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Overview of this manual

About this manual

This manual contains instructions for:

•

mechanical and electrical installation of the robot

•

maintenance of the robot

•

mechanical and electrical repair of the robot.

The manual also contains reference information for all procedures detailed in the
manual.

Usage

This manual should be used during:

•

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

•

maintenance work

•

repair work.

Who should read this manual?

This manual is intended for:

•

installation personnel

•

maintenance personnel

•

repair personnel.

Prerequisites

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

•

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

Organization of chapters

The manual is organized in the following chapters:

Contents

Chapter

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

Safety

Required information about lifting and installation of the robot.

Installation and commis-
sioning

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

Maintenance

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

Repair

Procedures that does not require specific calibration equipment.
General information about calibration.

Calibration information

Environmental information about the robot and its components.

Decommissioning

Continues on next page

3HAC026048-001 Revision: E

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© Copyright 2006-2013 ABB. All rights reserved.

Overview of this manual

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Summary of Contents for IRB 260

Page 1: ...ABB Robotics Product manual IRB 260 ...

Page 2: ...Trace back information Workspace R13 1 version a6 Checked in 2013 03 31 Skribenta version 1184 ...

Page 3: ...Product manual IRB 260 M2004 Document ID 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved ...

Page 4: ...r property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Additional copies of this manual may be obtained from ABB The original language for this publication is English Any ...

Page 5: ...6 1 3 1 Safety signals in the manual 38 1 3 2 Safety symbols on manipulator labels 43 1 3 3 DANGER Moving manipulators are potentially lethal 44 1 3 4 DANGER First test run may cause injury or damage 45 1 3 5 DANGER Make sure that the main power has been switched off 47 1 3 6 WARNING The unit is sensitive to ESD 49 1 3 7 WARNING Safety risks during handling of batteries 50 1 3 8 WARNING Safety ris...

Page 6: ...arings tilthouse 140 4 4 2 Replacement of turning disk 143 4 4 3 Replacement of complete upper arm 150 4 4 4 Replacement of linkage upper rod 153 4 4 5 Replacing the linkage lower rod 157 4 4 6 Replacement of linkage link 162 4 5 Lower arm 162 4 5 1 Replacement of complete lower arm 166 4 5 2 Replacement of parallel bar 170 4 6 Frame and base 170 4 6 1 Replacement of SMB unit 176 4 6 2 Replacement...

Page 7: ...d lifting instructions 237 8 Spare part lists and exploded views 237 8 1 Introduction 238 8 2 Spare parts overview 239 8 3 Spare parts cover 241 8 4 Spare parts robot IRB 260 244 8 5 Spare parts axes 1 3 253 8 6 Spare parts upper arm 255 8 7 Spare parts tilthouse 257 8 8 Spare parts linkage 258 8 9 Spare parts material set cabling axis 6 261 9 Circuit diagram 261 9 1 About circuit diagrams 263 Ind...

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Page 9: ...manual is organized in the following chapters Contents Chapter Safety information that must be read through before performing any installation or service work on robot Contains general safety aspects as well as more specific information about how to avoid personal injuries and damage to the product Safety Required information about lifting and installation of the robot Installation and commis sion...

Page 10: ...ual System parameters 3HAC030421 001 Application manual CalibWare Field 5 0 Revisions Description Revision First edition Changes made in Prerequisites in section Overview Oil change in section Maintenance A Content updated in chapter section Maintenance chapter section Maintenance schedule Interval for replacement of battery pack changed Section What is an emergency stop added to chapter Safety Th...

Page 11: ...ve been changed added see updated values in Screw joints on page 221 Added WARNING Safety risks during handling of batteries on page 49 D This revision includes the following updates Information about the type and amount of oil has been removed from the manual and can now be found in Technical reference manual Lubrication in gearboxes For article number see Refer ences on page 10 A new SMB unit an...

Page 12: ... joints lists of tools Spare parts list with exploded views or references to separate spare parts lists Circuit diagrams or references to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products Technical reference manual Lubrication in gearboxes Description of types and volumes of lubrication for the manipulator gearboxes Te...

Page 13: ... manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and trouble shooters The group of manuals includes among others Operating manual Emergency safety information Operating manual General safety information Operating manual Getting started IRC5 and RobotStudio Operating manual Introduction to RAPID Operating manual IRC5 wi...

Page 14: ...he procedures and completed with a reference to the section where the equipment is listed with further information that is article number and dimensions The designation in the procedure for the component or attachment point corresponds to the designation in the referenced list The table below shows an example of a reference to a list of required equipment from a step in a procedure Note Illustrati...

Page 15: ...applicable for all service work and are found in General safety information on page 16 Specific safety information pointed out in the procedures How to avoid and eliminate the danger is either described directly in the procedure or in specific instructions in the section Safety related instructions on page 36 3HAC026048 001 Revision E 15 Copyright 2006 2013 ABB All rights reserved 1 Safety 1 1 Int...

Page 16: ... during installation or service risks associated with live electrical parts Safety risks lists dangers relevant when working with the product The dangers are split into different categories fire extinguishing safe use of the FlexPendant Safety actions describes actions which may be taken to remedy or avoid dangers stopping functions description of emergency stop description of safety stop descript...

Page 17: ...lexPendant Product manual Connection of external safety devices Apart from the built in safety functions the manipulator is also supplied with an interface for the connection of external safety devices An external safety function can interact with other machines and peripheral equipment via this interface This means that control signals can act on safety signals received from the peripheral equipm...

Page 18: ...e appropriate training for the equipment in question and in any safety matters associated with it Spare parts and special equipment ABB does not supply spare parts and special equipment which have not been tested and approved by ABB The installation and or use of such products could negatively affect the structural properties of the manipulator and as a result of that affect the active or passive ...

Page 19: ...ards for that function The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner in accordance with the applicable standards for the emergency stop function Complete manipulator Description Safety risk CAUTION Motors and gears are HOT after running the manipulator Touching motors and gears may result in burns With a highe...

Page 20: ...he gears may be damaged if excessive force is used Gears may be damaged if excessive force is used Description Safety risk WARNING Do not under any circumstances deal with the balancing device in any other way than that detailed in the product documentation For example attempting to open the balan cing device is potentially lethal Dangerous balancing device 20 3HAC026048 001 Revision E Copyright 2...

Page 21: ...es on the manipulator get hot and may result in burns Elimination The instructions below detail how to avoid the dangers specified above Info Action Always use your hand at some distance to feel if heat is radiating from the potentially hot component before actually touching it 1 Wait until the potentially hot component has cooled if it is to be removed or handled in any other way 2 3HAC026048 001...

Page 22: ...ork pieces in the event of a power failure or a disturbance to the controller Unauthorized modifications of the originally delivered manipulator are prohibited Without the consent of ABB it is forbidden to attach additional parts through welding riveting or drilling of new holes into the castings The strength could be affected CAUTION Ensure that a gripper is prevented from dropping a work piece i...

Page 23: ...taken The pressure must be released in the complete pneumatic or hydraulic systems before starting to repair them Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics All pipes hoses and connections have to be checked regularly for leaks and damage Damage must be repaired immediately Splashed oil may cause injury or fire Safe design Gravi...

Page 24: ... Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts Extraordinary risks If the working process is interrupted extra care must be taken due to risks other than those associated with regular operation Such an interruption may have to be rectified manually 24 3HAC026048 0...

Page 25: ...in deadlock in an isolated state disconnected from power supply and protected against reconnection 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 Units such as I O modules can be supplied with power from an external source The mains supply mains...

Page 26: ...chapter Installation and commissioning on page 53 Voltage related risks tools material handling devices etc Tools material handling devices etc may be live even if the robot system is in the OFF position Power supply cables which are in motion during the working process may be damaged 26 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 1 Safety 1 2 3 6 Risks associated with li...

Page 27: ...dropped or released at maximum speed Determine the maximum speed from the maximum velocities of the manipulator axes and from the position at which the manipulator is working in the work cell see the section Robot motion in the Product specification Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the manipulator 3HAC026048 00...

Page 28: ... Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator system manipulator or controller 28 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 1 Safety 1 2 4 2 Fire extinguishing ...

Page 29: ...ng the brakes on page 64 The manipulator arm may be moved manually on smaller manipulator models but larger models may require using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the arms does not increase the pressure on the trapped person further increasing any injury 3HAC026048 001 Revision E 29 Copyright 2006 2013 ABB All right...

Page 30: ...1 Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized max static load 2 Switch the motor to the MOTORS OFF position with the operating mode selector on the controller 3 Check that the axis maintains its position If the manipulator does not change position as the motors are switched off then the brake function is adequate 30 3HAC026048 ...

Page 31: ...ansm gear ratio or other kinematic system parameters from the FlexPendant or a PC This will affect the safety function Reduced speed 250 mm s 3HAC026048 001 Revision E 31 Copyright 2006 2013 ABB All rights reserved 1 Safety 1 2 4 5 Risk of disabling function Reduced speed 250 mm s ...

Page 32: ... the MOTORS OFF state To ensure safe use of the FlexPendant the following must be implemented The enabling device must never be rendered inoperational in any way During programming and testing the enabling device must be released as soon as there is no need for the manipulator to move Anyone entering the manipulator working space must always bring the FlexPendant with him her This is to prevent an...

Page 33: ...who are aware of the risks that this entails Manual mode with full speed 100 is not available in USA or Canada Pay attention to the rotating axes of the manipulator Keep away from axes to not get entangled with hair or clothing Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell Test the motor brake on each axis according ...

Page 34: ...s with power available to the motors so that the manipulator path can be maintained When completed power is disconnected from the motors The default setting is an uncontrolled stop However controlled stops are preferred since they minimize extra unnecessary wear on the manipulator and the actions needed to return the manipulator system back to production Please consult your plant or cell documenta...

Page 35: ...mergency 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 There can also be other types of emergency stops on your manipulator Consult your plant or cell documentation to see how your manipulator system is configured 3HAC026048 001 Re...

Page 36: ...dent may occur if the instructions are not followed that can lead to serious injury pos sibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc WARNING xx0100000002 Warns for electrical hazards which could result ...

Page 37: ... conditions NOTE xx0100000004 Describes where to find additional information or how to do an operation in an easier way TIP xx0100000098 3HAC026048 001 Revision E 37 Copyright 2006 2013 ABB All rights reserved 1 Safety 1 3 1 Safety signals in the manual Continued ...

Page 38: ...identified and located on the product as shown in the section Inspection of information labels on page 98 Symbols on safety labels Description Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with hig...

Page 39: ... part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the manipulator arm can fall down Tip risk when loosening bolts xx0900000810 The manipulator can tip over if the bolts are not securely fastened Continues on next page 3HAC026048 001 Revision ...

Page 40: ...at can cause burns Moving robot xx0900000819 The robot can move unexpectedly xx1000001141 Brake release buttons xx0900000820 xx1000001140 Continues on next page 40 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 1 Safety 1 3 2 Safety symbols on manipulator labels Continued ...

Page 41: ...hibition if oil is not allowed Mechanical stop xx0900000824 No mechanical stop xx1000001144 Stored energy xx0900000825 Warns that this part contains stored energy Used in combination with Do not dismantle symbol Continues on next page 3HAC026048 001 Revision E 41 Copyright 2006 2013 ABB All rights reserved 1 Safety 1 3 2 Safety symbols on manipulator labels Continued ...

Page 42: ...urized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller 42 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 1 Safety 1 3 2 Safety symbols on manipulator labels Continued ...

Page 43: ...ke sure all emergency stop equipment is correctly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system para...

Page 44: ...rom the robot and its working area 1 Check that the fixture and workpiece are well secured if applicable 2 Install all safety equipment properly 3 Make sure all personnel are standing at a safe distance from the robot that is out of its reach behind safety fences and so on 4 Pay special attention to the function of the part previously serviced 5 Collision risks CAUTION When programming the movemen...

Page 45: ...eliminating the danger as detailed below Elimination Panel Mounted Controller Note illustration Action xx0600003255 Switch off the main switch for the controller 1 Elimination Single Cabinet Controller Note illustration Action xx0600002782 Switch off the main switch on the controller cabinet 1 A Main switch Continues on next page 3HAC026048 001 Revision E 45 Copyright 2006 2013 ABB All rights rese...

Page 46: ...n switch on the Drive Module 1 K Main switch Drive Module A Main switch Control Module Switch off the main switch on the Control Module 2 46 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 1 Safety 1 3 5 DANGER Make sure that the main power has been switched off Continued ...

Page 47: ...ntly to ensure that they are not damaged and are operating cor rectly Use a wrist strap 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of static voltages and must be grounded Use a dissipative table mat 3 Location of wrist strap button The location of the wrist strap button is shown in the following il...

Page 48: ... Panel Mounted Drive Module B Wrist strap button NOTE When not used the wrist strap must always be attached to the wrist strap button C 48 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 1 Safety 1 3 6 WARNING The unit is sensitive to ESD Continued ...

Page 49: ...nt explosion fire may follow depending upon the circumstances Note Appropriate disposal regulations must be observed Elimination Note Action Operating temperatures are listed in Pre install ation procedure on page 54 Do not short circuit recharge puncture incinerate crush immerse force discharge or expose to temperatures above the declared operating temperature range of the product Risk of fire or...

Page 50: ...ion Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling hot lubricant heated up to 90 C xx0100000002 Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction xx0100000002 Alle...

Page 51: ... Mixing types of oil may cause severe damage to the gearbox xx0100000002 Do not mix types of oil When changing gearbox oil first run the robot for a time to heat up the oil Warm oil drains quicker than cold oil xx0100000098 Heat up the oil After refilling check the lubricant level The specified amount of oil or grease is based on the total volume of the gearbox When changing the lubricant the amou...

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Page 53: ...tion is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page15 before performing any installation work Note If the IRB 260 is connected to power always make sure that the robot is connected to protective earth before starting any insta...

Page 54: ...ions robot on page 56 3 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 56 4 Before taking the robot to its installation site make sure that the site conforms to Loads on foundation robot on page 55 Protection classes robot on page 56 Requirements foundation on page 56 5 Before moving the robot please ...

Page 55: ...rces and torques working on the robot during different kinds of operation Note These forces and torques are extreme values that are rarely encountered during operation The values also never reach their maximum at the same time Floor mounted Max load emergency stop Endurance load in operation Force 2900 N 1400 N Force xy 3500 2300 N 3500 1100 N Force z 3900 Nm 2100 Nm Torque xy 950 Nm 650 Nm Torque...

Page 56: ...ditions robot The table shows the allowed storage conditions for the robot Value Parameter 25 C Minimum ambient temperature 55 C Maximum ambient temperature 70 C Maximum ambient temperature less than 24 hrs Max 100 at constant temperat ure gaseous only Maximum ambient humidity Operating conditions robot The table shows the allowed operating conditions for the robot Value Parameter 5 C Minimum ambi...

Page 57: ... of the robot are specified at the tool flange center dimensions in mm xx0500001926 Position at mechanical stop A Position at maximum working range axis 2 B Tool flange center C Continues on next page 3HAC026048 001 Revision E 57 Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range ...

Page 58: ...8 1313 7 Type of motion Range of movement Type of motion Axis 180º to 180º Rotation motion 1 85º to 28º Arm motion 2 119º to 17º Arm motion 3 400º to 400º default Turn motion 6 150 revolutions to 150 revolutions max 1 1 The default working range for axis 6 can be extended by changing parameter values in the software option Advanced Motion is required 58 3HAC026048 001 Revision E Copyright 2006 201...

Page 59: ...enter of gravity which may cause the robot to tip over The shipping position is the most stable position Do not change the robot position before securing it to the foundation WARNING The robot is likely to be mechanically unstable if not secured to the foundation 3HAC026048 001 Revision E 59 Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 2 3 Risk of tipping stabilit...

Page 60: ...ains Required equipment Specification Equipment Lifting capacity 500 kg Overhead crane Lifting slings Lengths axis 2 950 mm axis 3 920 mm upper arm 680 mm Lifting chains 3 pcs Continues on next page 60 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting of robot ...

Page 61: ... shown in the figure below The axis positions are specified below the figure xx0500002140 10º Axis 2 po sition 35º Axis 3 po sition Continues on next page 3HAC026048 001 Revision E 61 Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting of robot Continued ...

Page 62: ...he figure below The axis positions are specified below the figure xx0500002141 28º Axis 2 position 17º Axis 3 position Lifting chain axis 2 A Continues on next page 62 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting of robot Continued ...

Page 63: ...position on page 62 Move the robot to the correct lifting posi tion If necessary release the brakes of af fected axis according to section Manually releasing the brakes on page 64 1 CAUTION The robot weighs 340 kg All lifting equip ment used must be sized accordingly 2 Attach the lifting equipment to the robot as shown in the previous figures and lift the robot 3 3HAC026048 001 Revision E 63 Copyr...

Page 64: ...tor R1 MP on page 64 If the robot is not connected to the controller power must be supplied to the connector R1 MP 2 xx0500001930 The internal brake release unit is located at the base of the robot and equipped with but tons for controlling the holding brakes for each axis separately The buttons are numbered according to the numbers of the axes To release the brake on a particular robot axis push ...

Page 65: ... the robot base Supply 24 V on pin B8 0 V on pin C10 2 Release the brakes with the brake release unit as detailed in the previous procedure 3 3HAC026048 001 Revision E 65 Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 3 2 Manually releasing the brakes Continued ...

Page 66: ...joint must be able to withstand the stress loads defined in section Pre installation procedure on page 54 Attachment screws The table below specifies the type of securing screws and washers to be used for securing the robot to the base plate foundation M16 x 50 Suitable screws lightly lubricated Quality 8 8 Quality Thickness 3 mm Suitable washer Outer diameter 30 mm Inner diameter 17 mm 190 Nm Tig...

Page 67: ...e following figure xx0200000181 Cross section guide sleeve hole The figure below shows the cross section of the guide sleeve holes from previous figure xx0200000182 Continues on next page 3HAC026048 001 Revision E 67 Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 3 3 Orienting and securing the robot Continued ...

Page 68: ... to allow the same robot to be remounted without re adjusting the program Art no Equipment 2151 0024 169 Guide sleeves 68 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 3 3 Orienting and securing the robot Continued ...

Page 69: ...n the robot Main dimensions xx0500001928 At maximum working range axis 3 A Mounting hole for safety lamp B Mounting hole for external air hose C Continues on next page 3HAC026048 001 Revision E 69 Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 3 4 Fitting equipment on the robot and robot dimensions ...

Page 70: ... M8 3x Depth 16 mm R 92 B Max 35 kg total C The rear side of the robot D Continues on next page 70 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 3 4 Fitting equipment on the robot and robot dimensions Continued ...

Page 71: ...axis 2 xx0500001929 Continues on next page 3HAC026048 001 Revision E 71 Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 3 4 Fitting equipment on the robot and robot dimensions Continued ...

Page 72: ...mounting holes available for fitting equipment on the turning disk xx0500001932 72 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 3 4 Fitting equipment on the robot and robot dimensions Continued ...

Page 73: ... the robot References Load diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must also be defined in the software as detailed in Operating manual IRC5 with FlexPendant M2004 Stop time and braking distances Robot motor brake performance depends on any loads attached For information about brake performance read the product specification...

Page 74: ...gure below shows the maximum permitted load mounted on the robot tool flange at different positions center of gravity xx0500002100 74 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 3 6 Load diagram ...

Page 75: ... use the Signal Lamp option in a Clean Rom environment Signal lamp on robot The signal lamp is installed on the upper arm as shown in the figure below xx0500002125 Indicator lamp A Lamp holder B O ring C Cable gland D Continues on next page 3HAC026048 001 Revision E 75 Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 3 7 Installation of signal lamp option ...

Page 76: ...Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 1 Run the cables from inside the upper arm as shown in the figure Signal lamp on robot on page 75 Connect the two cables to the signal lamp 2 Connectors R3 H1 and R3 H2 2 pcs M6x16 Fit the signal lamp to the upper arm by securing the bracket with two attachment screws 3 Shown in the figure Signal lamp on robot on pa...

Page 77: ...cal stop Note The axis 2 stop is a fixed stop that must be installed during operation of robot Axis 3 hardware mechanical stop Note The axis 3 stop is a fixed stop that must be installed during operation of robot This section describes how to install hardware that restricts the working range Note Adjustments must also be made in the robot configuration software system parameters References to rele...

Page 78: ...50º to 140º as shown in the figure below The restrictions are made by fitting two extra stops to the robot base and adjusting the system parameter configuration xx0500002105 Continues on next page 78 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 4 2 Mechanically restricting the working range of axis 1 ...

Page 79: ...References on page 10 Technical reference manual System parameters Fitting mechanical stop axis 1 The procedure below details how to fit a mechanical stop to the robot base Note Action Decide where to fit the extra mechanical stops according to the figure Location of where to drill holes for extra stops on page 81 1 The template is also shown in the figure Drill template on page 83 in scale 1 1 Ma...

Page 80: ... working range between the stops 6 Tighten the screws 7 The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters Adjust the software working range limitations system parameter configuration to correspond to the mechanical limitations 8 WARNING If the mechanical stop pin is deformed after a hard collision it mus...

Page 81: ...nical stop C This mounting direction only D The minimum and maximum measurement between the mechanical stops The difference between the measurement and the minimum and maximum working range is 2 x 4º which corresponds to the width of the stop pin at the frame Continues on next page 3HAC026048 001 Revision E 81 Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 4 2 Mecha...

Page 82: ...not allowed inside this sector C Center lines for the hidden stiffening ribs D Continues on next page 82 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 4 2 Mechanically restricting the working range of axis 1 Continued ...

Page 83: ...Drill template xx0200000207 3HAC026048 001 Revision E 83 Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 4 2 Mechanically restricting the working range of axis 1 Continued ...

Page 84: ...etween the frame and the base as shown in the figure below xx0600002676 Position switch A Attachment screws position switch 2 pcs for each switch M4 x 16 B Holder ring C Attachment screws holder ring 6 pcs M8 x 12 D Continues on next page 84 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 4 3 Installation of position switch axis 1 ...

Page 85: ...The procedure below details how to install the position switch to the robot Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Shown in the figure Location of position switch axis 1 on page 84 Fit the two holder rings underneath the frame with the six attachment screws 2 6 pcs M8 x 12 Cut the cam...

Page 86: ... page 84 Secure the cabling with straps and clamps 7 The cabling and connection points are specified in section Position switch cables robot base to controller option on page94 Connect the position switch cabling 8 The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters Adjust the software working range limita...

Page 87: ...tion of mechanical stops xx0500002036 Mechanical stop spacer long A Mechanical stop spacer short B Fixed stops C Required equipment Note Art no Equipment Long 3HAC025740 001 Spacer axis 2 Short 3HAC025741 001 Spacer axis 2 Art no is specified in section References on page 10 Technical reference manual System parameters The content is defined in the section Standard tools on page 225 Standard toolk...

Page 88: ...ps must be in stalled correctly on axis 2 The robot may never be run without the stops fitted 3 2 4 pcs M8x25 Tightening torque 17 Nm xx0500002037 Fit the two spacers directly next to the fixed stops of axis 2 with attachment screws 4 A Attachment holes for the short stop spacer B Attachment holes for the long stop spacer Fit the dampers to the mechanical stops 5 Continues on next page 88 3HAC0260...

Page 89: ...orrespond to the mechanical limita tions 6 WARNING If the mechanical stop pin is deformed after a hard collision it must be replaced Deformed movable stops and or addition al stops as well as deformed attachment screws must also be replaced after a hard collision 7 3HAC026048 001 Revision E 89 Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 4 4 Mechanically restricti...

Page 90: ...f mechanical stop The figure below shows the location of the mechanical stop on axis 3 xx0500002039 Mechanical stop axis 3 A Required equipment Note Art no Equipment 3HAC024253 001 Mechanical stop axis 3 Loctite 243 Locking liquid Art no is specified in section References on page 10 Technical reference manual System parameters The content is defined in the section Standard tools on page 225 Standa...

Page 91: ...e system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters Adjust the software working range limita tions system parameter configuration to correspond to the mechanical limitations 3 WARNING If the mechanical stop pin is deformed after a hard collision it must be replaced Deformed movable stops and or additional st...

Page 92: ...ectors on the robot The figure below shows all connections of the robot cabling including the customer connections xx0500002434 92 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 2 Installation and commissioning 2 5 1 Connectors on robot ...

Page 93: ...ve ground Customer cables option See the product manual for the controller see document number in References on page 10 Robot cables These cables are included in the standard delivery They are completely pre manufactured and ready to plug in Connection point robot Connection point cabinet Description Cable sub category R1 MP XS1 Transfers drive power from the drive units in the control cabinet to ...

Page 94: ...cable axis 1 7 m XS8 R1 SW 3HAC7997 2 Position switch cable axis 1 15 m XS8 R1 SW 3HAC7997 3 Position switch cable axis 1 22 m XS8 R1 SW 3HAC7997 4 Position switch cable axis 1 30 m Customer cables option The customer cables specified below are connected between robot and controller Customer cables Connection point robot Art no Cable R1 CP CS 3HAC8183 1 Customer cable power signal 7 m R1 CP CS 3HA...

Page 95: ...d divided up according to the maintenance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 15 before performing any service work Note If the IRB 2...

Page 96: ...r not Operating time specified in operating hours More frequent running means more frequent maintenance activities SIS specified by the robot s SIS Service Information System A typical value is given for a typical work cycle but the value will differ depending on how hard each part is run The SIS used in M2004 is further described in the Operating manual Service Information System 96 3HAC026048 00...

Page 97: ... Battery low alert i Replacement of battery pack SMB unit Replacement of SMB battery on page 104 Battery pack measure ment system of type RMU101 or RMU102 3 pole battery contact 36 months or battery low alert ii Replacement of battery pack SMB unit Replace if required 36 mths Inspection of all signal cabling in lower and up per arm Replace if bent 60 mths Replacement of mechan ical stop axis 1 i T...

Page 98: ...gn Specified further in the following table F UL label G Instruction plate Specified further in the following table H List of labels Note Spare part no Equipment Item A in the figure 3HAC2814 2 Instruction plate Warning of brake release Item B in the figure 2945 4489 16 Instruction plate Item D in the figure 3HAC024307 001 Calibration label Item H in the figure 3HAC025469 001 Instruction plate Lif...

Page 99: ...electric power hydraulic and pneumatic pressure supplies to the robot 1 Shown in the figure Location of labels on page 98 Inspect that all labels are fitted to the robot Replace them if damaged or missing 2 3HAC026048 001 Revision E 99 Copyright 2006 2013 ABB All rights reserved 3 Maintenance 3 3 1 Inspection of information labels Continued ...

Page 100: ...tion in the specific gearbox It also describes the equipment needed when working with lubrication Location of gearboxes The figure shows the location of the gearboxes xx0500001950 Gearbox axis 1 A Gearbox axis 2 B Gearbox axis 3 C Gearbox axis 6 D Continues on next page 100 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 3 Maintenance 3 4 1 Type of lubrication in gearboxes ...

Page 101: ...est revision of this manual The revision of the manual published on the Documentation DVD released twice a year will only contain the latest updates when the Documentation DVD is released Any updates of the manual in between these releases will be published on ABB Library Therefore the manual published on the documentation DVD may not contain the latest updates about lubrication If ABB Library can...

Page 102: ... and amount of oil in gearboxes on page 101 The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel The content is defined in the section Standard tools on page 225 Standard toolkit Draining oil gearbox axis 6 The procedure below details how to drain the oil from the gearbox axis 6 Note Action DANGER Turn off all electric power hydraulic and pneu mati...

Page 103: ...on DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lub ricants oil or grease on page 50 2 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes...

Page 104: ...cally 36 months For an SMB board with 2 pole battery contact the typical lifetime of a new battery is 36 months if the robot is powered off 2 days week or 18 months if the robot is powered off 16 h day The lifetime can be extended for longer production breaks with a battery shutdown service routine See Operating manual IRC5 with FlexPendant for instructions WARNING See instructions for batteries W...

Page 105: ... the robot base as shown in the figure below xx0300000067 SMB battery 2 pole battery contact A SMB battery cable B Continues on next page 3HAC026048 001 Revision E 105 Copyright 2006 2013 ABB All rights reserved 3 Maintenance 3 4 3 Replacement of SMB battery Continued ...

Page 106: ...er lifetime for the battery It is important that the SMB unit uses the correct battery Make sure to order the correct spare parts Do not replace the battery contact Note Spare part no Equipment Lithium battery 3HAC16831 1 Battery pack 2 pole battery contact Can only be used with SMB unit 3HAC17396 1 containing SMB board 3HAC031851 001 Continues on next page 106 3HAC026048 001 Revision E Copyright ...

Page 107: ...G 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 47 xx0200000399 Remove the rear cover plate A on the robot by unscrewing its attachment screws B 3 Remove the battery terminals from the serial measuring board and cut the clasp that keeps the battery unit in place 4 Shown in the figure Location of ...

Page 108: ...ion type High pressure water or steam Rinse with water Wipe with cloth Vacuum cleaner No Yes It is highly re commended that water contain a rust prevention solution and that the robot be dried afterwards Yes With light cleaning deter gent Yes Standard Cleaning with water and steam Cleaning methods that can be used for ABB robots with protection Standard Foundry Plus Wash and Foundry Prime Note Equ...

Page 109: ... other cleaning equipment may shorten the life of the robot Always check that all protective covers are fitted to the robot before cleaning Never Never point the water jet at connectors joints sealings or gaskets Never use compressed air to clean the robot Never use solvents that are not approved by ABB to clean the robot Never spray from a distance closer than 0 4 meters Never remove any covers o...

Page 110: ...This page is intentionally left blank ...

Page 111: ... are listed in the respective procedures The details of equipment are also available in different lists in the chapter Reference information on page 217 Safety information There are general safety information and specific safety information The specific safety information describes the danger and safety risks while performing specific steps in a procedure Make sure to read through the chapter Safe...

Page 112: ...alue Apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approx 8 10 minutes No pressure loss may be detected 5 Wa...

Page 113: ...the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing gradually until the recommended pre tension is achieved Note The roller elements must be rotated a specified number of turns before pre tensioning is carried out and also rotated during the pr...

Page 114: ... as following description Grooved ball bearings must be filled with grease from both sides Tapered roller bearings and axial needle bearings must be greased in the split condition 114 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 4 Repair 4 2 2 Mounting instructions for bearings Continued ...

Page 115: ...the seal to ensure that The seal is of the correct type provided with cutting edge There is no damage to the sealing edge feel with a fingernail 1 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced since it may result in future leakage 2 Art no is specified in Equipment on page 115 Lubricate the seal with grease just before fitting Not too early ...

Page 116: ... the surface preferably with a brush 3 Tighten the screws evenly when fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings may not be used Check the o ring for surface defects burrs shape accuracy and so on 2 Defective o rings may not be used Check the o ring grooves 3 The grooves must ...

Page 117: ...se R1 MP1 3 and R2 BU1 3 At the serial measurement board R2 G battery R2 FB1 3 A Connectors at motor 2 R3 MP2 and R3 FB2 B Connectors at motor 3 R3 MP3 R3 FB3 R3 LS1 and R3 LS2 C Connectors at motor 1 R3 MP1 R3 FB1 D Upper bracket E Cable guide in the middle of the frame F Required equipment Note Art no Spare part no Equipment etc Includes cabling motor covers attachment screws gaskets motor 1 3 3...

Page 118: ...ure below details how to remove the cabling of axes 1 3 Note Illustration Action Axes 2 and 3 may be tilted slightly to im prove access In order to facilitate refitting of the cable harness move the robot to the specified position Axis 1 0 Axis 2 0 Axis 3 0 Axis 6 no significance 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 xx0200000399 Remove the r...

Page 119: ...harness from the frame Unscrew the four screws securing the cable gland 8 xx0200000404 Remove the cable guide in the middle of the frame by removing the attachment screws of the holder A Remove the cables from the guide 9 Note Different robot versions are fitted with different versions of the holder Make sure the correct one is used to avoid cable failure Note Do not remove or loosen any of the ca...

Page 120: ...e cable harness through the center hole of axis 1 2 The gasket is included in the spare part of the cable unit spare part no is spe cified in Required equipment on page 117 Fit a new gasket and fit the connection box on motor 1 2 and 3 using the three attach ment screws 3 xx0200000401 Reconnect all the connectors at motors 1 2 and 3 4 R3 MP1 3 R3 FB1 3 Connection box Refit the cover of the motors ...

Page 121: ...stomer cable Signal cable Signal cable Note Make sure that each cable is fitted in the same position as the old one otherwise the conduit entry will not be watertight Use six cable straps Note Always use a new sealing combined with a flange sealing Loctite 574 8 Art numbers are specified in Required equipment on page 117 xx0200000400 Connect the connectors R2 FB 1 3 to the connection R2 SMB1 4 C o...

Page 122: ...9 Refit the rear cover plate A on the robot with its attachment screws B together with a new gasket 13 Spare part no is specified in Required equipment on page 117 Detailed in the section Updating revolu tion counters on page 211 If the battery has been disconnected from the SMB unit the revolution counters must be updated 14 DANGER Make sure all safety requirements are met when performing the fir...

Page 123: ...side the upper arm D Cable guide in the middle of the frame view from above E Connectors at the base Power cable R1 MP4 6 signal cable R2 FB4 6 brake release R2 BU4 6 UL lamp R1 H1 Customer cable R1 CP and R1 CS air hose R1 CAIR F Connector at motor axis 6 R3 FB6 signal G Connector at motor axis 6 R3 MP6 power H Connector at UL lamp R3 H1 and R3 H2 K Customer connectors air hose are located on the...

Page 124: ...ositions Axis 1 0º Axis 2 45º Axis 3 upper arm horizontal Axis 6 no significance 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 xx0200000399 Remove the rear cover plate A from the base of the robot by unscrewing the attach ment screws B 3 Specified in the figure Location of cable unit axis 6 on page 123 Disconnect the connectors R1 MP4 6 and R2 BU4 6 ...

Page 125: ...4 Shown in the figure Location of cable unit axis 6 on page 123 Loosen the cable brackets by removing their attachment screws inside the base inside the frame inside the lower arm inside the upper arm 8 Shown in the figure Location of cable unit axis 6 on page 123 Loosen the cables from the cable guide in the middle of the frame by unscrewing the holder and assembling the guide 9 Gently pull up th...

Page 126: ...cable unit through the frame into the base 2 Connect the connectors R1 MP4 6 and R2 BU4 6 to the base Also connect the customer cables and the air hose 3 Connect the earth cables 4 xx0200000400 Connect the connector R2 FB4 6 to the SMB unit connector R2 SMB3 6 B 5 R2 SMB R2 SMB3 6 R2 SMB1 4 xx0200000398 Refit the SMB unit to the bracket by tighten ing the nuts D Reconnect the battery cable A if di...

Page 127: ...ment as shown in the figure 10 Shown in the figure Location of cable unit axis 6 on page 123 Run the cabling through the upper arm and secure the cable bracket inside the upper arm 11 Connect all the connectors at the upper arm at the UL lamp at motor axis 6 R3 MP6 and R3 FB6 at customer connections R2 CS R2 CP and R2 CAIR 12 xx0200000399 Refit the rear cover plate A to the base with its attachmen...

Page 128: ... position may be found in section Upper arm exploded view on page 254 in part 2 of the Product manual xx0500002566 Shaft tilthouse A Tilthouse B Sealing ring C Taper roller bearing 2 pcs D Sealing ring with dust lip E Lock nut 2 pcs F Protection hood 2 pcs G VK cover 2 pcs H M6 screws including washers 4 pcs I Continues on next page 128 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights ...

Page 129: ... defined in section Special tools on page 226 3HAC13086 1 Hydraulic pump 80 Mpa The content is defined in the section Standard tools on page 225 Standard toolkit Complete kit that also in cludes operating manual 3HAC15716 1 Calibration Pendulum toolkit These procedures include references to the tools re quired Other tools and proced ures may be required See references to these procedures in the st...

Page 130: ...ng race upper arm The tool for removing the bearing race from the upper arm is assembled with the parts shown in the figure below included in the toolkit for service Note The parts cannot be ordered separately but are included in the complete toolkit The article numbers are only given for identification Continues on next page 130 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserve...

Page 131: ...race tilthouse shaft The tool for removing the bearing race from the tilthouse shaft is assembled with the parts shown in the figure below included in the toolkit for service Note The parts cannot be ordered separately but are included in the complete toolkit The article numbers are only given for identification Continues on next page 3HAC026048 001 Revision E 131 Copyright 2006 2013 ABB All right...

Page 132: ...ft The tool for fitting the tilthouse shaft to the tilthouse is assembled with the parts shown in the figure below included in the toolkit for service Note The parts cannot be ordered separately but are included in the complete toolkit The article numbers are only given for identification Continues on next page 132 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 4 Repair 4 4 ...

Page 133: ... upper arm The tool for fitting the bearing race and sealing to the upper arm is assembled with the parts shown in the figure below included in the toolkit for service Note The parts cannot be ordered separately but are included in the complete toolkit The article numbers are only given for identification Continues on next page 3HAC026048 001 Revision E 133 Copyright 2006 2013 ABB All rights reser...

Page 134: ...lthouse shaft The tool for fitting a bearing race to the tilthouse shaft is assembled with the parts shown in the figure below included in the toolkit for service Note The parts cannot be ordered separately but are included in the complete toolkit The article numbers are only given for identification Continues on next page 134 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 4...

Page 135: ...r parallel rod 2 Shown in the figure Replacement of linkage upper rod on page 150 Remove the both VK covers by making a hole in the middle and bending them off 3 Shown in the figure Location of shaft and bearings on page 128 Remove the both protection hoods and lock nuts 4 The assembly is shown in the figure Dismantling tool tilthouse shaft on page 129 Gather the required parts to assemble a disma...

Page 136: ...bly is shown in the figure Dismantling tool bearing race tilt house shaft on page 131 If removing the remaining bearing race from the shaft rebuild the tool to a dismantling tool bear ing race tilthouse shaft 10 Refitting shaft and bearings The procedure below details how to refit the shaft bearings and the tilthouse Note Illustration Action DANGER Turn off all electric power hydraulic and pneu ma...

Page 137: ...h er hydraulic cylinder and fit the complete as sembly to the bar 6 Shown in the figure Mounting tool bearing race and sealing upper arm on page 133 Fit the nut to the end of the bar 7 Press both the sealing ring and the bearing race into the seating 8 Spare part no is specified in Required equipment on page 129 Repeat the procedure to fit the other bearing race and the new sealing ring with dust ...

Page 138: ... to the both lock nuts and fit the nuts on each side of the shaft facing the flat surface outwards 19 Locking liquid is specified in Required equipment on page 129 Tighten one of them with 30 Nm Tighten the other with 35 Nm untighten it and retighten with 30 Nm Shown in the figure Location of shaft and bearings on page 128 Fit the protection hoods on each side of the shaft Replace them if damaged ...

Page 139: ...General calibration information is in cluded in the section Calibration in formation on page 207 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 44 25 3HAC026048 001 Revision E 139 Copyright 2006 2013 ABB All rights reserved 4 Repair 4 4 1 Replacement of shaft and ...

Page 140: ...rning disk 6 pcs B Required equipment Note Art no Spare part no Equipment 3HAC023881 001 Turning disk Replace if damaged 3HAB3772 16 O ring 6 pcs one o ring at each at tachment screw Replace if damaged 3HAB3772 89 O ring Loctite 243 Locking liquid The content is defined in the section Standard tools on page 225 Standard toolkit Complete kit that also in cludes operating manual 3HAC15716 1 Calibrat...

Page 141: ...Re quired equipment on page 140 Make sure that the o ring is fitted properly to the turning disk Replace it if damaged 2 Spare part no is specified in Re quired equipment on page 140 Lubricate and fit the six o rings to the holes of the attachment screws Replace if damaged 3 6 pcs M8x20 Fit the turning disk to the axis 6 gearbox with the six attachment screws and o rings using locking liquid 4 Tig...

Page 142: ...hen performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 8 142 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 4 Repair 4 4 2 Replacement of turning disk Continued ...

Page 143: ... of 2 on page 242 in part 2 of the Product manual xx0600002601 Upper arm A Linkage upper parallel rod link and lower parallel rod B Parallel bar C Required equipment Note Art no Spare part no Equipment 2 pcs Always replace with new 3HAC7877 2 Sealing ring 3HAC025034 001 Shaft end Continues on next page 3HAC026048 001 Revision E 143 Copyright 2006 2013 ABB All rights reserved 4 Repair 4 4 3 Replace...

Page 144: ...udes operating manual 3HAC15716 1 Calibration Pendulum toolkit These procedures include ref erences to the tools required Other tools and proced ures may be required See references to these procedures in the step by step instructions be low Removal upper arm The procedure below details how to remove the upper arm from the robot Note Illustration Action DANGER Turn off all electric power hydraulic ...

Page 145: ...ut 8 Remove the bearing 9 Unfasten the shaft end by removing the flanged bolts from inside the lower arm 10 Remove the VK cover from the opposite side by making a hole in the middle 11 Be careful not to damage the parts under neath Untighten and remove the lock nut and the bearing also from this side of the upper arm 12 If necessary use the press tool link as a puller tool fit the auxiliary shaft ...

Page 146: ...rsonnel 2 Spare part no is specified in Required equipment on page 143 xx0600002602 Make sure that the sealing rings are fitted properly in the upper arm facing the flat sur face outwards Replace them if any damage is detected 3 Sealing rings xx0500002549 Fit the lifting equipment to the upper arm ac cording to the figure to the right Note The tilthouse is movable be careful not to damage it 4 Art...

Page 147: ...lower arm by fitting the shaft end with guid ance from the guide pins 9 Shaft end Guide pins 3 pcs Attachment screw and washer Specified in Required equipment on page 143 Remove the guide pins and secure the shaft end with three flanged bolts from the inside of the lower arm using locking liquid Do not tighten yet 10 1 pc M12 x 60 UNBRAKO 12 9 Tight ening torque 90 Nm Fit the one attachment screw ...

Page 148: ...nut to the opposite side of the upper arm 16 Use the extended KM nut and tighten the lock nut with 55 Nm then untighten and retighten with 35 Nm xx0600002607 Fit the distance and the radial sealing to the shaft end by hand Note Make sure to fit the radial sealing with the flat side outwards 17 Radial sealing Distance Detailed in section Refitting parallel bar on page 168 Refit the parallel bar 18 ...

Page 149: ...etailed in a separate calibration manual enclosed with the calibration tools Recalibrate the robot 21 General calibration information is in cluded in the section Calibration inform ation on page 207 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 44 22 3HAC026048 0...

Page 150: ...on of upper rod The upper rod is located as shown in the figure below xx0600002615 Upper rod A Sealing ring 2 pcs B Support washer 4 pcs C Lock nut 2 pcs D Link E Required equipment Note Art no Spare part no Equipment 3HAC024575 001 Parallel rod upper Continues on next page 150 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 4 Repair 4 4 4 Replacement of linkage upper rod ...

Page 151: ... upper rod of the linkage Note Action Check especially that it is possible to re move the lock nut at the link Put the robot in a position where it is possible to reach all parts that shall be removed 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 2 Remove the lock nuts and support washers holding the u...

Page 152: ...e shaft ends 4 Check that the rod is pushed in com pletely Refit the upper rod to its place on the shafts 5 xx1000001080 Lock nut 2 pcs Support washer 2 pcs Refit the support washers on the outside of the upper rod on the shaft ends 6 Apply locking liquid on the threads for the lock nuts 7 Tightening torque 20 Nm Refit the lock nuts on the link and tilthouse using locking liquid 8 DANGER Make sure...

Page 153: ...od and link see Replacement of linkage upper rod on page 150 Replacement of linkage link on page 157 Location of lower rod The lower rod is located as shown in the figure below xx0600002617 Lower rod A Sealing ring 2 pcs B Support washer 4 pcs C Lock nut 2 pcs D Link E Continues on next page 3HAC026048 001 Revision E 153 Copyright 2006 2013 ABB All rights reserved 4 Repair 4 4 5 Replacing the link...

Page 154: ...eeve Standard KM10 socket Content is defined in section Standard tools on page 225 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below Removal lower rod Use this procedure to remove the lower rod of the linkage Note Action DANGER Turn off all electric power...

Page 155: ...ck to the grease and can easily be forgotten and lost when removing the lock nuts 3 CAUTION The link weighs xx All lifting accessories used must be sized accordingly 4 Remove the lower rod by lifting it straight out Note The support washers on the inside of the rod can stick to the grease of the bearings when the rod is being removed Remove them from the rod 5 Remove the inner support washers and ...

Page 156: ...in position Check that the bearings in the lower rod are fitted correctly that is in the center of the hole The same distance from bearing to the edge of the lower rod on both sides 5 CAUTION The link weighs xx All lifting accessories used must be sized accordingly 6 Place the lower rod on the shaft ends of the link and frame Note Check that the lower rod is pushed com pletely in 7 Refit the suppo...

Page 157: ...ow It is fitted to the same shaft that holds the upper arm to the lower am xx0600002619 Link A Bearing shown as complete bearing but the outer race should already be mounted inside the seating prior to refitting of link B Lock nut C Protection hood D VK cover E Screws and washers for lubrication and venting holes 3 pcs F Continues on next page 3HAC026048 001 Revision E 157 Copyright 2006 2013 ABB ...

Page 158: ... on page 225 Standard toolkit These procedures include ref erences to the tools required Other tools and proced ures may be required See references to these procedures in the step by step instructions be low Press tool link The tool for fitting the bearing and the link to the upper arm shaft includes the parts shown in the figure below included in the toolkit for service Note The parts cannot be o...

Page 159: ...tion DANGER Turn off all electric power hydraulic and pneu matic pressure supplies to the robot 1 Secure the link with a roundsling in a crane 2 Use the hole in the middle of the link Detailed in sections Removal upper rod on page 151 Removal lower rod on page 154 Remove the upper and lower rods 3 Remove the center screw and washer in the hole for filling grease 4 Continues on next page 3HAC026048...

Page 160: ...k up side down in order to find room to knock on it from the inside as close to its center as possible 9 Use a pair of levers to bend the link loose 10 Remove the link 11 Wipe off residual grease 12 Refitting link The procedure below details how to refit the link to the robot Note Illustration Action DANGER Turn off all electric power hydraulic and pneumat ic pressure supplies to the robot 1 Check...

Page 161: ...tening torque of 35 Nm 9 Spare part no is specified in Re quired equipment on page 158 Fit a protection hood to the lock nut It must be replaced if damaged 10 Shown in the figure Location of link on page 157 Spare part no is specified in Re quired equipment on page 158 Fit the VK cover Replace if damaged 11 Fill the link with grease and refit the three screws and washers 12 Note Fill through the c...

Page 162: ...more detailed view of the component and its position may be found in section Axes 1 3 spare part view 2 on page 247 in part 2 of the Product manual xx0500002548 Lower arm A Sealing ring B Continues on next page 162 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 4 Repair 4 5 1 Replacement of complete lower arm ...

Page 163: ...required Other tools and proced ures may be required See references to these procedures in the step by step instructions be low Removal lower arm The procedure below details how to remove the complete lower arm Note Illustration Action DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 1 Detailed in section Removal upper arm on page 144 Remove the upper arm 2...

Page 164: ...7 Shown in the figure Location of lower arm on page 162 Remove the attachment screws and the spring tension plate 8 Remove the lower arm 9 Refitting lower arm The procedure below details how to refit the complete lower arm Note Action DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 1 Move the damper and calibration marking to the new lower arm 2 Continues ...

Page 165: ...ing parallel arm on page 180 Refit the parallel arm 7 Detailed in section Refitting parallel bar on page 168 Refit the parallel bar 8 Detailed in section Refitting upper arm on page 146 Refit the upper arm 9 Detailed in section Refitting cable unit axis 6 on page 126 Refit the cabling 10 Calibration is detailed in a separate calibration manual enclosed with the calibration tools Recalibrate the ro...

Page 166: ...lel bar A Attachment screw 2 pcs B Locking washer 2 pcs C Bearing sealing 2 pcs D Bearing sealing 2 pcs E Parallel arm F Spherical roller bearing 2 pcs G Required equipment Note Art no Spare part no Equipment etc Includes spherical roller bear ings bearing sealings 3HAC025714 001 Parallel bar complete 2 pcs 3HAA2167 12 Spherical roller bearing Continues on next page 166 3HAC026048 001 Revision E C...

Page 167: ...udes operating manual 3HAC15716 1 Calibration Pendulum toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below Removal parallel bar The procedure below details how to remove the parallel bar from the robot Note Action DANGER Turn off all electric power hydraulic and pne...

Page 168: ...er hydraulic and pneumatic pressure supplies to the robot 1 Use a crane Make sure the weight of the upper arm is properly secured 2 Shown in the figure Location of parallel bar on page 166 Fit the new spherical roller bearings to the parallel bar using the press tool parallel bar bearing Lubricate the bearings with bearing grease 3 Art no is specified in Required equip ment on page 166 Shown in th...

Page 169: ...ib ration manual enclosed with the calibra tion tools Recalibrate the robot 9 General calibration information is in cluded in the section Calibration informa tion on page 207 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 44 10 3HAC026048 001 Revision E 169 Copyri...

Page 170: ... the component and its position may be found in section Axes 1 3 spare part view 5 on page 252 Note that the robot is shown with the SMB cover already removed xx0200000451 Cable battery SMB board A Battery pack 2 pole battery contact B Serial measurement board C Lock nuts D Continues on next page 170 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 4 Repair 4 6 1 Replacement o...

Page 171: ...ry contact has longer lifetime for the battery It is important that the SMB unit uses the correct battery Make sure to order the correct spare parts Do not replace the battery contact Note Art no Spare part no Equipment Must always be replaced 3HAC3200 1 Gasket cover Continues on next page 3HAC026048 001 Revision E 171 Copyright 2006 2013 ABB All rights reserved 4 Repair 4 6 1 Replacement of SMB u...

Page 172: ...nit The content is defined in the section Standard tools on page 225 Standard toolkit See the chapter Circuit dia gram on page 261 Circuit Diagram These procedures include references to the tools re quired Other tools and proced ures may be required See references to these proced ures in the step by step instructions below Continues on next page 172 3HAC026048 001 Revision E Copyright 2006 2013 AB...

Page 173: ...Connector R2 SMB1 3 B Connector R2 SMB1 2 external axis C Connector R2 SMB D Connector R2 G battery unit E Continues on next page 3HAC026048 001 Revision E 173 Copyright 2006 2013 ABB All rights reserved 4 Repair 4 6 1 Replacement of SMB unit Continued ...

Page 174: ...t Note Action DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 1 xx0200000399 Remove the rear cover plate A from the base by unscrewing the attachment screws B 2 Detailed in section Replacement SMB battery on page 107 Remove the SMB battery 3 Continues on next page 174 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 4 Repair 4 6 1 Repl...

Page 175: ...connect the connectors to the new SMB unit and push the board in 7 Refit the SMB cover using the attachment lock nuts 8 Pull the battery cable through the hole in the SMB cover Reassemble the two locknuts and washers to the pins securing the board 9 Refit the SMB battery 10 Always replace a removed gasket with a new Fit a new gasket to the cover and refit the cover with the attachment screws 11 Ar...

Page 176: ...ay be required See references to these procedures in the step by step instructions below Replacement brake release unit The procedure below details how to replace the brake release unit from the robot base Action DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 1 Remove the cover at the rear of the base 2 Unscrew the six attachment screws of the brake relea...

Page 177: ...efit the cover to the rear of the base 7 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 44 8 3HAC026048 001 Revision E 177 Copyright 2006 2013 ABB All rights reserved 4 Repair 4 6 2 Replacement of brake release unit Continued ...

Page 178: ...pment Includes groove ball bearing sealing ring 3HAC025727 001 Parallel arm complete 3HAB3537 1 Bearing grease The content is defined in the section Standard tools on page 225 Standard toolkit Complete kit that also in cludes operating manual 3HAC15716 1 Calibration Pendulum toolkit Continues on next page 178 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 4 Repair 4 6 3 Repl...

Page 179: ...ow details how to remove the parallel arm Note Action DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 1 Detailed in section Removal par allel bar on page 167 Remove the parallel bar 2 Remove the parallel arm by removing its eight at tachment screws and washers 3 Continues on next page 3HAC026048 001 Revision E 179 Copyright 2006 2013 ABB All rights reserve...

Page 180: ...ils how to refit the complete parallel arm to the robot Note Action DANGER Turn off all electric power hydraulic and pneumat ic pressure supplies to the robot 1 8 pcs M10x60 Fit the complete parallel arm to the robot with the eight attachment screws and washers 2 Tightening torque 72 Nm Continues on next page 180 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 4 Repair 4 6 3 ...

Page 181: ... General calibration information is included in the section Calibration information on page 207 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 44 5 3HAC026048 001 Revision E 181 Copyright 2006 2013 ABB All rights reserved 4 Repair 4 6 3 Replacement of parallel arm...

Page 182: ...iled view of the component and its position may be found in section Axes 1 3 spare part view 1 on page 246 xx0200000465 Cover A Connection box B Attachment screws and washers motor 4 pcs C Motor axis 1 D Correct orientation of holes E Continues on next page 182 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 4 Repair 4 7 1 Replacement of motor axis 1 ...

Page 183: ...tep instruc tions below See the chapter Circuit diagram on page 261 Circuit Diagram Removal motor axis 1 The procedure below details how to remove the motor axis 1 Note Illustration Action DANGER Turn off all electric power hydraulic and pneu matic pressure supplies to the robot 1 Shown in the figure Location of motor axis 1 on page 182 Remove the cover of the connection box 2 xx0200000401 Disconn...

Page 184: ...g 3 Note the position of the motor Use the mark made on the motor base before removal See also orientation of the holes on top of the motor shown in the figure Location of mo tor axis 1 on page 182 Fit the motor by gently lowering it straight down 4 4 pcs TIghtening torque 2 Nm Tighten the four attachment screws and washers 5 Connect power supply to connector R3 MP1 pin 7 pin 8 In order to release...

Page 185: ...m 12 4 pcs Tightening torque 23 Nm Tighten the motor attachment screws 13 Shown in the figure Location of mo tor axis 1 on page 182 Refit the connection box with the three attach ment screws and plain washers Make sure the gasket is fitted properly 14 xx0200000401 Reconnect the connectors R3 MP1 and R3 FB1 15 A R3 MP1 B R3 FB1 C Connection box Shown in the figure Location of mo tor axis 1 on page ...

Page 186: ... 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 44 18 186 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 4 Repair 4 7 1 Replacement of motor axis 1 Continued ...

Page 187: ...he figure below xx0200000470 Attachment screws cover 5 pcs A Cover B Connection box C Gasket D Motor axis 2 E Attachment screws motor 4 pcs F O ring G Correct orientation of holes on top of motor H Continues on next page 3HAC026048 001 Revision E 187 Copyright 2006 2013 ABB All rights reserved 4 Repair 4 7 2 Replacement of motor axis 2 ...

Page 188: ... See the chapter Circuit dia gram on page 261 Circuit Diagram Removal motor axis 2 The procedure below details how to remove the motor axis 2 Note Illustration Action DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 1 Shown in the figure Location of mo tor axis 2 on page 187 Remove the cover of the connection box 2 xx0200000401 Disconnect the motor connecto...

Page 189: ... the motor by gently lifting it straight out 9 Refitting motor axis 2 The procedure below details how to refit the motor axis 2 Note Illustration Action DANGER Turn off all electric power hydraulic and pneu matic pressure supplies to the robot 1 Check that the assembly surfaces are clean and the motor is unscratched 2 Always fit a new one see art no in Required equipment on page 188 Fit the o ring...

Page 190: ...ch corresponds to a reading on the dial indicator of 0 13 mm 10 See the figure above Pull gently in one direction Note the reading The gear must not turn 11 See the figure above Then gently knock on the tool in the other direc tion and note the reading The difference in reading gear play The gear play should be 0 02 mm which corresponds to a reading on the dial indicator of 0 13 mm 12 4 pcs Tighte...

Page 191: ...enclosed with the calibration tools Recalibrate the robot 19 General calibration information is in cluded in the section Calibration in formation on page 207 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 44 20 3HAC026048 001 Revision E 191 Copyright 2006 2013 ABB...

Page 192: ...d its position may be found in section Axes 1 3 spare part view 2 on page 247 xx0200000471 Attachment screws cover A Cover B Connection box C Gasket D Motor axis 2 E Attachment screws motor 4 pcs F O ring G Correct orientation of holes on top of motor H Continues on next page 192 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 4 Repair 4 7 3 Replacement of motor axis 3 ...

Page 193: ...gram on page 261 Circuit Diagram Removal motor axis 3 The procedure below details how to remove the motor axis 3 Note Illustration Action DANGER Turn off all electric power hydraulic and pneu matic pressure supplies to the robot 1 Shown in the figure Location of mo tor axis 3 on page 192 Remove the cover of the connection box 2 xx0200000401 Disconnect the motor connectors R3 MP3 and R3 FB3 3 A R3 ...

Page 194: ...ut 9 Refitting motor axis 3 The procedure below details how to refit the motor axis 3 Note Illustration Action DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 1 Check that the assembly surfaces are clean and the motor is unscratched 2 Always mount a new one see art no in section Required equipment on page 193 Fit a new o ring to the motor 3 Note the positi...

Page 195: ...the figure above Pull gently in one direction Note the reading The gear must not turn 11 See the figure above Then gently knock on the tool in the other direction and note the reading The difference in reading gear play The gear play should be 0 02 mm which corresponds to a reading on the dial indicator of 0 13 mm 12 4 pcs Tightening torque 23 Nm Tighten the four motor attachment screws 13 Detaile...

Page 196: ...ual enclosed with the calibration tools Recalibrate the robot 19 General calibration information is in cluded in the section Calibration inform ation on page 207 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 44 20 196 3HAC026048 001 Revision E Copyright 2006 2013...

Page 197: ...rs R3 MP6 and R3 FB6 C Required equipment Note Art no Spare part no Equipment 3HAC025734 001 Rot ac motor incl pin ion 24 VDC max 1 5 A For re leasing the brakes Power supply Loctite 243 Locking liquid The content is defined in the section Standard tools on page 225 Standard toolkit Complete kit that also in cludes operating manual 3HAC15716 1 Calibration Pendulum toolkit See the chapter Circuit d...

Page 198: ... R3 MP6 pin 4 pin 5 In order to release the brakes connect the 24 VDC power supply to the motor 2 Gently fit the motor to the tilthouse Be careful not to damage the motor pinion when mating it to the gearbox 3 Shown in the figure Location of motor axis 6 on page 197 Secure the motor with its four attachment screws and washers using locking liquid 4 4 pcs M6x20 Tightening torque 10 Nm Locking liqui...

Page 199: ...en performing the first test run These are further de tailed in the section DANGER First test run may cause injury or damage on page 44 9 3HAC026048 001 Revision E 199 Copyright 2006 2013 ABB All rights reserved 4 Repair 4 7 4 Replacement of motor axis 6 Continued ...

Page 200: ... serviced or adjusted xx0300000007 Attachment screws gearbox unit A Bottom plate B Required equipment Note Art no Spare part no Equipment 3HAC025711 001 Gearbox axes 1 3 The content is defined in the section Standard tools on page 225 Standard toolkit Complete kit that also in cludes operating manual 3HAC15716 1 Calibration Pendulum toolkit These procedures include references to the tools re quire...

Page 201: ...cessories used must be sized accord ingly 7 Place the remaining parts of the robot upside down on a table or similar surface and remove the bot tom plate 8 Undo the 12 attachment screws 9 Lift away the base from the gearbox unit 10 Refitting gearbox axis 1 3 The procedure below details how to refit the gearbox axis 1 3 Note Action DANGER Turn off all electric power hydraulic and pneu matic pressur...

Page 202: ...er arm on page 164 Refit the complete lower arm 10 Detailed in section Refitting gearbox axis 1 3 on page 201 Refit the cable unit axes 1 3 11 Calibration is detailed in a separate calibration manual enclosed with the calibration tools Calibrate the robot 12 General calibration information is included in the section Calibration information on page 207 DANGER Make sure all safety requirements are m...

Page 203: ...d Used to lubricate o rings and contact surfaces 3HAB3537 1 Bearing grease The content is defined in the section Standard tools on page 225 Standard toolkit Complete kit that also in cludes operating manual 3HAC15716 1 Calibration Pendulum toolkit These procedures include references to the tools re quired Other tools and proced ures may be required See references to these procedures in the step by...

Page 204: ...1 Lubricate the contact surfaces inside the housing with grease 2 Spare part no is specified in Re quired equipment on page 203 Make sure the o ring is lubricated and fitted properly to the upper side of the gearbox Re place if damaged 3 8 pcs M5x25 Refit the gearbox with the attachment screws and washers using locking liquid 4 Tightening torque 8 Nm Locking li quid is specified in Required equip ...

Page 205: ...en performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 9 3HAC026048 001 Revision E 205 Copyright 2006 2013 ABB All rights reserved 4 Repair 4 8 2 Replacement of gearbox axis 6 Continued ...

Page 206: ...This page is intentionally left blank ...

Page 207: ...necessary to calibrate for new absolute accuracy The resolver values will change when parts affecting the calibration position are replaced on the robot for example motors or parts of the transmission The revolution counter memory is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 211 This will occur when The battery is discharged...

Page 208: ...n Pendulum standard method Calibration Pendulum is the standard method for calibration of all ABB robots except IRB 6400R IRB 640 IRB 1400H and IRB 4400S and is also the most accurate method for the standard type of calibration It is the recommended method in order to achieve proper performance Two different routines are available for the Calibration Pendulum method Calibration Pendulum II Referen...

Page 209: ... the mark on the calibration plate is visible above the mechanical stop as shown in the figure below xx0500002485 Mechanical stop of axis 3 A Calibration mark on calibration plate axis 3 B Calibration plate and marking axis 6 C Punch axis 1 3HAB8223 1 D Punch axis 2 3HAB8223 1 1 marking E 3HAC026048 001 Revision E 209 Copyright 2006 2013 ABB All rights reserved 5 Calibration information 5 3 Calibr...

Page 210: ...n gears and so on Positive directions are shown in the graphic below This is normally handled by the robot calibration software Calibration movement directions 4 axes Note The graphic shows an IRB 260 The positive direction is the same for all 4 axis robots xx0500001927 210 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 5 Calibration information 5 4 Calibration movement dire...

Page 211: ...ibration values not only according to the calibration marks The correct values are found on a label located either on the lower arm underneath the flange plate on the base or on the frame At delivery the manipulator is in the correct position do NOT rotate axis 4 or 6 at power up before the revolution counters are updated If one of the following mentioned axes are rotated one or more turns from it...

Page 212: ...Then tap Update 4 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 5 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator...

Page 213: ...on page209 and Updat ing revolution counters on page211 Check that the calibration marks for the axes align correctly If they do not update the revolution counters 6 Using the jogging window Use this procedure to jog the robot to the zero position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis 1 2 or 3 3 Man...

Page 214: ...This page is intentionally left blank ...

Page 215: ... Gearboxes Oil grease Covers synchronization brackets Aluminium Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with local regulations Do not dispose of oil and grease near lakes ponds ditches down drains or onto soil Incineration must be carried out under controlled conditions in accordance with local regulations...

Page 216: ...This page is intentionally left blank ...

Page 217: ...ral This chapter includes general information complementing the more specific information in the different procedures in the manual 3HAC026048 001 Revision E 217 Copyright 2006 2013 ABB All rights reserved 7 Reference information 7 1 Introduction ...

Page 218: ...MC Generic immunity EN IEC 61000 6 2 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1iii Arc welding equipment Part 10 EMC requirements EN IEC 60974 10iii Safety of machinery Electrical equipment of machines Part 1 General requirements EN IEC 60204 1 Degrees of protection provided by enclosures IP code IEC 60529 i There is a deviation from paragraph 6 2 in that only worst case sto...

Page 219: ...pment ANSI UL 1740 option 429 1 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 03 option 429 1 3HAC026048 001 Revision E 219 Copyright 2006 2013 ABB All rights reserved 7 Reference information 7 2 Applicable safety standards Continued ...

Page 220: ...ts Quantity 39 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 220 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 7 Reference information 7 3 Unit conversion ...

Page 221: ... rubber type should be used Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair maintenance or installation procedure descriptions In such cases proceed as follows 1 Apply lubricant to the screw thread 2 Apply lubricant between the plain washer and screw head 3 Screw dimensions of M8 or larger must be tightened with a torque wrench ...

Page 222: ...ue for oil lubricated screws with allen head screws Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The following table spec...

Page 223: ...table specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 3HAC026048 001 Revision E 223 Copyright 2006 2013 ABB All rights reserved 7 Reference information 7 4 Screw joint...

Page 224: ...ifting accessory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The robot weighs 340 kg All lifting accessories used must be sized accord ingly 224 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights r...

Page 225: ...standard toolkit and any tools listed in the instruction Contents standard toolkit Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 2 5 17 mm 1 Torx socket no 20 60 1 Torque wrench 8 100 Nm 1 Small screwdriver 1 Plastic mallet 1 Ratchet head for torque wrench 1 2 1 KM nut KM7 1 Socket head cap no 5 socket 1 2 bit L 20 mm 1 Socket head cap no 6 socket 1 2 bit L 20 mm 1 Socket head cap no 8 ...

Page 226: ...5 mm 3HAC023963 040 Extended KM nut KM7 The kit contains loose parts that are assembled into different tools for different service occasions 3HAC023963 026 Toolkit for service The content is specified in the follow ing table Content toolkit for ser vice 3HAC023963 026 on page226 The different assemblies are shown in the figures on the following pages as in the service procedures that require the t...

Page 227: ...039 Press head L D 55 mm 3HAC023963 037 Sleeve M D 70 mm 3HAC023963 015 Press sleeve N Mxx length xx mm 3HAC023081 003 Connecting rod O 3HAC024097 002 Press housing P 3HAC024097 005 Auxiliary shaft R 2 pcs M6 x 12 9ADA183 24 Hex socket head cap screw S 3HAC023062 001 Distance T Continues on next page 3HAC026048 001 Revision E 227 Copyright 2006 2013 ABB All rights reserved 7 Reference information ...

Page 228: ...ouse shaft Assembly is shown in the figure Mounting tool tilthouse shaft on page 229 B Mounting tool bearing race and sealing upper arm Assembly is shown in the figure Mounting tool bearing race and sealing upper arm on page 230 C Dismantling tool bearing race upper arm Assembly is shown in the figure Dismantling tool bearing race upper arm on page 231 D Press tool link Assembly is shown in the fi...

Page 229: ...p screw 9ADA183 25 2 pcs M6 x 25 C Connection rod M16 length 400 mm D Nut 3HAC5507 1 E Sleeve 3HAC023963 027 F Nut 3HAC023963 028 G Pad 3HAC023963 029 J Mounting tool tilthouse shaft The tool for fitting the tilthouse shaft to the tilthouse is assembled with the parts shown in the following figure included in the toolkit for service Note The parts cannot be ordered separately but are included in t...

Page 230: ...ealing upper arm The tool for fitting the bearing race and sealing to the upper arm is assembled with the parts shown in the following figure included in the toolkit for service Note The parts cannot be ordered separately but are included in the complete toolkit The article numbers are only given for identification Continues on next page 230 3HAC026048 001 Revision E Copyright 2006 2013 ABB All ri...

Page 231: ...ing race upper arm The tool for removing the bearing race from the upper arm is assembled with the parts shown in the following figure included in the toolkit for service Note The parts cannot be ordered separately but are included in the complete toolkit The article numbers are only given for identification Continues on next page 3HAC026048 001 Revision E 231 Copyright 2006 2013 ABB All rights re...

Page 232: ...earing race tilthouse shaft The tool for removing the bearing race from the tilthouse shaft is assembled with the parts shown in the following figure included in the toolkit for service Note The parts cannot be ordered separately but are included in the complete toolkit The article numbers are only given for identification Continues on next page 232 3HAC026048 001 Revision E Copyright 2006 2013 AB...

Page 233: ...ilthouse shaft The tool for fitting a bearing race to the tilthouse shaft is assembled with the parts shown in the following figure included in the toolkit for service Note The parts cannot be ordered separately but are included in the complete toolkit The article numbers are only given for identification Continues on next page 3HAC026048 001 Revision E 233 Copyright 2006 2013 ABB All rights reser...

Page 234: ... The tool for fitting the bearing and the link to the upper arm shaft includes the parts shown in the following figure included in the toolkit for service Note The parts cannot be ordered separately but are included in the complete toolkit The article numbers are only given for identification Continues on next page 234 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 7 Referen...

Page 235: ...1 T Calibration equipment Calibration Pendulum The following table specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method Note Art no Description Complete kit that also includes operating manual 3HAC15716 1 Calibration Pendulum toolkit 3HAC026048 001 Revision E 235 Copyright 2006 2013 ABB All rights reserved 7 Reference information 7 7 Special to...

Page 236: ...piece of lifting accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference 236 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 7 Reference information 7 8 Lifting accessories and lifting instructions...

Page 237: ...ws 8 1 Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot 3HAC026048 001 Revision E 237 Copyright 2006 2013 ABB All rights reserved 8 Spare part lists and exploded views 8 1 Introduction ...

Page 238: ... Warning sign 5 6 Lifting of robot 3HAC025469 001 Instruction plate 1 7 3HAC12558 2 Conn set R1 CP CS Foundry 1 10 3HAC025223 001 CP CS Conn set 1 11 3HAC0453 2 ABB Logotype 2 12 3HAC024307 001 Calibration label 3 13 Includes one switch 3HAC12062 1 Position switch axis 1 1 14 Includes two switches 3HAC12062 2 Position switch axis 1 1 14 Includes three switches 3HAC12062 3 Position switch axis 1 1 ...

Page 239: ...ttons DSQC 563 1 121 Replacement is detailed in section Replacement of brake release unit on page 176 M5X15 2125 2052 198 Distance bolt 4 122 Recommended spare part 3HAC2744 1 Push button guard 1 123 Recommended spare part 3HAC7819 1 Signal cable SMB 1 129 3HAB7328 1 Adaptor customer cabling 1 157 3HAC2809 1 Adaptor power cabling 1 158 3HAC3197 1 Cover pushbuttons 1 170 Continues on next page 3HAC...

Page 240: ...Cover spare part view xx0500002436 240 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 8 Spare part lists and exploded views 8 3 Spare parts cover Continued ...

Page 241: ...2103 15 Taper roller bearing 2 10 Radial sealing 2 11 2126 2851 106 Lock nut 1 12 Distance 1 13 M12x60 UNBRAKO 12 9 3HAB7700 71 Hex socket head cap screw 2 14 3HAC12165 2 VK cover 2 15 13x19x1 5 3HAA1001 134 Washer 2 16 Ring 4 17 3HAB6279 1 Support washer 8 18 Lock nut 4 19 3HAC10088 4 Bearing sealing 1 20 D 34 T 4 3HAB5523 1 Locking washer 1 21 M8x16 Steel 8 8 Fe Zn 5c 2121 2852 449 Hex socket co...

Page 242: ...2 2522 2101 17 Protection hood 1 33 2179 090 25 Lifting eye 1 35 13x24x2 5 9ADA312 9 Plain washer 1 37 3HAC10089 2 Bearing sealing 1 38 Robot IRB 260 exploded view 1 of 2 xx0500001936 Continues on next page 242 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 8 Spare part lists and exploded views 8 4 Spare parts robot IRB 260 Continued ...

Page 243: ...Robot IRB 260 exploded view 2 of 2 xx0500001937 3HAC026048 001 Revision E 243 Copyright 2006 2013 ABB All rights reserved 8 Spare part lists and exploded views 8 4 Spare parts robot IRB 260 Continued ...

Page 244: ...x socket head cap screw 4 8 M8x25 3HAB3409 37 Hex socket head cap screw 8 9 10 5x23x2 5 21542033 10 Spring washer 8 11 M10x40 3HAB3409 50 Hex socket head cap screw 12 12 3HAC2205 1 Spring tension plate 1 13 3HAC2180 1 Damper standard axis 2 1 14 3HAB5512 1 Damper axis 3 1 15 M6x16 9ADA629 56 Torx pan head roll screw 4 16 M10x60 3HAB3409 57 Hex socket head cap screw 8 17 Recommended spare part 3HAB...

Page 245: ... 50 3HAC025714 001 Parallel bar complete 1 51 Included in the complete parallel bar 3HAA2167 12 Spherical roller bearing 2 21212477 331 Torx pan head tapp screw 15 134 3HAC025727 001 Parallel arm complete 1 172 3HAC025729 001 Lower arm 1 173 Continues on next page 3HAC026048 001 Revision E 245 Copyright 2006 2013 ABB All rights reserved 8 Spare part lists and exploded views 8 5 Spare parts axes 1 ...

Page 246: ... 1 3 spare part view 1 xx0500002047 Continues on next page 246 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 8 Spare part lists and exploded views 8 5 Spare parts axes 1 3 Continued ...

Page 247: ...s detailed in section Replacement of cable unit axes 1 3 on page 117 3HAC025725 001 Cable unit axes 1 3 1 100 3HAC2828 1 Bottom plate 1 102 3HAC4554 1 Gasket 1 103 Recommended spare part 3HAC4113 1 Sealing 1 106 3HAB5923 1 Bracket 1 107 3HAB3299 1 Holder for cable guide 2 108 3HAB5924 1 Cable guide 1 109 3HAB3662 1 Spring 1 110 3HAC025749 1 Cover 3 112 Continues on next page 3HAC026048 001 Revisio...

Page 248: ...nit 3HAC17396 1 contain ing SMB board 3HAC031851 001 Replacement is described in section Replacement SMB battery on page 107 RMU 3HAC044075 001 Battery pack 3 pole battery contact 1 Lithium battery Can only be used with SMB unit 3HAC046277 001 con taining SMB board 3HAC044168 001 Replacement is described in section Replacement SMB battery on page 107 Contains all parts needed if SMB unit 3HAC17396...

Page 249: ...ange sealing 1 ml 150 11699198 301 Adhesive tape 300 mm 151 3HAB5921 1 Bracket 1 152 3HAC3785 3 Parallel pin hardened 1 156 3HAC5479 4 Sealing 1 161 18661903 1 Profile 120 mm 171 Continues on next page 3HAC026048 001 Revision E 249 Copyright 2006 2013 ABB All rights reserved 8 Spare part lists and exploded views 8 5 Spare parts axes 1 3 Continued ...

Page 250: ... 1 3 spare part view 3 xx0500002084 Continues on next page 250 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 8 Spare part lists and exploded views 8 5 Spare parts axes 1 3 Continued ...

Page 251: ...n A Conductors from R2 BU R2 BU1 3 R2 BU4 6 and PE conductors under strap B Option internal connectors C Option external connectors D Continues on next page 3HAC026048 001 Revision E 251 Copyright 2006 2013 ABB All rights reserved 8 Spare part lists and exploded views 8 5 Spare parts axes 1 3 Continued ...

Page 252: ...Axes 1 3 spare part view 5 xx0500002086 252 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 8 Spare part lists and exploded views 8 5 Spare parts axes 1 3 Continued ...

Page 253: ...ction Replacement of shaft and bearings tilthouse on page 128 Recommended spare part 3HAA2166 15 VK cover 2 7 Recommended spare part 3HAC024867 001 Shaft 1 8 Replacement is detailed in section Replacement of shaft and bearings tilthouse on page 128 3HAC025737 001 Upper arm machining 1 9 Recommended spare part 3HAC022673 001 Ballplug 1 10 Recommended spare part 3HAC023027 001 Protection cap 1 11 M6...

Page 254: ...Upper arm exploded view xx0500001934 254 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 8 Spare part lists and exploded views 8 6 Spare parts upper arm Continued ...

Page 255: ...are part Replacement is detailed in section Replacement of turning disk on page 140 3HAC023881 001 Turning disk 1 6 3HAC024689 001 Sync plate 1 7 M4x8 9ADA618 32 Torx pan head screw 2 8 2522122 1 Magnetic plug 2 9 R 1 8 25291920 2 Plug 1 10 3HAC025212 001 Protection cover 1 11 M8x20 Steel 12 9 Gleitmo 610 Hex socket head cap screw 6 12 Recommended spare part 3HAB3772 89 O ring 6 13 9ADA183 25 Hex ...

Page 256: ...Tilthouse exploded view xx0500001935 256 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 8 Spare part lists and exploded views 8 7 Spare parts tilthouse Continued ...

Page 257: ... 1 3HAC024575 001 Parallel rod upper 1 2 Radial Seal 35x62x7 1 3 Link machining 1 4 Taper roller bearing 2 5 3HAB6432 1 Needle bearing 4 6 Linkage exploded view 6 6 6 3 5 5 6 1 2 4 xx0500001933 3HAC026048 001 Revision E 257 Copyright 2006 2013 ABB All rights reserved 8 Spare part lists and exploded views 8 8 Spare parts linkage ...

Page 258: ...Cable unit axis 6 1 1 Recommended spare part 3HAC024194 001 Connection box CP CS AIR 1 2 3HEA800897 002 Dust cap 1 3 3HAB3333 20 Coupling 1 5 M6x20 Steel 8 8 A2F 9ADA618 57 Torx pan head screw 6 6 Square washer 2 7 M5x16 Steel 8 8 Fe ZN 5c Torx pan head screw 2 8 Recommended spare part 3HAC025783 001 Cable bracket tilt house 1 9 M3x8 Steel 8 8 A2F 9ADA618 23 Torx pan head screw 4 10 Continues on n...

Page 259: ...et cabling axis 6 spare part view xx0500002438 3HAC026048 001 Revision E 259 Copyright 2006 2013 ABB All rights reserved 8 Spare part lists and exploded views 8 9 Spare parts material set cabling axis 6 Continued ...

Page 260: ...This page is intentionally left blank ...

Page 261: ...09 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 type A 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB 2400 3HAC029570 007 Circuit diagram IRB 2600 3HAC9821 1 Circuit diagram IRB 4400 4450S 3HAC029038 003 ...

Page 262: ...iagram IRB 6650S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 262 3HAC026048 001 Revision E Copyright 2006 2013 ABB All rights reserved 9 Circuit diagram 9 1 About circuit diagrams Continued ...

Page 263: ...10 drilling pattern mechanical stop axis 1 81 E emergency stop definition 34 devices 35 enabling device 32 environmental information 215 ESD damage elimination 47 sensitive equipment 47 wrist strap connection point 47 F fence dimensions 27 figures connectors on robot 92 where to use special tools 228 fire extinguishing 28 fitting equipment on robot 69 FlexPendant jogging to calibration position 21...

Page 264: ...dards 218 R R1 MP connector supplying power to 64 references other manuals 10 releasing brakes 64 replacing brake release unit 176 cable unit axes 1 3 117 cabling axis 6 123 gearbox axes 1 3 200 gearbox axis 6 203 link linkage 157 lower arm 162 164 motor axis 1 182 motor axis 2 187 motor axis 3 192 motor axis 6 197 parallel arm 178 parallel bar 166 shaft and bearings at tilthouse 128 SMB battery 1...

Page 265: ...ISO 218 protection 218 safety 218 steel disposal 215 symbols safety 36 sync marks 209 T testing brakes 30 tie rod replacing 166 tightening torque gearbox axes 1 3 201 gearbox axis 6 204 lower arm 165 motor axis 1 185 motor axis 2 190 motor axis 3 195 motor axis 6 198 parallel arm 180 turning disk 141 upper arm 147 tilthouse shaft replacing 128 tools Calibration Pendulum equipment 235 dismantling t...

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Page 267: ......

Page 268: ... Motion Box 265 N 4349 BRYNE Norway Telephone 47 51489000 ABB Engineering Shanghai Ltd 5 Lane 369 ChuangYe Road KangQiao Town PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Discrete Automation and Motion Robotics 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 www abb com robotics 3HAC026048 001 Rev E en ...

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