ABB IRB 7600 Series Product Manual
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ABB IRB 7600 Series Product Manual

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Table of Contents

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工控帮助教小舒QQ2823408167
ABB Robotics
Product manual
IRB 7600

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Summary of Contents for ABB IRB 7600 Series

  • Page 1 工控帮助教小舒QQ2823408167 ABB Robotics Product manual IRB 7600...
  • Page 2 工控帮助教小舒QQ2823408167...
  • Page 3 工控帮助教小舒QQ2823408167 Product manual IRB 7600 - 500/2.55 IRB 7600 - 500/2.3 IRB 7600 - 400/2.55 IRB 7600 - 340/2.8 IRB 7600 - 325/3.1 IRB 7600 - 150/3.5 M2000 M2000A M2004 Document ID: 3HAC022033-001 Revision: K...
  • 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

    工控帮助教小舒QQ2823408167 Table of Contents Overview of this manual..............9 Product documentation, M2000/M2000A .
  • Page 6 工控帮助教小舒QQ2823408167 Table of Contents 2.5.7 Securing the base plate............90 2.5.8 Orienting and securing the robot .
  • Page 7 工控帮助教小舒QQ2823408167 Table of Contents 3.5.3 Rust preventive measures, sealing axis 4 (Foundry Prime) ......226 3.5.4 Rust preventive measures, support bearing in wrist (Foundry Prime) .
  • Page 8 工控帮助教小舒QQ2823408167 Table of Contents 5 Calibration information 5.1 Introduction ..............403 5.2 Calibration methods .
  • Page 9 工控帮助教小舒QQ2823408167 Table of Contents 10 Circuit Diagram 10.1 About circuit diagrams ............. 469 10.2 Circuit diagram 3HAC 025744-001.
  • Page 10 工控帮助教小舒QQ2823408167 Table of Contents 3HAC022033-001 Revision: K...

  • Page 11: Overview Of This Manual

    Prerequisites A maintenance/repair/installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters: Chapter...
  • Page 12 工控帮助教小舒QQ2823408167 Overview of this manual Continued Chapter Contents Reference information Useful information when performing installation, maintenance or repair work. Includes lists of necessary tools, additional documents, safety standards etc. Spare part list Complete spare part list shown in exploded views. Exploded views Detailed illustrations of the robot with reference numbers to the part list.
  • Page 13 工控帮助教小舒QQ2823408167 Overview of this manual Continued Revisions Revision Description First edition. Replaces previous manuals: • Installation and Commissioning Manual • Maintenance Manual • Repair Manual, part 1 • Repair Manual, part 2. Changes made in the material from the previous manuals: •...
  • Page 14 工控帮助教小舒QQ2823408167 Overview of this manual Continued Revision Description • New variant of the robot (IRB 7600 - 325/3.1) implemented throughout the manual. • In chapter 3 Maintenance section Oil in gearboxes type of oil and art. no. in gearbox axes 1 has been added. •...
  • Page 15 工控帮助教小舒QQ2823408167 Overview of this manual Continued Revision Description This revision includes the following additions and/or changes: • Circuit diagrams are not included in this document but delivered as separate files. See Circuit diagram. • List of standards updated, see Applicable safety standards on page 420.

  • Page 16: 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 17: Product Documentation, M2004

    The manipulator documentation is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional. All documents listed can be ordered from ABB on a DVD. The documents listed are valid for M2004 manipulator systems. Product manuals...
  • Page 18 工控帮助教小舒QQ2823408167 Product documentation, M2004 Continued Application manuals Specific applications (for example software or hardware options) are described in Application manuals. An application manual can describe one or several applications. An application manual generally contains information about: • The purpose of the application (what it does and when it is useful). •...

  • Page 19: How To Read The Product Manual

    工控帮助教小舒QQ2823408167 How to read the product manual How to read the product manual Reading the procedures The procedures contain references to figures, tools, material, and so on. The references are read as described below. References to figures The procedures often include references to components or attachment points located on the manipulator/controller.
  • Page 20 工控帮助教小舒QQ2823408167 How to read the product manual 3HAC022033-001 Revision: K...

  • Page 21: Safety

    工控帮助教小舒QQ2823408167 1 Safety 1.1. Introduction to safety information 1 Safety 1.1. Introduction to safety information Overview The safety information in this manual is divided into two categories: • General safety aspects, important to attend to before performing any service work on the robot.

  • Page 22: 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 manipulator will not cause injury or damage even if all safety instructions are complied with. Related information...

  • Page 23: Safety Risks

    Nation/region specific regulations To prevent injuries and damages during the installation of the manipulator, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Non-voltage related risks •...
  • Page 24 工控帮助教小舒QQ2823408167 1 Safety 1.2.2.1. Safety risks during installation and service work on manipulators Continued Complete manipulator Safety risk Description Hot components! CAUTION! Motors and gears are HOT after running the manipulator! Touching motors and gears may result in burns! With a higher environment temperature, more surfaces on the manipulator will get HOT and may also result in burns.

  • Page 25: Caution - Hot Parts May Cause Burns

    工控帮助教小舒QQ2823408167 1 Safety 1.2.2.2. CAUTION - Hot parts may cause burns! 1.2.2.2. CAUTION - Hot parts may cause burns! Description During normal operation, many manipulator parts become hot, especially the drive motors and gears. Sometimes areas around these parts also become hot. Touching these may cause burns of various severity.

  • Page 26: Safety Risks Related To Tools/Work Pieces

    工控帮助教小舒QQ2823408167 1 Safety 1.2.2.3. Safety risks related to tools/work pieces 1.2.2.3. Safety risks related to tools/work pieces 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 27: Safety Risks Related To Pneumatic/Hydraulic Systems

    工控帮助教小舒QQ2823408167 1 Safety 1.2.2.4. Safety risks related to pneumatic/hydraulic systems 1.2.2.4. Safety risks related to pneumatic/hydraulic systems General Special safety regulations apply to pneumatic and hydraulic systems. Residual energy • Residual energy can be present in these systems. After shutdown, particular care must be taken.

  • Page 28: Safety Risks During Operational Disturbances

    工控帮助教小舒QQ2823408167 1 Safety 1.2.2.5. Safety risks during operational disturbances 1.2.2.5. Safety risks during operational disturbances General • The industrial manipulator is a flexible tool that can be used in many different industrial applications. • All work must be carried out professionally and in accordance with the applicable safety regulations.

  • Page 29: Risks Associated With Live Electric Parts

    工控帮助教小舒QQ2823408167 1 Safety 1.2.2.6. Risks associated with live electric parts 1.2.2.6. Risks associated with live electric parts Voltage related risks, general • Although troubleshooting may, on occasion, need to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.
  • Page 30 工控帮助教小舒QQ2823408167 1 Safety 1.2.2.6. 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 31: Safety Actions

    工控帮助教小舒QQ2823408167 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 manipulator to ensure safe manipulator installation and operation. Dimensioning Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the manipulator is dropped or released at maximum speed.

  • Page 32: Fire Extinguishing

    工控帮助教小舒QQ2823408167 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 manipulator system (manipulator or controller)! 3HAC022033-001 Revision: K...

  • Page 33: Emergency Release Of The Manipulator's Arm

    工控帮助教小舒QQ2823408167 1 Safety 1.2.3.3. Emergency release of the manipulator’s arm 1.2.3.3. Emergency release of the manipulator’s arm Description In an emergency situation, any of the manipulator's axes may be released manually by pushing the brake release buttons on the manipulator. How to release the brakes is detailed in the section: •...

  • Page 34: Brake Testing

    工控帮助教小舒QQ2823408167 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 normally wears down. A test can be performed to determine whether the brake can still perform its function. How to test The function of the holding brake of each axis motor may be checked as described below: 1.

  • Page 35: Risk Of Disabling Function "Reduced Speed 250 Mm/S

    工控帮助教小舒QQ2823408167 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". 3HAC022033-001 Revision: K...

  • Page 36: Safe Use Of The Flexpendant

    工控帮助教小舒QQ2823408167 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, switches the system to MOTORS ON. When the enabling device is released or pushed all the way in, the manipulator switches to the MOTORS OFF state.

  • Page 37: Work Inside The Manipulator's Working Range

    工控帮助教小舒QQ2823408167 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 manipulator’s work area, 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 operational and to block operation from a computer link or remote control panel.

  • Page 38: Signal Lamp (Optional)

    工控帮助教小舒QQ2823408167 1 Safety 1.2.3.8. Signal lamp (optional) 1.2.3.8. Signal lamp (optional) Description A signal lamp with a 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 product manual for the controller.

  • Page 39: Safety Stops

    工控帮助教小舒QQ2823408167 1 Safety 1.2.4.1. What is an emergency stop? 1.2.4. Safety stops 1.2.4.1. What is an emergency stop? Definition of emergency stop An emergency stop is a state that overrides any other manipulator control, disconnects drive power from the manipulator motors, stops all moving parts, and disconnects power from any potentially dangerous functions controlled by the manipulator system.
  • Page 40 工控帮助教小舒QQ2823408167 1 Safety 1.2.4.1. What is an emergency stop? Continued Emergency stop devices In a manipulator system there are several emergency stop devices that can be operated in order to achieve an emergency stop. There are emergency stop buttons available on the FlexPendant and on the controller cabinet (on the Control Module on a Dual Cabinet Controller).

  • Page 41: Safety Related Instructions

    工控帮助教小舒QQ2823408167 1 Safety 1.3.1. Safety signals in the manual 1.3 Safety related instructions 1.3.1. Safety signals in the manual Introduction to safety signals This section specifies all dangers that can arise when doing the work described in this manual. Each danger consists of: •...
  • Page 42 工控帮助教小舒QQ2823408167 1 Safety 1.3.1. Safety signals in the manual Continued Symbol Designation Significance ELECTROSTATIC Warns for electrostatic hazards which could result in DISCHARGE (ESD) severe damage to the product. Electrostatic discharge (ESD) NOTE Describes important facts and conditions. Note Describes where to find additional information or how to do an operation in an easier way.

  • Page 43: Safety Symbols On Manipulator Labels

    工控帮助教小舒QQ2823408167 1 Safety 1.3.2. Safety symbols on manipulator labels 1.3.2. Safety symbols on manipulator labels Introduction to labels This section describes safety symbols used on labels (stickers) on the manipulator. Symbols are used in combinations on the labels, describing each specific warning. The descriptions in this section are generic, the labels can contain additional information such as values.
  • Page 44 工控帮助教小舒QQ2823408167 1 Safety 1.3.2. Safety symbols on manipulator labels Continued Symbol Description See user documentation Read user documentation for details. Which manual to read is defined by the symbol: • No text: Product manual. • EPS: Application manual - Electronic Position Switches. xx0900000813 Before dismantling see product manual xx0900000816...
  • Page 45 工控帮助教小舒QQ2823408167 1 Safety 1.3.2. Safety symbols on manipulator labels Continued Symbol Description Heat Risk of heat that can cause burns. xx0900000818 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 Brake release buttons xx0900000820 xx1000001140 Lifting bolt xx0900000821 Continues on next page 3HAC022033-001 Revision: K...
  • Page 46 工控帮助教小舒QQ2823408167 1 Safety 1.3.2. Safety symbols on manipulator labels Continued Symbol Description Chain sling with shortener xx1000001242 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824 No mechanical stop xx1000001144 Stored energy Warns that this part contains stored energy.
  • Page 47 工控帮助教小舒QQ2823408167 1 Safety 1.3.2. Safety symbols on manipulator labels Continued Symbol Description Pressure Warns that this part is pressurized. Usually contains additional text with the pressure level. xx0900000826 Shut off with handle Use the power switch on the controller. xx0900000827 3HAC022033-001 Revision: K...

  • Page 48: Danger - Moving Manipulators Are Potentially Lethal

    工控帮助教小舒QQ2823408167 1 Safety 1.3.3. DANGER - Moving manipulators are potentially lethal! 1.3.3. DANGER - Moving manipulators are potentially lethal! Description Any moving manipulator is a potentially lethal machine. When running, the manipulator may perform unexpected and sometimes irrational movements. Moreover, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the working range of the manipulator.

  • Page 49: Danger - First Test Run May Cause Injury Or Damage

    工控帮助教小舒QQ2823408167 1 Safety 1.3.4. DANGER - First test run may cause injury or damage! 1.3.4. 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.

  • Page 50: Warning - The Brake Release Buttons May Be Jammed After Service Work

    工控帮助教小舒QQ2823408167 1 Safety 1.3.5. WARNING - The brake release buttons may be jammed after service work 1.3.5. WARNING - The brake release buttons may be jammed after service work Description The brake release unit has push-buttons for the brake release of each axis motor. When service work is performed inside the SMB recess that includes removal and refitting of the brake release unit, the brake release buttons may be jammed after refitting.

  • Page 51: Warning - The Unit Is Sensitive To Esd

    工控帮助教小舒QQ2823408167 1 Safety 1.3.6. WARNING - The unit is sensitive to ESD! 1.3.6. 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 52 工控帮助教小舒QQ2823408167 1 Safety 1.3.6. WARNING - The unit is sensitive to ESD! Continued Assemble the wrist strap The picture illustrates how the ESD wrist strap is assembled in the controller. xx0400001055 The strap is fastened to a button on the side of the control module. When not used, the wrist strap is placed on the power supply unit.

  • Page 53: Warning - Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)

    工控帮助教小舒QQ2823408167 1 Safety 1.3.7. WARNING - Safety risks during work with gearbox lubricants (oil or grease) 1.3.7. WARNING - Safety risks during work with gearbox lubricants (oil or grease) Description When handling gearbox lubricants, there is a risk of both personal injury and product damage occurring.
  • Page 54 工控帮助教小舒QQ2823408167 1 Safety 1.3.7. WARNING - Safety risks during work with gearbox lubricants (oil or grease) Continued Warning Description Elimination/Action The specified amount of oil or After refilling, check the lubricant grease is based on the total level. volume of the gearbox. When changing the lubricant, the amount refilled may differ from the specified amount, depending...

  • Page 55: Installation And Commissioning

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.1. Introduction 2 Installation and commissioning 2.1. Introduction General This chapter contains information for installing the robot at the working site. More detailed technical data can be found in the Product specification for the robot, such as: •...

  • Page 56: Robot Transportation Precautions

    Transportation in any other way than method 1 or 2 can seriously damage the robot. If the robot is incorrectly transported and the instructions are not followed, the robot is not covered by the warranty and ABB will not accept any compensation claim. Method 1 Transportation according to method 1 is strongly recommended by ABB.
  • Page 57 2 Installation and commissioning 2.2. Robot transportation precautions Continued Method 2 Transportation according to method 2 is approved by ABB, if use of method 1 is not possible. Always follow these instructions when transporting an ABB robot according to method 2: •...
  • Page 58 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.2. Robot transportation precautions Continued IRB6620/Foundry Plus xx0800000036 Transport Support Hexagon socket head cap screw M10x50 Threaded bar M10x280 Nut M10 Continues on next page 3HAC022033-001 Revision: K...
  • Page 59 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.2. Robot transportation precautions Continued Transport position with a transport support All transportation of the robot with tool must follow these instructions. IRB 7600/IRB 66XX xx0800000040 Continues on next page 3HAC022033-001 Revision: K...
  • Page 60 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.2. Robot transportation precautions Continued IRB 6620/Foundy Plus xx0800000041 Continues on next page 3HAC022033-001 Revision: K...
  • Page 61 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.2. Robot transportation precautions Continued Recommended transport support Always use the recommended transport support when transporting a robot with tool. IRB 7600/IRB 66XX xx0800000039 Continues on next page 3HAC022033-001 Revision: K...
  • Page 62 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.2. Robot transportation precautions Continued IRB 6620 xx0800000038 3HAC022033-001 Revision: K...

  • Page 63: Securing The Robot

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.3. Securing the robot 2.3. Securing the robot General This section describes how to secure the robot using the transport support. DANGER! Releasing the brakes is a hazardous action that may cause injury and damage property. It must be done with great care and only when absolutely necessary.
  • Page 64 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.3. Securing the robot Continued Action Note 2. Jog the robot into a position as near above as possible to the recommended transport position for the specific robot, as specified in section Transport position CAUTION! with a transport support on page Do not try to jog the robot to the exact position (max distance 1mm).

  • Page 65: Unpacking

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.4.1. Pre-installation procedure 2.4 Unpacking 2.4.1. Pre-installation procedure General This instruction is primarily intended for use when unpacking and installing the robot for the first time. It also contains information useful during later re-installation of the robot. Checking the pre-requisites for installation The checklist below details what must be observed before proceeding with the actual installation of the robot:...
  • Page 66 Min. levelness 0.5 mm Max. tilt 5° The limit for the maximum payload on the robot is reduced if the robot is tilted from 0°. Contact ABB for further information about acceptable payload. Min. resonance 22 Hz frequency Storage conditions, robot...
  • Page 67 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.4.1. Pre-installation procedure Continued Protection classes, robot The table below shows the protection class of the robot: Equipment Protection class Robot, IRB 7600 IP 67 3HAC022033-001 Revision: K...

  • Page 68: Working Range, Irb 7600 - 150/3.5

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.4.2. Working range, IRB 7600 - 150/3.5 2.4.2. Working range, IRB 7600 - 150/3.5 Illustration The illustration below shows the unrestricted working range of IRB 7600 - 150/3.5: xx0100000101 3HAC022033-001 Revision: K...

  • Page 69: Working Range, Irb 7600 - 340/2.8

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.4.3. Working range, IRB 7600 - 340/2.8 2.4.3. Working range, IRB 7600 - 340/2.8 Illustration The illustration below shows the unrestricted working range of IRB 7600 - 340/2.8: xx0300000296 3HAC022033-001 Revision: K...

  • Page 70: Working Range, Irb 7600 - 400/2.55, Irb 7600 - 500/2.55

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.4.4. Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55 2.4.4. Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55 Illustration The illustration below shows the unrestricted working range of IRB 7600 - 400/2.55 and IRB 7600 - 500/2.55: xx0100000100 3HAC022033-001 Revision: K...

  • Page 71: Working Range, Irb 7600 - 500/2.3

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.4.5. Working range, IRB 7600 - 500/2.3 2.4.5. Working range, IRB 7600 - 500/2.3 Illustration The illustration below shows the unrestricted working range of IRB 7600 - 500/2.3: en0100000099 3HAC022033-001 Revision: K...

  • Page 72: Risk Of Tipping/Stability

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.4.6. Risk of tipping/stability 2.4.6. 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 73: On-Site Installation

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.1. Lifting robot with fork lift 2.5 On-site Installation 2.5.1. Lifting robot with fork lift General The robot may be moved using a fork lift, provided that available special aids are used. This section describes how to attach the fork lift equipment to the robot. Different designs There are two different versions of the fork lift that fit one design of the frame respectively.
  • Page 74 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Attachment points on robot The attachment points for the fork lift equipment are shown in this figure. xx0400000707 Attachment points, spacer and horizontal attachment screws Attachment points, horizontal attachment screws Attachment points, vertical attachment screws Attachment points, horizontal attachment screws Required equipment...
  • Page 75 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Fork lift set, 3HAC0604-2 The fork lift set, 3HAC0604-2, is fitted to the robot as shown in the figure below. xx0100000102 Vertical attachment screws (4 pcs / fork lift pocket) Fork lift pockets (2 pcs) Spacer (2 pcs) Continues on next page...
  • Page 76 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Fork lift set, 3HAC0604-1 The fork lift set, 3HAC0604-1, is fitted to the robot as shown in the figure below. xx0200000379 Fork lift pocket (2 pcs, different from each other) Spacer (2 pcs) Horizontal attachment screws (4 pcs / fork lift pocket) Vertical attachment screws (2 pcs)
  • Page 77 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Action Note 2. Position the robot as shown in the figure to the Release the brakes if required as right! detailed in section Manually releasing the brakes on page NOTE! No load is permitted on the robot if the fork lift set 3HAC0604-2 is used!
  • Page 78 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Action Note 5. Secure the longer fork lift pocket to the spacers Always use original screws (or replace- with four of the horizontal attachment screws ments of equivalent quality: M16, and washers.
  • Page 79 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Action Note 7. Secure fork lift pocket to robot with two vertical attachment screws and washers. (only valid for the fork lift set 3HAC 0604-1) NOTE! Vertically and the horizontally attached screws are identical, but tightened with different torques! xx0300000464...
  • Page 80 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Action Note CAUTION! The robot weighs 2550 kg! All lifting equipment used must be sized accordingly! 12. Carefully lift the robot and move it to its instal- lation site. WARNING! Personnel must not, under any circumstances, be present under the suspended load!

  • Page 81: Lifting Robot With Lifting Slings

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.2. Lifting robot with lifting slings 2.5.2. Lifting robot with lifting slings General This section contains a general overview of how to lift the complete robot using special lifting equipment. More detailed instructions are included with the equipment. NOTE! Move the robot to the recommended position shown in the figure and in the instruction! Attempting to lift a robot in any other position may result in the robot tipping over, causing...
  • Page 82 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.2. Lifting robot with lifting slings Continued Required equipment Equipment Art. no. Note Lifting device, robot 3HAC15607-1 Includes: • user instructions (3HAC15971-2). Slings attached directly onto robot This section details how to lift and move the robot using lifting slings when these are attached directly onto the robot frame.

  • Page 83: Lifting Robot With Roundslings

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.3. Lifting robot with roundslings 2.5.3. Lifting robot with roundslings General The figure below shows how to lift the complete robot with roundslings. Notice the recommended robot position shown in the figure below! Roundslings attached to the robot xx0200000315 Chain sling with shortener, 4250 kg, 3 pcs (0.5 m, 0.5 m, 0.265 m) Roundsling, 1000 kg, 2 pcs...
  • Page 84 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.3. Lifting robot with roundslings Continued Slings attached directly on to robot The section below details how to attach roundslings to the robot in order to lift the complete robot. Action Note Recommended robot position is described in section Risk of tipping/ stability on page...

  • Page 85: Manually Releasing The Brakes

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.4. Manually releasing the brakes 2.5.4. Manually releasing the brakes General This section details how to release the holding brakes of each axis motor. The brakes may be released by: • Internal brake release unit: using push buttons on the robot. This requires either the controller to be connected or that power is supplied to the R1.MP connector, according to the section Supplying power to connector R1.MP on page...
  • Page 86 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.4. Manually releasing the brakes Continued Location of brake release unit at frame The internal brake release unit is located either at the base or at the frame. The figure below shows the unit located at the frame. xx0200000376 Internal brake release unit with push buttons, located on the robot frame Releasing the brakes...
  • Page 87 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.4. Manually releasing the brakes Continued Supplying power to connector R1.MP If the robot is not connected to the controller, power must be supplied to connector R1.MP on the robot in order to enable the brake release buttons. Action Note DANGER!

  • Page 88: Manually Releasing The Brakes, External Brake Release Unit

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.5. Manually releasing the brakes, external brake release unit 2.5.5. Manually releasing the brakes, external brake release unit General The section below details how to release the holding brakes of each axis motor using push buttons on an external brake release unit.
  • Page 89 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.5. Manually releasing the brakes, external brake release unit Continued Connectors, external brake release unit The illustration below shows the connectors on the robot and on the external brake release unit. xx0200000081 Rear connector plate Connector R1.MP Connector R1.BU External brake release unit...
  • Page 90 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.5. Manually releasing the brakes, external brake release unit Continued Action Note DANGER! When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways! Make sure no personnel is near or beneath the robot arm! 5.

  • Page 91: Lifting The Base Plate

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.6. Lifting the base plate 2.5.6. Lifting the base plate Required equipment Equipment Art. no. Note Lifting eye, M16 3HAC14457-4 3 pcs Lifting slings 3 pcs Length: approx. 2 m Hole configuration xx0200000096 Attachment holes for lifting eyes (x3) Lifting, base plate Action Note...

  • Page 92: Securing The Base Plate

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.7. Securing the base plate 2.5.7. Securing the base plate Base plate, dimensions xx1000001053 Continues on next page 3HAC022033-001 Revision: K...
  • Page 93 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.7. Securing the base plate Continued xx0400000715 Four holes for alternative clamping, 4x Ø18 Continues on next page 3HAC022033-001 Revision: K...
  • Page 94 9ADA120-79 • attachment screws and washers for securing the robot to the base plate. A drawing of the base plate itself may be ordered from ABB Robotics! Standard toolkit Content is defined in section Standard toolkit on page 427.
  • Page 95 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.7. 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 96: Orienting And Securing The Robot

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.8. Orienting and securing the robot 2.5.8. Orienting and securing the robot General This section details how to orient and secure the robot to the base plate in order to run the robot safely. Illustration, robot fitted to base plate This illustration shows the robot base fitted to the base plate.
  • Page 97 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.8. Orienting and securing the robot Continued Securing the robot Use this procedure to secure robot to base plate after fitting plate to the foundation. Action Note 1. Lift the robot. Detailed in section Lifting robot with lifting slings on page Detailed in section Lifting robot with...
  • Page 98 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.8. Orienting and securing the robot Continued Hole configuration, base This illustration shows the hole configuration used when securing the robot. xx0300000046 Cross section, guide sleeve hole This illustration shows the cross section of the guide sleeve holes. xx0100000109 3HAC022033-001 Revision: K...

  • Page 99: Fitting Equipment On Robot

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.9. Fitting equipment on robot 2.5.9. 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 100 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.9. Fitting equipment on robot Continued xx0100000120 Illustration, fitting of extra equipment on upper arm The illustration below shows the mounting holes available for fitting extra equipment on the upper arm. xx0100000116 Continues on next page 3HAC022033-001 Revision: K...
  • Page 101 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.9. Fitting equipment on robot Continued xx0300000299 Robot variant IRB 7600 - 500/2.55 1056 mm IRB 7600 - 500/2.3 806 mm IRB 7600 - 400/2.55 1056 mm IRB 7600 - 340/2.8 1306 mm IRB 7600 - 325/3.1 1556 mm IRB 7600 - 150/3.5 2012 mm...
  • Page 102 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.9. Fitting equipment on robot Continued xx0100000118 Illustration, fitting on turning disk The illustration below shows the mounting holes available for fitting equipment on the turning disk. xx0100000119 Continues on next page 3HAC022033-001 Revision: K...
  • Page 103 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.9. Fitting equipment on robot Continued Fastener quality When fitting tools on the turning disk (see the figures above), only use screws with quality 12.9. When fitting other equipment to mounting holes standard screws with quality 8.8 may be used.

  • Page 104: Installation Of Base Spacers (Option)

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.10. Installation of base spacers (option) 2.5.10. Installation of base spacers (option) Illustration, installation of base spacers xx0500001570 Base spacer (4 pcs) Guide sleeve (4 pcs) Attachment screws and washers (12 pcs) Required equipment Equipment Art.
  • Page 105 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.10. Installation of base spacers (option) Continued Equipment Art. no. Note Other tools and procedures These procedures include may be required. See references to the tools references to these required. procedures in the step-by- step instructions below. Installation, base spacers The procedure below details how to fit the base spacers between the robot and the base plate.

  • Page 106: Installation Of Cooling Fan For Motors, Axes 1-3 (Option)

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) General A cooling fan can be installed on the motors of axes 1, 2 and 3. Cooling fans for axes 1 and 2 can not be combined! The cabling for the fans is available in different design: •...
  • Page 107 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued xx0700000671 Cooling fan, axis 2 Cooling fan, axis 1 Rear cover plate Cooling fan The details of the cooling fan are shown in the figure below. xx0500002158 Fanbox Attachment screws, fanbox plates (9 pcs)
  • Page 108 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued xx0900000137 Fanbox Groove in the connector Back plate Part of the fanbox that can be removed, if needed. Required equipment Equipment Art. no. Note Cooling fan 3HAC15374-1 Cabling, position switches...
  • Page 109 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued Equipment Art. no. Note Locking liquid Loctite 243. Used for the three tightening screws. Standard toolkit Content is defined in section Standard toolkit on page 427.
  • Page 110 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued Installation, fan The procedure below details how to install the cooling fan on any of the motors, axes 1-3 . Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Turn off all electric power and hydraulic but not the air pressure to the gearboxes, motors and SMB.
  • Page 111 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued Installation, separate fan cabling axis 1 or 2 The procedure below details how to install the separate cabling for the cooling fan of axis 1 or 2.
  • Page 112 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued Action Note 7. Secure the cable bracket to the bracket of the robot cabling inside the frame. Run the cable underneath the robot cabling and out through the side of the frame, at motor, axis 1 .
  • Page 113 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued Adjustments in RobotWare Action Note 1. Modify the settings in RobotWare to RobotWare 4.0: modify the settings in include the cooling fans. RobInstall. RobotWare 4.063 and older must be updated with a newer release.

  • Page 114: Installation Of Foundry Plus Cable Guard (Option No. 908-1)

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.12. Installation of Foundry Plus Cable guard (option no. 908-1) 2.5.12. Installation of Foundry Plus Cable guard (option no. 908-1) Introduction How to install the Foundry Plus Cable guard is described in the instruction delivered with the cable guard.

  • Page 115: Loads

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.5.13. Loads 2.5.13. Loads General Any loads mounted on the robot must be defined correctly and carefully (with regard to the position of center of gravity and mass moments of inertia) in order to avoid jolting movements and overloading motors, gears and structure.

  • Page 116: Restricting The Working Range

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.1. Introduction 2.6 Restricting the working range 2.6.1. Introduction General When installing the robot, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited. The working range of the following axes may be restricted: •...

  • Page 117: Mechanically Restricting The Working Range Of Axis 1

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.2. Mechanically restricting the working range of axis 1 2.6.2. Mechanically restricting the working range of axis 1 General The working range of axis 1 is limited by fixed mechanical stops and adjustment of the system parameter configuration.
  • Page 118 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.2. Mechanically restricting the working range of axis 1 Continued Installation, mechanical stops axis 1 Use this procedure to fit mechanical stops to axis 1 of the robot. An assembly drawing is also enclosed with the product. Action Note DANGER!

  • Page 119: Mechanically Restricting The Working Range Of Axis 2

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.3. Mechanically restricting the working range of axis 2 2.6.3. Mechanically restricting the working range of axis 2 General The working range of axis 2 is limited by fixed mechanical stops and can be reduced by adding up to six additional mechanical stops with 15 graduation in respective direction.
  • Page 120 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.3. Mechanically restricting the working range of axis 2 Continued Installation, mechanical stops axis 2 The procedure below details how to fit the mechanical stops for axis 2 to the robot. An assembly drawing is also enclosed with the product. Action Note DANGER!

  • Page 121: Mechanically Restricting The Working Range Of Axis 3

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.4. Mechanically restricting the working range of axis 3 2.6.4. Mechanically restricting the working range of axis 3 General The working range of axis 3 is limited by fixed mechanical stops and can be reduced by adding additional mechanical stops with 20 graduation in respective direction.
  • Page 122 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.4. Mechanically restricting the working range of axis 3 Continued xx0600002973 Mechanical stop pin, axis 3 Attachment screw and washer Required equipment Equipment, etc. Art. no. Note Mechanical stop set, axis 3 3HAC13128-2 Includes six stops, one with 80° restriction, 3HAC12708-4 (use when limitation angle >=80), and five with 20°, 3HAC 12708-2.
  • Page 123 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.4. Mechanically restricting the working range of axis 3 Continued Installation, mechanical stops axis 3 The procedure below details how to fit the mechanical stops for axis 3 to the robot. An assembly drawing is also enclosed with the product. Action Note DANGER!

  • Page 124: 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 125 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Axis 1 The illustration below shows the position switch for axis 1. There is no extra cabling installed on the robot, as for axes 2 and 3. Instead the switch is connected directly to the connector in the base, R1.SW1.
  • Page 126 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Axis 2 The illustration below shows the position switch for axis 2. In addition to the shown components, cabling must also be installed from the switch to the robot base. xx0100000159 Position switch, axis 2 Set screw, cam (cam stop)
  • Page 127 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Axis 3 The illustration below shows the position switch for axis 3. In addition to the shown components, cabling must also be installed from the switch to the robot base. xx0100000160 Position switch, axis 3 Set screw, cam (cam stop)
  • Page 128 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Connections The position switches are connected to different points on the robot system: • XT8, screw terminal in the controller cabinet when position switch cables are used. • R1.SW1 at the robot base.
  • Page 129 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Illustration, adjust and secure cams The illustration below show how to adjust and secure the position switch cams and profiles. xx0100000113 Cam stop, M5 nut and M5 x 6 set screw Adjustable cam Profile Illustration, cutting the cam...
  • Page 130 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Plate for customer connections, at base xx0500002301 Plate for customer connections Attachment screws, 3 pcs, M6x16 Cable harness for position switches and fans, axes 1-3 xx0500002305 Cable bracket, frame Cable bracket, lower arm Cable bracket, upper arm R1.SW2/3...
  • Page 131 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued R3.FAN3 Connected to the fan of axis 3 R2.SW2 Connected to the position switch of axis 2 R2.SW3 Connected to the position switch of axis 3 Installation of cable harness for position switches and fans The procedure below details how to fit the complete cable harness for position switches and cooling fans to the robot.
  • Page 132 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Action Note 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 133 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Action Note 7. Run the remaining cable harness up through the lower arm and: • secure with the bracket, lower arm, as shown in the figure to the right. •...
  • Page 134 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Action Note 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 135: Electrical Connections

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.7.1. Robot cabling and connection points 2.7 Electrical connections 2.7.1. Robot cabling and connection points Introduction Connect the robot and controller to each other after securing them to the foundation. The lists below specify which cables to use for each respective application. Main cable categories All cables between the robot and controller are divided into the following categories: Cable category...
  • Page 136 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.7.1. Robot cabling and connection points Continued Robot cable, power Cable Art. no. Robot cable, power: 7 m 3HAC11818-1 Robot cable, power: 15 m 3HAC11818-2 Robot cable, power: 22 m 3HAC11818-3 Robot cable, power: 30 m 3HAC11818-4 Robot cable, signals Cable...
  • Page 137 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.7.1. Robot cabling and connection points Continued Cabling between robot base and controller, cooling fans, M2004 The cables specified below are specific for the IRC5 controller and used when the robot is equipped with cooling fans. The cabling for the cooling fans runs all the way from the robot base to the inside of the cabinet.

  • Page 138: Making Robot Ready For Operation (Foundry Prime)

    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 quality for pressurizing of robot The air must be dry and clean, such as instrument air. The table below details the air specifications.
  • Page 139 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.8.1. Additional installation procedure Continued Air pressure for pressurizing of robot Parameter Value Air pressure supplied to robot Max 0.2 - 0.3 bar ± 0.0 bar 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, leading to personal injury or physical damage.
  • Page 140 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.8.1. Additional installation procedure Continued Protecting robot 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 141: Commissioning (Foundry Prime)

    工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.8.2. Commissioning (Foundry Prime) 2.8.2. 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 142 工控帮助教小舒QQ2823408167 2 Installation and commissioning 2.8.2. Commissioning (Foundry Prime) 3HAC022033-001 Revision: K...

  • Page 143: Maintenance

    工控帮助教小舒QQ2823408167 3 Maintenance 3.1. Introduction 3 Maintenance 3.1. Introduction Structure of this chapter This chapter describes all maintenance activities recommended for the manipulator. It is based on the maintenance schedule located at the beginning of the chapter. The schedule contains information about required maintenance activities including intervals and refers to procedures for the activities.

  • Page 144: Maintenance Schedule And Expected Life

    工控帮助教小舒QQ2823408167 3 Maintenance 3.2.1. Specification of maintenance intervals 3.2 Maintenance schedule and expected life 3.2.1. Specification of maintenance intervals Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the manipulator: •...

  • Page 145: Maintenance Schedule

    工控帮助教小舒QQ2823408167 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 146 工控帮助教小舒QQ2823408167 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Equipment Interval Detailed in section activity Changing Axis 1 gearbox oil: Every: • Oil change, gearbox axis 1 on page 199 Optimol Optigear • 12,000 hours RO 150 Changing Axis 1 gearbox oil: First change when Do not mix with other oils! reads:...
  • Page 147 工控帮助教小舒QQ2823408167 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Equipment Interval Detailed in section activity Changing Axis 4 secondary First change when Do not mix with other oils! gearbox, oil: reads: • Oil change, gearbox, Kyodo Yushi TMO 6,000 hours axis 4 on page 209 Second change when DTC reads:...
  • Page 148 工控帮助教小舒QQ2823408167 3 Maintenance 3.2.2. Maintenance schedule Continued powered off 16 hours/day. The lifetime can be extended (approx. 3 times) for longer production breaks by a battery shutdown service routine. See Operating manual - IRC5 with FlexPendant for instructions. • Replace when damage or cracks is detected or life limit is approaching as specified in section Expected component life on page 149.
  • Page 149 工控帮助教小舒QQ2823408167 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Equipment Interval Detailed in section activity Inspection Cable harness Every: Inspection, cable harness on page 174. • 6 months Replacement of cable Replacement If required harness, axes 1-4 on page Replacement of cable harness, axes 5-6 on page Inspection Air hoses...
  • Page 150 工控帮助教小舒QQ2823408167 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Equipment Interval Detailed in section activity Overhaul Robot 40,000 hours Expected component life on page 149 Overhaul Axis 6 gearbox Every: Replacement of gearbox, axis 6 on page 397 • 24 months Lubrication Balancing device, Every:...

  • Page 151: Expected Component Life

    Contact the local ABB Robotics Service team for more information. The given life for the balancing device is based on a test cycle of 4,000,000 cycles that starts from the initial position and goes to maximum extension, and back.

  • Page 152: Inspection Activities

    工控帮助教小舒QQ2823408167 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 as shown in the figure below. xx0200000111 Gearbox axis 1 Oil plug, filling...
  • Page 153 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.1. Inspection, oil level gearbox axis 1 Continued Inspection through the oil plug, filling The procedure below details how to inspect the oil level, axis 1 gearbox, when the oil plug for inspection (shown in figure Location of gearbox on page 150) is not available .
  • Page 154 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.1. Inspection, oil level gearbox axis 1 Continued Inspection through the oil plug, inspection The procedure below details how to inspect the oil level, axis 1 gearbox, when the oil plug for inspection (shown in the figure Location of gearbox on page 150) is available.

  • Page 155: Inspection, Oil Level Gearbox Axis 2

    工控帮助教小舒QQ2823408167 3 Maintenance 3.3.2. Inspection, oil level gearbox axis 2 3.3.2. Inspection, oil level gearbox axis 2 Different designs The cover of gearbox axis 2 is made in different designs, with different locations of the oil plug hole for filling. The oil plug hole of the later design is located 33 mm below the original placement.
  • Page 156 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.2. Inspection, oil level gearbox axis 2 Continued Oil plug, later design The axis 2 gearbox is located in the lower arm rotational center. The figure below shows the later design of the gearbox cover, where the oil plug for filling is located 33 mm below the original placement.
  • Page 157 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.2. Inspection, oil level gearbox axis 2 Continued Inspection, oil level gearbox axis 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.

  • Page 158: Inspection, Oil Level Gearbox Axis 3

    工控帮助教小舒QQ2823408167 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. xx0200000113 Gearbox, axis 3 Oil plug, filling Oil plug, draining Label, specifies the oil type of axis 3 gearbox...
  • Page 159 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.3. Inspection, oil level gearbox axis 3 Continued Inspection, oil level gearbox axis 3 The procedure below details how to inspect the oil level in gearbox axis 3. Action Note WARNING! Handling gearbox oil involves several safety risks.

  • Page 160: Inspection, Oil Level Gearbox Axis 4

    工控帮助教小舒QQ2823408167 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 at the rear of the upper arm as shown in the figure below. xx0200000107 Upper arm housing Cover, axis 4 gearbox Oil plug, filling, secondary gear...
  • Page 161 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.4. Inspection, oil level gearbox axis 4 Continued Equipment, etc. Art. no. Note Other tools and procedures These procedures include may be required. See references to the tools required. references to these procedures in the step-by-step instructions below.
  • Page 162 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.4. Inspection, oil level gearbox axis 4 Continued Action Note WARNING! Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in section Type of oil on page 192. 3HAC022033-001 Revision: K...

  • Page 163: Inspection, Oil Level, Gearbox Axis 5

    工控帮助教小舒QQ2823408167 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. xx0200000108 Wrist housing Cover, axis 5 gearbox Oil plug, filling secondary gear Oil plug, draining secondary gear Oil plug, filling, primary gearbox (draining on opposite side of wrist housing, not...
  • Page 164 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.5. Inspection, oil level, gearbox axis 5 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 axis 5 The procedure below details how to inspect the oil level in the gearbox axis 5.
  • Page 165 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.5. Inspection, oil level, gearbox axis 5 Continued Action Note WARNING! Do not mix oil types! If wrong oil is refilled, the gearbox must be rinsed as detailed in section Type of oil on page 192. 3HAC022033-001 Revision: K...

  • Page 166: Inspection, Oil Level Gearbox Axis 6

    工控帮助教小舒QQ2823408167 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 center of the wrist unit as shown in the figure below. The alternative locations of the oil plugs for filling affects the measured oil level.
  • Page 167 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 Continued Inspection, oil level gearbox axis 6 The procedure below details how to inspect the oil level in the gearbox axis 6. Action Note WARNING! Handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section WARNING - Safety risks during work...
  • Page 168 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 Continued Action Note 6. Add oil if required. Art. no. is specified in Required equipment on page 164. Detailed in section Oil change, gearbox axis 6 on page 215. 7. Refit the oil plug, filling. Tightening torque: 24 Nm.
  • Page 169 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 Continued Then..2. Less than 2% water in oil. Normal replacement interval is required for gearbox axis 6. See: • Activities and intervals, Foundry Prime on page 146 xx0600003156 • A: Water content in oil from gearbox axis 6 •...

  • Page 170: Inspection, Balancing Device

    工控帮助教小舒QQ2823408167 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 •...
  • Page 171 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.7. Inspection, balancing device Continued Inspection points, balancing device The balancing device is located at the top rear of the frame as shown in the figure below. The figure also shows the inspection points, further detailed in the instructions. xx0300000580 Balancing device Piston rod (inside)
  • Page 172 Action at detected faults on page 168. • balancing device (a ...replace the balancing device or consult ABB Robotics. tapping sound, How to replace the device is detailed in section caused by the Replacement of balancing device on page 307.
  • Page 173 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.7. Inspection, balancing device Continued Check for dissonance If dissonance is detected... from... • piston rod ... perform maintenance or upgrade according to given (squeaking may instructions in Maintenance kit, complete / Upgrade kit. indicate worn plain Art.
  • Page 174 工控帮助教小舒QQ2823408167 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 not be confused with incorrect leaks from the ear.
  • Page 175 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.7. Inspection, balancing device Continued Action Note 1. Clean the area at the front ear from old grease. 2. Run the robot for some minutes, in order to move the balancing device piston. 3. 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 176: Inspection, Cable Harness

    工控帮助教小舒QQ2823408167 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. xx0200000097 Lower arm Cables attached with velcro straps and mounting plate Connectors at cable harness division point, R2.M5/6 Connectors at base Required equipment...
  • Page 177 工控帮助教小舒QQ2823408167 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! Turn off all electric power and hydraulic but not the air pressure to the gearboxes, motors and SMB.
  • Page 178 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.8. Inspection, cable harness Continued Cable attachment, rear of upper arm Connectors at cable harness division point, R2.M5/6 Inspection, cable harness, axes 5-6 The procedure below details how to inspect the cable harness of axes 5-6. Action Note DANGER! Turn off all electric power, hydraulic and...

  • Page 179: Inspecting, Mechanical Stop Pin, Axis 1

    工控帮助教小舒QQ2823408167 3 Maintenance 3.3.9. Inspecting, mechanical stop pin, axis 1 3.3.9. Inspecting, mechanical stop pin, axis 1 WARNING! Mechanical stop pin can not be mounted on robot if option 561-1 Extended work range axis 1 is used. Location of mechanical stop pin The mechanical stop axis 1 is located at the base as shown in the figure below.
  • Page 180 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.9. Inspecting, mechanical stop pin, axis 1 Continued Action Note 4. If the mechanical stop pin is bent or damaged, it Art. no. is specified in Required must be replaced! equipment on page 177. NOTE! The expected life of gearboxes can be reduced as a result of collisions with the mechanical stop.

  • Page 181: Inspection, Mechanical Stop, Axes 1, 2 And 3

    工控帮助教小舒QQ2823408167 3 Maintenance 3.3.10. Inspection, mechanical stop, axes 1, 2 and 3 3.3.10. Inspection, mechanical stop, axes 1, 2 and 3 Location of the mechanical stops The figure below shows the location of the additional mechanical stops on axes 1, 2 and 3. xx0200000150 Additional stop Fixed stop...
  • Page 182 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.10. Inspection, mechanical stop, axes 1, 2 and 3 Continued Inspection, mechanical stops The procedure below details how to inspect the additional mechanical stops on axes 1, 2 and Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Turn off all electric power and hydraulic but not the air pressure to the gearboxes, motors and SMB.

  • Page 183: Inspection, Damper Axes 2-5

    工控帮助教小舒QQ2823408167 3 Maintenance 3.3.11. Inspection, damper axes 2-5 3.3.11. Inspection, damper axes 2-5 Location of dampers The figure below shows the location of all the dampers to be inspected. xx0200000099 Damper, axis 2 (2 pcs) Damper, axis 3 (2 pcs) Damper, axis 4 (2 pcs) Damper, axis 5 (2 pcs) Required equipment...
  • Page 184 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.11. Inspection, damper axes 2-5 Continued Inspection, damper axis 2-5 The procedure below details how to inspect the dampers, axis 2-5. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Turn off all electric power and hydraulic but not the air pressure to the gearboxes, motors and SMB.

  • Page 185: Inspection, Position Switch Axes 1, 2 And 3

    工控帮助教小舒QQ2823408167 3 Maintenance 3.3.12. Inspection, position switch axes 1, 2 and 3 3.3.12. Inspection, position switch axes 1, 2 and 3 Location of position switches The position switches, axes 1, 2 and 3, are located as shown in the figures below. xx0100000158 Position switch, axis 1 Set screw, cam...
  • Page 186 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.12. Inspection, position switch axes 1, 2 and 3 Continued The illustration below shows the position switch for axis 2. xx0100000159 Position switch, axis 2 Set screw, cam Rail Rail attachment Continues on next page 3HAC022033-001 Revision: K...
  • Page 187 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.12. Inspection, position switch axes 1, 2 and 3 Continued The illustration below shows the position switch for axis 3. xx0100000160 Position switch, axis 3 Set screw, cam Rail Rail attachment Required equipment Equipment, etc. Spare part no. Note Position switch, axis 1 3HAC15715-1...
  • Page 188 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.12. Inspection, position switch axes 1, 2 and 3 Continued Equipment, etc. Spare part 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.

  • Page 189: Inspection, Information Labels

    工控帮助教小舒QQ2823408167 3 Maintenance 3.3.13. Inspection, information labels 3.3.13. Inspection, information labels Location of labels These figures show the location of the information labels to be inspected. The symbols are described in section Safety symbols on manipulator labels on page xx0200000100 Warning label concerning high temperature Warning sign, symbol of a lightning flash (located on motor cover) Instruction label...
  • Page 190 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.13. Inspection, information labels Continued xx0200000101 Instruction label concerning lifting the robot Warning label concerning risk of tipping Foundry logotype Warning label concerning stored energy Information label, types of oil in gearboxes of each axis Label, type of oil in gearbox Required equipment Equipment Art.

  • Page 191: Inspection, Ul-Lamp

    工控帮助教小舒QQ2823408167 3 Maintenance 3.3.14. Inspection, UL-lamp 3.3.14. Inspection, UL-lamp Location of UL-lamp The UL-lamp is located as shown in figure below. Notice that the location can vary depending on how the customer harness for axes 4-6 is mounted. xx0200000117 UL signal lamp Warning sign Warning label Position for cable gland...
  • Page 192 工控帮助教小舒QQ2823408167 3 Maintenance 3.3.14. Inspection, UL-lamp Continued Inspection, UL-lamp The procedure below details how to inspect the function of the UL-lamp. Action Note 1. Check that the UL-lamp is lit, when the motors are in operation ("motors ON"). 2. If the lamp is not lit, trace the fault! Part no.

  • Page 193: Inspection Of Air Hoses (Foundry Prime)

    工控帮助教小舒QQ2823408167 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 months. Required equipment Equipment, etc. Art. no. Leak detection spray Pressure gauge Cut off valve Procedure...

  • Page 194: Changing/Replacement Activities

    工控帮助教小舒QQ2823408167 3 Maintenance 3.4.1. Type of oil 3.4 Changing/replacement activities 3.4.1. Type of oil Overview Different types of oil are used in the robot gearboxes depending on the robot serial number. This section describes: • Determining oil type on page 193 •...

  • Page 195: Determining Oil Type

    工控帮助教小舒QQ2823408167 3 Maintenance 3.4.1. Type of oil Continued Axis 6 gearbox Determining oil type Use this procedure to determine which type of oil is used in the gearboxes. Action 1. Read the section Which type of oil does the gearbox contain on page 193to find the type of oil.
  • Page 196 SI10177. Note 3 IRB 7600 robots delivered from ABB Robotics since Sept. 1, 2008 has Kyodo Yushi TMO 150 filled in gearboxes axis 1, 2, 3, 4 primary and secondary, 5 primary and secondary, and 6.

  • Page 197: Labels On The Robot

    工控帮助教小舒QQ2823408167 3 Maintenance 3.4.1. Type of oil Continued Labels on the robot If there are gearboxes filled with Shell Tivela S 150 or TMO 150 there are also labels attached next to oil plugs on each gearbox and on the base. Following figures show the labels. NOTE! Robots delivered with Optimol Optigear RMO150 are not equipped with labels.
  • Page 198 工控帮助教小舒QQ2823408167 3 Maintenance 3.4.1. Type of oil Continued Label at robot base Label located at robot base shows the types of oil in all gearboxes. xx0500001397 Article numbers and volumes, Alternative Optimol Optigear RMO 150 Alternative - Optimol Optigear RMO 150. Note 1 on page 196Note 2 on page 197 Gearbox Type of oil...

  • Page 199: Article Numbers And Volumes, Alternative Kyodo Yushi Tmo 150

    工控帮助教小舒QQ2823408167 3 Maintenance 3.4.1. Type of oil Continued Note 2 Optigear RO 150 and RMO 150 are mixable but none are mixable with Tivela S 150 or TMO150. Article numbers and volumes, Alternative Kyodo Yushi TMO 150 Alternative - Kyodo Yushi TMO 150. Note 1 on page 197 Note 2 on page 197 Gearbox Type of oil...

  • Page 200: Rinsing Gearbox

    工控帮助教小舒QQ2823408167 3 Maintenance 3.4.1. Type of oil Continued Rinsing gearbox Depending on which types of oil are mixed and which type of oil shall be filled in the gearbox after rinsing, use the appropriate procedure. The same applies if the type of oil shall be changed in the gearbox. NOTE! The explanation given for Kyodo Yushi TMO 150 also applies to Shell Tivela S 150.

  • Page 201: Oil Change, Gearbox Axis 1

    工控帮助教小舒QQ2823408167 3 Maintenance 3.4.2. Oil change, gearbox axis 1 3.4.2. Oil change, gearbox axis 1 Location of gearbox The axis 1 gearbox is located between the frame and base as shown in the figure below. The oil is drained with a hose that may be reached behind the rear cover of the robot base. xx0200000111 Gearbox, axis 1 Oil plug, filling...
  • Page 202 工控帮助教小舒QQ2823408167 3 Maintenance 3.4.2. Oil change, gearbox axis 1 Continued Oil plug in the base In some early versions of the robot, the oil plug for draining may be located in the base, as shown in the figure below. xx0300000065 Oil plug in the base Required equipment Equipment, etc.
  • Page 203 工控帮助教小舒QQ2823408167 3 Maintenance 3.4.2. Oil change, gearbox axis 1 Continued Draining, oil, gearbox axis 1 The procedure below details how to drain the oil from the gearbox axis 1. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no.
  • Page 204 工控帮助教小舒QQ2823408167 3 Maintenance 3.4.2. Oil change, gearbox axis 1 Continued Filling, oil, gearbox axis 1 The procedure below details how to fill oil in gearbox, axis 1. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no.

  • Page 205: Oil Change, Gearbox Axis 2

    工控帮助教小舒QQ2823408167 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. xx0200000112 Gearbox, axis 2 Oil plug, filling (later design) Oil plug, draining Label, specifies the type of oil in the gearbox Required equipment...
  • Page 206 工控帮助教小舒QQ2823408167 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 203.
  • Page 207 工控帮助教小舒QQ2823408167 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 203.

  • Page 208: Oil Change, Gearbox, Axis 3

    工控帮助教小舒QQ2823408167 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. xx0200000113 Gearbox, axis 3 Oil plug, filling Oil plug, draining Label, specifies the type of oil in gearbox...
  • Page 209 工控帮助教小舒QQ2823408167 3 Maintenance 3.4.4. Oil change, gearbox, axis 3 Continued Draining, oil The procedure below details how to drain oil from the gearbox, axis 3. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 206.
  • Page 210 工控帮助教小舒QQ2823408167 3 Maintenance 3.4.4. Oil change, gearbox, axis 3 Continued Filling, oil The procedure below details how to fill oil into 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 206.

  • Page 211: Oil Change, Gearbox, Axis 4

    工控帮助教小舒QQ2823408167 3 Maintenance 3.4.5. Oil change, gearbox, axis 4 3.4.5. Oil change, gearbox, axis 4 Different types of oil The primary and secondary gear may require different types of oil, that must never be mixed! If they are mixed, the gear must be rinsed according to section Flushing a contaminated gearbox on page 231.
  • Page 212 工控帮助教小舒QQ2823408167 3 Maintenance 3.4.5. Oil change, gearbox, axis 4 Continued Required equipment Equipment, etc. Art. no. Amount Note Lubricating oil 3HAC032140-001 900 ml Kyodo Yushi TMO 150 To be used in the primary gearbox. Lubricating oil 3HAC032140-001 3,850 ml Kyodo Yushi TMO 150 To be used in the secondary gearbox.
  • Page 213 工控帮助教小舒QQ2823408167 3 Maintenance 3.4.5. Oil change, gearbox, axis 4 Continued Action Note 7. Refit the both oil plugs, draining. Tightening torque: 24 Nm. Filling, oil, gearbox axis 4 The procedure below details how to fill oil in gearbox, axis 4. When using the oil exchange equipment, follow the instructions enclosed with the kit.

  • Page 214: Oil Change, Gearbox, Axis 5

    工控帮助教小舒QQ2823408167 3 Maintenance 3.4.6. Oil change, gearbox, axis 5 3.4.6. Oil change, gearbox, axis 5 Different types of oil The primary and secondary gear may require different types of oil, that must never be mixed! If they are mixed, the gear must be rinsed according to section Flushing a contaminated gearbox on page 231.
  • Page 215 工控帮助教小舒QQ2823408167 3 Maintenance 3.4.6. Oil change, gearbox, axis 5 Continued Required equipment Equipment, etc. Art. no. Amount Note Lubricating oil 3HAC032140-001 750 ml Kyodo Yushi TMO 150 To be used in the primary gearbox. Lubricating oil 3HAC032140-001 3,800 ml Kyodo Yushi TMO 150 To be used in the secondary gearbox.
  • Page 216 工控帮助教小舒QQ2823408167 3 Maintenance 3.4.6. Oil change, gearbox, axis 5 Continued Filling, oil, gearbox axis 5 The procedure below details how to fill oil in gearbox, axis 5. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no.

  • Page 217: Oil Change, Gearbox Axis 6

    工控帮助教小舒QQ2823408167 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. xx0200000114 Gearbox, axis 6 Oil plug, filling (notice the different locations of the plug, shown as B and B Oil plug, draining (can be located on the turning disk instead)
  • Page 218 工控帮助教小舒QQ2823408167 3 Maintenance 3.4.7. Oil change, gearbox axis 6 Continued NOTE! The specified amount of oil is based on the total volume of the gearbox. When changing the oil, the amount of refilled oil may differ from the specified amount, depending on how much oil has previously been drained from the gearbox.
  • Page 219 工控帮助教小舒QQ2823408167 3 Maintenance 3.4.7. Oil change, gearbox axis 6 Continued Filling, oil, gearbox axis 6 The procedure below details how to fill oil in the gearbox axis 6. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no.

  • Page 220: Replacing Smb Battery

    Required equipment Equipment, etc. Spare part no. Note Battery pack 3HAC16831-1 Battery includes protection circuits. Replace it only with a given spare part number or an ABB approved equivalent. Standard toolkit Content is defined in section Standard toolkit on page 427.
  • Page 221 218. 6. Remove SMB battery. Shown in figure Location of SMB battery on page 218. Battery includes protection circuits. Replace it only with the specified spare part or with an ABB approved equivalent. Continues on next page 3HAC022033-001 Revision: K...
  • Page 222 工控帮助教小舒QQ2823408167 3 Maintenance 3.4.8. Replacing SMB battery Continued Refitting, battery Use this procedure to refit the SMB battery. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Turn off all electric power and hydraulic but not the air pressure to the gearboxes, motors and SMB.

  • Page 223: Lubrication Activities

    工控帮助教小舒QQ2823408167 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 224 工控帮助教小舒QQ2823408167 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! Turn off all electric power and hydraulic but not the air pressure to the gearboxes, motors and SMB.

  • Page 225: Rust Preventive Measures, Bearing Axis 1 (Foundry Prime)

    工控帮助教小舒QQ2823408167 3 Maintenance 3.5.2. Rust preventive measures, bearing axis 1 (Foundry Prime) 3.5.2. Rust preventive measures, 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...
  • Page 226 工控帮助教小舒QQ2823408167 3 Maintenance 3.5.2. Rust preventive measures, bearing axis 1 (Foundry Prime) Continued Procedure The following procedure details how to apply the rust preventive on bearing axis 1. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Turn off all electric power and hydraulic but not the air pressure to the gearboxes, motors and SMB.
  • Page 227 工控帮助教小舒QQ2823408167 3 Maintenance 3.5.2. Rust preventive measures, bearing axis 1 (Foundry Prime) Continued Action Note 4. Apply rust preventive on the bearing with a brush. xx0600002867 Parts: • A: Bearing 5. Refit the plastic ring. 3HAC022033-001 Revision: K...

  • Page 228: Rust Preventive Measures, Sealing Axis 4 (Foundry Prime)

    工控帮助教小舒QQ2823408167 3 Maintenance 3.5.3. Rust preventive measures, sealing axis 4 (Foundry Prime) 3.5.3. Rust preventive measures, sealing axis 4 (Foundry Prime) Overview The sealing axis 4 is located as shown in the illustration. xx0500002869 Cover Cable guide Required equipment Equipment Art.
  • Page 229 工控帮助教小舒QQ2823408167 3 Maintenance 3.5.3. Rust preventive measures, sealing axis 4 (Foundry Prime) Continued Procedure The procedure describes how to apply rust preventive on sealing axis 1. Action Note 1. Put the robot in a suitable position. DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Turn off all electric power and...
  • Page 230 工控帮助教小舒QQ2823408167 3 Maintenance 3.5.3. Rust preventive measures, sealing axis 4 (Foundry Prime) Continued Action Note 6. Apply rust preventive on the radial sealing and the rear part of the tube with a brush. xx0600002868 Parts: • A: Radial sealing and rear part of tube •...

  • Page 231: Rust Preventive Measures, Support Bearing In Wrist (Foundry Prime)

    工控帮助教小舒QQ2823408167 3 Maintenance 3.5.4. Rust preventive measures, support bearing in wrist (Foundry Prime) 3.5.4. Rust preventive measures, 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...
  • Page 232 工控帮助教小舒QQ2823408167 3 Maintenance 3.5.4. Rust preventive measures, support bearing in wrist (Foundry Prime) Continued Action Note 3. Dismantle the air hose from motor axis 6. 4. Tighten the hose clamp on motor axis 6, and remove the air hose. 5. Remove the cover. xx0600002864 •...

  • Page 233: Cleaning Activities

    工控帮助教小舒QQ2823408167 3 Maintenance 3.6.1. Flushing a contaminated gearbox 3.6 Cleaning activities 3.6.1. Flushing a contaminated gearbox Different types of oil As the Shell Tivela S 150 is not compatible with mineral oil, contamination with other types of oils used in the gearboxes is not accepted. Equipment used in handling of Tivela S 150 must be carefully cleaned.
  • Page 234 工控帮助教小舒QQ2823408167 3 Maintenance 3.6.1. Flushing a contaminated gearbox Continued Flushing The procedure below details how to flush a contaminated gearbox. The procedure is the same for all gearboxes. Action Note 1. Run the Service program until the castings of the Recommended service program gearboxes axis 4, 5 and 6 have reached a detailed in section above:...

  • Page 235: Cleaning, Robot

    If cleaning ABB, spirit or solution. detergents are used they isopropyl must be approved by ABB alcohol. for Foundry Prime robots. Perform according to section Cleaning with water and steam on page 234. Continues on next page...
  • Page 236 工控帮助教小舒QQ2823408167 3 Maintenance 3.6.2. Cleaning, robot Continued Cleaning with water and steam Cleaning methods that can be used for ABB robots with protection Standard, Foundry Plus, Wash, Foundry Prime. Equipment, etc. Note Vacuum cleaner Cloth with mild detergent Water cleaner •...

  • Page 237: Service Information System, M2000

    工控帮助教小舒QQ2823408167 3 Maintenance 3.7.1. Using the SIS system 3.7 Service Information System, M2000 3.7.1. Using the SIS system General This is a brief description of how to use the Service Information System, SIS for M2000 robot systems. Details may be found in: •...

  • Page 238: Description Of Service Information System (Sis)

    工控帮助教小舒QQ2823408167 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 239 工控帮助教小舒QQ2823408167 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 240: 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 241 工控帮助教小舒QQ2823408167 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.

  • Page 242: Setting The Sis Parameters

    工控帮助教小舒QQ2823408167 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 243 工控帮助教小舒QQ2823408167 3 Maintenance 3.7.4. Setting the SIS parameters Continued Action Note 3. Select "0 SIS parameters" and press "Enter". en0200000047 xx0100000200 4. Select the required system The parameter list is displayed. en0200000048 en0200000049 5. Select the required Available parameters are described in section SIS system parameters by stepping up parameters on page...

  • Page 244: Reading The Sis Output Logs

    工控帮助教小舒QQ2823408167 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 245: Exporting The Sis Data

    工控帮助教小舒QQ2823408167 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".
  • Page 246 工控帮助教小舒QQ2823408167 3 Maintenance 3.7.6. Exporting the SIS data 3HAC022033-001 Revision: K...

  • Page 247: Repair

    工控帮助教小舒QQ2823408167 4 Repair 4.1. Introduction 4 Repair 4.1. Introduction Structure of this chapter This chapter describes all repair activities recommended for the robot and any external units of the robot. It is made up of separate procedures, each describing a specific repair activity. Each procedure contains all the information required to perform the activity, for example spare parts numbers, required special tools, and materials.

  • Page 248: General Procedures

    工控帮助教小舒QQ2823408167 4 Repair 4.2.1. Performing a leak-down test 4.2 General procedures 4.2.1. Performing a leak-down test General After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equipment Equipment, etc.

  • Page 249: Mounting Instructions For Bearings

    工控帮助教小舒QQ2823408167 4 Repair 4.2.2. Mounting instructions for bearings 4.2.2. Mounting instructions for bearings General This section describes how to mount and grease different types of bearings on the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB3537-1 Used to grease the bearings, if not specified otherwise.
  • Page 250 工控帮助教小舒QQ2823408167 4 Repair 4.2.2. Mounting instructions for bearings Continued Greasing of bearings The bearings must be greased after assembly according to the following instructions: • The bearings must not be completely filled with grease. However, if space is available beside the bearing fitting, the bearing may be totally filled with grease when mounted, as excessive grease will be pressed out from the bearing when the robot is started.

  • Page 251: Mounting Instructions For Seals

    工控帮助教小舒QQ2823408167 4 Repair 4.2.3. Mounting instructions for seals 4.2.3. Mounting instructions for seals General This section describes how to mount different types of seals onto the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB3537-1 Used to lubricate the seals. Rotating seals The procedure below describes how to fit rotating seals.
  • Page 252 If the flange surfaces are defective, the parts may not be used because leakage could occur. 2. Clean the surfaces properly in accordance with the recommendations of ABB. 3. Distribute the sealing compound evenly over the surface, preferably with a brush.

  • Page 253: Complete Robot

    工控帮助教小舒QQ2823408167 4 Repair 4.3.1. Replacement of cable harness, axes 1-4 4.3 Complete robot 4.3.1. Replacement of cable harness, axes 1-4 Location of cable harness The cable harness for axes 1-4 is run throughout the base, frame and lower arm as shown in the figure below.
  • Page 254 工控帮助教小舒QQ2823408167 4 Repair 4.3.1. Replacement of cable harness, axes 1-4 Continued Connectors at motor 5; R3.FB5 and R3.MP5 Connectors at motor 6; R3.FB6 and R3.MP6 Rear cover plate Connector R1.MP Connector R1.SMB Connection of earth cable Required equipment Equipment, etc. Spare part no.
  • Page 255 工控帮助教小舒QQ2823408167 4 Repair 4.3.1. Replacement of cable harness, axes 1-4 Continued Action Note 3. Remove the rear cover plate from the robot by Shown in the figure Location of removing its attachment screws. cable harness on page 251. 4. Disconnect the earth cable. Attachment point is shown in the figure Location of cable harness...
  • Page 256 工控帮助教小舒QQ2823408167 4 Repair 4.3.1. Replacement of cable harness, axes 1-4 Continued Action Note 10. 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 257 工控帮助教小舒QQ2823408167 4 Repair 4.3.1. Replacement of cable harness, axes 1-4 Continued Action Note 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 258 工控帮助教小舒QQ2823408167 4 Repair 4.3.1. Replacement of cable harness, axes 1-4 Continued Action Note 3. Pull the cable and connectors down through the Make sure the cables are not cable guide in the center of the frame. twisted with each other or with eventual customer harnesses! Make a note of the correct positions of the connectors!
  • Page 259 工控帮助教小舒QQ2823408167 4 Repair 4.3.1. Replacement of cable harness, axes 1-4 Continued Action Note 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 252. Secure the correct attachment plate (C) to the cable gland with its two attachment screws, using locking liquid.
  • Page 260 工控帮助教小舒QQ2823408167 4 Repair 4.3.1. Replacement of cable harness, axes 1-4 Continued Action Note 9. Reconnect connectors R2.SMB, R1.SMB1-3, R1.SMB4-6 to the SMB unit. Reconnect X8, X9 and X10 if the brake release board is located in frame. Reconnect R1.G if it has been disconnected. xx0200000118 10.
  • Page 261 工控帮助教小舒QQ2823408167 4 Repair 4.3.1. Replacement of cable harness, axes 1-4 Continued Action Note 16. Reconnect the connector R2.M5/6 gently at the Shown in the figure Location of cable division point. cable harness on page 251! Be careful not to bend the attachment plate when M6, 2 pcs.

  • Page 262: Replacement Of Cable Harness, Axes 5-6

    工控帮助教小舒QQ2823408167 4 Repair 4.3.2. Replacement of cable harness, axes 5-6 4.3.2. Replacement of cable harness, axes 5-6 Location of cable harness ax 5-6 The location of the cable harness, axes 5-6, is shown in the figure below. xx0100000145 Cable attachment, upper arm Cable attachment, rear Connector at cable harness division;...
  • Page 263 工控帮助教小舒QQ2823408167 4 Repair 4.3.2. Replacement of cable harness, axes 5-6 Continued Removal, cable harness, axes 5-6 The procedure below details how to remove the upper arm cable harness. Action Note 1. Position the upper arm as follows: • Axis 4: 0 degrees •...
  • Page 264 工控帮助教小舒QQ2823408167 4 Repair 4.3.2. Replacement of cable harness, axes 5-6 Continued Action Note 5. Secure the small plate to the large plate. Secure the spiral cup with its attachment screw in the bottom of the cup. 6. Secure any excess cable length tightly to the large Excess cable length may be plate in the wrist housing, using cable straps.

  • Page 265: Replacement Of Complete Arm System

    工控帮助教小舒QQ2823408167 4 Repair 4.3.3. Replacement of complete arm system 4.3.3. Replacement of complete arm system Location of complete arm system The complete arm system is defined as the complete robot except for the base and gearbox axis 1, that is the upper and lower arms, balancing device and frame. This is shown in the figure below.
  • Page 266 工控帮助教小舒QQ2823408167 4 Repair 4.3.3. Replacement of complete arm system Continued Required equipment Equipment, etc. Art. no. Note Lifting device, robot 3HAC15607-1 Instruction 3HAC15971-2 enclosed! Guide pins, M12 x 130 Used to guide the complete arm system when refitting. Standard toolkit Content is defined in section Standard toolkit on page 427.
  • Page 267 工控帮助教小舒QQ2823408167 4 Repair 4.3.3. Replacement of complete arm system Continued Action Note CAUTION! The complete arm system weighs 2000 kg! All lifting equipment used must be sized accord- ingly! 7. Fit the lifting device and adjust it as detailed in Art.
  • Page 268 工控帮助教小舒QQ2823408167 4 Repair 4.3.3. Replacement of complete arm system Continued Action Note 5. Fit two guide pins, M12 x 130, in the frame attachment holes as shown in the figure to the right. Fit one guide pin next to the guiding hole (for the spring pin in the gearbox) and the other guide pin straight across the frame.
  • Page 269 工控帮助教小舒QQ2823408167 4 Repair 4.3.3. Replacement of complete arm system Continued Action Note DANGER! Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: K...

  • Page 270: Replacement Of Air Nipple And Hose (Foundry Prime)

    工控帮助教小舒QQ2823408167 4 Repair 4.3.4. Replacement of air nipple and hose (Foundry Prime) 4.3.4. Replacement of air nipple and hose (Foundry Prime) Location The illustration below shows the routing of the Foundry Prime air hose. xx0500002176 Hose lengths xx0600003157 Pos 1A Hose length 40 mm Pos 1B Hose length 40 mm...
  • Page 271 工控帮助教小舒QQ2823408167 4 Repair 4.3.4. Replacement of air nipple and hose (Foundry Prime) Continued Pos 1H Hose length 570 mm Pos 1K Hose length 4040 mm Pos 1L Hose length 150 mm Pos 1M Hose length 120 mm Pos 1N Hose length 35 mm Pos 1P Hose length 1540 mm Pos 1Q...
  • Page 272 工控帮助教小舒QQ2823408167 4 Repair 4.3.4. Replacement of air nipple and hose (Foundry Prime) Continued Procedure The following procedures details how to replace the Foundry Prime air nipples and hose. The pos. no. in following procedures correspond to the illustration in Hose lengths on page 268and the table in Required equipment on page 269 Action...
  • Page 273 工控帮助教小舒QQ2823408167 4 Repair 4.3.4. Replacement of air nipple and hose (Foundry Prime) Continued Action Note 5. Balancing device. xx0600003397 Item in illustration is detailed in Hose lengths on page 268. Continues on next page 3HAC022033-001 Revision: K...
  • Page 274 工控帮助教小舒QQ2823408167 4 Repair 4.3.4. Replacement of air nipple and hose (Foundry Prime) Continued Action Note 6. Axis 1-2. xx0600003418 xx0600003420 xx0600003045 Continues on next page 3HAC022033-001 Revision: K...
  • Page 275 工控帮助教小舒QQ2823408167 4 Repair 4.3.4. Replacement of air nipple and hose (Foundry Prime) Continued Action Note 7. Upper arm housing. xx0600003046 xx0600003047 8. Tube shaft. xx0600003163 • 1P: Lay the hose in a spiral in the tube shaft. Continues on next page 3HAC022033-001 Revision: K...
  • Page 276 工控帮助教小舒QQ2823408167 4 Repair 4.3.4. Replacement of air nipple and hose (Foundry Prime) Continued Action Note 9. Wrist. NOTE! Make sure the cable length from 5a to the nipple of axis 6 = S, see Hose lengths on page 268. xx0600003097 3HAC022033-001 Revision: K...

  • Page 277: Upper And Lower Arm

    工控帮助教小舒QQ2823408167 4 Repair 4.4.1. Replacing turning disk 4.4 Upper and lower arm 4.4.1. Replacing turning disk Location of turning disk The turning disk is located in the center of the wrist unit as shown in the figure below. xx0100000129 Turning disk Oil plug, filling (oil plug for draining is located on the opposite side of the tilthouse) Turning disk attachment screws, 33 pcs Required equipment...
  • Page 278 工控帮助教小舒QQ2823408167 4 Repair 4.4.1. Replacing turning disk Continued Removing turning disk Use the procedure to remove the turning disk. Action Info DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Turn off all electric power and hydraulic but not the air pressure to the gearboxes, motors and SMB.
  • Page 279 工控帮助教小舒QQ2823408167 4 Repair 4.4.1. Replacing turning disk Continued Refitting turning disk Use this procedure to refit the turning disk. Action Info DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Turn off all electric power and hydraulic but not the air pressure to the gearboxes, motors and SMB.
  • Page 280 工控帮助教小舒QQ2823408167 4 Repair 4.4.1. Replacing turning disk Continued Action Info DANGER! Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: K...

  • Page 281: Replacement Of Complete Wrist Unit

    工控帮助教小舒QQ2823408167 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 282 工控帮助教小舒QQ2823408167 4 Repair 4.4.2. Replacement of complete wrist unit Continued Equipment, etc. Spare part no. Art. no. Note Standard toolkit Content is defined in section Standard toolkit on page 427. Calibration Pendulum 3HAC15716-1 Complete kit that also toolkit includes operating manual.
  • Page 283 工控帮助教小舒QQ2823408167 4 Repair 4.4.2. Replacement of complete wrist unit Continued Action Note 11. Remove the wrist unit attachment screws and washers. 12. Pull the cabling forwards through the upper arm tube. Make sure the attachments do not get stuck inside the tube! 13.
  • Page 284 工控帮助教小舒QQ2823408167 4 Repair 4.4.2. Replacement of complete wrist unit Continued Action Note 11. Reconnect connector R2.M5/6 at the rear cable Shown in the figure Location of division point. wrist unit on page 279. 12. Refit the rear cover with its attachment screws. Shown in the figure Location of wrist unit on page...

  • Page 285: Replacement Of Complete Upper Arm

    工控帮助教小舒QQ2823408167 4 Repair 4.4.3. Replacement of complete upper arm 4.4.3. Replacement of complete upper arm Location of upper arm The upper arm is located on top of the robot as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
  • Page 286 工控帮助教小舒QQ2823408167 4 Repair 4.4.3. Replacement of complete upper arm Continued Required equipment Equipment, etc. Art. no. Note Sealing, axis 2/3 3HAC11054-1 Always use a new sealing when reassembling! Washer 3HAC11828-1 Replace if damaged! Standard toolkit Content is defined in section Standard toolkit on page 427.
  • Page 287 工控帮助教小舒QQ2823408167 4 Repair 4.4.3. Replacement of complete upper arm Continued Action Note 6. Run the lifting chain from the rear lifting point through Art. no. is specified in Required the overhead crane hook, through the hoisting block to equipment on page 284.
  • Page 288 工控帮助教小舒QQ2823408167 4 Repair 4.4.3. Replacement of complete upper arm Continued Action Note/Illustration 2. Fit the two guide pins, sealing axis 2/3 in two of the Always use a new sealing when attachment screw holes on gearbox 3, see figure to reassembling! the right.
  • Page 289 工控帮助教小舒QQ2823408167 4 Repair 4.4.3. Replacement of complete upper arm Continued Action Note/Illustration 10. Insert the attachment screws. In some cases, removing the plastic mechanical stops may be Do not remove the guide pins until the attachment required before fitting the upper screws are tightened as detailed below! arm.

  • Page 290: Replacement Of Complete Lower Arm

    工控帮助教小舒QQ2823408167 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 291 工控帮助教小舒QQ2823408167 4 Repair 4.4.4. Replacement of complete lower arm Continued xx0200000031 Gearbox Lower arm Balancing device piston rod ear Frame Shaft hole Sealing, axis 2/3 Attachment screw Washer Bearing Thrust washer Bushing Retaining ring Shaft Protection plug Protection washer Required equipment Equipment, etc.
  • Page 292 4.4.4. Replacement of complete lower arm Continued Equipment, etc. Spare part no. Art. no. Note Lifting tool, lower 3HAC14691-1 Tool that may be rent from ABB. Includes • Guidances, 3HAC14445-1 The guidings are used for guiding the sealing, axis 2/3. Rotation tool...
  • Page 293 工控帮助教小舒QQ2823408167 4 Repair 4.4.4. Replacement of complete lower arm Continued Action Note 2. Remove the upper arm. Detailed in section Replacement of complete upper arm on page 283. 3. Disconnect and remove the cables from inside Detailed in section Replacement of the lower arm.
  • Page 294 工控帮助教小舒QQ2823408167 4 Repair 4.4.4. Replacement of complete lower arm Continued Action Note 11. Apply the lifting tool to the lower arm. Art. no. is specified in Required equipment on page 289! 12. Drain the oil from gearbox 2. Detailed in section Oil change, gearbox axis 2 on page 203.
  • Page 295 工控帮助教小舒QQ2823408167 4 Repair 4.4.4. Replacement of complete lower arm Continued Action Note 21. Remove the sealing from the lower arm. Shown in the figure Attachment points, lower arm on page 288. On reassembly a new sealing must be used! Refitting, lower arm The procedure below details how to refit the lower arm to the robot.
  • Page 296 工控帮助教小舒QQ2823408167 4 Repair 4.4.4. Replacement of complete lower arm Continued Action Note 8. In case the holes of the lower arm and the ones Connect power supply to connector of the gearbox axis 2 doesn´t match, use power R2.MP2: supply to release the motor axis 2 brakes and •...
  • Page 297 工控帮助教小舒QQ2823408167 4 Repair 4.4.4. Replacement of complete lower arm Continued Action Note 16. Set the indicator on the press tool to zero. 17. Press in the shaft with the hydraulic cylinder by setting the pressure of the hydraulic pump to approximately 35-55 MPa and the pressure of the glycerin pump to 55 MPa.
  • Page 298 工控帮助教小舒QQ2823408167 4 Repair 4.4.4. Replacement of complete lower arm Continued Action Note DANGER! Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: K...

  • Page 299: Frame And Base

    工控帮助教小舒QQ2823408167 4 Repair 4.5.1. Replacement of SMB unit 4.5 Frame and base 4.5.1. Replacement of SMB unit Location of SMB unit The SMB unit (SMB = serial measurement board) is located on the left hand side of the frame as shown in the figure below. xx0200000203 SMB cover SMB unit...
  • Page 300 工控帮助教小舒QQ2823408167 4 Repair 4.5.1. Replacement of SMB unit Continued Removal, SMB unit Use this procedure 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! Turn off all electric power and hydraulic but not the air pressure to the gearboxes, motors and SMB.
  • Page 301 工控帮助教小舒QQ2823408167 4 Repair 4.5.1. Replacement of SMB unit Continued Action Note WARNING! The unit is sensitive to ESD. Before handling the unit please read the safety information in the section WARNING - The unit is sensitive to ESD! on page 49 3.
  • Page 302 工控帮助教小舒QQ2823408167 4 Repair 4.5.1. Replacement of SMB unit Continued Action Note WARNING! The unit is sensitive to ESD. Before handling the unit please read the safety information in the section WARNING - The unit is sensitive to ESD! on page 3.

  • Page 303: Replacement Of Brake Release Unit

    工控帮助教小舒QQ2823408167 4 Repair 4.5.2. Replacement of brake release unit 4.5.2. Replacement of brake release unit Different designs Depending on the robot version, the brake release unit may be located either at the base or at the frame. The following two figures show the different locations. The early design includes a brake release unit with or without push buttons, located at the base.
  • Page 304 工控帮助教小舒QQ2823408167 4 Repair 4.5.2. Replacement of brake release unit Continued Location of brake release unit, frame The later design includes a brake release unit with push buttons, placed together with the SMB unit on the left hand side of the frame as shown in the figure below. xx0200000226 Brake release unit Attachment screws, brake release unit (4 pcs)
  • Page 305 工控帮助教小舒QQ2823408167 4 Repair 4.5.2. Replacement of brake release unit Continued Equipment, etc. Spare part no. Note Other tools and These procedures include references to the procedures may be tools required. required. See references to these procedures in the step-by-step instructions below.
  • Page 306 工控帮助教小舒QQ2823408167 4 Repair 4.5.2. Replacement of brake release unit Continued Action Note WARNING! The unit is sensitive to ESD. Before handling the unit please read the safety information in the section WARNING - The unit is sensitive to ESD! on page 49 3.
  • Page 307 工控帮助教小舒QQ2823408167 4 Repair 4.5.2. Replacement of brake release unit Continued Refitting of brake release circuit, located at base The procedure below details how to refit the brake release circuit, located at the rear of the base. See the figure Location of brake release unit, base on page 301.
  • Page 308 工控帮助教小舒QQ2823408167 4 Repair 4.5.2. Replacement of brake release unit Continued Action Note 3. Connect the connectors X8, X9 and X10 to the brake release unit. xx0200000129 A. Connector X8 B. Connector X9 C. Connector X10 D. Push buttons 4. Refit the SMB cover with its attachment screws. Shown in the figure Location of brake release unit, frame on page 302.

  • Page 309: Replacement Of Balancing Device

    工控帮助教小舒QQ2823408167 4 Repair 4.5.3. Replacement of balancing device 4.5.3. 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. xx0100000139 Balancing device Rear cover Support shaft inside (included in balancing device 3HAC14675-1) Attachment screws, rear cover Balancing device shaft, including screw and washer Bearing attachment...
  • Page 310 工控帮助教小舒QQ2823408167 4 Repair 4.5.3. 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. xx0600002653 Attachment hole for lifting eye, M12 Attachment hole for securing screw that secures the bearing attachment to the balancing device (protection plug fitted normally) Hole in frame to access the balancing device front eye shaft with the puller/press tool Attachment hole for locking screw that secures the lower arm to the frame...
  • Page 311 工控帮助教小舒QQ2823408167 4 Repair 4.5.3. Replacement of balancing device Continued Required equipment Equipment Spare part no. Art. no. Note Balancing device 3HAC14214-1 Includes: • balancing device 3HAC14675-1 or 3HAC023018-001 • o-ring 3HAB3772- 44 (2 pcs) O-ring 3HAB3772-44 2 pcs , to be replaced if damaged! (included with the new balancing device) Locking screw...
  • Page 312 工控帮助教小舒QQ2823408167 4 Repair 4.5.3. Replacement of balancing device Continued Equipment Spare part no. Art. no. Note Other tools and These procedures include procedures may be references to the tools required. See required. references to these procedures in the step-by-step instruc- tions below.
  • Page 313 工控帮助教小舒QQ2823408167 4 Repair 4.5.3. Replacement of balancing device Continued Action Note 8. Apply the puller tool, balancing device shaft to Art. no. is specified in Required the shaft through the hole in the frame. equipment on page 309! The shaft has a M20 thread diameter, as shown The hole in the frame is shown in the in the figure to the right.
  • Page 314 工控帮助教小舒QQ2823408167 4 Repair 4.5.3. Replacement of balancing device Continued Refitting, balancing device The procedure below details how to refit the balancing device. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Turn off all electric power and hydraulic but not the air pressure to the gearboxes, motors and SMB.
  • Page 315 工控帮助教小舒QQ2823408167 4 Repair 4.5.3. Replacement of balancing device Continued Action Note 10. Remove the guide pins. 11. Secure the rear of the balancing device by Shown in the figure Location of fastening the two bearing attachments to the balancing device on page 307! frame with their four attachment screws.
  • Page 316 工控帮助教小舒QQ2823408167 4 Repair 4.5.3. Replacement of balancing device Continued Action Note DANGER! The rear cover of the balancing device is a safety device for the piston rod during operation! Make sure the cover is properly secured before commissioning of the robot! 21.
  • Page 317 工控帮助教小舒QQ2823408167 4 Repair 4.5.3. Replacement of balancing device Continued Action Note 2. Pull out the sealing spacers, but let them still remain on the ear. • Apply rust preventive abundantly in the • press the sealing back in place • wipe off surplus material.

  • Page 318: Replacement Of Spherical Roller Bearing, Balancing Device

    工控帮助教小舒QQ2823408167 4 Repair 4.5.4. Replacement of spherical roller bearing, balancing device 4.5.4. 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...
  • Page 319 工控帮助教小舒QQ2823408167 4 Repair 4.5.4. Replacement of spherical roller bearing, balancing device Continued Equipment Spare part no. Art. no. Note Other tools and These procedures include procedures may be references to the tools required. See required. references to these procedures in the step-by-step instruc- tions below.
  • Page 320 工控帮助教小舒QQ2823408167 4 Repair 4.5.4. Replacement of spherical roller bearing, balancing device Continued Action Note 5. Fit the press tool and dolly to the threaded bar. Secure with the nut and washer at each end. xx0500002255 A. Threaded bar 3HAC15945-1 B. Dolly 3HAC15948-1 C.
  • Page 321 工控帮助教小舒QQ2823408167 4 Repair 4.5.4. Replacement of spherical roller bearing, balancing device Continued Action Note 5. Apply grease to the new sealing rings and o- Spare part no:s are specified in Required rings and fit one of each to the new sealing equipment on page 316.

  • Page 322: Unloading The Balancing Device Using Hydraulic Press Tool

    工控帮助教小舒QQ2823408167 4 Repair 4.5.5. Unloading the balancing device using hydraulic press tool. 4.5.5. Unloading the balancing device using hydraulic press tool. Prerequisite This section details how to unload the balancing device using the hydraulic press tool. The lower arm must be secured before unloading the balancing device! How to secure the lower arm is detailed in the current repair activity, for example removal of the balancing device.
  • Page 323 工控帮助教小舒QQ2823408167 4 Repair 4.5.5. Unloading the balancing device using hydraulic press tool. Continued Required equipment Equipment, etc. Art. no. Note Press tool, balancing device 3HAC020902-001 Includes • press device 3HAC15767-2 • press device 3HAC18100-1 Choose the correct device, depending on model of balancing device. Hydraulic cylinder 3HAC11731-1 To be used with the press tool.
  • Page 324 工控帮助教小舒QQ2823408167 4 Repair 4.5.5. Unloading the balancing device using hydraulic press tool. Continued Unloading the balancing device The procedure below details how to use the press tool in order to unload the balancing device. How to remove the press tool, is detailed in section Restoring the balancing device using a hydraulic press tool.
  • Page 325 工控帮助教小舒QQ2823408167 4 Repair 4.5.5. Unloading the balancing device using hydraulic press tool. Continued Action Note 11. Unload the hydraulic cylinder. 12. The hydraulic cylinder may now be removed from the tool, when necessary. 3HAC022033-001 Revision: K...

  • Page 326: Restoring The Balancing Device Using A Hydraulic Press Tool

    工控帮助教小舒QQ2823408167 4 Repair 4.5.6. Restoring the balancing device using a hydraulic press tool. 4.5.6. Restoring the balancing device using a hydraulic press tool. Overview This section details how to restore the balancing device and how to remove the press tool from the device.
  • Page 327 工控帮助教小舒QQ2823408167 4 Repair 4.5.6. Restoring the balancing device using a hydraulic press tool. Continued Required equipment Equipment, etc. Art. no. Note Hydraulic cylinder 3HAC11731-1 To be used with press tool. Hydraulic pump, 80 MPa 3HAC13086-1 To be used with hydraulic cylinder. Brush Rust preventive 3HAC026621-001...
  • Page 328 工控帮助教小舒QQ2823408167 4 Repair 4.5.6. Restoring the balancing device using a hydraulic press tool. Continued Action Note 9. Refit the rear cover to the balancing device with its attachment screws, using locking liquid. Apply sikaflex 521FX on the cover. xx0200000175 • E: 4 pcs: M10x30, tightening torque: 50 Nm.

  • Page 329: Motors

    工控帮助教小舒QQ2823408167 4 Repair 4.6.1. Replacement of motor, axis 1 4.6 Motors 4.6.1. Replacement of motor, axis 1 NOTE! This procedure requires calibration of the robot. Use the Calibration Pendulum tool 3HAC15716-1. Location of motor The motor axis 1 is located on the left hand side of the robotas shown in the figure below. xx0100000123 Motor, axis 1 Cable gland cover, motor axis...
  • Page 330 工控帮助教小舒QQ2823408167 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Equipment, etc. Spare part no. Art. no. Note Sikaflex 521FC 3HAC026759-001 Option Foundry Prime Brush Option Foundry Prime Mercasol 3106 3HAC026621-001 Option Foundry Prime Loctite 574 Gasket 3HAC3438-1 Option Foundry Prime Must be replaced if the cabling is dismantled from the motor.
  • Page 331 工控帮助教小舒QQ2823408167 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 3. Remove the cable gland cover at the cable exit by unscrewing its two attachment screws. NOTE! Make sure the gasket is not damaged! xx0200000199 • A: Cable gland cover 4.
  • Page 332 工控帮助教小舒QQ2823408167 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note CAUTION! The motor weighs 32 kg! All lifting equipment used must be sized accordingly! 4. Apply the lifting tool, motor axis 1, 4, 5 to the motor. Art no. is specified in Required equipment on page 327.
  • Page 333 工控帮助教小舒QQ2823408167 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Replacement of the motor axis 1 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level. The repair must be done according to the previous repair procedures with the following additions.
  • Page 334 工控帮助教小舒QQ2823408167 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 5. Fill the four screw recesses on the new motor with Sikaflex. (After hardening, Sikaflex can be formed with a knife) xx0600002875 • A: Motor unit • B: Sikaflex in screw recesses 6.

  • Page 335: Replacement Of Motor Axis 2

    工控帮助教小舒QQ2823408167 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. xx0100000124 Motor, axis 2 Cable gland cover, motor axis 2 Hole for lock screw Required equipment...
  • Page 336 工控帮助教小舒QQ2823408167 4 Repair 4.6.2. Replacement of motor axis 2 Continued Equipment, etc. Spare part no. Art. no. Note Grease 3HAB3537-1 For lubricating the o-ring. Locking screw 3HAA1001-266 M16 x 60 For securing the lower arm. Removal tool, motor 3HAC14973-1 Always use the removal M12x tools in pairs! Guide pins M10 x...
  • Page 337 工控帮助教小舒QQ2823408167 4 Repair 4.6.2. Replacement of motor axis 2 Continued Removal, motor The procedure below details how to remove the motor, axis 2. Action Note 1. Move the robot to a position close Shown in the figure Location of motor on page enough to its calibration position, to 333.
  • Page 338 工控帮助教小舒QQ2823408167 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note 12. If required, press the motor out of Art. no. is specified in Required equipment on position by fitting the removal tool, page 333. motor to the remaining motor Shown in the figure Location of motor on page attachment holes.
  • Page 339 工控帮助教小舒QQ2823408167 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note CAUTION! The motor weighs 32 kg! All lifting equipment used must be sized accordingly! 7. Lift the motor and guide it onto the guide pins, as close to the correct position as possible without pushing the motor pinion into the gear.
  • Page 340 工控帮助教小舒QQ2823408167 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note 19. 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 403.
  • Page 341 工控帮助教小舒QQ2823408167 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note 5. 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 342 工控帮助教小舒QQ2823408167 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note 10. Fill the four screw recesses on the new motor with Sikaflex. (After hardening, Sikaflex can be formed with a knife) xx0600002875 • A: Motor unit • B: Sikaflex in screw recesses 11.

  • Page 343: Replacement Of Motor, Axis 3

    工控帮助教小舒QQ2823408167 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) Required equipment...
  • Page 344 工控帮助教小舒QQ2823408167 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Equipment, etc. Spare part no. Art. no. Note Lifting tool, motor 3HAC15534-1 ax 2, 3, 4 Bolts M16x60 3HAB3409-86 (for mechanical stop axis 3) Washers (for 3HAA1001-186 mechanical stop axis 3) Guide pins M10 x 3HAC15521-1 For guiding the motor.
  • Page 345 工控帮助教小舒QQ2823408167 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Removal, motor The procedure below details how to remove motor, axis 3. Action Note 1. Unload the upper arm of the robot by either: • Move the robot to a position where the turning disk rests against the foundation (rec- ommended).
  • Page 346 工控帮助教小舒QQ2823408167 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note CAUTION! The motor weighs 32 kg! All lifting equipment used must be sized accordingly! 13. Lift the motor to get the pinion away from the gear. 14. Remove the motor by gently lifting it Make sure the motor pinion is not damaged! straight out and disconnect the brake release voltage.
  • Page 347 工控帮助教小舒QQ2823408167 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note 9. Use the rotation tool in order to rotate the motor Art no. is specified in Required pinion when mating it to the gear! equipment on page 341. Fit the motor, making sure the motor pinion is Make sure the motor pinion does not properly mated to the gear of gearbox, axis 3.
  • Page 348 工控帮助教小舒QQ2823408167 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note DANGER! Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page Replacement of the motor axis 3 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level.
  • Page 349 工控帮助教小舒QQ2823408167 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note NOTE! Keep the old top cover with the air nipple mounted. 5. Continue removal of the motor unit, according to step 6 and forwards in section Removal, motor on page 343.

  • Page 350: Replacement Of Motor, Axis 4

    工控帮助教小舒QQ2823408167 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) Required equipment...
  • Page 351 工控帮助教小舒QQ2823408167 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Equipment, etc. Spare part no. Art. no. Note Lifting tool, motor ax 3HAC14459-1 To be used if the upper arm is 1, 4, 5 positioned vertically. Lifting tool, motor ax 3HAC15534-1 To be used if the upper arm is 2, 3, 4...
  • Page 352 工控帮助教小舒QQ2823408167 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Turn off all electric power and hydraulic but not the air pressure to the gearboxes, motors and SMB.
  • Page 353 工控帮助教小舒QQ2823408167 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note 13. Fit the lifting tool to the motor. Choose the correct lifting tool: • lifting tool, motor axis 1, 4 and 5, if the upper arm is positioned vertically.
  • Page 354 工控帮助教小舒QQ2823408167 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note 6. Fit the two guide pins in two of the motor Art. no. is specified in Required attachment holes. equipment on page 348. Shown in the figure Location of motor on page 348.
  • Page 355 工控帮助教小舒QQ2823408167 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note DANGER! Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page Replacement of the motor axis 4 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application...
  • Page 356 工控帮助教小舒QQ2823408167 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note 4. Remove the motor unit, according to step 4 to 12 in section Removal, motor axis 4 on page 349. 5. Fill the four screw recesses on the new motor with Sikaflex.

  • Page 357: Replacement Of Motor, Axis 5

    工控帮助教小舒QQ2823408167 4 Repair 4.6.5. Replacement of motor, axis 5 4.6.5. Replacement of motor, axis 5 Location of motor The motor axis 5 is located in the rear of the wrist unit as shown in the figure below. Notice that the left hand side cover already is removed in the figure! xx0100000127 Motor, axis 5 Cable gland cover, motor axis 5...
  • Page 358 工控帮助教小舒QQ2823408167 4 Repair 4.6.5. Replacement of motor, axis 5 Continued Equipment, etc. Spare part no. Art. no. Note Calibration Pendulum 3HAC15716-1 Complete kit that also toolkit includes operating manual. Other tools and These procedures include procedures may be references to the tools required.
  • Page 359 工控帮助教小舒QQ2823408167 4 Repair 4.6.5. Replacement of motor, axis 5 Continued Action Note 12. Fit the two guide pins in two of the motor attachment Art. no. is specified in Required screw holes. equipment on page 355. 13. If required, press the motor out of position by fitting Art.
  • Page 360 工控帮助教小舒QQ2823408167 4 Repair 4.6.5. Replacement of motor, axis 5 Continued Action Note 8. If necessary, use the rotation tool in order to rotate Art. no. is specified in Required the motor pinion when mating it to the gear! equipment on page 355.

  • Page 361: Replacement Of Motor, Axis 6

    工控帮助教小舒QQ2823408167 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 on page 463 xx0100000128...
  • Page 362 工控帮助教小舒QQ2823408167 4 Repair 4.6.6. Replacement of motor, axis 6 Continued Equipment, etc. Spare part no. Art. no. Note Gasket 3HAC033206-001 Protection Foundry Plus, Foundry Prime Must be replaced when replacing motor Gasket, cover 3HAC033489-001 Must be replaced when opening cover. Removal tool, motor 3HAC14972-1 Always use the removal tools...
  • Page 363 工控帮助教小舒QQ2823408167 4 Repair 4.6.6. Replacement of motor, axis 6 Continued Action Note 3. In horizontal position: drain the oil from the axis 6 Detailed in section Draining, oil, gearbox. gearbox axis 6 on page 216. 4. Remove the rear motor cover by unscrewing the five attachment screws.
  • Page 364 工控帮助教小舒QQ2823408167 4 Repair 4.6.6. Replacement of motor, axis 6 Continued Action Note 12. 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 403.
  • Page 365 工控帮助教小舒QQ2823408167 4 Repair 4.6.6. Replacement of motor, axis 6 Continued Action Note 4. Remove the rear motor cover by unscrewing the five attachment screws. xx0600002885 • A: Motor unit • B: Attachment screw (5 pcs) • C: Air nipple • D: Rear motor cover •...
  • Page 366 工控帮助教小舒QQ2823408167 4 Repair 4.6.6. Replacement of motor, axis 6 Continued Action Note 7. For Foundry Prime robots: Fill the four screw recesses on the new motor with Sikaflex. (After hardening, Sikaflex can be formed with a knife). Remove the protection strip on the gasket and mount it on the motor.

  • Page 367: Gearboxes

    工控帮助教小舒QQ2823408167 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 on page 463 xx0100000133...
  • Page 368 工控帮助教小舒QQ2823408167 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Equipment, etc. Spare part no. Art. no. Note O-ring 3HAB3772-55 Replace only when damaged! Sealing ring 3HAC11581-4 Replace only when damaged! Grease 3HAC3537-1 For lubricating the o-rings. Brush Option Foundry Prime Rust preventive 3HAC026621-001 Mercasol 3106 (Option...
  • Page 369 工控帮助教小舒QQ2823408167 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note 3. Drain the oil from gearbox 1. Detailed in section Oil change, gearbox axis 1 on page 199. 4. Disconnect all cabling in the rear of the robot base and remove the cable support plate inside of the base.
  • Page 370 工控帮助教小舒QQ2823408167 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note 13. Unscrew the 18 attachment screws and remove the 3 washers, shown in the figure to the right. xx0200000227 A view from below: • A: Oil drain hose •...
  • Page 371 工控帮助教小舒QQ2823408167 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Refitting, gearbox axis 1 The procedure below details how to refit gearbox, axis 1. Action Note 1. If the base is not supported with support, base Mounting of the support, base and gear and gear 1, this should be done first.
  • Page 372 工控帮助教小舒QQ2823408167 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note 7. Make sure the guide pin in the bottom face of Shown in the figure xx0200000055 the gearbox is properly aligned with the base. above! 8. Secure the gearbox and the three washers 18 pcs, M16 x 90, 12.9 quality with the 18 attachment screws, gearbox axis UNBRAKO, tightening torque: 300 Nm.
  • Page 373 工控帮助教小舒QQ2823408167 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note 13. Refit the complete arm system. Detailed in section Refitting of complete system. This is a complex task to be performed with utmost care in order to avoid injury or damage! 14.
  • Page 374 工控帮助教小舒QQ2823408167 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note 2. Apply Mercasol 3106 on unpainted areas. xx0600003132 • A: Surface on the underside of the frame • B: Radial sealing gear axis 1, against base DANGER! Make sure all safety requirements are met when performing the first test run.

  • Page 375: Replacement Of Gearbox, Axis 2

    工控帮助教小舒QQ2823408167 4 Repair 4.7.2. Replacement of gearbox, axis 2 4.7.2. Replacement of gearbox, axis 2 Location of gearbox The axis 2 gearbox is located in the lower 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 376 工控帮助教小舒QQ2823408167 4 Repair 4.7.2. Replacement of gearbox, axis 2 Continued Equipment, etc. Spare part no. Art. no. Note Grease 3HAB3537-1 For lubricating the o-ring. Standard toolkit Content is defined in section Standard toolkit on page 427. Lifting tool, gearbox axis 2 3HAC12731-1 Fixture lower arm 3HAC13660-1...
  • Page 377 工控帮助教小舒QQ2823408167 4 Repair 4.7.2. Replacement of gearbox, axis 2 Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Turn off all electric power and hydraulic but not the air pressure to the gearboxes, motors and SMB. 4.
  • Page 378 工控帮助教小舒QQ2823408167 4 Repair 4.7.2. Replacement of gearbox, axis 2 Continued Action Note 10. Remove the 30 rear gearbox attachment screws (A) from inside the lower section of the lower arm. xx0300000064 11. Remove the motor attachment by unscrewing the Shown in the figure Location of front gearbox attachment screws.
  • Page 379 工控帮助教小舒QQ2823408167 4 Repair 4.7.2. Replacement of gearbox, axis 2 Continued Action Note 18. Remove the sealing from the lower arm. On reassembly a new sealing must be used! Art. no. is specified in the refitting instructions Required equipment on page 373! Refitting, gearbox axis 2 The procedure below details how to refit the gearbox, axis 2.
  • Page 380 工控帮助教小舒QQ2823408167 4 Repair 4.7.2. Replacement of gearbox, axis 2 Continued Action Note 6. Make sure the o-ring is fitted to the rear of the Art. no. is specified in Required gearbox. Lightly grease the o-ring. equipment on page 373. xx0100000136 A.
  • Page 381 工控帮助教小舒QQ2823408167 4 Repair 4.7.2. Replacement of gearbox, axis 2 Continued Action Note 13. Insert and secure 28 of the 30 attachment screws on the inside of the lower arm. xx0300000064 Tightening torque: 300 Nm. Reused screws may be used, providing they are lubricated as detailed in section Screw joints on page 423...

  • Page 382: Replacement Of Gearbox, Axis 3

    工控帮助教小舒QQ2823408167 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 383 工控帮助教小舒QQ2823408167 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Gearbox 3HAC12641-1 Includes gearbox and all o-rings. Does not include the sealing, axis 2/3. O-ring 3HAB3772-68 1 pc on the gearbox. 3HAB3772-51 Replace if damaged.
  • Page 384 工控帮助教小舒QQ2823408167 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Removal, gearbox axis 3 The procedure below details how to remove gearbox, axis 3. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Turn off all electric power and hydraulic but not the air pressure to the gearboxes, motors and...
  • Page 385 工控帮助教小舒QQ2823408167 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note 9. Fit the lifting eye to the gearbox, in Art. no. is specified in Required equipment on page one of the attachment screw holes 381. that attaches the gearbox to the lower arm .
  • Page 386 工控帮助教小舒QQ2823408167 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note CAUTION! The gearbox weighs 125 kg! All lifting equipment used must be sized accordingly! 5. Fit the lifting eye to the gearbox. Art. no. is specified in Required equipment on page 381.
  • Page 387 工控帮助教小舒QQ2823408167 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note DANGER! Make sure all safety require- ments are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page Refitting, gearbox axis 3 (Foundry Prime)

  • Page 388: Replacement Of Gearbox, Axis 4

    工控帮助教小舒QQ2823408167 4 Repair 4.7.4. Replacement of gearbox, axis 4 4.7.4. Replacement of gearbox, axis 4 Location of gearbox The axis 4 gearbox is located at the rear 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 389 工控帮助教小舒QQ2823408167 4 Repair 4.7.4. Replacement of gearbox, axis 4 Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Gear axis 4 3HAC17810-1 Includes all o-rings! O-ring 3HAB3772-49 Replace if damaged! O-ring 3HAB3772-50 Replace if damaged! Friction washer 3HAC10122-27 2 pcs.
  • Page 390 工控帮助教小舒QQ2823408167 4 Repair 4.7.4. Replacement of gearbox, axis 4 Continued Action Note 6. Loosen the gear attachment screws but do not Shown in the figure Location of remove the gear Z3. gearbox on page 386. 7. Remove the motor, axis 4. Detailed in section Removal, motor axis 4 on page...
  • Page 391 工控帮助教小舒QQ2823408167 4 Repair 4.7.4. Replacement of gearbox, axis 4 Continued Action Note 5. Fit two new friction washers onto the guide pins. Spare part no. is specified in Required equipment on page 387. NOTE! Make sure the surface beneath the friction washers is clean and dry! 6.
  • Page 392 工控帮助教小舒QQ2823408167 4 Repair 4.7.4. Replacement of gearbox, axis 4 Continued Action Note DANGER! Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC022033-001 Revision: K...

  • Page 393: Replacement Of Gearbox, Axis 5

    工控帮助教小舒QQ2823408167 4 Repair 4.7.5. Replacement of gearbox, axis 5 4.7.5. Replacement of gearbox, axis 5 Location of gearbox The axis 5 gearbox is located in 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 394 工控帮助教小舒QQ2823408167 4 Repair 4.7.5. Replacement of gearbox, axis 5 Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Gear axis 5 3HAC17810-1 Includes all o-rings! O-ring 3HAB3772-49 Replace if damaged! O-ring 3HAB3772-50 Replace if damaged! Friction washer 3HAC10122-27 2 pcs.
  • Page 395 工控帮助教小舒QQ2823408167 4 Repair 4.7.5. Replacement of gearbox, axis 5 Continued Action Note 4. Remove the motor, axis 5. Detailed in section Replacement of motor, axis 5 on page 355. 5. Remove the cover, axis 5 gearbox by unscrewing its Shown in the figure Location of attachment screws.
  • Page 396 工控帮助教小舒QQ2823408167 4 Repair 4.7.5. Replacement of gearbox, axis 5 Continued Action Note 5. Remove the attachment screws, gear Z4. xx0200000068 A. Gear Z4 B. Surface beneath VK-cover C. VK-cover D. Attachment screws, gear Z4, 21 pcs: M16 E. Attachment screws, bearing washer, 7 pcs: M6 6.
  • Page 397 工控帮助教小舒QQ2823408167 4 Repair 4.7.5. Replacement of gearbox, axis 5 Continued Action Note 7. Secure the gearbox with 16 of the 18 attachment 18 pcs: M10 x 40: tightening screws and washers. torque: 65 Nm. Shown in the figure Location of gearbox on page 391.
  • Page 398 工控帮助教小舒QQ2823408167 4 Repair 4.7.5. Replacement of gearbox, axis 5 Continued Refitting, wheel unit The procedure below details how to refit the wheel unit. Action Note 1. Clean the wheel unit and the tube mating surfaces. 2. Lubricate packing box with grease. Art.

  • Page 399: Replacement Of Gearbox, Axis 6

    工控帮助教小舒QQ2823408167 4 Repair 4.7.6. Replacement of gearbox, axis 6 4.7.6. 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. xx0100000131 Gearbox, axis 6 Attachment screws, gearbox Washers Oil plug, filling...
  • Page 400 工控帮助教小舒QQ2823408167 4 Repair 4.7.6. Replacement of gearbox, axis 6 Continued Equipment, etc. Spare part no. Art. no. Note O-ring (type 2) 3HAB3772-64 Must be replaced when reassembling gearbox. 150.0x2.0 O-ring (type 2) 12 pcs 3HAB3772-61 Must be replaced when reassembling gearbox. 13.1x1.6 Grease 3HAB3537-1...
  • Page 401 工控帮助教小舒QQ2823408167 4 Repair 4.7.6. Replacement of gearbox, axis 6 Continued Action Note 5. If required, fit the removal tool, motor M10 to the holes shown in the figure to the right, to press it free. xx0200000220 • A: M10 holes for pressing out the gearbox 6.
  • Page 402 工控帮助教小舒QQ2823408167 4 Repair 4.7.6. Replacement of gearbox, axis 6 Continued Action Note 2. Make sure the o-ring is fitted to the rear of Art. no. is specified in Required equipment the gearbox. Lubricate the o-ring with on page 397. grease. xx0100000132 •...
  • Page 403 工控帮助教小舒QQ2823408167 4 Repair 4.7.6. Replacement of gearbox, axis 6 Continued Action Note 7. If the robot is going to work in a water jet application cell: • apply Mercasol 3106 on unpainted surfaces between gearbox and turning disk • apply Mercasol 3106 on the screw heads in the front of the turning disk.
  • Page 404 工控帮助教小舒QQ2823408167 4 Repair 4.7.6. Replacement of gearbox, axis 6 3HAC022033-001 Revision: K...

  • Page 405: Calibration Information

    The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration. The different methods are briefly described in the section Calibration methods on page 404, and further detailed in separate calibration manuals.

  • Page 406: Calibration Methods

    工控帮助教小舒QQ2823408167 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 by ABB. Types of calibration Type of Description Calibration method calibration Standard The calibrated robot is positioned at home...
  • Page 407 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 408: Calibration Scale And Correct Axis Position

    工控帮助教小舒QQ2823408167 5 Calibration information 5.3. Calibration scale and correct axis position 5.3. Calibration scale 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 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 409: Calibration Movement Directions For All Axes

    工控帮助教小舒QQ2823408167 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 and so on. Positive directions are shown in the graphic below.

  • Page 410: Updating Revolution Counters

    工控帮助教小舒QQ2823408167 5 Calibration information 5.5. Updating revolution counters 5.5. Updating revolution counters Introduction This section describes how to do a rough calibration of each robot axis, which is updating the revolution counter value for each axis using the FlexPendant. Step 1 - Manually running the robot to the calibration position Use this procedure to manually run the robot to the calibration position.
  • Page 411 工控帮助教小舒QQ2823408167 5 Calibration information 5.5. Updating revolution counters Continued Step 2 - Storing the revolution counter setting with the TPU Use this procedure to store the revolution counter setting with the TPU (BaseWare 4.0). Action Note 1. Press the button Miscellaneous then ENTER to select the service window.
  • Page 412 Use this procedure to store the revolution counter setting with the FlexPendant (IRC5). Action 1. On the ABB menu, tap Calibration. All mechanical units connected to the system are shown with their calibration status. 2. Tap the mechanical unit in question.
  • Page 413 工控帮助教小舒QQ2823408167 5 Calibration information 5.5. Updating revolution counters Continued Action 5. A dialog box is displayed warning that the updating operation cannot be undone: • Tap Update to proceed with updating the revolution counters. • Tap Cancel to cancel updating the revolution counters. Tapping Update updates the ticked revolution counters and removes the tick from the list of axes.

  • Page 414: Checking The Calibration Position

    Use this procedure to create a program that 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:...
  • Page 415 Use this procedure to jog the robot to the zero position of all axes. Action Note 1. On the ABB menu, tap Jogging. 2. Tap Motion mode to select group of axes to jog. 3. Tap to select the axis to jog, axis 1, 2, or 3.
  • Page 416 工控帮助教小舒QQ2823408167 5 Calibration information 5.6. Checking the calibration position 3HAC022033-001 Revision: K...

  • Page 417: Decommissioning

    工控帮助教小舒QQ2823408167 6 Decommissioning 6.1. Environmental information 6 Decommissioning 6.1. Environmental information Hazardous material The table specifies some of the materials in the robot and their respective use throughout the product. Dispose components properly to prevent health or environmental hazards. Material Example application Batteries, NiCad or Lithium Serial measurement board...

  • Page 418: Decommissioning Of Balancing Device

    工控帮助教小舒QQ2823408167 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 419 工控帮助教小舒QQ2823408167 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 DANGER! There is stored energy built up by high...
  • Page 420 工控帮助教小舒QQ2823408167 6 Decommissioning 6.2. Decommissioning of balancing device 3HAC022033-001 Revision: K...

  • Page 421: Reference Information

    工控帮助教小舒QQ2823408167 7 Reference information 7.1. Introduction 7 Reference information 7.1. Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. 3HAC022033-001 Revision: K...

  • Page 422: Applicable Safety Standards

    工控帮助教小舒QQ2823408167 7 Reference information 7.2. Applicable safety standards 7.2. Applicable safety standards Standards, EN ISO The manipulator system is designed in accordance with the requirements of: Standard Description EN ISO 12100 -1 Safety of machinery - Basic concepts, general principles for design - Part 1: Basic terminology, methodology EN ISO 12100 -2 Safety of machinery - Basic concepts, general principles for...
  • Page 423 工控帮助教小舒QQ2823408167 7 Reference information 7.2. Applicable safety standards Continued Other standards Standard Description ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems ANSI/UL 1740 Safety standard for robots and robotic equipment (option 429-1) CAN/CSA Z 434-03 Industrial robots and robot Systems - General safety require- ments (option 429-1) 3HAC022033-001 Revision: K...

  • Page 424: Unit Conversion

    工控帮助教小舒QQ2823408167 7 Reference information 7.3. Unit conversion 7.3. Unit conversion Converter table Use the following table 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...

  • Page 425: 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 426 工控帮助教小舒QQ2823408167 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 following tables. Any special torques are specified in the repair, maintenance or installation procedure descriptions.
  • Page 427 工控帮助教小舒QQ2823408167 7 Reference information 7.4. Screw joints Continued The following table specifies the recommended standard tightening torque for Molycote- lubricated screws with allen head screws. Tightening torque (Nm) Tightening torque (Nm) Dimension Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated The following table specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass.

  • Page 428: Weight Specifications

    All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available for each manipulator model.

  • Page 429: Standard Toolkit

    工控帮助教小舒QQ2823408167 7 Reference information 7.6. Standard toolkit 7.6. Standard toolkit General All service (repairs, maintenance, and installation) procedures contains lists of tools required to perform the specified activity. All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the standard toolkit and defined in the following table.

  • Page 430: Special Tools

    工控帮助教小舒QQ2823408167 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 the section Standard toolkit on page 427, and of special tools, listed directly in the instructions and also gathered in this section.
  • Page 431 3HAC15943-1 Tools that may be rented The following table specifies the tools that may be rented from ABB in order to perform certain service procedures as described in the Product manual. The special tools are also listed directly in the instructions.
  • Page 432 工控帮助教小舒QQ2823408167 7 Reference information 7.7. Special tools Continued Calibration equipment, Levelmeter (alternative method) The following table specifies the calibration equipment required when calibrating the robot with the alternative method, Levelmeter Calibration. Description Art. no. Note Angel bracket 68080011-LP Calibration bracket 3HAC13908-9 Calibration tool ax1 3HAC13908-4...

  • Page 433: Lifting Accessories And Lifting Instructions

    工控帮助教小舒QQ2823408167 7 Reference information 7.8. Lifting accessories and lifting instructions 7.8. Lifting accessories and lifting instructions General Many repair and maintenance activities require different pieces of lifting accessories, which are specified in each procedure. The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories.
  • Page 434 工控帮助教小舒QQ2823408167 7 Reference information 7.8. Lifting accessories and lifting instructions 3HAC022033-001 Revision: K...

  • Page 435: Spare Part / Part List

    工控帮助教小舒QQ2823408167 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. 3HAC022033-001 Revision: K...

  • Page 436: Spare Parts

    工控帮助教小舒QQ2823408167 8 Spare part / part list 8.2.1. Introduction 8.2 Spare parts 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. 3HAC022033-001 Revision: K...

  • Page 437: Spare Part List

    工控帮助教小舒QQ2823408167 8 Spare part / part list 8.2.2. Spare part list 8.2.2. Spare part list Spare part list The list below specifies all the recommended spare parts for the robot. The item numbers given within parenthesis in the column Note refer to the exploded views in the chapter Exploded views on page 463.
  • Page 438 工控帮助教小舒QQ2823408167 8 Spare part / part list 8.2.2. Spare part list Continued Item Description Spare part no. Note Turning disk, dia. 250 3HAC13193-1 (103.28.5) Turning disk, insulated 3HAC023124-002 (103.28.3) Balancing device 3HAC14214-1 (104) Maintenance kit 3HAC15834-1 For balancing device. Maintenance kit 3HAC14962-1 For balancing device.

  • Page 439: Part List

    工控帮助教小舒QQ2823408167 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 440: Rebuilding Parts

    工控帮助教小舒QQ2823408167 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 version of the robot. The table below is a general overview of which parts belongs to which versions. Rebuilding parts 500/ 400/...

  • Page 441: Part List, Overview

    工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.3. Part list, overview 8.3.3. Part list, overview Overview The table below contains an overview of the parts of the robot. They are further specified in the referred sections and shown in the exploded views according to the item numbers. Item Qty Art.
  • Page 442 工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.3. Part list, overview Continued Item Qty Art. number Description Note / Dimension 3HAC16628-4 Wrist See section Wrist, 3HAC16628-4 / (spare part no.) 3HAC16628-3 on page 449. 3HAC16628-3 Wrist Insulated tool flange. (spare part no.) See section Wrist, 3HAC16628-4 /...

  • Page 443: Mechanical Stop Axis 1, 3Hac12812-2

    工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.4. Mechanical stop axis 1, 3HAC12812-2 8.3.4. Mechanical stop axis 1, 3HAC12812-2 Part list Item Art. number Description Dimension 3HAC12812-1 Mechanical stop 9ABA142-92 Spring pin, slotted 10 x 30 3HAC022033-001 Revision: K...

  • Page 444: Base Incl Frame Axis 1, 3Hac12304-1

    工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.5. Base incl frame axis 1, 3HAC12304-1 8.3.5. Base incl frame axis 1, 3HAC12304-1 Part list Item Qty Art. number Description Note 101.1 3HAC10044-1 Base, machining See section below. 101.2 3HAC12303-1 Frame incl ax 1 gearbox See section below.

  • Page 445: Axis 3-4, 3Hac13063-1 (Irb 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/2.55)

    工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.6. Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/2.55) 8.3.6. Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/ 2.55) Part list Item Art. no. Description Note 102.1 3HAC022181-001 Material set ax 4...
  • Page 446 工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.6. Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/2.55) Continued Item Art. number Description Note / Dimension 102.1.20 1 2216261-18 Sealing 170x200x15 102.1.21 1 21522012-535 O-ring 169,3x5,7 102.1.22 1 3HAC022620-001 Spacer ring 102.1.23 1 3HAC11461-1...
  • Page 447 工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.6. Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/2.55) Continued Cover axis 4, 3HAC11423-4 Item Art. number Description Note 102.1.9.1.1 3HAC11423-1 Cover axis 4, machined 102.1.9.1.2 3HAC11423-3 Gasket cover axis 4 Tube shaft 2,55, 3HAC10509-1 Item Art.

  • Page 448: Axis 3-4, 3Hac13063-2 (Irb 7600 - 500/2.3)

    工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.7. Axis 3-4, 3HAC13063-2 (IRB 7600 - 500/2.3) 8.3.7. Axis 3-4, 3HAC13063-2 (IRB 7600 - 500/2.3) Part list Item Art. number Description Note 102.1 3HAC022181-001 Material set ax 4 See table Material set axis 4, 3HAC022181-001 on page 443.

  • Page 449: Axis 3-4, Foundry, 3Hac13063-4 (Irb 7600 -150/3.5, - 325/3.1, - 340/2.8, - 400/2.55, - 500/2.55)

    工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.8. Axis 3-4, Foundry, 3HAC13063-4 (IRB 7600 -150/3.5, - 325/3.1, - 340/2.8, - 400/2.55, - 500/2.55) 8.3.8. Axis 3-4, Foundry, 3HAC13063-4 (IRB 7600 -150/3.5, - 325/3.1, - 340/2.8, - 400/ 2.55, - 500/2.55) Part list Item Art.

  • Page 450: Axis 3-4 Foundry, 3Hac13063-5 (Irb 7600 - 500/2.3)

    工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.9. Axis 3-4 Foundry, 3HAC13063-5 (IRB 7600 - 500/2.3) 8.3.9. Axis 3-4 Foundry, 3HAC13063-5 (IRB 7600 - 500/2.3) Part list Item Art. no. Description Note 102.1 3HAC022181-001 Material set ax 4 See table Material set axis 4, 3HAC022181-001 on page...

  • Page 451: Wrist, 3Hac16628-4 / 3Hac16628-3

    工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3 8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3 Part list Item Art. number Description Note / Dimension 103.1 3HAC11409-7 Cover, right See table Cover, right, 3HAC11409-7 on page 451. Spare part number 3HAC11409-9.
  • Page 452 工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3 Continued Item Art. number Description Note / Dimension 103.28 3HAC024852-002 Axis 6 complete Foundry See table Axis 6 complete Foundry and 3HAC024852-001 Axis 6 complete standard standard, 3HAC024852-002 / 3HAC024852-001 on page 452.
  • Page 453 Only for the insulated wrist! See table Axis 6, insulated, 3HAC024924-001 on page 454. 103.100 2 3HAC021480-001 Label 103.101 2 3HAC17765-1 ABB-logotype Cover, right, 3HAC11409-7 Spare part number 3HAC11409-9 Item Art. number Description Note 103.1.1 3HAC11409-1 Cover, right machining 103.1.2 3HAC11409-5...
  • Page 454 工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3 Continued Wheel unit, tightened, 3HAC022184-001 Item Art. number Description Dimension 103.33.1 3HAC020487-001 Gear Z4 / 5 103.33.2 3HAC10503-12 Bearing Washer 103.33.3 3HAB3710-19 Groove ball bearing 160x220x28 103.33.4 3HAC10503-15 Support Ring 103.33.5 3HAB7116-2...
  • Page 455 工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3 Continued Rot AC motor incl pinion, 3HAC024842-001 Item Art. number Description Note 103.28.13.1 3HAC17484-3 Rotational AC motor M3 103.28.13.2 3HAC10122-19 Pinion RV 125F-178.4 103.28.13.3 21522012-430 O-ring Axis 6 insulated, 3HAC024594-001 Item Art.
  • Page 456 工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3 Continued Axis 6, insulated, 3HAC024924-001 Item Art. number Description Note 103.51.4 750 ml 3HAC032140-001 Lubricating oil: Kyodo Yushi TMO 150 103.51.10 3HAC14263-1 Protection Cover 103.51.11 9ADA624-69 Torx counters. head screw M8x20 103.51.12 3HAC024842-001 Rot.

  • Page 457: Material Set Robot, 3Hac13079-1

    工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.11. Material set robot, 3HAC13079-1 8.3.11. Material set robot, 3HAC13079-1 Part list Item Art. number Description Note 108.201 3HAC17213-1 Sealing axis 2/3 108.202 3HAB3409-84 Hex socket head cap screw M16x50 108.203 3HAC11828-1 Washer axis 3 108.204 3HAA1001-186 Washer...

  • Page 458: Material Set Axis 1-2, 3Hac13077-1

    工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.12. Material set axis 1-2, 3HAC13077-1 8.3.12. Material set axis 1-2, 3HAC13077-1 Part list Item Art. number Description Note / Dimension 109.301 1 3HAC12641-1 RV 700F incl. gear See table RV 700F incl. gear, 3HAC12641-1 on page 457.
  • Page 459 工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.12. Material set axis 1-2, 3HAC13077-1 Continued Item Art. number Description Note / Dimension 109.331 1 3HAC13152-1 Bracket SMB 109.332 1 3HAC14791-3 Cover battery box See table Cover battery box, 3HAC14791-3 on page 458.
  • Page 460 工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.12. Material set axis 1-2, 3HAC13077-1 Continued RV 700F-269,21 assembly, 3HAC17272-1 Item Art. number Description Note 109.301.1.1 3HAC10122-21 RV 700F, i=269,21 109.301.1.2 3HAB3772-51 O-ring Rot ac motor incl pinion, 3HAC14723-1 Item Art. number Description Note 109.306.1...

  • Page 461: Material Set Balancing Device, 3Hac13082-1

    工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.13. Material set balancing device, 3HAC13082-1 8.3.13. Material set balancing device, 3HAC13082-1 Part list Item Art. number Description Note 110.401 3HAC4310-1 Sealed spherical bearing 110.402 3HAC13124-1 Thrust washer 110.403 3HAC13122-1 Bushing 110.404 9ABA135-32 Retaining ring, shaft 110.405 3HAC13123-1...

  • Page 462: Arm Extension Set, 956 Mm, 3Hac12311-1 (Irb 7600 - 150/3.5)

    工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.14. Arm extension set, 956 mm, 3HAC12311-1 (IRB 7600 - 150/3.5) 8.3.14. Arm extension set, 956 mm, 3HAC12311-1 (IRB 7600 - 150/3.5) Part list Item Art. number Description Dimension 111.501 3HAC9760-5 Arm extender 956 mm 111.501 3HAC15932-4 Arm extender 956 mm, Foundry...

  • Page 463: Arm Extension Set, 250 Mm, 3Hac12311-2 (Irb 7600 - 340/2,8)

    工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.15. Arm extension set, 250 mm, 3HAC12311-2 (IRB 7600 - 340/2,8) 8.3.15. Arm extension set, 250 mm, 3HAC12311-2 (IRB 7600 - 340/2,8) Part list Item Art. number Description Dimension 111.501 3HAC9760-1 Arm extender 250 mm 111.501 3HAC15932-3 Arm extender 250 mm Foundry...
  • Page 464 工控帮助教小舒QQ2823408167 8 Spare part / part list 8.3.15. Arm extension set, 250 mm, 3HAC12311-2 (IRB 7600 - 340/2,8) 3HAC022033-001 Revision: K...

  • Page 465: Exploded Views

    工控帮助教小舒QQ2823408167 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 466: Base Incl. Frame

    工控帮助教小舒QQ2823408167 9 Exploded views 9.2. Base incl. Frame 9.2. Base incl. Frame Exploded view xx0200000329 3HAC022033-001 Revision: K...

  • Page 467: Frame-Lower Arm 1

    工控帮助教小舒QQ2823408167 9 Exploded views 9.3. Frame-Lower arm 1 9.3. Frame-Lower arm 1 Exploded view xx0200000330 3HAC022033-001 Revision: K...

  • Page 468: Frame-Lower Arm 2

    工控帮助教小舒QQ2823408167 9 Exploded views 9.4. Frame-Lower arm 2 9.4. Frame-Lower arm 2 Exploded view xx0200000331 3HAC022033-001 Revision: K...

  • Page 469: Upper Arm

    工控帮助教小舒QQ2823408167 9 Exploded views 9.5. Upper arm 9.5. Upper arm Exploded view xx0200000333 3HAC022033-001 Revision: K...

  • Page 470: Wrist Complete

    工控帮助教小舒QQ2823408167 9 Exploded views 9.6. Wrist complete 9.6. Wrist complete Exploded view xx0200000332 3HAC022033-001 Revision: K...

  • Page 471: Circuit Diagram

    工控帮助教小舒QQ2823408167 10 Circuit Diagram 10.1. About circuit diagrams 10 Circuit Diagram 10.1. About circuit diagrams Overview The circuit diagrams are not included in this manual, but delivered as separate documents on the documentation DVD. See following for correct article numbers. Controllers Product Article numbers for circuit diagrams...
  • Page 472 工控帮助教小舒QQ2823408167 10 Circuit Diagram 10.1. About circuit diagrams Continued Product Article numbers for circuit diagrams IRB 7600 3HAC13347-1 3HAC025744-001 3HAC022033-001 Revision: K...

  • Page 473: Circuit Diagram 3Hac 025744-001

    工控帮助教小舒QQ2823408167 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 474: Circuit Diagram 3Hac 13347-1

    工控帮助教小舒QQ2823408167 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 475: Index

    工控帮助教小舒QQ2823408167 Index Absolute Accuracy, calibration 405 damage to mechanical stop 177 aluminum 415 danger levels 39 dimensions frame 99 balancing device bearing, replacement 316 lower arm 97 balancing device, replacement 307 turning disk 100 base plate upper arm 98 securing 90 direction of axes 407 batteries 415 battery shutdown service routine 218...
  • Page 476 工控帮助教小舒QQ2823408167 Index information labels location 187 inspecting disposal 415 information lables 187 oil change mechanical stop 177 safety risks 51 installation oil in gearboxes 192 mechanical stop axis 1 115 operating conditions, robot 64 mechanical stop axis 2 117 mechanical stop axis 3 119 plastic 415 installing position switches...
  • Page 477 工控帮助教小舒QQ2823408167 Index standards ANSI 421 safety CAN 421 brake testing 32 EN 420 emergency stop 37 EN IEC 420 ESD 49 EN ISO 420 fence dimensions 29 protection 420 fire extinguishing 30 safety 420 FlexPendant 34 storage conditions, robot 64 introduction 19 symbols manipulator system 20...
  • Page 478 工控帮助教小舒QQ2823408167 Index working range IRB 7600 - 150/3.5 66 IRB 7600 - 340/2.8 67 IRB 7600 - 400/2.55 68 IRB 7600 - 500/2.3 69 IRB 7600 - 500/2.55 68 restricting axis 1 115 restricting axis 2 117 restricting axis 3 119 wrist unit, insulated 279 3HAC022033-001 Revision: K...
  • Page 479 工控帮助教小舒QQ2823408167...
  • Page 480 工控帮助教小舒QQ2823408167 Contact us ABB AB Discrete Automation and Motion Robotics S-721 68 VÄSTERÅS SWEDEN Telephone +46 (0) 21 344 400 www.abb.com...

This manual is also suitable for:

Irb 7600-500/2.55Irb 7600-500/2.3Irb 7600-325/3.1Irb 7600-150/3.5M2000aM2000 ... Show all

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