx0600003124 Upper arm Stainless steel ring hose clamp 3HAC020993-001 Revision: G...
  • Page 378 5 Calibration information 5.7. Additional calibration instruction, IRB4400 3HAC020993-001 Revision: G...

  • Page 379: Decommissioning

    6 Decommissioning 6.1. Environmental information 6 Decommissioning 6.1. Environmental information Hazardous material The table specifies some of the materials in the manipulator and their respective use throughout the product. Dispose the components properly to prevent health or environmental hazards. Material Example application Batteries, NiCad or Lithium Serial measurement board...

  • Page 380: Decommissioning Of Balancing Device

    6 Decommissioning 6.2. Decommissioning of balancing device 6.2. Decommissioning of balancing device General There is much energy stored in the balancing device. Therefore a special procedure is required to dismantle it. The coil springs inside the balancing device exert a potentially lethal force unless dismantled properly.
  • Page 381 6 Decommissioning 6.2. Decommissioning of balancing device Continued Decommissioning at decommissioning company, balancing device The instruction below details how to decommission the balancing device. Contact ABB Robotics for further consultation. Action Note/Illustration DANGER! There is stored energy built up by high...
  • Page 382 6 Decommissioning 6.2. Decommissioning of balancing device 3HAC020993-001 Revision: G...

  • Page 383: Reference Information

    7 Reference information 7.1. Introduction 7 Reference information 7.1. Introduction General This chapter includes general information, complementing the more specific information in Product manual (part 1 of 2), procedures. 3HAC020993-001 Revision:G...

  • Page 384: Applicable Safety Standards

    7 Reference information 7.2. Applicable Safety Standards 7.2. Applicable Safety Standards Standards, general The robot is designed in accordance with the requirements of: • EN ISO 10218-1:2006 - Robots for industrial environments - Safety requirements - Part 1 Robot. • EN 292-1 - Basic terminology.

  • Page 385: Unit Conversion

    7 Reference information 7.3. Unit conversion 7.3. Unit conversion Converter table Use the table below to convert units used in this manual. Quantity Units Length 3.28 ft 39.37 in Weight 1 kg 2.21 lb Pressure 1 bar 100 kPa 14.5 psi Force 0.738 lbf Moment...

  • Page 386: 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 387 7 Reference information 7.4. Screw joints Continued Tightening torque Before tightening any screw, note the following: • Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description.
  • Page 388 7 Reference information 7.4. Screw joints Continued The table below specifies the recommended standard tightening torque for oil-lubricated screws with Allen head screws. Tightening torque Tightening torque Tightening torque (Nm) (Nm) (Nm) Dimension Class 8.8, oil-lubri- Class 10.9, oil-lubri- Class 12.9, oil-lubri- cated cated cated...

  • Page 389: 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 390: Standard Toolkit

    7 Reference information 7.6. Standard toolkit 7.6. Standard toolkit General All service (repairs, maintenance and installation) procedures contain lists of tools required to perform the specified activity. All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the Standard toolkit and defined in the table below.

  • Page 391: Special Tools

    7 Reference information 7.7. Special tools 7.7. Special tools General All service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in section Standard toolkit on page 388, and of special tools, listed directly in the instructions and also gathered in this section.
  • Page 392 3HAC021984-001 Tools that may be rented The table below specifies the tools that may be rented from ABB in order to perform certain service procedures as described in the Product manual. The special tools are also listed directly in the instructions.
  • Page 393 7 Reference information 7.7. Special tools Continued Description Art. no. Note Calibration tool ax1 3HAC 13908-4 Levelmeter 2000 kit 6369901-347 Includes one sensor. Measuring pin 3HAC 13908-5 Sensor fixture 68080011-GM Sensor plate 3HAC 0392-1 Sync. adapter 3HAC 13908-1 Turn disk fixture 3HAC 68080011-GU Calibration equipment, Calibration Pendulum The table below specifies the calibration equipment needed when calibrating the robot with...

  • Page 394: Lifting Equipment And Lifting Instructions

    7 Reference information 7.8. Lifting equipment and lifting instructions 7.8. Lifting equipment and lifting instructions General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure. The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment.

  • Page 395: Spare Part / Part List

    8 Spare part / part list 8.1. Introduction 8 Spare part / part list 8.1. Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot. 3HAC020993-001 Revision:G...

  • Page 396: Spare Part List

    8 Spare part / part list 8.2.1. Introduction 8.2 Spare part list 8.2.1. Introduction Overview This section specifies all articles considered spare parts of the robot. The spare parts are also specified as required equipment directly in the repair instruction of the current spare part. 3HAC020993-001 Revision:G...

  • Page 397: Spare Part List

    8 Spare part / part list 8.2.2. Spare part list 8.2.2. Spare part list Repair instructions Each spare part is replaced as described in corresponding repair instruction in the Product manual, procedures. Location, spare parts The figure below shows the spare parts of the robot. xx0400001023 Parts The table below specifies all the recommended spare parts for the robot.
  • Page 398 8 Spare part / part list 8.2.2. Spare part list Continued Item Description Spare part no. Note Motor including pinion 3HAC15885-2 Axis 3 Motor including pinion 3HAC026976-001 Foundry Prime Gearbox 3HAC021127-001 Axis 3 Motor including pinion 3HAC15889-2 Axis 4 Motor including pinion 3HAC026977-001 Foundry Prime SMB unit...
  • Page 399 8 Spare part / part list 8.2.2. Spare part list Continued Optional equipment All components required for installation of optional equipment, such as cabling, extra attachment plates etc., are listed in the installation procedure for the equipment. The table below points out the installation procedures for the equipment (in part 1: Procedures, of the Product manual).

  • Page 400: Part List

    8 Spare part / part list 8.3.1. Introduction 8.3 Part list 8.3.1. Introduction Overview This section specifies all the replacement articles of the robot. The parts are shown in exploded views or in foldouts, either in this or in a separate chapter. Specific spare parts are listed separately in a Spare part list.

  • Page 401: Rebuilding Parts

    8 Spare part / part list 8.3.2. Rebuilding parts 8.3.2. Rebuilding parts Overview The robot has some rebuilding parts that differ from eachother, depending on the robot version. This section is a general overview of which parts belong to which versions. The following section, Part list on page 398 also gives further details of the parts specified...
  • Page 402 8 Spare part / part list 8.3.2. Rebuilding parts Continued Item no Art. no. Part IRB 6600- IRB 6650- IRB 6650S- and type 175/ 225/ 175/ 200/ 125/ 200/ 125/ 2.55 2.55 2.75 3HAA1001-134 Washer 13x19x1,5 24X 111.504 9ABA107-56 Parallel pin 10x20 111.505 9ADA618-56 Screw M6x16...

  • Page 403: Part List, Overview

    8 Spare part / part list 8.3.3. Part list, overview 8.3.3. Part list, overview Part list Item Qty Art. number Description Note / Dimension 3HAC 12812-2 Mechanical stop ax 1, assembly 3HAC 020214-001 Base incl frame ax 1 See section Base incl frame ax 1 on page 402 3HAC 10746-1...

  • Page 404: Base Incl Frame Ax 1

    8 Spare part / part list 8.3.4. Base incl frame ax 1 8.3.4. Base incl frame ax 1 Part list Item Qty Art. number Description Note / Dimension 101.1 3HAC 10044-1 Base, machining See block Base, machining on page 402. 101.1 3HAC026572-001 Base, machining (Foundry...

  • Page 405: Axis 3-4

    8 Spare part / part list 8.3.5. Axis 3-4 8.3.5. Axis 3-4 Overview Item Qty Art. number Description Note 102.1 3HAC 13350-1 Material set ax 4 See block Material set ax 4, 3HAC 13350-1 on page 403 102.2 3HAC 020049-001 Tube shaft 2,55 See block Tube shaft 2.55, 3HAC 020049-001 on page 405...
  • Page 406 8 Spare part / part list 8.3.5. Axis 3-4 Continued Item Art. number Description Dimension / Note 102.1.23 2 2213 253-5 Ball bearing 170 x 215 x 22 102.1.24 1 2216 261-18 Sealing 170 x 200 x 15 102.1.25 1 2216 0086-4 Sealing (Nilos) 180 x 215 x 4...
  • Page 407 8 Spare part / part list 8.3.5. Axis 3-4 Continued Tube shaft 2.55, 3HAC 020049-001 Item Art. number Description Note 102.2.1 3HAC 10139-2 Tube shaft 2,55, casting 102.2.2 3HAC 1383-2 Protection Cover compl. See sub-block Protection cover compl., 3HAC 1383-2 on page 405 Protection cover compl., 3HAC 1383-2 Item...
  • Page 408 8 Spare part / part list 8.3.5. Axis 3-4 Continued Item Art. number Description Dimension 102.3.5.2 3HAC 10122-15 Input gear 102.3.5.3 2152 2012-430 O-ring 89.5 x 3 102.3.5.4 9ADA 183-444 Hex socket head cap screw M8 x 130 102.3.5.5 3 ml 3HAB 7116-1 Locking liquid Rot ac motor incl gearbox...

  • Page 409: Axis 3-4, Foundry

    8 Spare part / part list 8.3.6. Axis 3-4, Foundry 8.3.6. Axis 3-4, Foundry Overview Item Art. number Description Note 102.1 3HAC 13350-1 Material set ax 4 See block Material set ax 4, 3HAC 13350-1 on page 403 102.2 3HAC 020053-001 Tube shaft 2,55 foundry 102.3 3HAC 13351-1 Axis 3...

  • Page 410: Axis 3-4 Foundry Prime

    8 Spare part / part list 8.3.7. Axis 3-4 Foundry Prime 8.3.7. Axis 3-4 Foundry Prime Overview Item Art. number Description Note 102.1 3HAC 13350-1 Material set ax 4 102.2 3HAC 020053-001 Tube shaft 2,55 foundry 102.3 3HAC 13351-1 Axis 3 102.4 3HAC 14753-1 Rot ac motor incl gearbox...

  • Page 411: Wrist, Type 2, Standard

    8 Spare part / part list 8.3.8. Wrist, type 2, standard 8.3.8. Wrist, type 2, standard Overview Item Art. number Description Dimension / Note 103.1 3HAC 8114-4 Material set See block Material set, 3HAC 8114-4 on page 409 103.2 3HAC 7941-30 Rot ac motor incl See block Rot ac motor incl...
  • Page 412 8 Spare part / part list 8.3.8. Wrist, type 2, standard Continued Item Art. number Description Dimension / Note 103.1.26 1 3HAC 7941-6 Interm.wheel unit/5 225kg See sub-block Interm. wheel unit/5 225 kg, 3HAC 7941-6 on page 103.1.27 1 3HAC 022695- Screw 103.1.28 1 3HAC 7941-21...
  • Page 413 8 Spare part / part list 8.3.8. Wrist, type 2, standard Continued Item Art. number Description Dimension 103.1.28.4 1 ml 3HAB 7116-2 Locking liquid Rot ac motor incl gearbox Item Art. number Description Dimension 103.2.1 3HAC 17484-10 Rotational ac motor M10 103.2.2 3HAC 7941-1 Bevelgear set unit z1-3/5...
  • Page 414 8 Spare part / part list 8.3.8. Wrist, type 2, standard Continued Rot ac motor incl. pinion, 3HAC 14754-1 Item Art. number Description Dimension 103.4.4.1 3HAC 17484-8 Rotational ac motor M8 103.4.4.2 3HAC 11173-3 Pinion RV 70F.125,8 103.4.4.3 2152 2012-430 O-ring 89.5 x 3 103.4.4.4...

  • Page 415: Wrist, Type 2, Foundry

    8 Spare part / part list 8.3.9. Wrist, type 2, Foundry 8.3.9. Wrist, type 2, Foundry Overview Item Art. number Description Dimension 103.1 3HAC 8114-4 Material set See block Material set, 3HAC 8114-4 on page 103.2 3HAC 7941-30 Rot ac motor incl gearbox See block Rot ac motor incl gearbox on page 411...

  • Page 416: Wrist, Type 2, Insulated

    8 Spare part / part list 8.3.10. Wrist, type 2, insulated 8.3.10. Wrist, type 2, insulated Overview Item Qty Art. no. Description Note/Dimension 103.1 3HAC 8114-4 Material set See block Material set, 3HAC 8114-4 on page 409. 103.2 3HAC 7941-30 Rot ac motor incl gearbox See block Rot ac motor incl...

  • Page 417: Wrist, Type 2, Foundry Prime

    8 Spare part / part list 8.3.11. Wrist, type 2, Foundry Prime 8.3.11. Wrist, type 2, Foundry Prime Overview Item Art. number Description Dimension 103.1 3HAC 8114-4 Material set 103.2 3HAC 7941-30 Rot ac motor incl gearbox 103.3 3HAB 3409-89 Hex socket head cap screw 103.4 3HAC 13890-2...

  • Page 418: Material Set, Manipulator, 3Hac 13263-1

    8 Spare part / part list 8.3.12. Material set, manipulator, 3HAC 13263-1 8.3.12. Material set, manipulator, 3HAC 13263-1 Overview Dimension / Item Qty Art. number Description Note 108.201 1 3HAC 020123-001 Sealing axis 2/3 Axis 2 108.201 1 3HAC 17212-1 Sealing axis 2/3 Axis 3 108.202 18...

  • Page 419: Material Set, Axis 1-2, 3Hac 13264-1

    8 Spare part / part list 8.3.13. Material set, axis 1-2, 3HAC 13264-1 8.3.13. Material set, axis 1-2, 3HAC 13264-1 Overview Item Art. number Description Dimension / Note 109.301 3HAC 021541-001 Reduction gear See block Reduction gear on page 418 109.302 3HAC 022812-003 Cover, axis 2...
  • Page 420 8 Spare part / part list 8.3.13. Material set, axis 1-2, 3HAC 13264-1 Continued Item Art. number Description Dimension / Note 109.332 3HAC 14791-3 Cover battery box See block Cover, battery box, 3HAC 14791-3 on page 419 109.322 3HAC026190-001 Cover battery box (Foundry Prime) 109.334 9ADA 618-53...
  • Page 421 8 Spare part / part list 8.3.13. Material set, axis 1-2, 3HAC 13264-1 Continued Motor incl pinion, 3HAC 020219-001 Item Art. number Description Dimension 109.307.1 1 3HAC 020208-001 Rotation AC motor, M11 109.307.2 1 3HAC 020131-001 Pinion 109.307.3 1 9ADA 183-446 Hexagon socket head screw M8 x 150 109.307.4 1...

  • Page 422: Material Set, Balancing Device, 3Hac 13265-1

    8 Spare part / part list 8.3.14. Material set, balancing device, 3HAC 13265-1 8.3.14. Material set, balancing device, 3HAC 13265-1 Overview Item Art. number Description Dimension 110.401 3HAC 12441-2 Spherical roller bearing 65 x 120 x 38 110.402 3HAC 12481-1 Thrust washer 110.403 3HAC 12627-1...

  • Page 423: Arm Extension Set, 450 Mm, 3Hac 12311-5

    8 Spare part / part list 8.3.15. Arm extension set, 450 mm, 3HAC 12311-5 8.3.15. Arm extension set, 450 mm, 3HAC 12311-5 Overview Item Art. number Description Dimension 111.501 3HAC 9760-7 Arm extender, 450mm 111.501 3HAC 15859-3 Arm extender, 450mm, Foundry 111.503 3HAB 7700-69 Hex socket head cap screw...
  • Page 424 8 Spare part / part list 8.3.15. Arm extension set, 450 mm, 3HAC 12311-5 3HAC020993-001 Revision:G...

  • Page 425: Exploded Views

    9 Exploded views 9.1. Introduction 9 Exploded views 9.1. Introduction Definitions This chapter contains detailed views of the components on the manipulator. The numbered details are specified with item numbers in the Part List. The exploded views are divided into: •...

  • Page 426: Base Incl. Frame

    9 Exploded views 9.2. Base incl. Frame 9.2. Base incl. Frame Exploded view xx0200000329 3HAC020993-001 Revision:G...

  • Page 427: Frame - Lower Arm 1

    9 Exploded views 9.3. Frame - lower arm 1 9.3. Frame - lower arm 1 Exploded view xx0400001036 3HAC020993-001 Revision:G...

  • Page 428: Frame - Lower Arm 2

    9 Exploded views 9.4. Frame - lower arm 2 9.4. Frame - lower arm 2 Exploded view xx0400001037 3HAC020993-001 Revision:G...

  • Page 429: Upper Arm

    9 Exploded views 9.5. Upper arm 9.5. Upper arm Exploded view xx0200000337 3HAC020993-001 Revision:G...

  • Page 430: Wrist Complete

    9 Exploded views 9.6. Wrist complete 9.6. Wrist complete Exploded view xx0200000336 3HAC020993-001 Revision:G...

  • Page 431: Circuit Diagram

    10 Circuit Diagram 10.1. Introduction 10 Circuit Diagram 10.1. Introduction Overview This chapter includes the circuit diagram for the robot. Use the correct circuit diagram (IRB 6600, IRB 6650 and IRB 6650S) The cable harness of the robot is available in two different designs. Either the cabling is divided between the upper and lower arm, or not.

  • Page 432: Circuit Diagram 3Hac 025744-001

    10 Circuit Diagram 10.2.1. Validity of circuit diagram 3HAC 025744-1 10.2 Circuit diagram 3HAC 025744-001 10.2.1. Validity of circuit diagram 3HAC 025744-1 Is this circuit diagram valid for your robot? The validity of the circuit diagram depends on which cable harness is fitted to the robot. Check the article number of the cable harness fitted to the robot and see page 3 of the circuit diagram in order to determine if the diagram is valid for the harness or not.

  • Page 433: Circuit Diagram 3Hac 13347-1

    ABB for losses, damages to persons or property, fitness for a specific purpose or the like. In no event shall ABB be liable for incidental or consequential damages arising from use of this document. This document and parts thereof must not be reproduced or copied without ABB's written permission, and contents therof must not be imparted to a third party nor be used for any unauthorized purpose.
  • Page 434 Table of contents ABB Contents1 Page Page description Comment COPYRIGHT page Table of contents: (1 - 150) Valid For Connection point location IRB 6600 / 6640 / 6650 / 7600 Connection point location IRB 6660 Legend IRB 66XX / 7600...

  • Page 435: Index

    Valid For: This circuit diagram is valid for the following cable harness assemblies: 3HAC 024385-001 Manipulator harness axis 1-6 (IRB 6600 / 6640) 3HAC 024386-001 Manipulator harness axis 1-6 (IRB 6640 / 6650 / 6650S) 3HAC14940-1 rev 3 and later. Manipulator harness axis 1-4 (IRB 6600 ID / 6640 ID / 7600) 3HAC16331-1 rev 1 and later.
  • Page 436 R3.FB5 (IRB 7600, 6600 ID, 6640 ID, 6650 ID) R3.MP5 (IRB 7600, 6600 ID, 6640 ID, 6650 ID) R1.MP R2.M5/6 R3.MP6 R3.MP5 (IRB 6600, 6640, 6650, 6650S) (On IRB7600, 6600 ID, R3.FB6 R3.FB5 (IRB 6600, 6640, 6650, 6650S) 6640 ID, 6650 ID) R4.MP5 (IRB 6600, 6640, 6650, 6650S) R4.FB5 (IRB 6600, 6640, 6650, 6650S) R2.MP4...

  • Page 437: Connection Point Location

    R3.MP6 R3.FB6 R3.MP5 R3.FB5 R2.CP/CS R2.MP4 R2.FB4 R2.MP3 R2.FB3 R2.H1 R2.H2 R2.MP2 R2.FB2 R2.MP1 R2.FB1 R1.SMB1-3 R1.SMB4-6 R2.SMB R1.MP R1.SMB R1.CP/CS Lab/Office: Latest revision: Status: Plant: IRB6660 Location: Manipulator APPROVED Connection point location Sublocation: Document no. Rev. Ind Page 5 Next 3HAC025744-001 IRB 6660...
  • Page 438 Motor Protective Earth Brake Twisted wires Temp sensor (PTC- resistor) Screened wires Resolver Any number i.e. 66XX can be 6600, 6640, 6660 or 6650 Battery Pack Brake Release Unit Feedback unit Serial Measurment Board Position switch Keypin Location pin to avoid mismatch Lab/Office: Latest revision: Status:...

  • Page 439: Brake Release Unit

    BU Brake Release (Simplified) -R1.MP Brake Release -X10 -X10 R1.MP -BU M1 / +Axis 1/30;2 Brake PB Brake Bleed Circuit -BU 0V M1 / +Axis 1/30;2 R1.MP -BU M2 / +Axis 2/40;2 -BU 0V M2 / +Axis 2/40;2 -BU 0V M3 / +Axis 3/50;2 Brake Bleed Circuit -BU 0V M4 / +Axis 4/60;2 R1.MP...

  • Page 440: Serial Measuring Board

    +Axis 3/50;3 / -0V EXT.LAMP R1.SMB R2.SMB R2.SMB SDI-N WHBK SDO-N WHBN WHRD KEYPIN +Axis 3/50;3 / -24V EXT.LAMP R2.G R1.G(X3) R1.G(X3) Lab/Office: Latest revision: Status: 2005-10-17 Plant: 66XX/7600 Location: APPROVED Serial Measuring Board Sublocation: Document no. Rev. Ind Page 20 Next 3HAC025744-001 IRB 66XX / 7600...
  • Page 441 R1.MP -R2.MP1 -R2.MP1 R (U) T (W) S (V) GNYE GNYE GNYE GNYE +BU/10;7 / -BU M1 BU M1 BU + Brake +BU/10;2 / -BU 0V M1 BU 0V M1 BU - -PTC1 PTC M +Axis 2/40;2 / -PTC M2 PTC M2 R1.SMB1-3 R1.SMB1-3...
  • Page 442 R1.MP -R2.MP2 -R2.MP2 R (U) T (W) S (V) GNYE GNYE GNYE GNYE +BU/10;7 / -BU M2 BU M2 BU + Brake +BU/10;2 / -BU 0V M2 BU 0V M2 BU - -PTC2 +Axis 1/30;2 / -PTC M2 PTC M2 +Axis 3/50;2 / -PTC M3 PTC M3 R1.SMB1-3...
  • Page 443 R1.MP -R2.MP3 -R2.MP3 R (U) T (W) S (V) GNYE GNYE GNYE GNYE +BU/10;7 / -BU M3 BU M3 BU + Brake +BU/10;2 / -BU 0V M3 BU 0V M3 BU - -PTC3 +Axis 2/40;2 / -PTC M3 PTC M3 +Axis 4/60;2 / -PTC M4 PTC M4 KEYPIN...
  • Page 444 R1.MP -R2.MP4- -R2.MP4- R (U) T (W) S (V) GNYE GNYE +BU/10;7 / -BU M4 BU M4 BU + Brake +BU/10;2 / -BU 0V M4 BU 0V M4 BU - -PTC4 +Axis 3/50;2 / -PTC M4 PTC M4 =7600+Axis 5/70;2 PTC M5 =66XX+Axis 5/80;2 A Keypin...
  • Page 445 R1.MP R2.M5/6 -R3.MP5 -R3.MP5- R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M5 BU M5 BU M5 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M5 BU 0V M5 BU 0V M5 BU - -PTC5 =66XX/7600+Axis 4/60;2 / -PTC M5 PTC M5 PTC M5 PTC 0V...
  • Page 446 R1.MP R3.MP5 -R4.MP5- -R4.MP5- R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M5 BU M5 BU M5 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M5 BU 0V M5 BU 0V M5 BU - -PTC5 =66XX/7600+Axis 4/60;2 / -PTC M5 PTC M5 PTC M5 +Axis 6/110;2 / -PTC M6.1...
  • Page 447 R1.MP R2.M5/6 -R3.MP5 -R3.MP5- R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M5 BU M5 BU M5 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M5 BU 0V M5 BU 0V M5 BU - -PTC5 =66XX/7600+Axis 4/60;2 / -PTC M5 PTC M5 PTC M5 PTC 0V...
  • Page 448 R1.MP -R2.M5/6- -R3.MP6 -R3.MP6 R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M6 BU M6 BU M6 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M6 BU 0V M6 BU 0V M6 BU - -PTC6 +Axis 5/70;5 / -PTC M6 PTC M6 +Axis 5/70;3 / -PTC 0V PTC 0V...
  • Page 449 R1.MP -R3.MP6- -R3.MP6- R (U) T (W) S (V) GNYE GNYE =66XX/7600+BU/10;7 / -BU M6 BU M6 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M6 BU 0V M6 BU - -PTC6 +Axis 5/80;2 / -PTC M6.1 PTC M6 PTC 0V R1.SMB4-6 R1.SMB4-6 -R3.FB6...
  • Page 450 R1.MP -R2.M5/6- -R3.MP6 -R3.MP6 R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M6 BU M6 BU M6 BU + Brake +Axis 5/90;5 / -BU 0V M6.1 BU 0V M6 BU - -PTC6 +Axis 5/90;5 / -PTC M6.2 PTC M6 +Axis 5/90;3 / -PTC 0V.1 PTC 0V...

  • Page 451: Axis 1

    -SW1.1 Power 1.1.1 Location of position switches Power 1.1.2 Signal 1.1.2 Signal 1.1.1 SW1.6 -SW1.2 SW1.5 Power 1.2.1 Power 1.2.2 SW1.4 Signal 1.2.2 SW1.3 Signal 1.2.1 -SW1.3 SW1.2 Power 1.3.1 SW1.1 Power 1.3.2 Signal 1.3.2 Signal 1.3.1 Position switches -SW1.4 Axis 1 Power 1.4.1 Power 1.4.2...

  • Page 452: Axis

    Location of position switches -SW2.1 R1.SW2/3 R2.SW2 Power 2.1.1 Power 2.1.1 Power 2.1.2 Power 2.1.2 Signal 2.1.2 Signal 2.1.2 Signal 2.1.1 Signal 2.1.1 -SW2.2 Power 2.2.1 Power 2.2.1 Power 2.2.2 Power 2.2.2 Signal 2.2.2 Signal 2.2.2 Signal 2.2.1 Signal 2.2.1 Position switches -SW2.3 Axis 2...

  • Page 453: Axis

    Location of Position switches -SW3.1 R1.SW2/3 R2.SW3 Power 3.1.1 Power 3.1.1 Power 3.1.2 Power 3.1.2 Signal 3.1.2 Signal 3.1.2 Signal 3.1.1 Signal 3.1.1 -SW3.2 Power 3.2.1 Power 3.2.1 Power 3.2.2 Power 3.2.2 Signal 3.2.2 Signal 3.2.2 Signal 3.2.1 Signal 3.2.1 Position switches -SW3.3 Axis 3...
  • Page 454 10 Circuit Diagram 10.3.1. Validity of circuit diagram 3HAC 13347-1 10.3 Circuit diagram 3HAC 13347-1 10.3.1. Validity of circuit diagram 3HAC 13347-1 Is this circuit diagram valid for your robot? The validity of the circuit diagram depends on which cable harness is fitted to the robot. Check the article number of the cable harness fitted to the robot.
  • Page 455 Circuit Diagram 3HAC 13347-1 / Rev. 02 CONTENTS S h e e t Contents ........................101 Connection Point Location ...................102 Legend ..........................103 Brake Release Unit .......................104 Serial Measurement Board ...................105 Axis 1..........................106 Axis 2..........................107 Axis 3..........................108 Axis 4..........................109 Axis 5 (IRB 7600) ......................110 Axis 6..........................111 Switches axis 1 ......................113 Switches/Fan axis 2 ......................114...
  • Page 456 s h e e t R e v i s i o n Contents...
  • Page 457 s h e e t R e v i s i o n Connection Point Location...
  • Page 458 s h e e t R e v i s i o n Legend...
  • Page 459 s h e e t R e v i s i o n Brake Release Unit...
  • Page 460 s h e e t R e v i s i o n Serial Measurement Board...
  • Page 461 s h e e t R e v i s i o n Axis 1...
  • Page 462 s h e e t R e v i s i o n Axis 2...
  • Page 463 s h e e t R e v i s i o n Axis 3...
  • Page 464 s h e e t R e v i s i o n Axis 4...
  • Page 465 s h e e t R e v i s i o n Axis 5 (IRB 7600)
  • Page 466 s h e e t R e v i s i o n Axis 6...
  • Page 467 s h e e t R e v i s i o n Switches axis 1...
  • Page 468 s h e e t R e v i s i o n Switches/Fan axis 2...
  • Page 469 s h e e t R e v i s i o n Switches/Fan axis 3...
  • Page 470 s h e e t R e v i s i o n Axis 5 (IRB 6600)
  • Page 471 s h e e t R e v i s i o n Design changes, note 1.1...
  • Page 472 s h e e t R e v i s i o n Design changes, note 2.1-2.7...
  • Page 473 10 Circuit Diagram 10.3.1. Validity of circuit diagram 3HAC 13347-1 3HAC020993-001 Revision:G...
  • Page 474 Index Absolute Accuracy, calibration 367 gearbox axis 1, replacement 339 gearbox axis 2, replacement 346 gearbox axis 3, replacement 354 balancing device bearing, replacement 281 gearbox axis 6, replacement 360 balancing device, replacement 286 brake release unit, replacement 277 brakes installation testing function 29 mechanical stop axis 1 86...
  • Page 475 Index replacement balancing device 286 testing, brakes 29 bearing, balancing device 281 tightening torque brake release unit 277 mechanical stop axis 1 87 cable harness axes 1-4 216 mechanical stop axis 2 89 cable harness axes 1-6 204 tool set, balancing device bearing replacement 282 cabling axis 5 229 tools complete arm system 231...
  • Page 477 ABB AB Robotics Products S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...

This manual is also suitable for:

Irb 6650s - 125/3.5Irb 6650s - 90/3.9

Table of Contents