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1.2.2 Safety in the manipulator system

Validity and responsibility

The information does not cover how to design, install and operate a complete
system, nor does it cover all peripheral equipment that can influence the safety of
the entire system. To protect personnel, the complete system must be designed
and installed in accordance with the safety requirements set forth in the standards
and regulations of the country where the manipulator is installed.

The users of ABB industrial manipulators are responsible for ensuring that the
applicable safety laws and regulations in the country concerned are observed and
that the safety devices necessary to protect people working with the manipulator
system are designed and installed correctly. Personnel working with manipulators
must be familiar with the operation and handling of the industrial manipulator as
described in the applicable documents, for example:

•

Operating manual - IRC5 with FlexPendant

•

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
equipment as well as from the manipulator.

Limitation of liability

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

Related information

Section

Detailed in document

Type of information

Installation and
commissioning

Product manual for the manipulator

Installation of safety devices

Operating modes

Operating manual - IRC5 with FlexPend-
ant

Changing operating modes

Installation and
commissioning

Product manual for the manipulator

Restricting the working space

3HAC033453-001 Revision: H

21

© Copyright 2009-2013 ABB. All rights reserved.

1 Safety

1.2.2 Safety in the manipulator system

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Summary of Contents for IRB 4600 - 20/2.50

Page 1: ...ABB Robotics Product manual IRB 4600 ...

Page 2: ...Trace back information Workspace R13 2 version a3 Checked in 2013 10 15 Skribenta version 4 0 378 ...

Page 3: ...Product manual IRB 4600 60 2 05 IRB 4600 45 2 05 IRB 4600 40 2 55 IRB 4600 20 2 50 M2004 Document ID 3HAC033453 001 Revision H Copyright 2009 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: ... 2 5 1 What is an emergency stop 42 1 3 Safety related instructions 42 1 3 1 Safety signals in the manual 44 1 3 2 Safety symbols on manipulator labels 49 1 3 3 DANGER Moving manipulators are potentially lethal 50 1 3 4 DANGER First test run may cause injury or damage 51 1 3 5 WARNING The brake release buttons may be jammed after service work 52 1 3 6 DANGER Make sure that the main power has been ...

Page 6: ...4 3 3 7 Inspecting information labels 137 3 3 8 Inspecting the mechanical stop pin axis 1 140 3 3 9 Inspecting additional mechanical stops 142 3 3 10 Inspecting dampers 144 3 3 11 Inspecting the pressure relief valve 146 3 3 12 Inspecting Signal lamp option 148 3 4 Replacement activities 148 3 4 1 Type of lubrication in gearboxes 150 3 4 2 Changing the oil axis 1 gearbox on floor mounted robots 15...

Page 7: ...n counters 328 5 6 Checking the calibration position 329 6 Decommissioning 329 6 1 Introduction 330 6 2 Environmental information 331 7 Robot description 331 7 1 Type C of IRB 4600 333 8 Reference information 333 8 1 Introduction 334 8 2 Applicable safety standards 336 8 3 Unit conversion 337 8 4 Screw joints 340 8 5 Weight specifications 341 8 6 Standard tools 342 8 7 Special tools 344 8 8 Liftin...

Page 8: ...371 Index 8 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved Table of contents ...

Page 9: ...f 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 the robot Contains general safety aspects as well as more specific information on how to avoid personal injuries and damage to the product Safety Required information about lifting and installation of the robot Installation...

Page 10: ...5 with main computer DSQC 639 3HAC047136 001 Product manual IRC5 IRC5 with main computer DSQC1000 3HAC027098 001 Operating manual Emergency safety information 3HAC16590 1 Operating manual IRC5 with FlexPendant 3HAC020738 001 Operating manual Trouble shooting IRC5 3HAC16578 1 Operating manual Calibration Pendulum 3HAC025709 001 Operating manual Service Information System 3HAC042927 001 Technical re...

Page 11: ...anually releasing the brakes on page 70 Restricting working range with software added in section Mechanically restricting the working range of axis 1 on page 87 The sections describing Replacing motors axes 1 through 6 has been updated Two new sections Removing motors on page278 and Refitting motors on page 286 replaces the older ones A The following updates have been made in this revision Missing...

Page 12: ...ction Inspecting oil level axis 1 gearbox on page 114 Inspection of oil level on suspended robot updated in section Inspecting oil level axis 1 gearbox on page 114 C The following updates have been made in this revision Added information about the bracket on the mechanical stop pin axis 1 has been updated in section Mechanically restricting the working range of axis 1 on page 87 Inspecting the mec...

Page 13: ... 4 5 and 6 motors on page 296 Additional step about removing refitting axis 1 motor when replacing the axis 1 gearbox Also added information about guide pins See Replacing gearbox axis 1 on page297 Also minor additions concerning the mating of gearbox and motor in all such instructions New section about calibration movement directions for axes is added see Calibration movement directions for all a...

Page 14: ... Replacing wrist unit on page 257 Added information about disconnecting the battery cable when removing the cable harness see Removing the complete cable harness on page195 Added a funnel to equipment list see Changing the oil axis 3 gearbox on page 166 Added Profibus to the section about connections to extra equipment see Customer connection on robot on page 104 Some general tightening torques ha...

Page 15: ... and for motors see Motors Type C on page 365 Several more spare part numbers are corrected throughout the spare part chapter Section describing inspection of oil level in axis 1 gearbox for suspended robots is clarified see Inspecting oil level axis 1 gearbox on page 114 H 3HAC033453 001 Revision H 15 Copyright 2009 2013 ABB All rights reserved Overview of this manual Continued ...

Page 16: ... 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 17: ...e 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 w...

Page 18: ...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 19: ...applicable for all service work and are found in General safety information on page 20 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 42 3HAC033453 001 Revision H 19 Copyright 2009 2013 ABB All rights reserved 1 Safety 1 1 Int...

Page 20: ... 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 21: ...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 22: ...n 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 safety operation ABB is not liable for damages caused by t...

Page 23: ...terlocked in accordance with the applicable standards 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 ...

Page 24: ...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 24 3HAC033453 001 Revision H Copyright 2...

Page 25: ...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 3HAC033453 001...

Page 26: ...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 27: ...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 28: ...Safety risks The pressure relief valve is a vital part preventing too much air pressure being built up inside the manipulator If too much air pressure has been built up there is a risk of personal injury and mechanical damage 28 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 1 Safety 1 2 3 5 Safety risks with pressure relief valve ...

Page 29: ... 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 3HAC033453 001 ...

Page 30: ...regulations are followed All work must be performed by qualified personnel on machine manipulator system 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 contr...

Page 31: ...chapter Installation and commissioning on page 57 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 3HAC033453 001 Revision H 31 Copyright 2009 2013 ABB All rights reserved 1 Safety 1 2 3 7 Risks associated with li...

Page 32: ...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 32 3HAC033453...

Page 33: ... Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator system manipulator or controller 3HAC033453 001 Revision H 33 Copyright 2009 2013 ABB All rights reserved 1 Safety 1 2 4 2 Fire extinguishing ...

Page 34: ...ng the brakes on page 70 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 34 3HAC033453 001 Revision H Copyright 2009 2013 ABB All right...

Page 35: ...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 3HAC033453 001...

Page 36: ...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 36 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 1 Safety 1 2 4 5 Risk of disabling function Reduced speed 250 mm s ...

Page 37: ... 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 38: ...lable 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 to the section Brake testing on page 35 To prevent anyone else from taking control of th...

Page 39: ...lator as a safety device Function The lamp is active in MOTORS ON mode Further information Further information about the MOTORS ON MOTORS OFF mode may be found in the product manual for the controller 3HAC033453 001 Revision H 39 Copyright 2009 2013 ABB All rights reserved 1 Safety 1 2 4 8 Signal lamp optional ...

Page 40: ...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 41: ...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 3HAC033453 001 Re...

Page 42: ...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 43: ... conditions NOTE xx0100000004 Describes where to find additional information or how to do an operation in an easier way TIP xx0100000098 3HAC033453 001 Revision H 43 Copyright 2009 2013 ABB All rights reserved 1 Safety 1 3 1 Safety signals in the manual Continued ...

Page 44: ...information in text English German and French 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 high voltage electrical units explosion or fire risk risk of po...

Page 45: ... 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 3HAC033453 001 Revision ...

Page 46: ...at can cause burns Moving robot xx0900000819 The robot can move unexpectedly xx1000001141 Brake release buttons xx0900000820 xx1000001140 Continues on next page 46 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 1 Safety 1 3 2 Safety symbols on manipulator labels Continued ...

Page 47: ...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 3HAC033453 001 Revision H 47 Copyright 2009 2013 ABB All rights reserved 1 Safety 1 3 2 Safety symbols on manipulator labels Continued ...

Page 48: ...urized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller 48 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 1 Safety 1 3 2 Safety symbols on manipulator labels Continued ...

Page 49: ...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 50: ...k 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 movements of the manipulator always check potent...

Page 51: ... injuries and damage to the manipulator Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action Make sure the power is turned off 1 Remove the push button guard if necessary 2 Check the push buttons of the brake release unit by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a button g...

Page 52: ...limination Single Cabinet Controller Note illustration Action xx0600002782 Switch off the main switch on the controller cabinet 1 A Main switch Elimination Dual Cabinet Controller Note illustration Action xx0600002783 Switch off the main 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 52 3HAC033453 001 Revision...

Page 53: ...sted frequently 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 f...

Page 54: ...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 58 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 55: ...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 56: ... 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...

Page 57: ...that all safety information 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 page19 before performing any installation work Note If the IRB 4600 is connected to power always make sure that the robot is connected to protective earth b...

Page 58: ...Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 60 4 Before taking the robot to its installation site make sure that the site conforms to Loads on foundation robot on page 59 Protection classes robot on page 60 Requirements foundation on page 60 5 Before moving the robot please observe the stability of...

Page 59: ...f 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 7790 N 3940 N Force xy 4350 6360 N 4350 2460 N Force z 14090 Nm 6850 Nm Torque xy 2960 Nm 1610 Nm Torque z Suspended Max load emergency stop Endurance load in oper...

Page 60: ...m 0 15 Maximum tilt Contact ABB for further information about accept able loads 22 Hz Minimum resonance frequency Storage conditions 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 95 at constant temperature gaseous only Maximum ambient humidity Ope...

Page 61: ...hen the robot is floor mounted xx0800000267 Pos F Pos E Pos D Pos C Pos B Pos A Variant 2051 mm 1701 mm 593 mm 1028 mm 1260 mm 2371 mm IRB 4600 60 2 05 2051 mm 1701 mm 593 mm 1028 mm 1260 mm 2371 mm IRB 4600 45 2 05 2552 mm 2202 mm 680 mm 1393 mm 1735 mm 2872 mm IRB 4600 40 2 55 2513 mm 2163 mm 665 mm 1361 mm 1696 mm 2833 mm IRB 4600 20 2 50 Continues on next page 3HAC033453 001 Revision H 61 Copy...

Page 62: ...8 mm 1260 mm 2371 mm IRB 4600 60 2 05 2051 mm 1701 mm 593 mm 1028 mm 1260 mm 2371 mm IRB 4600 45 2 05 2552 mm 2202 mm 680 mm 1393 mm 1735 mm 2872 mm IRB 4600 40 2 55 2513 mm 2163 mm 665 mm 1361 mm 1696 mm 2833 mm IRB 4600 20 2 50 Continues on next page 62 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range and type of motion Co...

Page 63: ...RB 4600 60 2 05 45 2 05 40 2 55 The table specifies the types and ranges of motion in every axes Range of movement Type of motion Location of motion 180 Rotation motion Axis 1 150 90 Arm motion Axis 2 75 180 Arm motion Axis 3 400 Wrist motion Axis 4 120 125 Bend motion Axis 5 400 Turn motion Axis 6 Continues on next page 3HAC033453 001 Revision H 63 Copyright 2009 2013 ABB All rights reserved 2 In...

Page 64: ...tion Location of motion 180 Rotation motion Axis 1 150 90 Arm motion Axis 2 75 180 Arm motion Axis 3 400 Wrist motion Axis 4 120 Bend motion Axis 5 400 Turn motion Axis 6 64 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range and type of motion Continued ...

Page 65: ...bot position before securing it to the foundation Shipping and transport position This figure shows the robot in its shipping position which also is a recommended transport position The position of the calibration mark A in the figure is approximate and is used as aming aid 1 5 45 A 0 xx0800000263 WARNING The robot is likely to be mechanically unstable if not secured to the foundation 3HAC033453 0...

Page 66: ...e 69 Required equipment Note Equipment Lifting capacity 1 000 kg Max load at 90 Overhead crane Lifting capacity roundsling 1 000 kg Length 2 m Roundslings 2 pcs Lifting Attach the roundslings as shown in the figure xx0800000262 Roundsling put folded in U shape through the lifting lug A Roundsling put folded in U shape around gearbox axis 3 B Lifting lug C Continues on next page 66 3HAC033453 001 R...

Page 67: ...obot to its most stable position 4 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 5 See the figure in Lifting on page 66 Attach roundsling A to the lifting lug on the frame and put folded in a U shape on either side of the upper arm 6 See the figure in Lifting on page 66 Attach roundsling B at axis 3 gearb...

Page 68: ...t to damage the connec tion box at the base of the robot 9 A Area where the connection box can be damaged while lifting Lifting capacity See Required equipment on page 66 Lift the robot with an overhead crane 10 68 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting robot with roundslings Continued ...

Page 69: ...e numbers for the accessory and the instruction is specified in Special tools on page 342 Contact ABB for more information How to lift and turn the robot into position for wall or tilted position Contact ABB for more information Illustration xx1000000181 Turning accessory A 3HAC033453 001 Revision H 69 Copyright 2009 2013 ABB All rights reserved 2 Installation and commissioning 2 3 2 Lifting and t...

Page 70: ... the robot arm Using the push button when the robot is connected to the controller The procedure details how to release the holding brakes with push buttons when the robot is connected to the controller Note Action xx0800000272 The internal brake release unit is located at the base of the robot 1 The brake release unit is equipped with six buttons for controlling the axes brakes The buttons are nu...

Page 71: ... connections can cause all brakes to be released simultaneously 1 Connect to connector R1 MP 0V to pin 12 24V to pin 11 The brake release unit is equipped with six buttons for controlling the axes brakes The buttons are numbered accord ing to the numbers of the axes Release the holding brake on a particular axis by pressing the corresponding button on the push button unit and keeping it de pressed...

Page 72: ...ke built into the axis motor This holding brake may be re leased by connecting 24VDC power supply directly to one of the connectors in the motor DANGER When power is connected directly to the brake cable the brake will be released imme diately when the power is switched on This may cause some unexpected robot movements 1 See chapter Circuit diagram on page369 72 3HAC033453 001 Revision H Copyright...

Page 73: ...n robot on page 59 and Requirements foundation on page 60 Hole configuration base The illustration shows the hole configuration used when securing the robot xx0800000271 Center axis 1 See graphic in Fitting equipment on base and frame on page 79 A Hole for guide sleeve C Rear bolt holes D Continues on next page 3HAC033453 001 Revision H 73 Copyright 2009 2013 ABB All rights reserved 2 Installation...

Page 74: ...cure the robot to the foundation or base plate Note Dimension Securing parts Facts 6 pcs M16 x 60 quality 8 8 A3F Securing screws oiled Tightening torque 200 Nm 6 pcs 17 x 30 x 3 Washers Article number 21510024 169 Guide sleeves 2 pcs xx1200000885 Added to the rear bolt holes to allow the same robot to be re mounted without program adjustments Continues on next page 74 3HAC033453 001 Revision H Co...

Page 75: ...ibed in sec tion Lifting robot with roundslings on page 66 Lift the robot to its installation site 5 Fit two guide sleeves to the rear bolts in the base 6 Make sure the robot base is correctly fit ted onto the guide sleeves Guide the robot gently using the attachment screws while lowering it into its mounting position 7 Fit the securing screws and washers in the attachment holes of the base 8 Tigh...

Page 76: ... path performance and path accuracy Some functions will not work properly for example Load Identification and Collision detection Mounting angles and values The parameter Gravity Beta specifies the robot s mounting angle in radians It is calculated in the following way Gravity Beta A x 3 141593 180 B radians where A is the mounting angle in degrees and B is the mounting angle in radians Gravity Be...

Page 77: ...RC5 with FlexPendant or Operating manual RobotStudio Article numbers for the manuals are specified in References on page 10 3HAC033453 001 Revision H 77 Copyright 2009 2013 ABB All rights reserved 2 Installation and commissioning 2 3 5 Setting the system parameters for a suspended robot Continued ...

Page 78: ...d area indicates the permitted positions center of gravity for any extra equipment fitted in the holes intended for this purpose xx0800000275 Max load D Max load A C Max load C Max load B Max load A Variant 35 kg 15 kg 15 kg 5 kg i 15 kg IRB 4600 60 2 05 35 kg 15 kg 15 kg 5 kg ii 15 kg IRB 4600 45 2 05 35 kg 15 kg 15 kg 5 kg iii 15 kg IRB 4600 40 2 55 35 kg 10 kg 10 kg 1 kg 10 kg IRB 4600 20 2 50 ...

Page 79: ...ing holes available for fitting extra equipment on the base and frame of the robot xx0800000276 Attachment holes on base A Center axis 2 B Continues on next page 3HAC033453 001 Revision H 79 Copyright 2009 2013 ABB All rights reserved 2 Installation and commissioning 2 3 6 Fitting equipment on robot Continued ...

Page 80: ...wer and upper arm of the robot 16 3x M8 90 216 2x M8 16 A C L 0 3 190 110 80 2x M8 16 0 3 16 65 130 3x M8 190 80 B xx0800000280 Center axis 4 A Center axis 3 B Continues on next page 80 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 2 Installation and commissioning 2 3 6 Fitting equipment on robot Continued ...

Page 81: ...55 237 28 20 85 1230 5 1496 5 315 1095 1922 20 2 50 i Position H and measurement C is only applicable to IRB 4600 40 2 55 and IRB 4600 20 2 50 Attachment screws Variant 4x M8 through 60 2 05 4x M8 through 45 2 05 6x M8 through 40 2 55 6x M8 through 20 2 50 Continues on next page 3HAC033453 001 Revision H 81 Copyright 2009 2013 ABB All rights reserved 2 Installation and commissioning 2 3 6 Fitting ...

Page 82: ...ation below xx0800000281 Screws not to be removed Do not use these holes for fitting equipment on the wrist A Screw hole intended for swivel fitting B Extra equipment on mounting flange robot versions IRB 4600 60 2 05 45 2 05 and 40 2 55 The illustration shows the mechanical interface for the mounting flange xx0800000282 Continues on next page 82 3HAC033453 001 Revision H Copyright 2009 2013 ABB A...

Page 83: ...ration also shows the mechanical interface for the mounting flange of the robot version IRB 4600 20 2 50 79 2x M6 110 6 12 5 12 2x M 25 A R98 D B B C 0 05 C 0 3 D 5 0 30 6x M6 6 0 6 H7 8 P P B P P C 7 31 5 H8 63 h8 10 xx0800000278 Smallest circumscribed radius axis 4 A Note Use attachment screws M6 quality 12 9 and 10 mm used thread length 3HAC033453 001 Revision H 83 Copyright 2009 2013 ABB All r...

Page 84: ... to 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 Stop time and braking distances Robot motor brake performance depends on any loads attached For information about brake performance read the product specification fo...

Page 85: ...lamp option Signal lamp See the assembly instruction delivered with the signal lamp 3HAC033453 001 Revision H 85 Copyright 2009 2013 ABB All rights reserved 2 Installation and commissioning 2 3 8 Installation of signal lamp option ...

Page 86: ...llowing axes may be restricted Axis 1 hardware mechanical stop and software Axis 2 software Axis 3 software 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 relevant manuals are included in the installation procedures 86 3HAC033453 001 Revision H Copyright 2009 2013...

Page 87: ...joint bound are described in Technical reference manual System parameters Required equipment Note Art no Equipment etc Includes two additional stop lugs attachment screws washers and instruction See Spare part list on page 345 Mechanical stop axis 1 2 pcs stop lug See Spare part list on page 345 Attachment screw Hex socket head cap screw M12x40 quality 8 8 A3F 2 pcs lug See Spare part list on page...

Page 88: ...he procedure Mounting instructions are also supplied with the kit Note Action See the figure Additional stops on page 88 for guidance Determine the position of the stop lugs 1 Specified in Required equipment on page 87 Fit the stop lugs firmly with attachment screws and washers according to the figure Additional stops on page 88 2 Tightening torque 82 Nm Continues on next page 88 3HAC033453 001 Re...

Page 89: ... supply to the robot before entering the robot work ing area 1 xx1100000091 A Attachment screw B Bracket stop axis 1 Remove the two screws holding the mechan ical stop and the bracket 2 Remove the bracket 3 Refit the attachment screws 4 3HAC033453 001 Revision H 89 Copyright 2009 2013 ABB All rights reserved 2 Installation and commissioning 2 4 2 Mechanically restricting the working range of axis ...

Page 90: ...n of cooling fans The fans are installed on the motors axes 1 2 as shown in the figure below xx0900000135 Fan motor axis 2 A Fan motor axis 1 B Protection cover C Continues on next page 90 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 2 Installation and commissioning 2 5 1 Installation of cooling fan for motors option ...

Page 91: ... axis 2 A Attachment screws fanbox plates 9 pcs B Groove in the connector C Tightening screws fanbox 3 pcs D Continues on next page 3HAC033453 001 Revision H 91 Copyright 2009 2013 ABB All rights reserved 2 Installation and commissioning 2 5 1 Installation of cooling fan for motors option Continued ...

Page 92: ... set Loctite 243 Used for the three tightening screws Locking liquid Content is defined in section Standard tools on page 341 Standard toolkit See chapter Circuit diagram on page369 Circuit diagram These procedures include references 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 Continues on next page 92...

Page 93: ... back plate of the fanbox 4 See the figure in Cooling fan on page 91 Tip If there is a lack of space between motor and robot it is possible to remove part of the fanbox 5 Align the upper part of the fan with the lower part of the connection box A B C xx1000000124 Push the fanbox in line with the connection box 6 Parts A Connection box B Position where the fan shall be aligned with connection box C...

Page 94: ...0406 After fitting the motor cover fit the protection cover using two attachment screws for the motor cover 9 Parts A Protection cover B Fan Secure the fan cable to the protection cover with a cable strap 10 Continues on next page 94 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 2 Installation and commissioning 2 5 1 Installation of cooling fan for motors option Continued ...

Page 95: ...the fanbox 2 Place the fanbox around motor axis 1 3 See the figure in Cooling fan on page 91 Refit the back plate of the fanbox 4 Fit the fanbox with two attachment screws M6x30 5 xx0900000405 Connect the fan connector to motor and fan 6 Parts A Connector signal B Connector power C Fan cable D Connector fan E Cable gland F Motor cover with fan cable Continues on next page 3HAC033453 001 Revision H...

Page 96: ... protection cover using two attachment screws for the mo tor cover 7 Parts A Protection cover B Fan 96 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 2 Installation and commissioning 2 5 1 Installation of cooling fan for motors option Continued ...

Page 97: ...and 7600 are available in English German French Spanish and Italian and can be found on the DVD delivered with the Cable guard article number 3HAC035933 001 xx1100000097 3HAC033453 001 Revision H 97 Copyright 2009 2013 ABB All rights reserved 2 Installation and commissioning 2 5 2 Installation of Foundry Plus Cable guard option no 908 1 ...

Page 98: ...Robots ordered as suspended robots have the expansion container installed on delivery Expansion container xx1000000318 Cover A Attachment screw M6x16 quality 8 8 A2F 5 pcs B Oil expansion container with cover C Base D O ring D220x5 E Attachment screw M5x20 quality 8 8 A2F and washer 2 2 pcs F O ring D1 9 5 D2 1 6 G Oil plug to be removed H Continues on next page 98 3HAC033453 001 Revision H Copyri...

Page 99: ...g 4 Apply some grease on the small o ring and place it in the recess on the expansion con tainer 5 Place the expansion container in the base and place it so the drain holes match 6 Secure the expansion container with the at tachment screws and washers 7 Check the o ring used on the cover Replace it if damaged 8 Refit the cover on the base with its attach ment screws 9 Turn the robot so it is not s...

Page 100: ...y hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 CAUTION Before approaching the potentially hot robot component observe the safety information in section CAUTION Hot parts may cause burns on page 25 2 Note Before opening the oil plug make certain that the oil plug is above the oil level Place the robot accordingly 3 Tip Hold a cloth or some pap...

Page 101: ...h the RAPID code instructions and the instruction AccSet Start the robot with its normal program but with lowered velocity 1 Adjusting velocity Depending on how cold the environment is and the program being used the ramping up of velocity has to be adjusted The table shows examples of how to adjust velocity Velocity AccSet Workcycles 100 20 20 3 Work cycles 400 40 40 5 Work cycles 600 60 60 5 Work...

Page 102: ... product manual for the controller see document number in References on page 10 Handles power supply to and control of the external axes motors as well as feedback from the servo system External axes cables option See the Application manual Additional axes and stand alone controller M2004 see document number in Refer ences on page 10 Robot cables These cables are included in the standard delivery ...

Page 103: ...e not included in the standard delivery but are included in the delivery if the fan option is ordered The cables are completely pre manufactured and ready to plug in Cabling to be installed on the robot is specified in section Installation of cooling fan for motors option on page 90 3HAC033453 001 Revision H 103 Copyright 2009 2013 ABB All rights reserved 2 Installation and commissioning 2 8 1 Rob...

Page 104: ...he front part of the upper arm The customer connections are located on the robot as shown in the figure Customer connection upper arm A B C xx0800000289 Air M16x1 5 24 cone sealing A R2 CP B R2 CS C Customer connections base xx0800000288 R1 CP CS A Air M16x1 5 B R1 CBUS C R1 SMB D Continues on next page 104 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 2 Installation and co...

Page 105: ...therNet R1 CBUS Connection sets To connect power and signal conductors to the robot base upper arm connectors the following parts are recommended Content Art no Connector Connection set Sockets for cable area of 0 14 2 5 mm Hood foundry Hinged frame hood Multicontact module female 3HAC16667 1 R1 CP CS PROC1 on base Hose coupling M12 connector male 3HAC033181 001 R1 CP CS Connector set on base Pins...

Page 106: ...t and controller not supplied Customer Contact on Upper arm R2 Customer Ter minal Controller Signal name R1 CP CS d1 R2 CP A XP6 1 CPA R1 CP CS d6 R2 CP B XP6 2 CPB R1 CP CS d3 R2 CP C XP6 3 CPC R1 CP CS d4 R2 CP D XP6 4 CPD R1 CP CS d1 R2 CP E XP6 1 CPE R1 CP CS d6 R2 CP F XP6 2 CPF R2 CP G Earth CPG R1 CP CS d7 R2 CP H CPH R1 CP CS d3 R2 CP J XP6 3 CPJ R1 CP CS d4 R2 CP K XP6 4 CPK Continues on ...

Page 107: ... CS b9 R2 CS J XP5 1 11 CSJ R1 CP CS b10 R2 CS K XP5 1 12 CSK R1 CP CS b11 R2 CS L XP5 1 3 CSL R1 CP CS b12 R2 CS M XP5 1 4 CSM R1 CP CS b13 R2 CS N XP5 1 5 CSN R1 CP CS b14 R2 CS P XP5 1 6 CSP R1 CP CS b15 R2 CS R XP5 3 1 CSR R1 CP CS b16 R2 CS S XP5 3 2 CSS R1 CP CS b18 R2 CS T XP5 3 3 CST R1 CP CS b19 R2 CS U XP5 3 4 CSU R1 CP CS b20 R2 CS V XP5 3 5 CSV R1 CP CS b21 R2 CS W XP5 3 6 CSW R1 CP CS...

Page 108: ...This page is intentionally left blank ...

Page 109: ... different sections and 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 19 before performing any service ...

Page 110: ...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 110 3HAC033453 0...

Page 111: ...tenance activity Robot Cleaning Every 12 months Oil level in axis 1 gearbox Inspection Every 12 months Oil level in axis 2 gearbox Inspection Every 12 months Oil level in axis 3 gearbox Inspection Every 12 months Oil level in axis 4 gearbox Inspection Every 12 months Oil level in axis 5 6 gearbox Inspection Every 12 monthsi Robot harness Inspection Every 12 months Information labels Inspection Eve...

Page 112: ...e recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced See the replacement instruction for more details v The battery low alert 38213 Battery charge low is displayed when remaining backup capacity robot powered off is less than 2 months The typical lifetime of a new battery is 36 months if the robot is powered off 2 da...

Page 113: ...ge in regard to movement press tending very severe palletizing applications major use of axis 1 movement iv Depending on application the lifetime can vary The Service Information System SIS integrated in the robot software can be used as a guidance for planning service of gearbox for the individual robot This applies to gearboxes on axes 1 2 and 3 The lifetime of gearbox axes 4 5 and 6 is not calc...

Page 114: ...floor mounted position and then the oil level can be inspected according to Inspecting the gearbox oil level in a floor mounted robot on page 115 The method described in this section of inspecting the oil level in a suspended robot is only valid for Other design than Type C Read more about design Type C in section Type C of IRB 4600 on page 331 Required equipment Note Equipment 3HAC029646 001 Only...

Page 115: ...he oil plug for inspection is shown in the figure Type C xx1200000632 Oil plug filling and inspection A Oil plug draining B Other design 1 than Type C xx0800000304 Oil plug inspection A Oil plug gearbox B Continues on next page 3HAC033453 001 Revision H 115 Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 3 1 Inspecting oil level axis 1 gearbox Continued ...

Page 116: ...he section WARNING Safety risks during work with gearbox lubricants oil or grease on page 55 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 See Location of ...

Page 117: ...le Required oil level 35 3 mm below the surface for the motor flange The oil level shall only just start to be ob served when looking through the oil filling hole See figure 6 Parts A 35 3 mm B Surface for motor flange C Filling hole D Oil level How to fill oil is described in section Changing the oil axis 1 gearbox on floor mounted robots on page 150 Add oil if required 7 Tightening torque 24 Nm ...

Page 118: ...3 Oil plug filling A Oil plug draining B Other design 2 than Type C A B C xx1000001436 Filling oil plug on gearbox A Draining oil plug on surface for motor flange B Surface for motor flange C Continues on next page 118 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 3 1 Inspecting oil level axis 1 gearbox Continued ...

Page 119: ...ed position the oil level can only be inspected in the inverted position If the robot was taken down to stand on the floor the oil level would be above the oil plug hole which would result in oil leakage if the plug would be opened while robot stands on the floor Note Action WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the secti...

Page 120: ...oor mounted robots on page 150 Add oil if required 6 Tightening torque 3 Nm Refit the oil plug Note Only valid for Other design than Type C Before refitting the oil plug in the gearbox always replace the oil plug sealing washer with a new one If not there is a risk of leakage 7 120 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 3 1 Inspecting oil level axis 1...

Page 121: ...ealing washer gearbox See section Type of lubrication in gearboxes on page 148 Lubrication oil For article number see Spare part list on page 345 Oil plug Quick connect fitting Content is defined in section Standard tools on page 341 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step b...

Page 122: ...axis 2 gearbox on page 121 Open the correct oil plug depending on how the robot is fitted Floor mounted oil plug filling Suspended oil plug draining Quick connect fitting Note Always open the oil plug on top depending how the robot is fitted 4 Measure the oil level at the oil plug hole 5 Required oil level 42 mm 5 mm below the lower edge of the oil plug hole How to fill oil is described in section...

Page 123: ...erneath the motor attachment The oil plug for inspection is shown in the figure Type C xx1200000633 Oil plug armhouse Not visible in this figure See enlarged figure A Oil plug armhouse B Continues on next page 3HAC033453 001 Revision H 123 Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 3 3 Inspecting the oil level axis 3 gearbox ...

Page 124: ...rocedures in the step by step instructions below Inspecting the oil level axis 3 gearbox Use this procedure to inspect the oil level in the axis 3 gearbox Note Action 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 55 1 Move the robot to whe...

Page 125: ...se pos B Other design than Type C Open the oil plug armhouse 5 Measure the oil level at the oil plug hole 6 Required oil level oil in the gearbox shall be just below the edge of the oil plug hole How to fill oil is described in section Changing the oil axis 3 gearbox on page 166 Add oil if required 7 Tightening torque Other design than Type C in armhouse 10 Nm Other design than Type C in gearbox 3...

Page 126: ...s to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Inspecting the oil level axis 4 gearbox Use this procedure to inspect the oil level in the axis 4 gearbox Note Action WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section WARNING Safety...

Page 127: ...pen the oil plug carefully in order to let out the excess pres sure 4 See the figure in Location of axis 4 gearbox on page 126 Open the oil plug 5 Measure the oil level at the oil plug hole 6 Required oil level 35 5 mm below the oil plug flange How to fill oil is described in section Changing the oil axis 4 gearbox on page 172 Add oil if required 7 Tightening torque 10 Nm Refit the oil plug fillin...

Page 128: ... kg A B xx0800000308 Oil plug tilthouse A Oil plug wrist also used as air inlet when draining from oil plug A B The figure shows IRB 4600 20 2 50 with wrist 12 20 kg xx0900000139 Oil plug tilthouse A Oil plug wrist also used as air inlet when draining from oil plug A B Continues on next page 128 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 3 5 Inspecting oi...

Page 129: ... oil or grease on page 55 1 Move the robot to where the upper arm is placed in its calibration position 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 3 CAUTION The gearbox can contain an excess of pres sure that can be hazardous Open the oil plug carefully in order to let out the excess pres sure 4 See...

Page 130: ...t on top Move the upper arm axis 3 to a horizontal position then rotate axis 4 90 3 See the figure in Location of gearbox axes 5 6 on page 128 Note In this position it is not possible to open the oil plug tilthouse in order to level up oil in axes 5 and 6 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 4 C...

Page 131: ...work ing area 2 CAUTION The gearbox can contain an excess of pres sure that can be hazardous Open the oil plug carefully in order to let out the excess pres sure 3 See the figure in Location of gearbox axes 5 6 on page 128 Remove the oil plug wrist 4 Required oil level 3 3 mm from the lower edge of the oil plug in the wrist house Open the oil plug in the tilthouse to allow the oil level between ax...

Page 132: ...et armhouse H Required equipment Note Equipment Content is defined in section Standard tools on page 341 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below See chapter Circuit diagram on page 369 Circuit diagram Continues on next page 132 3HAC033453 001 Revis...

Page 133: ...ng area 1 Make an overall visual inspection of the cable harness in order to detect wear or damage 2 Check the connectors at the base 3 Check the connectors at the armhouse 4 Check all brackets and straps are properly attached to the robot 5 How to replace the cable harness is de scribed in Repair on page 189 Replace the cable harness if wear cracks or damage is detected 6 3HAC033453 001 Revision ...

Page 134: ...g Symbol of flash A Warning Risk of tipping B Label Lifting instruction C Warning High temperature D Label Max air pressure E Warning Brake release unit F Label Calibration G AbsAcc Information Sign H UL Label J Oil quality K Continues on next page 134 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting information labels ...

Page 135: ...ipment Labels are sold separately For spare part number of a specific label see Spare part list on page 345 Labels Inspecting labels Use this procedure to inspect the labels on the robot Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 Continues on next page 3HAC033453 001 Revision H 135 Copyr...

Page 136: ...cation of information labels on page 134 Check all labels 2 Replace any missing or damaged labels 3 136 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting information labels Continued ...

Page 137: ...Spare part list on page 345 Mechanical stop pin axis 1 Content is defined in section Standard tools on page 341 Standard 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 instructions below Continues on next page 3HAC033453 001 Revision H 137 Copyright 2009 2013 ABB All rights reserv...

Page 138: ...he mechanical stop pin is not bent or damaged in any other way 2 How to replace the stop pin is described in section Replacing stop pin axis 1 on page 275 Note If the mechanical stop pin has been deformed or damaged it must be replaced 3 xx0800000045 Parts A Attachment screws B Bracket C O ring 2 pcs D Bracket E Stop pin Check that the mechanical stop pin is prop erly attached 4 Continues on next ...

Page 139: ...chanical stop pin can move freely in both directions and the bracket works as it is supposed to 5 3HAC033453 001 Revision H 139 Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the mechanical stop pin axis 1 Continued ...

Page 140: ...Includes Stop Attachment screws plus washers Document for movable mechanical stop For spare part no see chapter Spare Parts Mechanical stop set axis 1 Content is defined in section Standard tools on page 341 Standard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these procedures in the step by step instructions below...

Page 141: ...in Location of additional mechanical stops on page 140 Check the additional mechanical stops on axis 1 for damage 2 Tightening torque 82 Nm Make sure the stops are properly attached 3 Attachment screws M12x40 quality 8 8 A3F 2 pcs stop lug If any damage on stops or attachment screws etc is detected the mechanical stops must be replaced 4 3HAC033453 001 Revision H 141 Copyright 2009 2013 ABB All ri...

Page 142: ...page 345 Damper Content is defined in section Standard tools on page 341 Standard toolkit Inspecting dampers Use this procedure to inspect the dampers Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 Continues on next page 142 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserv...

Page 143: ... cracks 2 Check all dampers for existing impressions larger than 2 3 mm 3 Check attachment screws for deformation 4 If any damage is detected the damper must be replaced 5 3HAC033453 001 Revision H 143 Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting dampers Continued ...

Page 144: ...this procedure to inspect the pressure relief valve Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 1 DANGER It is important to keep the pressure relief valve open and clean If the air pressure is stopped up too much pressure can be built up which can be hazardous 2 Continues on next page 144 3...

Page 145: ... 144 Check if the pressure relief valve is not con taminated or covered with litter 3 Note Use a cloth or a brush Clean if necessary 4 3HAC033453 001 Revision H 145 Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 3 11 Inspecting the pressure relief valve Continued ...

Page 146: ...tandard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Inspecting signal lamp Use this procedure to inspect the function of the signal lamp Note If the signal lamp is damaged it shall be replaced Note Action Check that the signal lamp is lit when motors are put in...

Page 147: ... to the robot before entering the robot work ing area 3 Check whether the signal lamp is broken If so replace 4 Check the cable connections 5 24V Measure the voltage in connectors motor axis 3 6 Check the cabling If a fault is detected re place 7 3HAC033453 001 Revision H 147 Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 3 12 Inspecting Signal lamp option Continued ...

Page 148: ...ion of the manual A new revision will be published on ABB Library immediatly after any updates Before starting any inspection maintenance or changing activities of lubrication always check ABB Library for the latest 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 ...

Page 149: ...gested dispenser or a similar one Orion OriCan art no 22590 pneumatic Type C Used on the axes 1 and 2 gearboxes Nipple for quick connect fitting with o ring Other design than Type C Used on the axis 2 gearbox Used when the robot is fitted in a suspended position Not valid for type C Expansion container gearbox axis 1 3HAC033453 001 Revision H 149 Copyright 2009 2013 ABB All rights reserved 3 Maint...

Page 150: ...n a suspended robot How to change the oil in a suspended robot see Changing the oil axis 1 gearbox on suspended robots on page 156 Location of oil plugs The axis 1 gearbox is located between the frame and base of the robot The oil plugs of the different types are shown in the figures Type C Note Only valid for type C Oil plugs for filling and draining are not depending on in which position the rob...

Page 151: ...ing on which position the robot is mounted Floor mounted Draining Oil plug on gearbox Filling Oil plug on surface for motor flange Mounted in suspended position Draining and filling Oil plug on surface for motor flange Continues on next page 3HAC033453 001 Revision H 151 Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 4 2 Changing the oil axis 1 gearbox on floor mounted robots Continue...

Page 152: ...x1000000669 Oil plug draining A Oil plug filling B Surface for motor flange C Continues on next page 152 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 4 2 Changing the oil axis 1 gearbox on floor mounted robots Continued ...

Page 153: ...ic oil dispenser can be used to suck out the oil from the gearbox Follow the instructions below 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 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks du...

Page 154: ...in the gearbox 7 Using a low air pressure start sucking the oil out from the gearbox with the oil ejector equipment 8 Note Time consuming activity Only valid if an oil dispenser is not used If an oil dispenser is not used open the oil plug draining and drain oil into an oil collect ing vessel 9 WARNING Used oil is hazardous material and must be disposed of in a safe way See section De commissionin...

Page 155: ...ion of oil plugs on page150 Open the oil plug filling 4 The type and amount of oil in the gearbox is detailed in section Type of lubrication in gear boxes on page 148 Refill the gearbox with lubrication oil Note The exact amount of oil to be filled depends on the amount previously being drained 5 How to inspect the oil level is de scribed in section Inspecting oil level axis 1 gearbox on page 114 ...

Page 156: ...is to fill the same amount of oil that was drained Measure the amount of oil that was drained and make a note of the result The same amount shall later be refilled Location of oil plugs The axis 1 gearbox is located between the frame and base of the robot The oil plugs are shown in the figures Other design than Type C Note Use correct oil plugs for filling and draining depending on which position ...

Page 157: ...il plug sealing washer gearbox See section Type of lubrication in gearboxes on page 148 Lubricating oil The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 148 Oil dispenser Continues on next page 3HAC033453 001 Revision H 157 Copyright 2009 2013 ABB All ...

Page 158: ...information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 55 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 See Required equipment on page 157 Connect the oil dispenser to the oil plug for draining 4 See Location of oil plugs on page 156 The capacity...

Page 159: ...unted in a suspended position is to fill the same amount of oil that was drained The only way to inspect the oil level after some repair work is to make a note how much oil was drained and to refill with the same amount If in doubt the suspended robot must be dismantled from its inverted position and the oil being inspected with the robot in a floor mounted position Note Action DANGER Turn off all...

Page 160: ...refill the gearbox with lubrication oil 7 How to inspect the oil level is de scribed in section Inspecting oil level axis 1 gearbox on page 114 Inspect the oil level 8 Disconnect the oil tool and put on the protective hood on the oil plug 9 Tightening torque Other design than Type C 3 Nm Type C 24 Nm Refit the oil plug for venting Note Only valid for Other design than Type C Before refitting the o...

Page 161: ...led on delivery on the robot if ordered as option suspended inverted mounted If a floor mounted robot shall be fitted in a suspended mounted position an expansion container must be installed See Installing an expansion container on page 98 3HAC033453 001 Revision H 161 Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 4 3 Changing the oil axis 1 gearbox on suspended robots Continued ...

Page 162: ...gearbox Information about the oil is found in Technical reference manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page 148 The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel To be fitted on a hose and then used for draining connected to the quick connect fit ting Nipple TEMA IF 3820 S06 See Location of o...

Page 163: ...s pressure 3 See the figure in Location of oil plugs on page 162 Either connect a nipple to the quick connect fitting in the hole for draining or remove the quick connect fitting 4 See the figure in Location of oil plugs on page 162 Note Drainage will be quicker if the oil plug filling is removed Open the oil plug filling 5 Note Draining is time consuming Elapsed time varies depending on the tempe...

Page 164: ...safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 55 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 See the figure in Location of oil plugs on page 162 Open oil plug filling 4 Where to fin...

Page 165: ...ng torque 24 Nm Refit oil plug Note Only valid for Other design than Type C Before refitting the oil plug in the gearbox always replace the oil plug sealing washer with a new one If not there is a risk of leakage 7 3HAC033453 001 Revision H 165 Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 4 4 Changing the oil axis 2 gearbox Continued ...

Page 166: ... upper arm rotational center Oil plugs are shown in the figure Type C xx1200000633 Oil plug armhouse not visible in this figure A Oil plug armhouse B Continues on next page 166 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 4 5 Changing the oil axis 3 gearbox ...

Page 167: ...es on page 148 The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 148 Oil dispenser xx1200000862 Funnel Content is defined in section Standard tools on page 341 Standard toolkit Continues on next page 3HAC033453 001 Revision H 167 Copyright 2009 2013 ABB...

Page 168: ...fety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 55 3 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug care fully in order to let out the excess pressure 4 See the figure in Location of oil plugs on page166 Open the oil plug armhouse 5 See the figure in Location of oil plugs on page166 Type C...

Page 169: ...il plug gearbox is pointing at the floor 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug care fully in order to let out the excess pressure 3 An example of oil dispenser is detailed in section Type of lubricati...

Page 170: ...d of in a proper way See section De commissioning for more information 9 Note There will be some oil left in the gearbox after draining 10 See the figure in Location of oil plugs on page166 Tightening torque Refit the oilplugs 11 Other design than Type C in arm house 10 Nm Other design than Type C in gear box 3 Nm Type C both plugs 10 Nm Filling oil axis 3 gearbox Use this procedure to fill the ge...

Page 171: ...igure in Location of oil plugs on page166 Open the oil plug armhouse 5 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 148 Refill the gearbox with lubricating oil Tip Use a funnel 6 Note The amount of oil to be filled depends on the amount previously being drained How to inspect oil is described in section Inspecting the oil level axis 3 gearbo...

Page 172: ...in the gear box see section Type of lubrication in gear boxes on page 148 Lubricating oil The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel Used for venting the gearbox during draining A suitable hose would be a hose normally used for compressed air Plastic hose Length minimum 300 mm Diameter 5 mm xx1200000862 Funnel Continues on next page 172 3...

Page 173: ...2 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 lubricants oil or grease on page 55 3 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 4 See the figure in Location of oil plugs ...

Page 174: ...a safe way See section De commissioning on page329 for more inform ation 7 Tightening torque 10 Nm Refit the oil plug 8 Filling oil Use this procedure to fill oil in the gearbox Note Action xx0800000330 Move the upper arm to the position shown in the figure 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area ...

Page 175: ... let out the ex cess pressure 4 See the figure in Location of oil plugs on page 172 Open the oil plug filling 5 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 148 Refill the gearbox with lubricating oil Tip Use a funnel 6 Note The amount of oil to be filled depends on the amount previously being drained Tightening torque 10 Nm Refit the oil pl...

Page 176: ...plug is shown in the figure The figure shows wrist variant 60 kg A B xx0800000308 Oil plug tilthouse A Oil plug wrist unit also used as air inlet when draining from oil plug A B Continues on next page 176 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 4 7 Changing oil axes 5 and 6 gearboxes ...

Page 177: ...must be sufficient to take the complete amount of oil Oil collecting vessel Content is defined in section Standard tools on page 341 Standard toolkit Draining axes 5 and 6 gearbox wrist 60 kg Use this procedure to drain oil from the gearbox CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the excess pressure Note Action Mov...

Page 178: ...house 6 See the figure in Location of oil plugs on page 176 Open the oil plug wrist air inlet This is done for the ventilation of the gear box and to fascilitate draining 7 Note Draining is time consuming Elapsed time varies depending on the temperature of the oil Drain the gearbox 8 WARNING Used oil is hazardous material and must be disposed of in a safe way See section De commissioning on page32...

Page 179: ...g hole tilthouse 8 Filling oil axes 5 and 6 gearbox wrist 60 kg Use this procedure to fill oil in the gearbox CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the excess pressure Note Action See the figure in Location of oil plugs on page 176 Move the upper arm to a position where the oil plug wrist points upwards 1 See the...

Page 180: ... of oil in gearboxes on page 148 Refill the gearbox with lubrication oil Note The amount of oil to be filled depends on the amount previously being drained 8 How to inspect the oil level is described in section Inspecting oil level gearbox axes 5 6 on page 128 Inspect the oil level 9 Tightening torque 10 Nm Refit both oil plugs 10 Filling oil axes 5 and 6 gearbox wrist 12 20 kg Use this procedure ...

Page 181: ...and amount of oil in gearboxes on page 148 Refill the gearbox with lubrication oil Note The amount of oil to be filled depends on the amount previously being drained 6 How to inspect the oil level is described in section Inspecting oil level gearbox axes 5 6 on page 128 Inspect the oil level 7 Note If the robot is fitted in a suspended position the wrist should be turned 180 8 Tightening torque 10...

Page 182: ...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 183: ... DSQC 633A xx0800000322 SMB battery 2 pole battery contact A Battery cover B Attachment screws C SMB battery cable D How to arrange the battery cable E Continues on next page 3HAC033453 001 Revision H 183 Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 4 8 Replacing SMB battery Continued ...

Page 184: ...correct battery Make sure to order the correct spare parts Do not replace the battery contact Note Equipment Battery includes protection circuits Replace it only with given spare part no or an ABB approved equivalent SMB battery pack See Spare part list on page 345 Content is defined in section Standard tools on page 341 Standard toolkit See chapter Circuit diagram on page 369 Circuit diagram Cont...

Page 185: ... out the SMB battery 5 See the figure in Location of SMB battery on page 183 Disconnect the battery cable and remove the bat tery 6 How to dispose of the used SMB battery see chapter Decommissioning on page 329 7 Refitting SMB battery Use this procedure to refit the SMB battery Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before e...

Page 186: ...ver with its attachment screws 5 Detailed in Updating revolution counters on page 326 Update the revolution counter 6 DANGER Make sure all safety requirements are met when performing the first test run These are further de tailed in the section DANGER First test run may cause injury or damage on page 50 7 186 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 3 Maintenance 3 4 8...

Page 187: ...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 Yes i It is highly recom mended that water and steam contains rust pre ventive without cleaning detergents Yes It is highly re commended that water contain a rust prevention solution Yes With light...

Page 188: ...a crusty surface for example from dry release agents Dos and don ts The section below specifies some special considerations when cleaning the robot Always Always use cleaning equipment as specified above Any other cleaning equipment may shorten the life of the robot Always check that all protective covers are fitted to the robot before cleaning Never Never point the water jet at connectors joints ...

Page 189: ...ecific repair activity are listed in the respective procedures The details of equipment are also available in different lists in the chapter Reference information on page 333 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 th...

Page 190: ...he correct value is shown on the manometer CAUTION The pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 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 ...

Page 191: ...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 192: ... 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 192 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 2 2 Mounting instructions for bearings Continued ...

Page 193: ...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 193 Lubricate the seal with grease just before fitting Not too early ...

Page 194: ... 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 195: ...section Removing the complete cable harness consists of the following parts presented in the order the work is recommended to be performed Removal in the base Removing cable harness in base on page 198 Removal in the frame Removing cable harness in frame on page 203 Removal in lower arm and armhouse Removing cable harness in lower arm and armhouse on page 204 How to replace the SMB unit brake rele...

Page 196: ...gures Cable harness base and frame xx0900000009 Cover base A Bracket B Cable harness C Axis 1 motor cable D Axis 2 motor cable E Axis 2 motor F Axis 1 motor G Continues on next page 196 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 3 1 Removing the complete cable harness Continued ...

Page 197: ...ipment Width 30 mm Deep well hexagon socket Content is defined in section Standard tools on page 341 Standard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these procedures in the step by step instructions below Continues on next page 3HAC033453 001 Revision H 197 Copyright 2009 2013 ABB All rights reserved 4 Repair ...

Page 198: ...ed Tip Do not remove the R1 SMB connector and air hose connector at this stage It will be easier to remove these two when the cover base has been removed 2 Parts A R1 CP CS B R1 MP C Air hose connector D Position of R1 CBUS if used E R1 SMB A B C xx0800000456 A Base B Cover base C Attachment screws Remove the cover base 3 Disconnect connectors on the brake release unit X8 X9 X10 4 Continues on nex...

Page 199: ...nscrew the thin nut securing the R1 SMB connector on the outside of the bracket Tip Use a deep well hexagon socket width 30 mm like the ones used for spark plugs or similar xx1200000888 7 Unscrew the nut for the air connection on the inside of the bracket 8 Continues on next page 3HAC033453 001 Revision H 199 Copyright 2009 2013 ABB All rights reserved 4 Repair 4 3 1 Removing the complete cable ha...

Page 200: ...se caution when performing this procedure in order not to damage cables or other components 10 Parts A Bracket at a 90 angle B Base A B C D xx1200000890 A R1 CP CS B R1 MP C Air hose connector D R1 SMB Remove connectors and air hose connector completely from the bracket R1 CP CS R1 MP R1 SMB Air hose connector R1 CBUS if used 11 How to remove the SMB unit is described in section Removing the SMB u...

Page 201: ... screen connections of R1 SMB1 2 R1 SMB2 6 14 Parts A Screen connection 4 pcs xx0900000015 Disconnect the earth cables 15 Parts A Earth B Distance screws Continues on next page 3HAC033453 001 Revision H 201 Copyright 2009 2013 ABB All rights reserved 4 Repair 4 3 1 Removing the complete cable harness Continued ...

Page 202: ...ket securing the cable package inside the base on the left side by following these steps Unscrew the attachment screws just enough to be able to remove the bracket Lift the bracket off the screws 17 Parts A Base B Attachment screws C Bracket How to remove the cable package from the frame is described in section Removing cable harness in frame on page 203 Continue removal of the cable package from ...

Page 203: ... on page 196 Remove the bracket securing the cable package to the frame 3 See the figure in Location of the cable harness on page 196 Cut the cable straps securing the cable harness to the frame and lower arm 4 A C E F B D xx1200000886 A Tape B Connectors to SMB unit and Brake release unit C R1 CP CS D Air hose E R1 MP F R1 SMB Connector bent and taped upwards Prepare the end of the cable package ...

Page 204: ...move the cable harness in the lower arm and armhouse Tip Before starting this procedure first remove the cable harness in the base Removing the complete cable harness on page 195 and frame Removing the complete cable harness on page 195 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 See the f...

Page 205: ...r arm C Bracket armhouse D Cable bracket xx0800000335 Remove the bracket on the armhouse 4 Parts A Tubular shaft unit B Attachment screws C Bracket armhouse Continues on next page 3HAC033453 001 Revision H 205 Copyright 2009 2013 ABB All rights reserved 4 Repair 4 3 1 Removing the complete cable harness Continued ...

Page 206: ...the motor cables from the axis 3 axis 4 axis 5 and axis 6 motors see section Removing motors on page 278 Continue the removal of the cable package by disconnecting the motor cables of the axis 3 axis 4 axis 5 and axis 6 motors 7 206 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 3 1 Removing the complete cable harness Continued ...

Page 207: ...ble harness consists of the following parts presented in the order the work is recommended to be performed Refitting in the frame Refitting the cable harness in the frame on page 210 Refitting in the base Refitting the cable harness in the base on page 213 Refitting in the lower arm and armhouse Refitting the cable harness in the lower arm and armhouse on page 219 How to refit the SMB unit brake r...

Page 208: ...ures Cable harness base and frame xx0900000009 Cover base A Bracket B Cable harness C Axis 1 motor cable D Axis 2 motor cable E Axis 2 motor F Axis 1 motor G Continues on next page 208 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete cable harness Continued ...

Page 209: ...mm Deep well hexagon socket Content is defined in section Standard tools on page 341 Standard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these procedures in the step by step instructions below Shell Alvania WR2 Cable grease Continues on next page 3HAC033453 001 Revision H 209 Copyright 2009 2013 ABB All rights res...

Page 210: ...ge in frame and base are presented below Chose one of the methods 3 A C E F B D xx1200000886 A Tape B Connectors to SMB unit and Brake release unit C R1 CP CS D Air hose E R1 MP F R1 SMB Connector bent and taped upwards Use this procedure when replacing the old cable harness Method 1 step 1 Prepare the end of the cable package in the base with tape as shown in the figure Tip In order to protect th...

Page 211: ...on when performing this procedure in order not to damage cables or other components Tip In order to protect the connectors from get ting residual grease on the cable harness put some plastic over them prior to pushing it through the hole in the frame Note Check that cables and air hose are placed as shown in the figure above Use this procedure when fitting a new cable harness Without removing the ...

Page 212: ...bot xx0900000016 Secure the cover to the frame with its attach ment screws 9 Parts A Frame B Hole in frame C Cover How to refit the motor cables is described in section Refitting motors on page 286 Connect the axis 1 and axis 2 motor cables 10 Continues on next page 212 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete cable harness Continu...

Page 213: ...tting of the cable harness in the base 12 Refitting the cable harness in the base Use this procedure to refit the cable harness in the base Tip Before starting this procedure first refit the cable harness in the frame See Refitting the complete cable harness on page 207 Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering ...

Page 214: ...acket C Cable harness xx0900000098 Valid for other design than Type C Attach the cable harness to the bracket 3 Parts A Attachment screw and nut B Bracket C Cable harness Continues on next page 214 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete cable harness Continued ...

Page 215: ...e bracket on the attachment screws Secure the bracket with its attach ment screws 4 Parts A Base B Attachment screws 2 pcs C Bracket xx0900000015 Refit the earth cables 5 Parts A Earth B Distance screws Connect the contacts on the SMB unit R1 SMB1 2 R1 SMB3 6 R2 SMB 6 How to refit the SMB unit is described in section Refitting the SMB unit on page 226 Refit the SMB unit 7 Continues on next page 3H...

Page 216: ...acket put it at a 90 angle 9 Parts A Bracket B Base A B C xx1200000857 A R1 CP CS B R1 MP C Air hose Before refitting the connectors on the bracket arrange cables and connectors as shown in the figure 10 Continues on next page 216 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete cable harness Continued ...

Page 217: ... Connectors A Earth cables B R1 SMB1 2 C R1 SMB3 6 D R2 SMB E R1 CP CS F R1 MP G Air hose H Position of R1 CBUS if used J R1 SMB A B C D xx1200000887 A Base B Distance screw C Attachment screw D Bracket Secure the bracket on the distance screws 12 Reconnect connectors on the brake release unit X8 X9 X10 13 Continues on next page 3HAC033453 001 Revision H 217 Copyright 2009 2013 ABB All rights rese...

Page 218: ... plugs or similar xx1200000888 14 Refit the air hose connector on the bracket Note Check that there is no leakage from the air hose 15 Reconnect the battery cable 16 xx0900000099 Secure the battery cable with cable straps 17 Parts A Cable straps 2 pcs Continues on next page 218 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete cable harness...

Page 219: ...able harness on the lower arm and armhouse is described in section Refitting the cable harness in the lower arm and armhouse on page 219 Continue the refitting of the cable package on lower arm and armhouse 22 Refitting the cable harness in the lower arm and armhouse Use this procedure to refit the cable harness in the lower arm and armhouse Tip Before starting this procedure first refit the cable...

Page 220: ...t lower arm B Bracket lower arm C Bracket armhouse D Cable bracket See the figure in Location of the cable harness on page208 Cable harness lower arm Refit the cable straps securing the cable harness to the lower arm 3 Push the cable harness carefully into the armhouse 4 Continues on next page 220 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 3 2 Refitting the co...

Page 221: ...otors on page 286 Reconnect the axis 3 axis 4 axis 5 and axis 6 motor cables 7 Calibration is detailed in a separate calib ration manual enclosed with the calibration tools Recalibrate the robot 8 General calibration information is included in section Calibration on page 319 WARNING The cover on the armhouse must be fitted when the robot is running It is a vital part for the stability of the robot...

Page 222: ...erforming the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 50 10 222 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 3 2 Refitting the complete cable harness Continued ...

Page 223: ... equipment Note There are different variants of SMB units and batteries The variant with the 3 pole battery 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 Equipment Content is defined in section Standard tools on page 341 Standard toolkit Continues on next page...

Page 224: ...ocedure to remove the SMB unit 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 A B C xx0900000103 Remove the base cover 2 Parts A Attachment screws 6 pcs B Base cover C Cable straps securing the bat tery cable 2 pcs Cut the cable straps securing the battery cable 3 Continues on next page 224 3...

Page 225: ...ews and put it at a 90 angle from the base Putting the bracket at a 90 angle facilitates the disconnecting of cables from the bracket Note Use caution when performing this procedure order not to damage cables or other com ponents 5 Parts A Bracket at a 90 angle B Base A xx0900000035 Disconnect cable clamps 6 Parts A Cable clamps See the figure in Location of SMB unit on page 223 Unscrew the attach...

Page 226: ...he SMB unit R1 SMB1 2 R1 SMB3 6 R2 SMB Battery cable 2 See the figure in Location of SMB unit on page 223 Place the SMB unit on its attachment screws 3 Secure the SMB unit with its attachment screws 4 A xx0900000035 Refit the cable clamps 5 Parts A Cable clamps See the figure in Location of SMB unit on page 223 Put back the cable harness in the base and refit the bracket on the distance screws Not...

Page 227: ...ailed in a separate calib ration manual enclosed with the calibra tion tools Recalibrate the robot 10 General calibration information is included in section Calibration on page 319 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 50 11 3HAC033453 001 Revision H 227 ...

Page 228: ... push button unit The connectors X8 X9 and X10 are placed on the push button unit as shown in the figure below xx0300000201 Required equipment Note Equipment Content is defined in section Standard tools on page 341 Standard toolkit Continues on next page 228 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 3 4 Replacing the brake release unit ...

Page 229: ...bot before entering the robot working area 1 A B C xx0800000456 Remove the base cover 2 Parts A Base B Base cover C Attachment screws M6x16 quality 8 8 A2F 6 pcs See the figure in Connectors on push button unit on page 228 Disconnect connectors X8 X9 and X10 from the brake release unit 3 See the figure in Location of brake release unit on page 228 Remove the nuts securing the brake release unit 4 ...

Page 230: ...nd X10 to the brake release unit 3 A B C xx0800000456 Use caution when pushing the base cover into position while at the same time checking that no cables are damaged 4 Parts A Base B Base cover C Attachment screws M6x16 quality 8 8 A2F 6 pcs Secure the base cover with its attachment screws 5 How to check and fix the brake release buttons if jammed is described in sec tion WARNING The brake releas...

Page 231: ... after service work on page 51 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 50 8 3HAC033453 001 Revision H 231 Copyright 2009 2013 ABB All rights reserved 4 Repair 4 3 4 Replacing the brake release unit Continued ...

Page 232: ...arm frame The location of the base and the complete arm system is shown in the figure xx0800000345 Base A Frame B Lower arm C Armhouse part of Upper arm complete D Tubular shaft unit part of Upper arm complete E Wrist unit part of Upper arm complete F Continues on next page 232 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 3 5 Replacing the base ...

Page 233: ...ipment Note Equipment 3 pcs Lengths 2 m 2 pcs 1 5 m 1 pc Roundslings Lifting capacity 1 000 kg Small Crowbar Guide pins Content is defined in section Standard tools on page 341 Standard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these procedures in the step by step instructions below For cleaning Loctite 7063 For ...

Page 234: ...x Note Draining is time consuming Elapsed time varies depending on the tem perature of the oil 3 How to remove the cable harness in base and frame is detailed in sections Removing cable harness in base on page 198 Removing cable harness in frame on page 203 Removing cable harness in lower arm and armhouse on page 204 Remove the cable harness in the base the frame and the lower arm of the robot Tip...

Page 235: ...en replacing base from complete arm system on page 233 Tip Put the robot on its side on a couple of loading pallets put on top of each other in order to create a more comfortable working situation 7 DANGER Do not remove either motor axis 2 or 3 at this stage This will make the upper and lower arms move in a dangerous way and can cause serious personal injury or mechanical dam age to the robot 8 Co...

Page 236: ...llet Small movements can make the robot alter its position which can cause personal injury or mechanical damage Remove the bolts securing the robot to the foundation and carefully put it on the load ing pallets as shown in the figure 9 Continues on next page 236 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 3 5 Replacing the base Continued ...

Page 237: ...quality Steel 12 9 Gleitmo and washers 24 24 pcs D O ring Not visible behind cover plate in figure of Type C E Cover plate F Attachment screws M6x16 qual ity 8 8 A2F 5 pcs CAUTION The robot base weighs 60 kg All lifting accessories used must be sized accordingly 11 Secure the base of the robot with round slings in an overhead crane or similar 12 Continues on next page 3HAC033453 001 Revision H 237...

Page 238: ...fitting the base Use this procedure to refit the base to the complete arm system 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 Tip Use Loctite 7063 or similar for cleaning Remove residues of old Loctite and other contaminations from surfaces before apply ing new Loctite 574 2 Continues on ne...

Page 239: ...The robot base weighs 60 kg All lifting accessories used must be sized accordingly 4 Secure the base with a roundsling in an overhead crane or similar and lift it to the mounting site 5 Apply guide pins in opposite holes in the axis 1 gearbox 6 Continues on next page 3HAC033453 001 Revision H 239 Copyright 2009 2013 ABB All rights reserved 4 Repair 4 3 5 Replacing the base Continued ...

Page 240: ...uality Steel 12 9 Gleitmo and washers 24 24 pcs C Type C Attachment screws M12x50 quality Steel 12 9 Gleitmo and washers 24 24 pcs D O ring Not visible behind cover plate in figure of Type C E Cover plate F Attachment screws M6x16 qual ity 8 8 A2F 5 pcs Apply some grease to the o ring and refit the o ring between the cover and base 8 Refit the cover plate at the bottom of the base with its attachm...

Page 241: ...anual enclosed with the calibra tion tools Recalibrate the robot 12 General calibration information is included in section Calibration on page 319 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 50 13 3HAC033453 001 Revision H 241 Copyright 2009 2013 ABB All rights...

Page 242: ...s located as shown in the figure xx1200000635 Upper arm A Lower arm B Washer 3 pcs xx1200000520 C Attachment screws M10x40 quality steel 12 9 Gleitmo 15 pcs D Axis 3 gearbox E Continues on next page 242 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 4 1 Replacing the complete upper arm ...

Page 243: ...quired equipment Note Equipment For spare part no see chapter Spare parts sec tion Upper arm IRB 4600 60 2 05 40 2 05 40 2 50 20 2 55 on page 352 Armhouse For spare part no see chapter Spare parts sec tion Upper arm IRB 4600 60 2 05 40 2 05 40 2 50 20 2 55 on page 352 Tubular shaft unit Continues on next page 3HAC033453 001 Revision H 243 Copyright 2009 2013 ABB All rights reserved 4 Repair 4 4 1 ...

Page 244: ...ide pins Other design than Type C M8 2 pcs Content is defined in section Standard tools on page 341 Standard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these proced ures in the step by step instructions be low Removing the complete upper arm Use this procedure to remove the complete upper arm This procedure can be...

Page 245: ...e upper arm by stretching the roundslings Tip Turn on the power temporarily and release the brakes of axis 3 to rest the weight onto the roundslings 5 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 6 How to disconnect cables from motors is detailed in sections Removing motors on page 278 Disconnect all mot...

Page 246: ... C Cable bracket Using caution pull the cable package out of the hole where the cable bracket was fit ted 11 See the figure in Location of the complete upper arm on page 242 Note Do not remove the attachment screws securing the gearbox axis 3 to the arm house Remove the attachment screws securing the upper arm to the lower arm 12 Continues on next page 246 3HAC033453 001 Revision H Copyright 2009 ...

Page 247: ...w does not bottom Use an extra washer if the screw does bottom Tightening torque 30 Nm 2 xx1100000566 Dimension is specified in Required equipment on page 243 Run a roundsling through each rotating lifting point and fasten both ends at the lifting hook 3 See figure Attaching the roundslings to the upper arm on page 248 Dimension is specified in Required equipment on page 243 Make a loop of the thi...

Page 248: ... house 2 pcs Length 1 5 m D Refitting the complete upper arm Use this procedure to refit the complete upper arm 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 Continues on next page 248 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 4 1 Replacing the complete...

Page 249: ... Nm Tightening torque and angle Type C 50 Nm and 90 angle Refit the upper arm to the lower arm with its attachment screws Note Use new attachment screws It may be necessary to turn the gear by ro tating the motor pinion with a rotation tool motor beneath the motor cover 8 xx0800000338 Using caution push the cable package through the hole where the cable bracket will be fitted 9 Parts A Signal lamp...

Page 250: ...sed with the calibra tion tools Recalibrate the robot 14 General calibration information is included in section Calibration on page 319 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 50 15 250 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4...

Page 251: ...tion Upper arm IRB 4600 60 2 05 40 2 05 40 2 50 20 2 55 on page 352 Tubular shaft unit 2 pcs Dimension M8 Guide pins Isopropanol Cleaning agent Loctite 574 Sealing liquid Content is defined in section Standard tools on page 341 Standard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these proced ures in the step by st...

Page 252: ...ot before entering the robot working area 3 xx0800000335 Remove the bracket securing the cable package to the tubular shaft unit by remov ing its attachment screws 4 Parts A Tubular shaft unit B Attachment screws M6x16 qual ity 8 8 A2F 2 pcs C Bracket Place the cable package in a way that it will not be damaged in the continued removal procedure 5 How to remove motors is described in section Remov...

Page 253: ...l stop for the roundsling At the other end of the tubular shaft unit a shackle can be fitted if the wrist unit is re moved 9 See the figure in Location of tubular shaft unit on page 251 Remove the attachment screws that secure the tubular shaft unit 10 Note There are two parallel pins guiding the tubular shaft unit into its place See figure in Replacing complete tubular shaft unit on page 251 Remo...

Page 254: ...th a knife A B C D xx0800000457 Apply sealing liquid Loctite 574 on the surface between the tubular shaft unit and the armhouse Make sure to apply the sealing liquid in circles around each of the attachment holes 3 Parts A Armhouse B Surface where Loctite 574 shall be applied C Tubular shaft unit D Cylindrical pin 2 pcs CAUTION The robot arm tube weighs 65 kg All lifting accessories used must be s...

Page 255: ...hen refitting the tubular shaft unit 7 See the figure in Location of tubular shaft unit on page 251 Tightening torque 22 Nm Secure the tubular shaft unit with its attach ment screws 8 How to refit motors is described in sec tion Refitting motors on page 286 Refit motors axes 4 5 and 6 9 See Performing a leak down test on page 190 Perform a leak down test 10 xx0800000335 Refit the bracket securing ...

Page 256: ...th oil 13 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 50 14 256 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 4 2 Replacing complete tubular shaft unit Continued ...

Page 257: ... 45 2 05 40 2 55 xx0800000333 Upper arm A Gear B O ring sealing plate C Wrist unit D Spring washer conical 8 4x18x2 quality steel mZn12c 7 pcs E Attachment screw M8x40 quality steel 12 9 Gleitmo 7 pcs F Continues on next page 3HAC033453 001 Revision H 257 Copyright 2009 2013 ABB All rights reserved 4 Repair 4 4 3 Replacing wrist unit ...

Page 258: ...ist unit Replace if damaged O ring For spare part number see Upper arm IRB 4600 60 2 05 40 2 05 40 2 50 20 2 55 on page 352 For adjusting the play Measuring tool Content is defined in section Standard tools on page 341 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instruct...

Page 259: ...ing in an overhead crane or similar 4 See the figure in Location of wrist unit on page 257 Remove the attachment screws and carefully remove the wrist unit CAUTION Do not damage gears 5 Refitting of wrist unit Use this procedure to refit the wrist unit Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working ...

Page 260: ...ing tool at the rear of the motor Push the wrist as shown in the figure to locate the smallest play in the same way as for adjustment of motors for axes 4 5 and 6 See Refitting motors on page286 8 Parts A Gears on drive shaft unit axes 5 6 B Gears on the wrist See the figure in Location of wrist unit on page 257 Tightening torque 35 Nm Secure the wrist unit with its attachment screws and washers 9...

Page 261: ...calibration tools Recalibrate the robot 13 General calibration information is in cluded in section Calibration on page 319 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 50 14 3HAC033453 001 Revision H 261 Copyright 2009 2013 ABB All rights reserved 4 Repair 4 4 3...

Page 262: ...er tools and procedures may be required See references to these procedures in the step by step instructions below Measurement axis 5 The procedure below details how to measure the play of axis 5 Note The measuring tool and measuring values differ depending on robot version Info Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before enteri...

Page 263: ... 50 A Measuring tool play B 140 mm C 85 mm F 40N Remove the load and set the dial indicator to zero 5 xx0300000187 Apply load F in the opposite direction as shown in the figure to the right 6 Values for IRB 4600 60 2 05 45 2 05 40 2 55 A Measuring tool play B 135 mm C 100 mm F 90N Values for IRB 4600 20 2 50 A Measuring tool play B 140 mm C 85 mm F 40N Continues on next page 3HAC033453 001 Revisio...

Page 264: ... 5 is for robot version IRB 4600 60 2 05 45 2 05 40 2 55 0 15 mm IRB 4600 20 2 50 0 12 mm Remove the load and measure the play by reading the dial indicator 7 264 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 4 4 Measuring the play axis 5 Continued ...

Page 265: ...nces to the tools re quired Other tools and procedures may be required See references to these procedures in the step by step instructions below Measurement axis 6 The procedure below details how to measure the play in axis 6 Note The measuring tool and measuring values differ depending on robot version Info Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure su...

Page 266: ...Measuring tool play B 140 mm m 10 kg xx0300000189 Apply load F in one direction Note Different load and distances for the differ ent robot versions as specified to the right 4 Values for robot versions IRB 4600 60 2 05 45 2 05 40 2 55 A Measuring tool play B 100 mm C 100 mm F 50N Values for robot version IRB 4600 20 2 50 A Mearuring tool play B 100 mm C 150 mm F 40N Remove the load and set the dia...

Page 267: ...n IRB 4600 20 2 50 A Measuring tool play B 100 mm C 150 mm F 40N The maximum play allowed at the given distance B from the center of axis 6 is for robot version IRB 4600 60 2 05 45 2 05 40 2 55 0 16 mm Values for IRB 4600 20 2 55 0 22 mm Remove the load and measure the play by reading the dial indicator 7 3HAC033453 001 Revision H 267 Copyright 2009 2013 ABB All rights reserved 4 Repair 4 4 5 Meas...

Page 268: ...tion of lower arm Type C The lower arm is located as shown in the figure xx1200000636 Upper arm A Axis 3 gearbox B Continues on next page 268 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 5 1 Replacing the lower arm ...

Page 269: ...s H Attachment screws M12x50 quality Steel 12 9 Gleitmo 18 pcs J Other design than Type C The lower arm is located as shown in the figure A B C D E F G H J xx0800000360 Upper arm A Axis 3 gearbox B Lower arm C Continues on next page 3HAC033453 001 Revision H 269 Copyright 2009 2013 ABB All rights reserved 4 Repair 4 5 1 Replacing the lower arm Continued ...

Page 270: ...d Other tools and procedures may be re quired See references to these procedures in the step by step instructions below Removing the lower arm Use this procedure to remove the lower arm CAUTION The robot lower arm weighs 65 kg All lifting accessories used must be sized accordingly Note Action xx0800000336 Move the robot to the position shown in the figure 1 DANGER Turn off all electric power suppl...

Page 271: ...remove the complete upper arm is described in section Removing the complete upper arm on page 244 Remove the complete upper arm and put it on a loading pallet 5 The figure shows other design than Type C but the principle of fitting the lifting lug is the same on Type C xx0800000379 Fit a lifting lug in one of the upper holes in the lower arm for the attachment screws 6 Parts A Lifting lug Continue...

Page 272: ...ing the lower arm Use this procedure to refit the lower arm 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 CAUTION The robot lower arm weighs 65 kg All lifting accessories used must be sized accordingly 2 Continues on next page 272 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights ...

Page 273: ...nd lift it to the robot 4 A B D E C xx0800000377 Refit the attachment screws securing the lower arm to gearbox axis 2 5 Tightening torque 110 Nm Parts A Frame B Gearbox axis 2 C Lower arm D Washer 18 pcs E Attachment screws M12x50 quality steel Gleitmo 12 9 18 pcs Secure the complete upper arm with round slings in an overhead crane and lift it to the robot 6 Continues on next page 3HAC033453 001 R...

Page 274: ... on page 219 Refit the cable package 8 Calibration is detailed in a separate calib ration manual enclosed with the calibra tion tools Recalibrate the robot 9 General calibration information is included in section Calibration on page 319 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 injur...

Page 275: ... pcs A Bracket B O ring 2 pcs C Bracket D Stop pin E Required equipment Note Equipment For spare part no see chapter Spare parts section Lower arm and frame on page 350 Stop pin Content is defined in section Standard tools on page 341 Standard toolkit Continues on next page 3HAC033453 001 Revision H 275 Copyright 2009 2013 ABB All rights reserved 4 Repair 4 6 1 Replacing stop pin axis 1 ...

Page 276: ...p pin axis 1 on page 275 Remove the attachment screws securing the bracket and stop pin 2 See the figure in Location of stop pin axis 1 on page 275 Remove the bracket and stop pin 3 Refitting the stop pin axis 1 Use this procedure to refit the stop pin axis 1 Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot w...

Page 277: ...re in Location of stop pin axis 1 on page 275 Secure the stop pin on the frame with its attachment screws 4 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 50 5 3HAC033453 001 Revision H 277 Copyright 2009 2013 ABB All rights reserved 4 Repair 4 6 1 Replacing stop ...

Page 278: ...ent screws M5x16 quality Steel 8 A2F 7 pcs A Motor cover B Attachment screws axis 1 motor 4 pcs washers See Tightening torques and attachment screws on page 290 C Attachment screws axis 2 motor 4 pcs washers See Tightening torques and attachment screws on page 290 C Connection box D Axis 1 motor E Axis 2 motor E O ring F Hole G Cable gland cover H Continues on next page 278 3HAC033453 001 Revision...

Page 279: ...Attachment screws axis 3 motor 4 pcs washers See Tightening torques and attachment screws on page 290 B Attachment screws axis 4 axis 5 and axis 6 motors 3x4 pcs washers Tightening torques and attachment screws on page 290 B Axis 3 motor C Axis 4 motor D Axis 5 motor E Axis 6 motor F O ring axis 4 axis 5 and axis 6 G Armhouse H Continues on next page 3HAC033453 001 Revision H 279 Copyright 2009 20...

Page 280: ...to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Weights The motors for the different axes weighs according to the table Weight in kg Motor 13 kg Axis 1 motor 25 kg Axis 2 motor 13 kg Axis 3 motor 8 kg Axis 4 motor 8 kg Axis 5 motor 8 kg Axis 6 motor Continues on next page 280 3HAC033453 001 Revision H Copyri...

Page 281: ...osition where the lower arm rests firmly on the damper of axes 2 and 3 Release the brake of axis 2 to be sure that the lower arm rests in the end position Axis 3 motor Move axis 2 to 0 and axis 3 to maximal Release the brake of axis 3 to be sure that the upper arm is completely vertical and rests against the damper of axis 2 and axis 3 Draining gearbox Use this procedure to drain gearboxes if need...

Page 282: ... 3 axis 4 axis 5 and axis 6 motors Note The procedure contains information how to remove motors on all axes of the robot Some steps are only applicable to a certain motor Follow the steps carefully in order not to miss vital information Note Action See Position of robot on page 281 Move the robot to the recommended position for the motor that shall be removed 1 DANGER Turn off all electric power s...

Page 283: ...Only applicable to axis 1 and axis 2 motors Remove the motor cover 6 See the figure in Location of axis 1 and axis 2 motors on page 278 Only applicable to axis 1 and axis 2 motors Remove the cable gland cover 7 See the figure in Location of axis 1 and axis 2 motors on page 278 Only applicable to axis 1 and axis 2 motors Remove the connection box Note Only needed if the motor shall be replaced with...

Page 284: ...C power supply to the motor Only applicable to motors axes 2 and 3 Release the brake of axis 2 untill the lower arm firmly rests on the damper 11 Note Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used 12 See the figure in Location of axis 1 and axis 2 motors on page 278 Remove the attachment screws securing the motor If needed use a 300 mm extension for ...

Page 285: ... hole if replacement of motor axis 1 is not immediate in order to avoid contamina tion 16 See the figure in Location of axis 1 and axis 2 motors on page 278 Only applicable to motors axes 4 5 and 6 Check that the o ring also is removed It might stay in the armhouse when the motor is re moved 17 3HAC033453 001 Revision H 285 Copyright 2009 2013 ABB All rights reserved 4 Repair 4 7 1 Removing motors...

Page 286: ... screws 4 pcs washers See Tightening torques and attachment screws on page 290 C Axis 2 motor Attachment screw 4 pcs washers See Tightening torques and attachment screws on page 290 C Connection box D Axis 1 motor E Axis 2 motor E O ring F Hole G Cable gland cover H Location of axis 3 axis 4 axis 5 and axis 6 motors The axis 3 axis 4 axis 5 and axis 6 motors are located as shown in the figures Mot...

Page 287: ...ment screws on page 290 B Attachment screws axis 4 axis 5 and axis 6 motors 3x4 pcs washers See Tightening torques and attachment screws on page 290 B Axis 3 motor C Axis 4 motor D Axis 5 motor E Axis 6 motor F O ring axis 4 axis 5 and axis 6 G Armhouse H Continues on next page 3HAC033453 001 Revision H 287 Copyright 2009 2013 ABB All rights reserved 4 Repair 4 7 2 Refitting motors Continued ...

Page 288: ...ferences to these procedures in the step by step instructions below For art no see Reference information Lifting tool axis 2 For art no see Reference information Lifting tool axis 3 For spare part no see Spare part list on page 345 Motors Weights The motors for the different axes weighs according to the table Weight in kg Motor 13 kg Axis 1 motor 25 kg Axis 2 motor 13 kg Axis 3 motor 8 kg Axis 4 m...

Page 289: ... the gearbox xx1100000548 Axis 2 motor Move the robot to a position where the lower arm rests firmly on the axis 3 damper Release the axis 2 brake to be sure that the lower arm rests in the end position Axis 3 motor Move axis 2 to 0 and axis 3 to maximal Release the axis 3 brake to be sure that the upper arm is completely vertical and rests against the damper Filling oil in gearbox Use this proced...

Page 290: ... A2F Screwlengths depending on flange thickness on page 290 Motor axis 2 22 Nm 8 8 A2F Screwlengths depending on flange thickness on page 290 Motor axis 3 22 Nm 8 8 A2F M8x25 Motor axis 4 22 Nm 8 8 A2F M8x25 Motor axis 5 22 Nm 8 8 A2F M8x25 Motor axis 6 Screwlengths depending on flange thickness Screwlengths can vary depending on when the robot is delivered The different screwlengths depends on th...

Page 291: ...ate the o ring with grease 5 xx0900000082 Make sure the o ring on the flange of the motor is seated properly 6 Parts A Correct position of o ring B Incorrect position of o ring Replace with a new o ring if damaged Connectors Motor axis 1 R2 MP1 Motor axis 2 R2 MP2 Motor axis 3 R2 MP3 Motor axis 4 R2 MP4 Motor axis 5 R2 MP5 Motor axis 6 R2 MP6 Connect to pins pin 2 pin 5 CAUTION The connections for...

Page 292: ...iss vital information Info Action See Preparations before the refitting of motors on page 291 Note Before starting the refitting of the motor first make the necessary preparations 1 Note Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used 2 Place the motor carefully in the gearbox 3 Make sure that the motor is turned the correct way the pinion or gear of t...

Page 293: ... page 296 Only applicable to motors axes 4 5 and 6 Adjust the play of the motor 8 Tightening torque and attachment screws are specified in the table Tightening torques and attach ment screws on page 290 Secure the motor with its attachment screws and washers Note Apply the correct tightening torque 9 Disconnect the brake release voltage 10 See the figure in Location of axis 1 and axis 2 motors on ...

Page 294: ...covers Make sure that the o ring is in place 14 How to fill oil in the gearbox is de scribed in sections Changing the oil axis 2 gearbox on page 162 Changing the oil axis 3 gearbox on page 166 Only applicable to motors axis 2 Refill gearbox oil 15 If the gasket is damaged it need to be replaced Only applicable to motors axes 3 4 5 and 6 Check that the gasket on the cover on the armhouse is intact ...

Page 295: ...ws M6x25 quality 8 8 A2F 10 pcs Tightening torque 14 Nm Calibration is detailed in a separate calibration manual enclosed with the calibration tools Recalibrate the robot 18 General calibration information is in cluded in section Calibration on page 319 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test ru...

Page 296: ...find the smallest play within this range Axis 5 motor 1 Turn the outgoing shaft for axis 4 in intervals of 90 for one full turn and find the smallest play for the axis 5 motor within this range 2 Turn the axis 5 motor one full turn at a time for a total of five turns and find the smallest play within this range Axis 6 motor 1 Turn the outgoing shaft for axis 4 in intervals of 90 for one full turn ...

Page 297: ...ng on its side See illustration in section Replacing the base Position of robot when replacing base from complete arm system on page 233 Type C xx1200000637 Frame A Radial sealing B Axis 1 gearbox with O ring C Harness pipe D Washer 16 pcs E Attachment screws M10x100 quality Steel 12 9 Gleitmo 16 pcs F Continues on next page 3HAC033453 001 Revision H 297 Copyright 2009 2013 ABB All rights reserved...

Page 298: ...esign than Type C M8 2 pcs Used to guide the gearbox during removal re fitting Content is defined in section Standard tools on page 341 Standard toolkit These procedures include references to the tools required Other tools and procedures may be re quired See references to these procedures in the step by step instructions below Continues on next page 298 3HAC033453 001 Revision H Copyright 2009 201...

Page 299: ...otor 4 How to remove the base from the com plete arm system is described in section Removing the base on page 234 In order to reach gearbox axis 1 it is neces sary first to remove the base from the com plete arm system 5 xx0800000440 Fit a lifting lug in the uppermost hole for the attachment screws securing the base as shown in the figure 6 Parts A Roundsling B Lifting lug C Uppermost attachment h...

Page 300: ...e gearbox when it is removed Put some exorbant material to catch the oil 12 Note Always use removal tools in pairs diagon al to each other Using caution slide the gearbox out onto the guide pins and lift it away If necessary use removal tools to remove the gearbox 13 Refitting gearbox axis 1 Use this procedure to refit the gearbox Note Action DANGER Turn off all electric power supply hydraulic pre...

Page 301: ...er the gearbox is fitted as shown in the figure The oil plugs shall be placed in the openings in the frame 3 Parts A Opening for oil plug in frame B Oil plug See the figure in Location of gearbox on page 297 Replace o ring if damaged Apply grease on the o ring 4 Clean all assembly surfaces 5 Remove any painting from the assembly surfaces with a knife Always use guide pins in pairs Fit guide pins i...

Page 302: ...efitting the cable harness in the base on page 213 Refitting the cable harness in the frame on page 210 Refitting the cable harness in the lower arm and armhouse on page 219 Refit the cable harness in the base the frame and the lower arm 12 How to fill oil in gearbox is described in section Changing the oil axis 1 gearbox on floor mounted robots on page 150 Refill oil in the gearbox 13 Calibration...

Page 303: ...ews M12x50 quality Steel 12 9 Gleitmo 15 pcs A Washers 15 pcs B Gearbox axis 2 C O ring D Frame E Required equipment Note Art no Equipment 3HAB7887 1 Rotation tool Roundslings Lifting accessories Continues on next page 3HAC033453 001 Revision H 303 Copyright 2009 2013 ABB All rights reserved 4 Repair 4 8 2 Replacing gearbox axis 2 ...

Page 304: ... replace the gearbox without removing the cable harness only by loosening it This means that the upper and lower arm will be separated from the frame but still be connected to the frame through the cabling Be careful not to damage the cables Note Action The figure shows IRB 2600 but the position of the robot is correct xx1200000068 Move the robot to the position shown in the figure Upper arm shoul...

Page 305: ...o cable brackets and a cable strap 4 Attach a roundsling around the upper arm house 5 Unload the weight of the lower and upper arm package by stretching the roundslings with the overhead crane Turn on the power temporarily and re lease the brakes of axis 2 to rest the weight onto the roundslings 6 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot ...

Page 306: ...e WARNING The cable harness is still installed on the robot Make sure not to damage the cables or the cable brackets on the robot 9 CAUTION The gearbox weighs 51 kg All lifting accessories used must be sized accordingly 10 Continues on next page 306 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 8 2 Replacing gearbox axis 2 Continued ...

Page 307: ... the frame 13 Fit guide pins to help guiding the gearbox out from the frame 14 Note Always use removal tools in pairs diagonal to each other If necessary use removal tools to re move the gearbox 15 Remove the gearbox CAUTION Use caution in order not to damage gearbox or pinion 16 Refitting gearbox axis 2 Use this procedure to refit the gearbox Note Action DANGER Turn off all electric power supply ...

Page 308: ...gearbox axis 2 Clean all assembly surfaces 4 Remove any painting from the assembly surfaces with a knife See the figure in Location of gearbox axis 2 on page 303 Apply some grease on the o ring before fit ting 5 Fit two guide pins in opposite holes in the frame 6 Secure the gearbox with a roundsling in an overhead crane or similar 7 Release the brakes of the axis 2 motor 8 Continues on next page 3...

Page 309: ... 10 See Performing a leak down test on page 190 Perform a leak down test 11 Fit the guide pins to the gearbox 12 Lift the upper and lower arms into mounting position and guide them in place with the guide pins 13 It might be necessary to rotate the motor pinion with the rotating tool to find the mat ing position A B D E C xx0800000377 Refit the attachment screws that secure the lower arm to the ax...

Page 310: ...s detailed in a separate calib ration manual enclosed with the calibra tion tools Recalibrate the robot 17 General calibration information is included in section Calibration on page 319 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 50 18 310 3HAC033453 001 Revisi...

Page 311: ... shown in the figure Type C xx1200000638 Upper arm A Axis 3 gearbox B Washers 16 pcs C Attachment screws M10x50 quality Steel 12 9 Gleitmo 16 pcs D Continues on next page 3HAC033453 001 Revision H 311 Copyright 2009 2013 ABB All rights reserved 4 Repair 4 8 3 Replacing gearbox axis 3 ...

Page 312: ...pare part list on page 345 Gearbox Type C M10 2 pcs Guide pins Other design than Type C M8 2 pcs Used to guide the gearbox and the upper arm during removal refitting 3HAB7887 1 Rotation tool Content is defined in section Standard tools on page 341 Standard toolkit Continues on next page 312 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 4 Repair 4 8 3 Replacing gearbox axis ...

Page 313: ...arm will be separated but still be connected to eachother through the cabling Be careful not to damage the cables Note Action How to drain the gearbox is described in section Changing the oil axis 3 gearbox on page 166 Drain the gearbox 1 xx0800000336 Move the robot to the position shown in the figure 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the ...

Page 314: ...ttach the lifting accessories to the upper arm 6 Connect the 24 VDC power supply to the axis 3 motor and release the brakes 7 Releasing the brakes of the axis 3 motor unloads the weight of the upper arm by stretching the roundslings 8 See the figure in Location of the complete upper arm on page 242 Remove the attachment screws that secure the upper arm to the lower arm Note Do not remove the attac...

Page 315: ...ure in Location of gearbox axis 3 on page 311 Remove the remaining attachment screws that secures the gearbox 14 Note There will be some surplus oil in the gear box Place some absorbant cloth or similar under the gearbox 15 Note Always use removal tools in pairs diagon al to each other Slide the gearbox carefully out onto the guide pins and lift it away If necessary use a pair of screws to push ou...

Page 316: ...ide the gearbox into position while rotating the motor pinion to find the mating position Use a rotation tool Tip Two persons are required for this step since the upper arm is hanging freely in the air One person needs to hold the upper arm still while the other fits the gearbox into the upper arm 11 Rotate the motor pinion and slide the gear box into position 12 See the figure in Location of gear...

Page 317: ...cable strap to the lower arm 22 How to fill the gearbox with oil is de scribed in section Changing the oil axis 3 gearbox on page 166 Refill the gearbox with lubrication oil 23 Calibration is detailed in a separate calib ration manual enclosed with the calibra tion tools Recalibrate the robot 24 General calibration information is included in section Calibration on page 319 DANGER Make sure all saf...

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Page 319: ...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 326 This will occur when The battery is discharged...

Page 320: ... robot at home position the Absolute accuracy calibration also com pensates for Mechanical tolerances in the robot structure Deflection due to load Absolute accuracy calibration focuses on pos itioning accuracy in the Cartesian coordinate system for the robot Absolute accuracy calibration option al Absolute accuracy calibration data is found on the SMB serial measurement board in the robot For rob...

Page 321: ...rtesian coordinate system Absolute Accuracy calibration is used as a TCP calibration The CalibWare tool guides through the calibration process and calculates new compensation parameters This is further detailed in the Application manual CalibWare Field 5 0 If a service operation is done to a robot with the option Absolute Accuracy a new absolute accuracy calibration is required in order to establi...

Page 322: ...arks IRB 4600 The figures show the calibration scales positions for all the robot variants IRB 4600 60 2 05 45 2 05 40 2 55 20 2 50 xx0800000312 Calibration mark axis 1 A Calibration mark axis 2 B Calibration mark axis 3 C Continues on next page 322 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 5 Calibration 5 3 Calibration scale and correct axis position ...

Page 323: ... Calibration mark axis 4 D Calibration mark axis 5 E Calibration mark axis 6 F Continues on next page 3HAC033453 001 Revision H 323 Copyright 2009 2013 ABB All rights reserved 5 Calibration 5 3 Calibration scale and correct axis position Continued ...

Page 324: ... mark axis 4 D Calibration mark axis 5 E IRB 4600 20 2 50 xx0800000321 Calibration mark axis 6 F 324 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 5 Calibration 5 3 Calibration scale and correct axis position Continued ...

Page 325: ...re shown in the graphic below This is normally handled by the robot calibration software Calibration movement directions 6 axes Note The graphic shows an IRB 7600 The positive direction is the same for all 6 axis robots except the positive direction of axis 3 for IRB 6400R which is in the opposite direction xx0200000089 3HAC033453 001 Revision H 325 Copyright 2009 2013 ABB All rights reserved 5 Ca...

Page 326: ... calibration 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 fro...

Page 327: ... axes 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 manip...

Page 328: ...ition on page322 and Updat ing revolution counters on page326 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...

Page 329: ...gislation of the country in which the robot and the control unit are installed If the robot or the control unit is partially or completely disposed of the various parts must be grouped together according to their nature which is all iron together and all plastic together and disposed of accordingly These parts must also be disposed of in accordance with the current legislation of the country in wh...

Page 330: ...s 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 Also not...

Page 331: ...bes all the types of gearboxes Interchangeable parts Type C gearboxes are not interchangeable with other designs of the axis 1 and axis 3 gearboxes Notable changes connected to the Type C gearboxes Dimension and number of attachments screws are different Washers between the lower arm and axis 3 gearbox are different Tightening torques are different Tightening torque with angle 90 degrees added whe...

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Page 333: ...ral This chapter includes general information complementing the more specific information in the different procedures in the manual 3HAC033453 001 Revision H 333 Copyright 2009 2013 ABB All rights reserved 8 Reference information 8 1 Introduction ...

Page 334: ...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 335: ...pment ANSI UL 1740 option 429 1 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 03 option 429 1 3HAC033453 001 Revision H 335 Copyright 2009 2013 ABB All rights reserved 8 Reference information 8 2 Applicable safety standards Continued ...

Page 336: ...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 336 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 8 Reference information 8 3 Unit conversion ...

Page 337: ... 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 338: ...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 339: ...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 3HAC033453 001 Revision H 339 Copyright 2009 2013 ABB All rights reserved 8 Reference information 8 4 Screw joint...

Page 340: ...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 440 kg All lifting accessories used must be sized accord ingly 340 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights r...

Page 341: ...f the 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 10 100 Nm 1 Small screwdriver 1 Plastic mallet 1 Ratchet head for torque wrench 1 2 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 socket...

Page 342: ...ols may be ordered separately and are also specified directly in concerned instructions in the product manual Art no Qty Description 2 pcs Guide pins removal refitting of axis 1 gearbox 2 pcs Guide pins removal refitting of axis 3 gearbox Calibration equipment Levelmeter alternative method The following table specifies the calibration equipment required when calibrating the robot with the alternat...

Page 343: ...on Art no Description 3HAC034766 001 Turning tool includes lifting instruction Lifting accessories This table specifies the lifting accessories required during several of the service procedures The lifting accessories can be ordered separately and are also specified directly in concerned instructions Note Article no Qty Description Lifting accessory axis 2 Lifting accessory axis 3 For lifting of u...

Page 344: ...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 344 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 8 Reference information 8 8 Lifting accessories and lifting instructions...

Page 345: ...Variant X IRB 4600 60 2 05 X IRB 4600 45 2 05 X IRB 4600 40 2 55 X IRB 4600 20 2 50 Other design than Type C The table shows which lower arm can be used on which variant Lower arm 3HAC031002 005 Lower arm 3HAC030817 006 Variant X IRB 4600 60 2 05 X IRB 4600 45 2 05 X IRB 4600 40 2 55 X IRB 4600 20 2 50 Wrist unit The table shows which wrist unit can be used on which variant Wrist unit 3HAB9398 1 W...

Page 346: ...verting to or from a IRB 4600 20 2 5 Motor unit 3HAC030211 001 Motor unit 3HAC029034 004 Variant X IRB 4600 60 2 05 X IRB 4600 45 2 05 X IRB 4600 40 2 55 X IRB 4600 20 2 50 346 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 9 Spare part list 9 1 Rebuilding parts Continued ...

Page 347: ... 3HAC029187 001 Sealing 3 3HAC13416 1 Protection cover 4 3HAC6499 1 Push button guard 5 3HAC038465 001 Type C 6 O ring 3 pcs 21522012 428 Other design than Type C 6 O Ring 3 pcs Illustration base cover assembly Link to Spare parts base cover assembly on page 347 1 6 3 2 5 4 xx1300000188 3HAC033453 001 Revision H 347 Copyright 2009 2013 ABB All rights reserved 9 Spare part list 9 2 Base cover assem...

Page 348: ...349 Spare part number Base and frame parts Posi tion 3HAC030041 001 Cover plate A 3HAB3772 109 O ring for cover plate B 3HAC028525 005 Base C 3HAC035837 001 Bracket mechanical stop pin D 3HAC027499 005 Bracket E 3HAC027588 005 Stop pin F 3HAB3772 104 O ring for stop pin G 3HAC028524 006 Frame H 3HAB3701 29 Radial sealing not shown in the figure 3HAC025310 002 Cover not shown in the figure 3HAB3732...

Page 349: ...n base and frame unit Link to Spare parts base and frame unit on page 348 xx1300000203 3HAC033453 001 Revision H 349 Copyright 2009 2013 ABB All rights reserved 9 Spare part list 9 3 Base and frame unit Continued ...

Page 350: ...ction Type of lubrica tion in gearboxes on page 148 Lubricating oil 24 3HAC16721 1 Magnetic plug 24 3HAC033192 001 Plug IF3820 S06 EXT 23 See Electrical connections on page 361 200 Other design than Type C Spare part number Parts lower arm frame Posi tion 3HAC16721 1 Magnetic plug A 3HAC12320 1 Damper B 3HAC030817 006 Lower arm IRB 4600 60 2 05 45 2 05 C 3HAC031002 005 Lower arm IRB 4600 40 2 55 2...

Page 351: ...lower arm and frame Link to Spare parts list lower arm and frame on page 350 xx1300000189 3HAC033453 001 Revision H 351 Copyright 2009 2013 ABB All rights reserved 9 Spare part list 9 4 Lower arm and frame Continued ...

Page 352: ...r arm 40 2 55 on page 356 Spare parts no Upper arm parts Pos 3HAC042870 005 Type C 1 Arm housing 3HAC028633 004 Other design than Type C 1 Arm housing 3HAC034549 005 Other design than Type C 1 Arm housing type A 3HAC3785 2 Parallel pin hardened 2 pcs 2 3HAC029029 008 Tubular shaft unit 3 3HAB3772 12 O ring 6 3HAB9398 1 Wrist complete including o ring pos 6 7 3HAC037925 001 Magnetic plug 18 3HAC029...

Page 353: ...over arm housing on page 357 Spare parts no Cover arm housing parts Pos 3HAC028763 003 Cover Arm housing 1 3HAC029312 001 Gasket 2 Spare parts upper arm gearbox oil in vessel Type and amount of oil is detailed in a separate manual Technical reference manual Lubrication in gearboxes also see information in section Type of lubrication in gearboxes on page 148 Continues on next page 3HAC033453 001 Re...

Page 354: ...to Spare parts upper arm 60 2 05 45 2 05 on page 352 xx0800000317 Continues on next page 354 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 9 Spare part list 9 5 Upper arm IRB 4600 60 2 05 40 2 05 40 2 50 20 2 55 Continued ...

Page 355: ...to Spare parts upper arm 20 2 50 on page 352 xx0800000358 Continues on next page 3HAC033453 001 Revision H 355 Copyright 2009 2013 ABB All rights reserved 9 Spare part list 9 5 Upper arm IRB 4600 60 2 05 40 2 05 40 2 50 20 2 55 Continued ...

Page 356: ...to Spare parts upper arm 40 2 55 on page 352 xx0800000364 Continues on next page 356 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 9 Spare part list 9 5 Upper arm IRB 4600 60 2 05 40 2 05 40 2 50 20 2 55 Continued ...

Page 357: ...sing Link to Spare parts cover arm housing on page 353 1 2 xx0800000375 3HAC033453 001 Revision H 357 Copyright 2009 2013 ABB All rights reserved 9 Spare part list 9 5 Upper arm IRB 4600 60 2 05 40 2 05 40 2 50 20 2 55 Continued ...

Page 358: ...gnetic plug 4 3HAC029646 001 Washer 5 3HAA2166 21 VK Cover 6 3HAC029256 001 Damper axis 5 7 Complete wrist 60 kg Foundry Plus Spare part no Wrist Pos 3HAC029030 008 Wrist complete 1 Complete wrist 12 20 kg Link to Complete wrist 12 20 kg on page 358 Spare parts no Wrist parts Pos 3HAB9398 1 Wrist complete 1 Complete wrist 20 kg Spare parts no Wrist parts Pos 3HAC7101 4 Wrist complete 1 Continues o...

Page 359: ...60 kg Link to Spare parts wrist 60 kg 45 kg on page 358 xx0800000318 Continues on next page 3HAC033453 001 Revision H 359 Copyright 2009 2013 ABB All rights reserved 9 Spare part list 9 6 Wrist unit 60 kg 45 kg 20 kg Continued ...

Page 360: ...12 20 kg is used on variant IRB 4600 20 2 50 Link to Complete wrist 12 20 kg on page 358 xx0800000369 360 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 9 Spare part list 9 6 Wrist unit 60 kg 45 kg 20 kg Continued ...

Page 361: ... 001 Cable harness multibus 3HAC037798 001 Cable harness profibus Other parts Spare part number Spare part Item 3HAC029297 002 Connection box FS130 A 3HAB3772 110 O ring 2 pcs B 3HAC029302 002 Cover box FS130 C 3HAC029299 002 Connection box FS180 D 3HAB3772 111 O ring 2 pcs E 3HAC029303 002 Cover box FS180 F 3HAC16035 1 Brakerelease unit with buttons DSQC 536 G 3HAC16831 1 Battery pack 2 pole batt...

Page 362: ...asurement unit Contains serial measure ment board 3HAC044168 001 and battery pack 3HAC044075 001 3HAC4050 1 Signal cable SMB 3HAC046686 001 SMB replacement set Illustration electrical connections xx1300000258 G H J H DSQC 663A RMU G xx1300000342 362 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 9 Spare part list 9 7 Electrical connections Continued ...

Page 363: ...S245RHS i 125 X X X X 3HAC031958 002 Axis 2 B RV 320E3 i 171 X X X X 3HAC031074 004 Axis 3 C TS225R i 137 X X X X 3HAC034535 003 Axis 3 type A C TS225R i 142 0588 X X X X 3HAC039109 002 Axis 3 type B C TS225R i 137 O rings oil plug sealing washer Other design than Type C Type C Spare parts no Gearbox Pos X 3HAB3772 149 Axis 1 o ring X 3HAB3772 128 Axis 1 o ring X 3HAC029646 001 Axis 1 oil plug gas...

Page 364: ...Location of gearboxes xx1300000187 364 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 9 Spare part list 9 8 Gearboxes Continued ...

Page 365: ...e C 20 2 55 40 2 55 45 2 05 60 2 05 Spare part number Axis Pos X X X X 3HAC029031 004 Axis 1 A X X X X 3HAC029032 004 Axis 2 B X X X X 3HAC031184 003 Axis 3 C X X X X 3HAC034647 003 Axis 3 Type A C X X X 3HAC029034 004 Axis 4 D X 3HAC030211 004 Axis 4 D X X X 3HAC029034 004 Axis 5 E X 3HAC030211 004 Axis 5 E X X X 3HAC029034 004 Axis 6 F X 3HAC030211 004 Axis 6 F O rings Spare parts no Motor Pos 3...

Page 366: ...Location of motors xx1300000186 366 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 9 Spare part list 9 9 Motors Continued ...

Page 367: ...temperature 2 pcs 3HAC023271 001 Label Max Air pressure 1 pc 3HAB8431 1 Designation sign 1 pc 3HAC034755 001 Label Suspended robot 1 pc 3HAC2763 1 UL label 1 pc 3HAC14257 1 AbsAcc information sign 1 pc 3HAC5127 1 ABB logotype dimension 75x30 mm 1 pc 3HAC17765 1 ABB logotype dimension 112x44 mm 3 pcs 3HAC5089 1 ABB logotype dimension 150x60 mm 3HAC7835 1 Foundry Plus logotype 3HAC032726 001 Oil lab...

Page 368: ...HAC033862 005 Expansion container with cover set 224 2 Suspended position 3HAC16667 1 CP CS Proc1 base 239 1 3HAC033134 001 Working range limit axis 1 28 1 3HAC033181 001 Connector set on base 3HAC025396 001 Connector set R2 CP R2 CS 3HAC033134 001 Additional mechanical stop set axis 1 368 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 9 Spare part list 9 11 Options ...

Page 369: ...AC025611 001 Circuit diagram IRB 260 3HAC028647 009 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...

Page 370: ...agram IRB 6650S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 370 3HAC033453 001 Revision H Copyright 2009 2013 ABB All rights reserved 10 Circuit diagram 10 1 About circuit diagrams Continued ...

Page 371: ...rap connection point 53 expansion container installing 98 expected life 113 F fence dimensions 32 fire extinguishing 33 FlexPendant jogging to calibration position 328 MoveAbsJ instruction 328 updating revolution counters 326 foundation requirements 60 G gearboxes location of 149 Gravity Beta 76 grease disposal 330 H hazardous material 330 hold to run 37 I intervals for maintenance 111 inverted mo...

Page 372: ... electric parts 30 hot parts 25 hydraulic system 27 installation 22 oil change 55 operational disturbance 29 pneumatic system 27 pressure relief valve 28 service work 22 tools 26 voltage 30 work pieces 26 safety signals in manual 42 safety standards 334 scales on robot 322 schedule for maintenance 111 signal lamp 39 signals safety 42 special tools 342 stability 65 standards ANSI 334 CAN 334 EN 334...

Page 373: ......

Page 374: ...ne 46 0 21 344 400 ABB AS Robotics Discrete Automation and 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 www abb com robotics 3HAC033453 001 Rev H en ...

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