ABB IRB 6600 - 175/2.8 type B Product Manual Download

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3 Maintenance

3.4.6. Oil change, gearbox, axis 5

3HAC023082-001 Revision: E

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3.4.6. Oil change, gearbox, axis 5

Location of gearbox

The axis 5 gearbox is located in the wrist unit as shown in the figure below.

xx0200000232

xx0500002013

Wrist unit of IRB 6600 and IRB 6650

Oil plug, filling

Oil plug, draining

Wrist unit of IRB 6600ID and IRB 6650ID

Oil plug, filling

Oil plug, draining

Continues on next page

Summary of Contents for IRB 6600 - 175/2.8 type B

Page 1: ...Product manual Articulated robot IRB 6600 225 2 55 type B IRB 6600 175 2 8 type B IRB 6650 200 2 75 type B IRB 6650 125 3 2 type B IRB 6600ID 185 2 55 IRB 6650ID 170 2 75 M2000 M2000A M2004 ...

Page 2: ......

Page 3: ...ll rights reserved Product manual IRB 6600 225 2 55 type B IRB 6600 175 2 8 type B IRB 6650 200 2 75 type B IRB 6650 125 3 2 type B IRB 6600ID 185 2 55 IRB 6650ID 170 2 75 M2000 M2000A M2004 Document ID 3HAC023082 001 Revision E ...

Page 4: ...ss 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 and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravention will be prosecuted...

Page 5: ...te the information on safety and information labels 34 1 3 Safety related instructions 35 1 3 1 Safety signals general 35 1 3 2 DANGER Moving manipulators are potentially lethal 37 1 3 3 DANGER First test run may cause injury or damage 38 1 3 4 WARNING The brake release buttons may be jammed after service work 39 1 3 5 WARNING The unit is sensitive to ESD 40 1 3 6 WARNING Safety risks during work ...

Page 6: ... 3 6 Inspection oil level gearbox axis 6 149 3 3 7 Inspection balancing device 153 3 3 8 Inspection cable harness 158 3 3 9 Inspection information labels 162 3 3 10 Inspection mechanical stop axis 1 164 3 3 11 Inspection additional mechanical stops 166 3 3 12 Inspection damper axes 2 5 169 3 3 13 Inspection position switch axes 1 2 and 3 171 3 3 14 Inspection signal lamp 173 3 3 15 Inspection of a...

Page 7: ...acement of upper arm 286 4 4 5 Replacement of complete lower arm 292 4 4 6 Replacement of lower arm shaft 299 4 4 7 Securing the lower arm 305 4 5 Frame and base 309 4 5 1 Replacement of SMB unit 309 4 5 2 Replacement of brake release unit 313 4 5 3 Replacement of spherical roller bearing balancing device 317 4 5 4 Replacement of balancing device 322 4 5 5 Unloading the balancing device 331 4 5 6 ...

Page 8: ...ction 442 9 2 2 Spare part list 443 9 3 Part list 448 9 3 1 Introduction 448 9 3 2 Rebuilding parts 449 9 3 3 Part list overview 451 9 3 4 Base incl frame ax 1 453 9 3 5 Axis 3 4 454 9 3 6 Axis 3 4 Foundry 458 9 3 7 Axis 3 4 Foundry Prime 459 9 3 8 Wrist type 2 standard IRB 6600 and IRB 6650 460 9 3 9 Wrist process IRB 6600ID and 6650ID 464 9 3 10 Wrist type 2 Foundry 466 9 3 11 Wrist type 2 insul...

Page 9: ...08 ABB All rights reserved 11 Circuit Diagram 485 11 1 Introduction 485 11 2 Circuit diagram 3HAC 025744 001 486 11 2 1 Validity of circuit diagram 3HAC 025744 1 486 11 3 Circuit diagram 3HAC 13347 1 487 11 3 1 Validity of circuit diagram 3HAC 13347 1 487 Index 489 ...

Page 11: ...on repair maintenance work Organization of chapters The manual is organized in the following chapters Chapter Contents Safety Safety information that must be read through before performing any installation or service work on robot Contains general safety aspects as well as more specific information about how to avoid personal injuries and damage to the product Installation and commis sioning Requi...

Page 12: ... Product manual S4Cplus M2000 3HAC021333 001 Product manual S4Cplus M2000A 3HAC022419 001 Operating manual IRC5 with FlexPendant 3HAC16590 1 Operating manual Calibration Pendulum 3HAC16578 1 Operating manual Levelmeter Calibration 3HAC022907 001 User s guide S4Cplus 3HAC7793 1 Operating manual Service Information System 3HAC025709 001 Technical reference manual System parameters 3HAC17076 1 Applic...

Page 13: ...lso added to section Robot cabling and connection points on page 122 Supplementary details about required cabling for position switches are added to section Installation of position switches option on page 111 together with a procedure for how to install the cabling A complete undivided cabling from axis 1 to axis 6 is added to the spare parts in Spare part list on page 443 New procedure Replaceme...

Page 14: ... calibration decommissioning Product manual reference information Reference information article numbers for documentation referred to in Product manual procedures lists of tools safety standards Part list Foldouts or exploded views Circuit diagrams The product manual published as a PDF consists of only one file where the two parts are presented together as one Product manual Software manuals The s...

Page 15: ...tallation electrical connections Maintenance descriptions of all required preventive maintenance procedures including intervals Repair descriptions of all recommended repair procedures including spare parts Additional procedures if any calibration decommissioning Product manual reference information Reference information article numbers for documentation referred to in Product manual procedures li...

Page 16: ...f the application what it does and when it is useful What is included e g cables I O boards RAPID instructions system parameters CD with PC software How to use the application Examples of how to use the application Operating manuals This group of manuals is aimed at those having first hand operational contact with the robot i e production cell operators programmers and trouble shooters The group o...

Page 17: ...ude references to equipment spare parts tools etc required for the different actions in the procedure The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information i e article number dimension The denomination in the procedure for the component or attachment point corresponds to the denomination in th...

Page 19: ... to attend to before performing any service work on the robot These are applicable for all service work and are found in section General safety information on page 18 specific safety information pointed out in the procedure at the moment of the danger How to avoid and eliminate the danger is either detailed directly in the procedure or further detailed in separate instructions found in section Saf...

Page 20: ...ial robot described in the applicable documents e g User s Guide S4Cplus M2000 Operating Manual IRC5 with FlexPendant M2004 Product Manual Connection of external safety devices Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices Via this interface an external safety function can interact with other machines and periphe...

Page 21: ... be crossed before admittance must be set up in front of the robot s working space Light beams or sensitive mats are suitable devices Turntables or the like should be used to keep the operator out of the robot s working space The axes are affected by the force of gravity when the brakes are released In addition to the risk of being hit by moving robot parts you run the risk of being crushed by the...

Page 22: ...the lower arm with fixtures if removing motor axis 2 Safety risk Description Cable packs are sensitive to mechanical damage CAUTION The cable packs are sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them Safety risk Description Gears may be damaged if excessive force is used CAUTION Whenever parting mating motor and gearbox the ge...

Page 23: ...safely turn off tools such as milling cutters etc Make sure that guards remain closed until the cutters stop rotating It should be possible to release parts by manual operation valves Safe design Grippers end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller CAUTION Ensure that a gripper is prevented from dropping a workpie...

Page 24: ... to pneumatic and hydraulic systems Residual energy Residual energy may be present in these systems After shutdown particular care must be taken The pressure in pneumatic and hydraulic systems must be released before starting to repair them Safe design Gravity may cause any parts or objects held by these systems to drop Dump valves should be used in case of emergency Shot bolts should be used to p...

Page 25: ...rried out professionally and in accordance with the applicable safety regulations Care must be taken at all times Qualified personnel 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 d...

Page 26: ...side the robot s working space Voltage related risks controller S4Cplus A danger of high voltage is associated with the following parts Be aware of stored electrical energy DC link in the controller Units inside the controller e g I O modules can be supplied with power from an external source The mains supply mains switch The power unit The power supply unit for the computer system 230 VAC The rec...

Page 27: ...VAC The service outlets 115 230 VAC The customer power supply 230 VAC The power supply unit for additional tools or special power supply units for the machining process The external voltage connected to the controller remains live even when the robot is disconnected from the mains Additional connections Voltage related risks robot A danger of high voltage is associated with the robot in The power ...

Page 28: ...sion the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell see Product Specification Description Robot Motion Also consider the maximum possible impact caused by a b...

Page 29: ...xtinguishing 27 3HAC023082 001 Revision E Copyright 2004 2008 ABB All rights reserved 1 2 3 2 Fire extinguishing NOTE Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the robot system manipulator or controller ...

Page 30: ...ke release buttons on the robot How to release the brakes is detailed in section Manually releasing the brakes on page 71 Manually releasing the brakes in the product manual for the robot The robot arm may be moved manually on smaller robot models but larger models may require using an overhead crane or similar Increased injury Before releasing the brakes make sure that the weight of the arms does...

Page 31: ...ction How to test The function of the holding brake of each axis motor may be checked as detailed below 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 do...

Page 32: ...01 Revision E 30 Copyright 2004 2008 ABB All rights reserved 1 2 3 5 Risk of disabling function Reduced speed 250 mm s NOTE Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC This will affect the safety function Reduced speed 250 mm s ...

Page 33: ...released or pushed all the way in the robot is taken to the MOTORS OFF state To ensure safe use of the FlexPendant the following must be implemented The enabling device must never be rendered inoperative in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move The programmer must always bring the FlexPendant with him her when ...

Page 34: ...ntrol panel The robot s speed is limited to max 250 mm s when the operating mode selector is in position manual mode with reduced speed This should be the normal position when entering the working space The position manual mode with full speed 100 may only be used by trained personnel who are aware of the risks that this entails Pay attention to the rotating axes of the manipulator Keep a distance...

Page 35: ...erved 1 2 3 8 Signal lamp optional Description A signal lamp with an yellow fixed light can be mounted on the manipulator as a safety device Function The lamp is active in MOTORS ON mode Further information Further information about the MOTORS ON MOTORS OFF mode may be found in the controller documentation ...

Page 36: ...age 162 Translation possibilities The labels fitted to the product contain space for adding a fourth language underneath the three standard languages English German and French Add a local language to the label by Using a transparent sticker over the standard label with text added in a fourth language Drawings detailing the design text figure dimensions of the standard labels can be ordered from AB...

Page 37: ...h 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 WARNING 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 volt...

Page 38: ...lectrostatic discharge ESD symbol indicates electrostatic hazards which could result in severe damage to the product Note NOTE Note symbols alert you to important facts and conditions Tip TIP Tip symbols direct you to specific instructions where to find additional information or how to perform a certain operation in an easier way Symbol Designation Signification Continued ...

Page 39: ...ination Action Note 1 Before attempting to run the manipulator make sure all emergency stop equipment is correctly installed and connected Emergency stop equipment such as gates tread mats light curtains etc 2 If possible use the hold to run function whenever possible The hold to run function is used in manual mode not in automatic mode How to use the hold to run function in RobotWare 5 0 is detai...

Page 40: ...ks to take into consideration before the first test run Elimination Follow the procedure below when performing the first test run after a service activity repair installation or maintenance Action 1 Remove all service tools and foreign objects from the robot and its working area 2 Install all safety equipment properly 3 Make sure all personnel are standing at a safe distance from the robot i e out...

Page 41: ...se the power is turned on while a brake release button is jammed in depressed position the affected motor brake is released This may cause serious personal injuries and damage to the robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action 1 Make sure the power is turned off 2 Remove the push button guard if necessary 3...

Page 42: ... grounded may potentially transfer high static charges This discharge may destroy sensitive electronics Elimination Location of wrist strap button The wrist strap button is located in the top right corner as shown in the illustration below xx0500002171 Action Note 1 Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly 2 Use an ESD...

Page 43: ...e opening Do not overfill the gearbox when filling Do not overfill Overfilling of gearbox oil can lead to internal over pressure inside the gearbox which in turn may damage seals and gaskets completely press out seals and gaskets preventthemanipulator from moving freely Make sure not to overfill the gearbox when filling with oil After filling check the correct oil level Do not mix types of oil Mix...

Page 45: ...erved 2 Installation and commissioning 2 1 Introduction General This chapter contains information for installing the robot to the working site More detailed technical data such as load diagram permitted extra loads equipment and location of extra loads equipment may be found in the Product Specification for the robot ...

Page 46: ...er way than method 1 or 2 can seriously damage the robot If the robot is incorrectly transported and the instructions are not followed the robot is not covered by the warranty and ABB will not accept any compensation claim Method 1 Transportation according to method 1 is strongly recommended by ABB xx0800000030 Always follow these instructions when transporting an ABB robot according to method 1 A...

Page 47: ...obot according to method 2 Always read and follow the instructions in section Securing the robot Always place the robot in the ABB recommended transport position for robot with tool detailed in sub section Transport position with a transport support Always use the recommended transport support detailed in sub section Recommended transport support IRB7600 IRB66XX xx0800000037 A Transport Support B ...

Page 48: ...transportation precautions 3HAC023082 001 Revision E 46 Copyright 2004 2008 ABB All rights reserved IRB6620 xx0800000036 A Transport Support B Hexagon socket head cap screw M10x50 C Threaded bar M10x280 D Nut M10 Continued Continues on next page ...

Page 49: ...cautions 47 3HAC023082 001 Revision E Copyright 2004 2008 ABB All rights reserved Transport position with a transport support All transportation of the robot with tool must follow these instructions IRB 7600 IRB 66XX xx0800000040 Continued Continues on next page ...

Page 50: ...2 Installation and commissioning 2 2 Robot transportation precautions 3HAC023082 001 Revision E 48 Copyright 2004 2008 ABB All rights reserved IRB 6620 xx0800000041 Continued Continues on next page ...

Page 51: ...precautions 49 3HAC023082 001 Revision E Copyright 2004 2008 ABB All rights reserved Recommended transport support Always use the recommended transport support when transporting a robot with tool IRB 7600 IRB 66XX xx0800000039 Continued Continues on next page ...

Page 53: ...erved 2 3 Securing the robot General This section describes how to secure the robot using the transport support DANGER Releasing the brakes is a hazardous action that may cause injury and damage property It must be done with great care and only when absolutely necessary Securing the robot xx0800000062 Continues on next page ...

Page 54: ...t support CAUTION Do not try to jog the robot to the exact position max distance 1mm 3 Use the brake release for axis 3 to reach the final resting position on the transport support see section Manually releasing the brakes See attachment point for the specific robot in section Transport position with a transport support 4 Tightening all the attachment screws A and B in figure with the brake releas...

Page 55: ... robot on page 53 4 If the robot is not installed directly it must be stored as described in Storage conditions robot on page 54 5 Make sure the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 54 6 Before taking the robot to its installation site make sure the site conforms to Loads on foundation robot on page 54 Require...

Page 56: ...g conditions robot The table below shows the allowed operating conditions for the robot Force Endurance load operation Max load emergency stop Force xy 10 1 kN 20 7 kN Force z 18 0 13 8 kN 18 0 22 4 kN 11 0 3 7 kN Torque xy 27 6 kNm 30 4 kNm 50 6 kNm 55 7 kNm Torque z 7 4 kNm 14 4 kNm Requirement Value Note Min levelity 0 5 mm Max tilt 5 The limit for the maximum load on the robot is reduced if th...

Page 57: ...tallation procedure 55 3HAC023082 001 Revision E Copyright 2004 2008 ABB All rights reserved Protection classes robot The table below shows the protection class of the robot Equipment Protection class Robot IP 67 Cooling fans option IP 54 Continued ...

Page 58: ...ved 2 4 2 Working range and type of motion Working range Following figures show the working ranges of the robot models The extreme positions of the robot arm are specified at the wrist center dimensions in mm IRB 6600 225 2 55 IRB 6600ID 185 2 55 The illustration below shows the unrestricted working range xx0200000025 Continues on next page ...

Page 59: ...2 4 2 Working range and type of motion 57 3HAC023082 001 Revision E Copyright 2004 2008 ABB All rights reserved IRB 6600 175 2 8 The illustration below shows the unrestricted working range xx0200000026 Continued Continues on next page ...

Page 60: ...2 4 2 Working range and type of motion 3HAC023082 001 Revision E 58 Copyright 2004 2008 ABB All rights reserved IRB 6650 125 3 2 The illustration below shows the unrestricted working range xx0200000338 Continued Continues on next page ...

Page 61: ...4 and 6 Axis Type of motion Range of movement Note 1 Rotation motion 180º to 180º Movement range of IRB 6600 6650 can be set to 220º to 220º option 561 1 2 Arm motion 85º to 65º 3 Arm motion 70º to 180º 4 Wrist motion 300º to 300º IRB 6600ID 6650ID the range of movement is the combined value for axis 4 and 6 together 5 Bend motion IRB 6600 6650 120º to 120º IRB 6600ID 6650ID 100º to 100º 6 Turn mo...

Page 62: ...d standing still the robot is not stable in the whole working area Moving the arms will displace the center of gravity which may cause the robot to tip over Do not change the robot position before securing it to the foundation Stabililty The figure below shows the robot in its shipping position which also is its most stable position xx0100000103 WARNING The robot is likely to be mechanically unsta...

Page 63: ...vided that available special aids are used This section describes how to attach the fork lift equipment to the robot Attachment points The attachment points for the fork lift equipment are shown in the figure below xx0400000707 A Attachment points spacer and horizontal attachment screws B Attachment points horizontal attachment screws C Attachment points vertical attachment screws D Attachment poi...

Page 64: ...000379 Equipment etc Art no Note Fork lift set incl all required hardware 3HAC 0604 1 See the figure Fork lift set 3HAC 0604 1 on page 62 Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual A Fork lift pocket 2 pcs different from each other B Spacer 2 pcs C Horizontal attachment screws 4 pcs fork lift pocket D Vertical attachment screws...

Page 65: ...y releasing the brakes on page 71 xx0200000387 3 Fit the two spacers to the robot and secure Attachment points on the robot are shown in the figure Attachment points on page 61 4 CAUTION The fork lift pocket weighs 60 kg 5 Secure the longer fork lift pocket to the spacers with four of the horizontal attachment screws and washers Note The vertically and the horizontally attached screws are identica...

Page 66: ... A vertical attachment screws 2 pcs M16x60 Tightening torque 270 Nm Make sure the original screws are always used or replacements of equivalent quality M16 quality 12 9 Attachment points on the robot are shown in the figure Attachment points on page 61 8 CAUTION The fork lift pocket weighs 22 kg 9 Secure the shorter fork lift pocket on the other side of the robot with the four remaining horizontal...

Page 67: ...any before using a fork lift 11 CAUTION The robot models weigh IRB 6600 IRB 6650 1780 kg IRB 6600ID IRB 6650ID 1880 kg All lifting equipment used must be sized accordingly 12 Carefully lift the robot and move it to its instal lation site 13 WARNING Personnel must not under any circumstances be present under the suspended load 14 Refit the cooling fan to the motor if any Detailed in section Install...

Page 68: ...ngs General The robot may be lifted with roundslings according to the illustration below The illustration is identical with the label attached to the robot s lower arm Attachment points The figure below shows how to attach the roundslings to the robot xx0200000282 A Chain sling with shortener B Roundsling robot C Roundsling upper arm Note Do not stretch Continues on next page ...

Page 69: ...50 kg 0 47 m 0 54 m 0 76 m Roundsling robot 3 pcs 2 000 kg 2 m Roundsling upper arm 2 pcs 2 000 kg Note Do not stretch 2 5 m Action Note 1 Attach the roundslings to the robot according to the figure Attachment points on page 66 2 CAUTION The robot models weigh IRB 6600 IRB 6650 1780 kg IRB 6600ID IRB 6650ID 1880 kg All lifting equipment used must be sized accord ingly 3 WARNING Personnel must not ...

Page 70: ...uctions are included with the equipment Illustration lifting slings The figure below shows how to lift the complete robot with lifting slings Note the recommended robot position shown in the figure below and in the instruction Attempting to lift a robot in any other position may result in the robot tipping over causing severe damage or injury xx0200000153 A Load hook B Swivelling lifting eyes 4 pc...

Page 71: ...verhead crane to a position above the robot 2 Make sure the robot is positioned as shown in the figure on the right If it is not position it that way Release the brakes if required as detailed in section Manually releasing the brakes on page 71 xx0100000103 3 Fit the lifting device manipulator to the robot as described in the enclosed instruction Art no is specified in Required equipment on page 6...

Page 72: ...ion E 70 Copyright 2004 2008 ABB All rights reserved 6 Raise the overhead crane to lift the robot Make sure all hooks and attachments maintain their correct positions while lifting the robot Always move the robot at very low speeds making sure it does not tip Action Note Illustration Continued ...

Page 73: ...ttons Action Note Illustration 1 The internal brake release unit is equipped with six buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes If the robot is not connected to the controller power must be supplied to the connector R1 MP according to section Supplying power to connector R1 MP on page 72 The buttons are shown in the figure Location of bra...

Page 74: ... If the robot is not connected to the controller power must be supplied to connector R1 MP in the robot base in order to enable the brake release buttons on the robot Action Note Illustration 1 DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 2 Supply 0V on pin 12 and 24V on pin 11 xx0300000565 Continued ...

Page 75: ...fting base plate Equipment Art no Note Lifting eye M16 3HAC 14457 4 3 pcs Lifting slings 3 pcs Length approx 2 m A Attachment holes for lifting eyes x3 Action Note 1 CAUTION The base plate weighs 353 kg All lifting equipment used must be sized accordingly 2 Fit the lifting eyes in the three lifting holes Shown in the figure Hole con figuration on page 73 3 Fit the lifting slings to the eyes and to...

Page 76: ...ecuring the base plate 3HAC023082 001 Revision E 74 Copyright 2004 2008 ABB All rights reserved 2 5 6 Securing the base plate General This section details how to secure the base plate Base plate dimensions xx0100000105 Continues on next page ...

Page 77: ...ion and commissioning 2 5 6 Securing the base plate 75 3HAC023082 001 Revision E Copyright 2004 2008 ABB All rights reserved xx0400000715 Note1 Four holes for alternative clamping Continued Continues on next page ...

Page 78: ...pcs Equipment Art no Note Base plate 3HAC 12937 8 Includes guide sleeves 3HAC 12937 3 levelling screws 9ADA 120 79 attachment screws and washers for securing the manipulator to the base plate A drawing of the base plate itself may be ordered from ABB Robotics Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Other tools and procedures...

Page 79: ...lation to the robot work location using the three grooves in the base plate Shown in the figure Base plate grooves and holes on page 76 4 Lift the base plate to its mounting position Detailed in section Lifting the base plate on page 73 5 Use the base plate as a template and drill 16 attachment holes as required by the selected bolt dimension If possible observe the recommenda tions specified in s...

Page 80: ...bot fitted to base plate The illustration below shows the robot base fitted to the base plate xx0300000566 Attachment screws The table below specifies the type of securing screws and washers to be used for securing the robot to the base plate foundation A Robot attachment bolts and washers 8 pcs M24 x 140 B Orienting grooves in the robot base and in the base plate C Levelling screws D Base plate a...

Page 81: ...o the vicinity of its installation location 3 Fit two guide sleeves to the guide sleeve holes in the base plate Shown in the figure Base plate grooves and holes on page 76 Note that one of the guide sleeve holes is elongated 4 Guide the robot gently using two M24 screws while lowering it into its mounting position Make sure the robot base is correctly fitted onto the guide sleeves 5 Fit the bolts ...

Page 82: ...5 7 Orienting and securing the robot 3HAC023082 001 Revision E 80 Copyright 2004 2008 ABB All rights reserved Cross section guide sleeve hole The illustration below shows the cross section of the guide sleeve holes xx0600002629 Continued ...

Page 83: ...ot cell The robot IRB 6600ID and IRB 6650ID is delivered with DressPack SpotPack and there may not be any additional equipment fitted to the robot except at the turning disk and the frame Illustration fitting of extra equipment on lower arm The illustration below shows the mounting holes available for fitting extra equipment on the lower arm Make sure not to damage the robot cabling on the inside ...

Page 84: ...5 8 Fitting equipment on robot 3HAC023082 001 Revision E 82 Copyright 2004 2008 ABB All rights reserved xx0300000571 xx0300000572 Only valid for IRB 6600 and IRB 6650 Only valid for IRB 6600 and IRB 6650 Continued Continues on next page ...

Page 85: ...ting of extra equipment on upper arm The illustration below shows the mounting holes available for fitting extra equipment on the upper arm Note Extra equipment may not be mounted on the upper arm of IRB 6600ID or IRB 6650ID xx0300000573 xx0200000196 Only valid for IRB 6600 and IRB 6650 Only valid for IRB 6600 and IRB 6650 Continued Continues on next page ...

Page 86: ... Copyright 2004 2008 ABB All rights reserved Illustration fitting of extra equipment on frame The illustration below shows the mounting holes available for fitting extra equipment on the frame xx0500001568 1 Early version of the frame 2 Later version of the frame Continued Continues on next page ...

Page 87: ...2004 2008 ABB All rights reserved Illustration fitting on turning disk The illustration below shows the mounting holes available for fitting equipment on the turning disk xx0200000197 Turning disk for robot version IRB 6600 225 2 55 and 175 2 8 IRB 6650 125 3 2 and 200 2 75 Continued Continues on next page ...

Page 88: ... 2004 2008 ABB All rights reserved xx0500001580 Fastener quality When fitting tools on the turning disk see the figures above use only screws with quality 12 9 When fitting other equipment standard screws with quality 8 8 can be used Turning disk unit for robot versions IRB 6600ID and IRB 6650ID Continued ...

Page 89: ...so details how to remove the proctection when necessary Illustration equipment mounted on robot The illustration below shows the chip and dust protection mounted on the robot xx0400001071 Required equipment A Bearing unit lower arm shaft B Bearing unit axis 2 motor C Stop D Shield 4 pcs E Cover balancing device F Sliding cover G Cover lower arm Equipment Art no Note Chip and dust protection 3HAC 0...

Page 90: ...chment screws of the rear cover at the end of the balancing device Standard toolkit 3HAC 15571 1 The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Equipment Art no Note Action Note Illustration 1 Fit the bearing unit lower arm shaft to the robot by inserting it through the shaft and securing with the washer and nut xx0400001077 A Bearing unit B Lower ...

Page 91: ...r to the robot with the enclosed attachment screws Make sure the bearing unit is orientated correctly The opening must be orientated approximately as shown in the figure to the right B xx0400001079 Attachment screws 4 pcs M8 x 40 Tightening torque 24 Nm Also shown in the figure Illustration equipment mounted on robot on page 87 4 Remove the securing screws that are fitted to the bearing unit durin...

Page 92: ...23082 001 Revision E 90 Copyright 2004 2008 ABB All rights reserved 5 Fit the stop to the robot Use the enclosed attachment screws xx0400001080 C Attachment screws 2 pcs M6x25 6 Remove the rear bracket from the upper shield xx0400001099 Action Note Illustration Continued Continues on next page ...

Page 93: ...ttom and continue upwards correct order is shown in the figure to the right Make sure to fit the border tabs to eachother so that the upper shields lift the lower ones when the robot moves xx0400001082 D Attachment screws 2 pcs M12 x 20 E Attachment screws 16 pcs M6 x 10 8 Remove the two upper attachment screws shown in the figure to the right from the rear cover of the balancing device xx04000010...

Page 94: ...arlier removed from the rear cover of the balancing device Use locking liquid Fit the enclosed clamp I around the balancing device and insert it through the holes on top of the cover xx0400001085 H Attachment screws 2 pcs M10 x 30 tightening torque 50 Nm I Clamp Locking liquid is specified in Required equipment on page 87 10 Fit the sliding cover to the robot xx0400001087 J Bushing K Hub Action No...

Page 95: ...shield Attach the rear bracket with enclosed attachment screws xx0400001100 L Rubber cloth M Upper shield N Rear bracket 12 Fit the cover lower arm to the robot using the enclosed screws If the attachment holes are used for other equipment the cover may be fitted beneath the equipment xx0400001088 O Attachment screws 2 pcs M12 x 20 Action Note Illustration Part to be removed Action Cover lower arm...

Page 96: ...ust protection option 3HAC023082 001 Revision E 94 Copyright 2004 2008 ABB All rights reserved Bearing unit axis 2 motor 1 Remove all the shields 2 Remove the bearing unit 3 Refit the original attachment screws to the cover axis 2 Part to be removed Action Continued ...

Page 97: ...ation of base spacers xx0500001570 Required equipment A Base spacer 4 pcs B Guide sleeve 4 pcs C Attachment screws and washers 8 pcs Equipment Art no Note Base spacers 3HAC 021899 002 Includes mounting set with attachment screws and mounting instruction Base plate 3HAC 12937 8 Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Continue...

Page 98: ...ay with lifting slings Make sure the robot is positioned in the most stable position the transport position Detailed in section Lifting robot with lifting slings on page 68 3 Install the base plate to the foundation if not used previously Detailed in section Securing the base plate on page 74 4 Fit the four base spacers and guiding sleeves to the base plate Shown in the figure Illustration instal ...

Page 99: ...nd 3 Installation of this complete cabling is detailed in section Installation of cable harness for position switches and fans on page 118 separate cabling for axis 1 or 2 including only connections for the cooling fans on axes 1 or 2 Installation of this cabling is detailed in section Installation separate fan cabling axis 1 or 2 on page 101 If both cooling fans and position switches are installe...

Page 100: ...n the connector D Tightening screws fanbox 3 pcs Equipment Art no Note Cooling fan 3HAC15374 1 Cabling position switches and cooling fans axes 1 2 and 3 3HAC15390 1 IRB 6600 6600ID 3HAC16659 1 IRB 6650 6650ID Choose this cabling if equipping the robot with both position switches and cooling fans or with cooling fans on axis 3 Cabling cooling fans axes 1 or 2 3HAC023599 001 Choose this cabling if o...

Page 101: ...de the controller Specified in section Position switch and fan cables robot base to controller option on page 123 Locking liquid Loctite Used for the three tightening screws Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Circuit diagram See chapter Circuit diagram in the Product manual reference information Other tools and procedur...

Page 102: ...rfaces of the motor when fitting the fanbox turn the connector to the correct position axis 1 groove pointing inwards as shown in the figure Cooling fan on page 98 Positions for axis 2 and 3 are shown in the figure Location of cooling fans on page 97 Shown in the figure Cooling fan on page 98 3 Temporarily lift the motor cabling out of the way of the current motor to make room for the fanbox 4 Fit...

Page 103: ... from the robot base Shown in the figure Location of cooling fans on page 97 4 Fit the plate for customer connections if not already fitted to the connection plate of the robot base Shown in the figure Plate for customer connections at base on page 99 Art no is specified in Required equipment on page 98 5 Run the cabling through the base and frame up beneath the balancing device 6 Secure the cable...

Page 104: ...er plate to the robot base 10 Install additional cabling to and inside the controller Also make adjustments in RobotWare as described in the following procedure Cabling is specified in section Position switch and fan cables robot base to controller option on page 123 Action Note Illustration Action Note 1 Modify the settings in RobotWare to include the cooling fans RobotWare 4 0 modify the setting...

Page 105: ...ents and overloading the motors CAUTION Incorrect defined loads may result in operational stops or major damage in bearings 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 User s Guide RobotWare 4 0 Operating manual RobotWare 5 0 Stop time and braking distances Robo...

Page 106: ...ftware signal from adjustable position switch Axis 2 hardware mechanical stop and software signal from adjustable position switch Axis 3 hardware mechanical stop and software signal from adjustable position switch As standard configuration axis 1 is allowed to move 180º The working range may however be increased to 220º with option 561 1 Extended working range axis 1 Notice that this option also r...

Page 107: ...135 in both directions Mechanical stops axis 1 The illustration below shows the mounting position of the stop pin and one of the additional mechanical stops available for axis 1 xx0300000049 Required equipment A Additional mechanical stop B Stop pin Equipment etc Art no Note Mechanical stop for axis 1 7 5 3HAC 11076 1 Includes attachment screws and an assembly drawing Mechanical stop for axis 1 15...

Page 108: ... pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Fit the additional mechanical stop to the frame according to the figure Mechanical stops axis 1 on page 105 Tightening torque 120 Nm 3 Note The software working range limitations must be re defined to correspond to the changes in the mechanical limitations of the working range How to defin...

Page 109: ...chanical stops axis 2 The illustration below shows the mounting position of the mechanical stops on axis 2 xx0300000047 Required equipment A Additional mechanical stops B Fixed mechanical stop Equipment etc Art no Note Mechanical stop set axis 2 3HAC 020885 001 Includes six stops attachment screws washers and assembly drawings Standard toolkit The contents are defined in section Standard toolkit o...

Page 110: ...tors and SMB 2 Fit and tighten the additional stops in a row starting from the fixed stop Tightening torque 115 Nm Shown in the figure Mechanical stops axis 2 on page 107 3 The software working range limitations must be re defined to correspond to the changes in the mechanical limitations of the working range How to define the range of movement in RobotWare 4 0 is detailed in User s guide S4Cplus ...

Page 111: ...n below shows the mounting position of the mechanical stops on axis 3 xx0300000048 Required equipment A Additional mechanical stops B Fixed mechanical stop Equipment etc Art no Note Mechanical stop set axis 3 3HAC 13128 1 Includes six stops one with 80 restriction 3HAC 12708 3 use when limitation angle 80 and five with 20 3HAC 12708 1 attachment screws Standard toolkit The contents are defined in ...

Page 112: ...ure to motors and SMB 2 Mount and tighten the additional stops in a row starting from the fixed stop Shown in the figure Mechanical stops axis 3 on page 109 3 Note The software working range limitations must be re defined to correspond to the changes in the mechanical limitations of the working range How to define the range of movement in RobotWare 4 0 is detailed in User s guide S4Cplus chapter S...

Page 113: ...ncludes position swtich and plate for customer connections Position switch axis 2 3HAC 021885 001 Includes only the position switch Position switch axis 3 3HAC 16417 2 Includes only the position switch Cabling position switches and cooling fans axes 1 2 and 3 3HAC 15390 1 IRB 6600 IRB 6600ID Cabling to be installed on the robot Cabling position switches and cooling fans axes 1 2 and 3 3HAC 16659 1...

Page 114: ...xis 1 The illustration below shows the position switch for axis 1 There is no extra cabling installed on the robot as for axes 2 and 3 Instead the switch is connected directly to the connector in the base R1 SW1 xx0100000158 A Position switch axis 1 B Cam C Set screw cam cam stop D Protection sheet E Rail F Rail attachment Continued Continues on next page ...

Page 115: ...4 2008 ABB All rights reserved Axis 2 The illustration below shows the position switch for axis 2 In addition to the shown components cabling must also be installed from the switch to the robot base xx0100000159 A Position switch axis 2 B Cam C Set screw cam cam stop E Rail F Rail Attachment Continued Continues on next page ...

Page 116: ...ow shows the position switch for axis 3 In addition to the shown components cabling must also be installed from the switch to the robot base xx0100000160 Specifications Maximum voltage current for the position switches A Position switch axis 3 B Cam C Set screw cam cam stop E Rail F Rail attachment Parameter Value Voltage Max 50 VDC Current Max 1 A Continued Continues on next page ...

Page 117: ...struction below details how to fit and adjust the parts of the position switches Action 1 Remove the cable protection from the lower arm 2 Fit the rail by pushing it against the support surface on the lower arm and tightening the two screws 3 Fit the cam and the position switch unit 4 Refit the cable protection to the lower arm with two screws Action Note 1 Cut the cam to a suitable length Use a s...

Page 118: ...ation adjust and secure cams The illustration below show how to adjust and secure the position switch cams and profiles xx0100000113 Illustration cutting the cam The illustration below show how to cut the position switch cam xx0100000114 A Cam stop M5 nut and M5 x 6 set screw B Adjustable cam C Profile A Remove the gray section Continued Continues on next page ...

Page 119: ...r customer connections at base xx0500002301 Cable harness for position switches and fans axes 1 3 xx0500002305 A Plate for customer connections B Attachment screws 3 pcs M6x16 A Cable bracket frame B Cable bracket lower arm C Cable bracket upper arm R1 SW2 3 Connected to the robot base R3 FAN2 Connected to the fan of axis 1 or 2 Continued Continues on next page ...

Page 120: ... SW3 Connected to the position switch of axis 3 Action Note Illustration 1 Move the robot to its calibration position 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Remove the rear cover A from the robot base and replace the protection B with a plate for customer connections i...

Page 121: ...xisting velcro strap B attached around the robot cabling Connect the connector R2 SW2 to the position switch of axis 2 Note There is a risk of the balancing device damaging the fan cable if it is not protected by correct routing underneath the robot cabling xx0500002309 A Cable bracket frame Also shown in the figure Cable harness for position switches and fans axes 1 3 on page 117 B Velcro strap C...

Page 122: ...n of axis 3 together with the robot cabling with a velcro strap xx0500002313 A Bracket lower arm Also shown in the figure Cable harness for position switches and fans axes 1 3 on page 117 B Bracket for robot cabling C Connector R2 SW3 D Velcro strap 8 Secure the axis 3 fan cable with the bracket upper arm Shown in the figure Cable harness for position switches and fans axes 1 3 on page 117 9 Conne...

Page 123: ...he base of the robot Make sure that the cabling run through the base frame and lower arm is not twisted and is running free from the robot cabling 11 Refit the rear cover to the robot base 12 Install additional cabling to and inside the control cabinet Cabling is specified in section Position switch and fan cables robot base to controller option on page 123 Action Note Illustration Continued ...

Page 124: ... fan cables option Handles supply to and feedback from any position switches and cooling fans on the robot Specified in the table Position switch and fan cables robot base to controller option on page 123 Customer cables option Handles communication with equipment fitted on the robot by the customer including databus communication low voltage signals and high voltage power supply protective ground...

Page 125: ...es below are only used for position switches Cabling for the cooling fans is specified in the table Cabling between robot base and controller cooling fans M2004 on page 124 Robot cable power 15 m 3HAC 11818 2 Robot cable power 22 m 3HAC 11818 3 Robot cable power 30 m 3HAC 11818 4 Cable Art no Cable Art no Robot cable signal shielded 7 m 3HAC 7998 1 Robot cable signal shielded 15 m 3HAC 7998 2 Robo...

Page 126: ...robot base to the inside of the cabinet and the additional cabling specified below is therefor not needed Cable Art no Connection point Distributing cable 3HAC 022708 001 Robot base R1 SW2 3 Harness cooling 7 m 3HAC 022723 001 Distributing cable R1 FAN SW2 3 Inside cabinet A43 X10 and A43 X11 Harness cooling 15 m 3HAC 022723 004 Distributing cable R1 FAN SW2 3 Inside cabinet A43 X10 and A43 X11 Ha...

Page 127: ...followed and documented Commissioning Never switch off the overpressure in motors and serial measurement compartment during cooling down of robot after it has been switched off When turning off an cleaning cell we recommend that the humid air inside a cell is ventilated out to avoid that the humid air is sucked into e g gearboxes due to the raised vacuum when cooled down Environmental conditions A...

Page 128: ...surement board cavity The robots are prepared with hoses to the motors and the serial measurement board cavity to enable pressurizing of them WARNING The robot must be pressurized also when it is switch off to avoid that the humid environmental air is sucked into the motors when cooling down Action Note Illustration 1 Connect a compressed air hose to air connector on robot base see illustration xx...

Page 129: ... xx0600002792 Recommendations NOTE To reduce the risk for corrosion due to condensation in gearboxes it is recommendable that the robot is running with high speed on each axes at least on one occasion each hour This is to lubricate the gearbox cavities WARNING Never switch off the overpressure in motors and serial measurement compartment during cooling down of robot after it has been switched off ...

Page 131: ...cluding intervals and refers to procedures for the activities Each procedure contains all information required to perform the activity e g required tools and materials The procedures are gathered in different sections divided according to the maintenance activity Safety information Before any service work is commenced it is extremely important that all safety information is observed There are gene...

Page 132: ...tivity to be carried out and the working conditions of the robot Calendar time specified in months regardless of whether the robot system is run or not Operating time specified in operating hours More frequent running of the robot 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 wi...

Page 133: ... axis 2 on page 139 Inspection Axis 3 gear oil level 12 mths 1 Inspection oil level gearbox axis 3 on page 141 Inspection Axis 4 gear oil level 12 mths Inspection oil level gearbox axis 4 on page 143 Inspection Axis 5 gear oil level 12 mths Inspection oil level gearbox axis 5 on page 146 Inspection Axis 6 gear oil level 12 mths 1 Inspection oil level gearbox axis 6 on page 149 Inspection Balancing...

Page 134: ...s 1 gearbox As specified by the SIS or typically 96 mths Replacement of gearbox axis 1 on page 383 Replacement Axis 2 gearbox As specified by the SIS or typically 96 mths Replacement of gearbox axis 2 on page 391 Replacement Axis 3 gearbox As specified by the SIS or typically 96 mths Replacement of gearbox axis 3 on page 399 Replacement Axis 4 gearbox 5 96 mths 2 Replacement of upper arm on page 2...

Page 135: ...cifies the required maintenance activities and intervals for common optional equipment Maintenance of other external equipment for the robot is detailed in separate documentation Activities and intervals Foundry Prime The table below specifies the required maintenance activities and intervals for Foundry Prime Maintenance activity Equipment Interval Detailed in section Inspection Signal lamp Inspe...

Page 136: ...f cable harness axes 1 6 on page 228 Replacement SMB Battery pack 36 mths Replacement of SMB battery on page 200 Replacement Axis 1 gearbox As specified by the SIS or typically 96 mths Replacement of gearbox axis 1 on page 383 Replacement Axis 2 gearbox As specified by the SIS or typically 96 mths Replacement of gearbox axis 2 on page 391 Replacement Axis 3 gearbox As specified by the SIS or typic...

Page 137: ...er 3000H or 6 mounths If the working conditions changes analyse again after 3000h or 6 mounths 3 The service time for gearboxes axes 4 and 5 is not calculated by the SIS see expected life in section Expected component life on page 136 4 It is recommended to replace the complete upper arm house instead of only replacing the gearbox 5 It is recommended to replace the complete wrist unit instead of o...

Page 138: ... cycle will result in differences in expected life 3 The robot is dimensioned for a life of 8 years 350 000 cycles per year in a normal spot welding application Depending on the actual application the life of individual gearboxes may vary greatly from this specification The Service Information System SIS integrated in the robot software keeps track of the gearbox life in each individual case and w...

Page 139: ... oil plugs are shown in the figure below xx0200000228 Required equipment A Gearbox axis 1 B Oil plug inspection C Motor axis 1 D Oil plug filling Equipment Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 177 Standard toolkit The cont...

Page 140: ...RNING Safety risks during work with gearbox oil on page 41 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Open the oil plug inspection Shown in the figure Location of gearbox on page 137 4 Required oil level max 10 mm below the oil plug hole 5 Add oil if required Art no is spe...

Page 141: ...C Oil plug draining D Vent hole gearbox axis 2 Equipment etc Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 177 Standard toolkit The contents are defined in section Standard toolkit on page 436 Other tools and procedures may be requ...

Page 142: ...pplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Open the oil plug filling Shown in the figure Location of gearbox on page 139 4 Measure the oil level at the oil plug filling Required oil level max 5 mm below the oil plug hole Shown in the figure Location of gearbox on page 139 5 Add oil if required Art no is specified in Required equipment on page ...

Page 143: ...r as shown in the figure below xx0200000230 Required equipment A Gearbox axis 3 B Oil plug filling C Oil plug draining Equipment etc Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 177 Standard toolkit The contents are defined in sec...

Page 144: ...ge 41 2 Move the robot to the calibration position Detailed in section Calibration scales and correct axis position on page 412 3 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 4 Open the oil plug filling Shown in the figure Location of gearbox on page 141 5 Required oil level max...

Page 145: ...l rights reserved 3 3 4 Inspection oil level gearbox axis 4 Location of gearbox The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure below xx0200000231 xx0600002962 A Oil plug filling B Oil plug draining A Oil plug filling inspection B Oil plug draining Continues on next page ...

Page 146: ...ired Action Note 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 2 Move the robot to the calibration position Shown in section Calibration scales and correct axis position on page 412 3 DANGER Turn off all electric power hydraulic and pneumatic pressure suppl...

Page 147: ...AC023082 001 Revision E Copyright 2004 2008 ABB All rights reserved 8 WARNING Do not mix the oil types If wrong oil is refilled the gearbox must be rinsed as detailed in section WARNING Mixed oils may cause severe damage to gearbox on page 42 Action Note Continued ...

Page 148: ...Location of gearbox The axis 5 gearbox is located in the wrist unit as shown in the figure below xx0200000232 xx0500002013 The figure above shows the wrist unit of IRB 6600 and IRB 6650 A Oil plug filling B Oil plug draining The figure above shows the wrist unit of IRB 6600ID and IRB 6650ID A Wrist unit axis 5 B Oil plug filling C Oil plugs draining Continues on next page ...

Page 149: ...uired Action Note 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Turn the wrist unit so ...

Page 150: ...3082 001 Revision E 148 Copyright 2004 2008 ABB All rights reserved 8 WARNING Do not mix the oil types If wrong oil is refilled the gearbox must be rinsed as detailed in section WARNING Mixed oils may cause severe damage to gearbox on page 42 Action Note Continued ...

Page 151: ...n of gearbox The axis 6 gearbox is located in the wrist unit as shown in the figure below xx0400001092 xx0500002017 The figure above shows the wrist unit of IRB 6600 and IRB 6650 A Gearbox axis 6 B Oil plug filling C Oil plug draining The figure above shows the wrist unit of IRB 6600ID and IRB 6650ID A Gearbox axis 6 B Oil plugs draining C Oil plug filling Continues on next page ...

Page 152: ...Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Action Note 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 2 DANGER Turn off all el...

Page 153: ...is 6 on page 199 6 Refit the oil plug filling Tightening torque 24 Nm 7 WARNING Do not mix the oil types If wrong oil is refilled the gearbox must be rinsed as detailed in section WARNING Mixed oils may cause severe damage to gearbox on page 42 Action Note If Then 1 More than 2 water in oil With more than 2 water content there is a risk for corrosion in the gearbox and reduced viscosity in the oil...

Page 154: ...8 ABB All rights reserved 2 Less than 2 water in oil normal replacement interval as specified by SIS or typically 96 months for gearbox axis 6 is required xx0600003156 A Water content in oil from gearbox axis 6 B Months or hours in operation If Then A B 2 6 12 18 24 30 3000 6000 9000 12000 15000 Continued ...

Page 155: ...arding dissonance damage leakage contamination lack of free space Inspection points balancing device The balancing device is located at the top rear of the frame as shown in the figure below The figure also shows the inspection points further detailed in the instructions xx0300000580 A Balancing device B Piston rod inside C Shaft including securing screw D Ear bearing and o rings E Label with arti...

Page 156: ...84 001 Puller for separator 4552 2 Bahco Used for removing the spherical roller bearings Separator 4551 C Bahco Used for removing the spherical roller bearings Standard toolkit 3HAC 15571 1 The contents are defined in section Standard toolkit on page 436 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include ref...

Page 157: ...ndicate worn plain bearings internal contamination or insuffi cient lubrication perform maintenance according to given instructions in Maintenance kit complete Art no for the kit and the documentation are specified in section Required equipment on page 154 Check for dissonance from If dissonance is detected Check for damage on If damage is detected 1 the piston rod part of the piston rod that is v...

Page 158: ...from the ear Leaks at the o rings however are not acceptable and must be attended to immediately in order to avoid any damage to the bearing Check the o rings in the front ear of the balancing device for leaks as shown and detailed below xx0500002506 A Shaft B O ring C Sealing spacer D Sealing ring in sealing spacer E Correct way out for excessive grease from inside the front ear F Incorrect leaka...

Page 159: ...gs and seals already assembled with sealing spacers and sealing rings Art no for the kit is specified in Required equipment on page 154 The replacement of the complete bearing is also detailed in section Replacement of spherical roller bearing balancing device on page 317 Incorrect leakage is shown in the previous figure Action Note Action 1 DANGER Turn off all electric power hydraulic and pneumat...

Page 160: ...the harness that runs undivided from axis 1 to axis 6 xx0200000097 Required equipment A Lower arm B Cables attached with velcro straps and mounting plate C Connectors at cable harness division point R2 M5 6 D Connectors at base Equipment etc Art no Note Standard toolkit 3HAC 15571 1 The contents are defined in section Standard toolkit on page 436 Other tools and procedures may be required See refe...

Page 161: ... at the division point and at the base Shown in the figure Location of cable harness axes 1 6 on page 158 4 note If the manipulator is used in a Foundry Prime application check the cables for cracks in insulation 5 Check that velcro straps and the mounting plate are properly attached to the frame Also check the cabling leading into the lower arm Make sure it is attached by the straps and not damag...

Page 162: ...igure below Note The cable harness is also available without the division point R2 M5 6 Except for the connectors at the division point the rest of the inspection points are the same for the harness that runs undivided from axis 1 to axis 6 xx0200000234 A Connectors at cable harness division point R2 M5 6 B Cable attachment rear of upper arm C Cable attachment upper arm tube Continued Continues on...

Page 163: ... detect wear and damage 3 Check the attachments at the rear of the upper arm and in the upper arm tube Check the connectors at the cable harness division Make sure the attachment plate is not bent or in other way damaged Shown in the figure Location of cabling axes 5 6 on page 160 4 note If the manipulator is used in a Foundry Prime application check the cables for cracks in insulation Shown in th...

Page 164: ...arning label High temperature 3HAC4431 1 4 pcs B Warning sign symbol of a flash located on motor cover 3HAC1589 1 5 pcs C Instruction label Safety instructions 3HAC4591 1 D Warning label Brake release 3HAC9508 1 I Warning label tools are not allowed around the balancing device during operation 3HAC020611 001 J Warning label Shut off power 3HAC17804 1 Information labels at gearboxes and at robot ba...

Page 165: ...l labels specified in the two previous figures The labels are in english Label set oil labels 3HAC021670 002 Includes only the oil labels at the gearboxes and at the robot base Are fitted to the robot if the gearboxes include Kyodo Yushi TMO 150 Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air p...

Page 166: ...axis 1 Location of mechanical stop The mechanical stop axis 1 is located at the base as shown in the figure below xx0200000151 Required equipment A Mechanical stop stop pin Equipment etc Art no Note Mechanical stop ax 1 3HAC12812 2 To be replaced when damaged Standard toolkit The contents are defined in section Standard toolkit on page 436 Continues on next page ...

Page 167: ...umatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Inspect the mechanical stop axis 1 Shown in the figure Location of mechanical stop on page 164 3 Make sure the mechanical stop can move in both directions 4 If the stop pin is bent or damaged it must be replaced Note The expected life of gearboxes can be reduced as a result of collis...

Page 168: ... Copyright 2004 2008 ABB All rights reserved 3 3 11 Inspection additional mechanical stops Location of mechanical stops The figure below shows the location of the additional mechanical stops on axes 1 2 and 3 IRB 7600 shown xx0200000150 A Additional stop B Fixed stop Continues on next page ...

Page 169: ...nical stop axis 1 Equipment etc Art no Note Mechanical stop axis 1 3HAC11076 1 Limits the robot working range by 7 5 Mechanical stop axis 1 3HAC11076 2 Limits the robot working range by 15 Mechanical stop axis 2 3HAC020885 1 Mechanical stop axis 3 3HAC13128 1 Standard toolkit The contents are defined in section Standard toolkit on page 436 Continued Continues on next page ...

Page 170: ...ies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Check the additional stops on axes 1 2 and 3for damage Shown in the figure Location of mechanical stops on page 166 3 Make sure the stops are properly attached Correct tightening torque mechanical stop axis 1 120 Nm 4 If any damage is detected the mechanical stops must be replaced Correct attachment scre...

Page 171: ...d xx0300000040 Required equipment A damper must be replaced if damaged A Damper axis 2 2 pcs B Damper axis 3 2 pcs C Damper axis 4 1 pc D Damper axis 5 IRB 6600 IRB 6650 2 pcs IRB 6600ID IRB 6650ID 4 pcs Equipment Spare part art no Note Damper axis 2 3HAC12991 1 Damper axis 3 3HAC12320 1 Damper axis 4 3HAC13564 1 Damper axis 5 3HAB4337 2 IRB 6600 and IRB 6650 Damper 1 axis 5 2 pcs 3HAC021325 001 I...

Page 172: ... art no Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Check all dampers for damage and for cracks or existing impressions larger than 1 mm To inspect the damper axis 4 remove the two covers on top of the upper arm Shown in the figure Location of dampers on pa...

Page 173: ...n Instal lation of position switches option on page 111 Standard toolkit The contents are defined in section Standard toolkit on page 436 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure suppl...

Page 174: ...n axis 1 Check that the three sheets are in position and not damaged Deformation can result in rubbing against the cams Check that the area inside of the sheets is clean enough not to interfere the function of the position switch 6 If any damage is detected the position switch must be replaced Art no is specified in Required equipment on page 171 Action Note Continued ...

Page 175: ...p The signal lamp is located as shown in the figure below Note that the position can differ depending on how the customer harness for axis 4 6 is mounted See assembly drawing on the current harness for alternative positioning xx0200000240 A Signal lamp B Clamp C Position for cable gland D Warning label on motor cover E Warning sign on motor cover Continues on next page ...

Page 176: ...chment screw M6x8 quality 8 A2F 2 pcs Equipment etc Art no Note Signal lamp 3HAC10830 1 To be replaced in case of detected damage Standard toolkit The contents are defined in section Standard toolkit on page 436 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Continued Con...

Page 177: ...ration MOTORS ON 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 If the lamp is not lit trace the fault by Checking whether the signal lamp is broken If so replace it Checking the cable connections Measuring the voltage in connectors motor axis 3 24V Checking the cabling Replac...

Page 178: ...uge Cut off valve Action Note Illustration 1 Apply compressed air to the air connector on robot base and raise the pressure with the knob until the correct value is shown on the pressure gauge Recommended pressure 0 2 0 1 0 bar xx0600002794 A Air connection 2 Close the shut off valve It should take at least 5 sec for the pressure to reach 0 bar 3 If the time is shorter that 5 sec IF Yes Localize t...

Page 179: ...ities 3 4 1 Type of oil in gearboxes Location of gearboxes The figure show the location of the gearboxes on the robot xx0800000247 xx0500002226 A Axis 1 gearbox B Axis 2 gearbox C Axis 3 gearbox D Axis 4 gearbox E Axis 5 gearbox F Axis 6 gearbox E Axis 5 gearbox IRB 6600ID 6650ID F Axis 6 gearbox IRB 6600ID 6650ID A B C D F E Continues on next page ...

Page 180: ...ated next to oil plugs of each gearbox show which type of oil it contains All gearboxes must have the correct label clearly visible xx0800000230 xx0800000234 Gearbox Type of oil Art no Amount Axis 1 Kyodo Yushi TMO 150 3HAC032140 001 7 300 ml Axis 2 Kyodo Yushi TMO 150 3HAC032140 001 5 800 ml Axis 3 Kyodo Yushi TMO 150 3HAC032140 001 2 500 ml Axis 4 Mobilgear 600 XP320 11712016 604 8 100 ml Axis 5...

Page 181: ...tly used types of oil UL Liftingof robot Warning Axis 1 Kyodo Yushi TMO 150 Axis 2 Kyodo Yushi TMO 150 Axis 3 Kyodo Yushi TMO 150 Axis 6 Kyodo Yushi TMO 150 Axis 4 Mobilgear 600 XP320 Axis 5 Mobilgear 600 XP320 Bal device Optimol longtime PD 0 3HAC021505 002 UL Liftingof robot Warning Axis 1 Kyodo Yushi TMO 150 Axis 2 Kyodo Yushi TMO 150 Axis 3 Kyodo Yushi TMO 150 Axis 6 Mobilgear 600 XP320 Axis 4...

Page 182: ... Always use the oil recommended by the manufacturer Rinsing gearbox Depending on which types of oil are mixed and which type of oil shall be filled in the gearbox after rinsing use the appropiate procedure The same applies if the type of oil shall be changed in the gearbox NOTE What is said about Kyodo Yushi TMO 150 also applies to Shell Tivela S 150 What is said about Mobilgear 600 XP320 also app...

Page 183: ...rved Equipment Equipment Art no Note Label set See Spare Parts Includes small labels to each gearbox and the complete label to be fitted at the robot base NOTE The correct labels must be fitted to the robot in case of changing of oil types Oil change equipment 3HAC021745 001 Includes pump with outlet pipe Continued ...

Page 184: ...of the robot base not shown in the figure xx0200000228 Required equipment A Gearbox axis 1 B Oil plug inspection C Motor axis 1 D Oil plug filling Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 7 300 ml Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 177 Oil ...

Page 185: ... 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 3 Remove the rear cover on the base by unscrewing its attachment screws 4 Pull the oil draining hose out of the rear of the base xx0200000237 The hose is located beneath the base as shown in the figure with a v...

Page 186: ...s several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 3 Open the oil plug filling Shown in the figure Location of oil plugs on page 182 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in section ...

Page 187: ...C Oil plug draining D Vent hole gearbox axis 2 Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 5 800 ml Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 177 Oil collecting vessel Capacity 6 000 ml Oil exchange equipment 3HAC021745 001 The contents are defined i...

Page 188: ...essure to motors and SMB 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 3 Remove the plug of the vent hole Shown in the figure Location of oil plugs on page 185 4 Remove the oil plug draining and drain the gearbox oil using a hose with nipple and an oil coll...

Page 189: ... Location of oil plugs on page 185 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in section Inspection oil level gearbox axis 2 on page 139 Art no and total amount are specified in Required equipment on page 185 5 WARNING Do not mix the oil types If wrong oil is refilled the gearbox must b...

Page 190: ...uired equipment A Gearbox axis 3 B Oil plug filling C Oil plug draining Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 2 500 ml Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 177 Oil exchange equipment 3HAC021745 001 The contents are defined in section Speci...

Page 191: ...ssure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 3 Remove the oil plug draining and drain the gearbox oil using a hose with nipple and an oil collecting ves...

Page 192: ...ase observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 3 Remove the oil plug filling Shown in the figure Location of gearbox on page 188 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in section Inspection oil level gearbox axis 3 on page ...

Page 193: ...equired equipment A Oil plug filling B Oil plug draining Equipment etc Art no Amount Note Lubricating oil 11712016 604 8 100 ml Mobilgear 600 XP320 This is a common oil that can be replaced with an equivalent oil from another manufacturer Oil exchange equipment 3HAC 021745 001 The contents are defined in section Special tools on page 437 Oil collecting vessel Capacity 9 000 ml Standard toolkit The...

Page 194: ...obot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 4 Drain the oil from the gearbox into an vessel by opening theoil plug draining Remove the oil plug filling in order to drain the ...

Page 195: ... oil plug filling The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in section Inspection oil level gearbox axis 4 on page 143 Shown in the figure Location of gearbox on page 191 Art no and total amount are specified in Required equipment on page 191 4 WARNING Do not mix the oil types If wrong oil is refilled the gearbox must be rinse...

Page 196: ...Oil change gearbox axis 5 Location of gearbox The axis 5 gearbox is located in the wrist unit as shown in the figure below xx0200000232 xx0500002013 Wrist unit of IRB 6600 and IRB 6650 A Oil plug filling B Oil plug draining A Wrist unit of IRB 6600ID and IRB 6650ID B Oil plug filling C Oil plug draining Continues on next page ...

Page 197: ...37 Oil collecting vessel Capacity 7 000 ml Standard toolkit The contents are defined in section Standard toolkit on page 436 Action Note 1 Run axis 5 to a position where the oil plug draining is facing downwards 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 WARNING Handling g...

Page 198: ... with gearbox oil on page 41 3 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 4 Refill the gearbox with lubricating oil through the oil plug filling The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in section Inspect...

Page 199: ...axis 6 gearbox is located in the center of the wrist unit as shown in the figure below xx0400001092 xx0500002017 The figure above shows the wrist unit of IRB 6600 and IRB 6650 A Gearbox axis 6 B Oil plug filling C Oil plug draining The figure above shows the wrist unit of IRB 6600ID and IRB 6650ID A Gearbox axis 6 B Oil plug draining C Oil plug filling Continues on next page ...

Page 200: ...ge 437 Oil collecting vessel Vessel capacity 500 ml IRB 6600 6650 7 000 ml IRB 6600ID 6650ID Standard toolkit The contents are defined in section Standard toolkit on page 436 Action Note 1 IRB 6600 6650 Run the robot to a position where the oil plug draining of axis 6 gearbox is facing downwards and the oil plug filling is facing upwards IRB 6600ID 6650ID Run the robot to a position where the oil ...

Page 201: ...safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 3 Remove the oil plug filling Shown in the figure Location of gearbox on page 197 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in section Inspection...

Page 202: ...e below details how to remove the SMB battery A SMB battery cover B SMB battery pack C Battery cable Equipment etc Spare part no Note Battery pack 3HAC 16831 1 Battery includes protection circuits Replace it only with given spare part no or an ABB approved eqvivalent Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Circuit Diagram Se...

Page 203: ...ts attachment screws Shown in the figure Location of SMB battery on page 200 5 Pull out the battery and disconnect the battery cable Shown in the figure Location of SMB battery on page 200 6 Remove the SMB battery Battery includes protection circuits Replace it only with the specified spare part or with an ABB approved eqvivalent Shown in the figure Location of SMB battery on page 200 Action Note ...

Page 204: ...re Location of SMB battery on page 200 4 Secure the SMB battery cover with its attachment screws Shown in the figure Location of SMB battery on page 200 5 Update the revolution counter Detailed in chapter Calibration section Updating revolution counters on page 415 6 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER Fir...

Page 205: ...ller bearing is located at the front ear of the balancing device as shown in the figure below Note The balancing device must be mounted on the robot when lubricating the bearing xx0200000109 Required equipment A Ear spherical roller bearing located inside B Lubrication nipple or securing screw C Sealing spacer D Hole through which the shaft is pressed Equipment etc Art no Note Grease 3HAA 1001 294...

Page 206: ...er bearing through the lubrication nipple in the ear with grease Fill until excessive grease is forced out between the shaft and the sealing spacer Art no and amount is specified in Required equipment on page 203 Shown in the figure Location of bearing on page 203 The balancing device must be mounted on the robot when lubricating the bearing 4 Remove the lubrication nipple and refit the securing s...

Page 207: ...n View from above xx0600002866 Required equipment A Plastic ring bearing cover A Equipment Art no Note Brush Rust preventive 3HAC026621 001 Equivalent Mercasol 3106 Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Other tools and procedures may be required See references to these procedures in the step by step instructions below Thes...

Page 208: ...axis 1 Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Remove the plastic ring xx0600002866 A plastic ring 3 Wipe the surface under the ring 4 Apply the rust preventive on the bearing with the brush xx0600002867 A bearing 5 Refit the plastic ring A A Co...

Page 209: ...ails how to grease the bearing axis 1 A Plastic cover B Plastic ring Equipment Art no Note Brush Rust preventive 3HAC026621 001 Equivalent Mercasol 3106 Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures...

Page 210: ...umatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Remove the plastic cover at the rear end of the upper arm xx0600002872 A plastic cover B plastic ring 4 Remove the plastic ring that covers the bearing xx0600002871 A plastic ring 5 Wipe the surface under the plastic ring Action Note Illustration Continued Continues on next page ...

Page 211: ...dry Prime 209 3HAC023082 001 Revision E Copyright 2004 2008 ABB All rights reserved 6 Apply the rust preventive on the bearing with the brush xx0600002868 A bearing axis 4 B plastic ring 7 Refit the plasitc ring and cover Action Note Illustration Continued ...

Page 212: ... below details how to grease the bearing in the wrist A Bearing B Cable bracket C Cover Equipment Art no Note Brush Rust preventive 3HAC026621 001 Equivalent Mercasol 3106 Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Other tools and procedures may be required See references to these procedures in the step by step instructions bel...

Page 213: ...not turn off the air pressure to motors and SMB 3 Dismantle the air hose from motor axis 6 4 Tighten the hose clamp on motor axis 6 and remove the air hose 5 Remove thew cover according to the illustration xx0600002864 A cover 6 Apply the rust preventive on the bearing and cable bracket with the brush See Location of bearing on page 210 7 Refit the cover 8 Perform leakdown test See Inspection of a...

Page 214: ...ction specifies how to clean the robot Periodicity The periodicity of cleaning the robot varies a great deal depending on the actual environment and function of the robot Clean a contamined robot as required Special points Special points to be observed are shown in the figure below xx0200000239 A Spiral cables to motor 6 B Inside of upper arm tube C Rear of upper arm tube D Inside of lower arm E I...

Page 215: ...th a high pressure cleaner onto the sealing cup at the bottom of the motor 6 spiral cable item A in the figure Special points Although the robot is watertight avoid spraying connectors and similar items with a high pressure cleaner Foundry versions In working environments e g foundries where the robot may be exposed to fluids that dry to make a crusty surface e g release agents clean the cable har...

Page 216: ...values are adequate and suitable for your application in your production environment Recommendations on how to define these are given in SIS system parameters on page 217 Maintenance intervals recommended by ABB are specified in section Maintenance schedule on page 131 3 Enter these parameters in the system How to do this is detailed in Setting the SIS parameters on page 219 4 Run the robot in nor...

Page 217: ... 2 gearbox service interval Gearbox 3 operation time counter based on percentage of the axis 3 gearbox service interval Gearbox 6 operation time counter based on percentage of the axis 6 gearbox service interval Counters are reset when maintenance has been performed The counter status is displayed after running the service routine for maintenance Status OK indicates that no service interval limit ...

Page 218: ...tine When resetting the counter variables are reset The variables are described in section Exporting the SIS data on page 222 Service interval exceeded When the service time has been exceeded for the selection made an error message Service interval exceeded is displayed No data available When no data is available for the selection made a message No data available is displayed when trying to displa...

Page 219: ...ce interval E g by setting the value 20 000 the SIS will save this as the nominal time for activating the alarm not counting the percentage described below Operation time warning A percentage of the Operation time limit specified above E g by setting the value 90 the SIS will alert the operator 18 000 hours after an operation time Reset was made the last time Calendar time limit service level The ...

Page 220: ...ing the value 90 the SIS will alert the operator after 90 of the expected service interval of each gearbox The robot system automatically detects and stores all required variables to calculate the expected service interval of each gearbox This is done by extrapolating data from earlier operation into a function of time using a formula including input and output torque gearbox spindle speed other v...

Page 221: ...the SIS system is to function properly a number of parameters must be set This is detailed below Procedure M2000 This is an instruction of how to enter SIS parameters to the M2000 robot system Action Note 1 Open System parameters using the TPU Detailed in the User s Guide 2 Go to System parameters Manipulator types 2 xx0200000045 en0200000046 Continues on next page ...

Page 222: ...0 SIS parameters and press Enter en0200000047 xx0100000200 4 Select the required system The parameter list is displayed en0200000048 en0200000049 5 Select the required parameters by stepping up and down through the parameter list Available parameters are described in section SIS system parameters on page 217 Action Note Continued ...

Page 223: ...hown is detailed in section Setting the SIS parameters on page 219 Operation time Service Message Service is due X production hours since last service The manually set operation time limit has expired How to set the limit is detailed in section Setting the SIS parameters on page 219 Proceed with the required service as detailed in chapter Repair on page 223 or chapter Maintenance on page 129 depen...

Page 224: ...hich the supervision was started reset last time sisCalendarT sec Calendar time The number of hours since start last reset sisTotRunT sec Operation time Total number of operation hours since the system was started Corresponds to the operating time counter on the control cabinet sisRunT sec Operation time The number of operation hours since start last reset of the operation time counter Corresponds...

Page 225: ...hered in sections divided according to the component location on the robot Required equipment All equipment required to perform a specific repair activity is listed together with the current procedure The equipment is also gathered in different lists in the Product manual reference information Safety information Before any service work is commenced it is extremely important that all safety informa...

Page 226: ...ay be required which are included in the leakdown tester kit Art no is specified above 3 Apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer Recommended value 0 2 0 25 bar 20 25 kPa 4 Disconnect the compressed air supply 5 Wait for approx 8 10 minutes No pressure loss must be detected If the compressed air is signifi cantly colder or warmer t...

Page 227: ...able the roller elements to adjust to the correct position against the race flange 1 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 pre tensioning sequence 2 Make sure the bearing is properly aligned as this will directly affect the life...

Page 228: ... to lubricate the seals Action Note 1 Check 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 2 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced as it may result in future leakage 3 Lubricate the seal with grease just before fitting Not too early as t...

Page 229: ...ver the surface preferably with a brush 4 Tighten the screws evenly when fastening the flange joint Action Action Note 1 Ensure that the correct o ring size is used 2 Check the o ring for surface defects burrs shape accuracy etc Defective o rings may not be used 3 Check the o ring grooves The grooves must be geometrically correct and free from pores and contamination Defective o rings may not be u...

Page 230: ... axis 6 In case the cabling has a division point at the upper arm it should instead be replaced as detailed in sections Replacement of cable harness axes 1 4 on page 240 Replacement of cable harness axes 5 6 on page 249 Location of cable harness The cable harness of axes 1 6 is run throughout the robot as shown in the figure below xx0500002176 A Rear cover plate B Cable guide inside the frame C Ca...

Page 231: ... 3HAC026621 001 Equivalent Mercasol 3106 Gasket 3HAC3537 1 motor axes 1 5 Gasket 3HAC12877 1 motor axis 6 Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Circuit diagram See chapter Circuit diagram in the Product manual reference information A Cable bracket wrist unit B Cable bracket upper arm tube C Cable attachment rear Action Not...

Page 232: ...screws Two of the attachment screws are visibly located at the rear attachment and the third is located at the bottom of the cable bracket in the center Shown in the figure Cable brackets of the upper arm on page 229 xx0200000254 B Attachment screws rear of cable bracket 2 pcs C Attachment screw bottom of cable bracket 1 pc 7 Pick out the cabling from motor axis 6 8 Loosen the cable bracket in the...

Page 233: ...nnect the earth cable beneath 3 Disconnect connectors R1 MP and R1 SMB Shown in the figure Location of cable harness on page 228 4 Pull the cable and connectors up through the cable guide in the center of the frame 5 Disconnect all connectors at motor 1 and motor 2 6 Open the SMB cover carefully The cable between the battery and the SMB unit may stay connected in order to avoid an update of the re...

Page 234: ...removing the attachment screws and the velcro strap D Note Different robot versions are fitted with different versions of the attachment plate When replacing the cable harness make sure the correct one is used to avoid cable failure xx0300000560 A Cable gland B Attachment screws cable gland C Attachment plate D Velcro strap 9 Remove the cable gland securing the cables inside the lower arm Action N...

Page 235: ... On Foundry Prime robots Apply rust preventive around all dismantled covers and attachment screws with a brush See Required equipment on page 229 2 Pull the cable and connectors down through the cable guide in the center of the frame Make sure the cables are not twisted with each other or with eventual customer harnesses Make a note of the correct positions of the connectors 3 Reconnect connectors...

Page 236: ...234 Copyright 2004 2008 ABB All rights reserved 6 Reconnect all connectors at motor 1 and motor 2 7 NOTE On Foundry Prime robots When dismantling the cables from the motors the gasket must be replaced See Required equipment on page 229 Action Note Continued Continues on next page ...

Page 237: ...te C to the cable gland with its two attachment screws using locking liquid Refit the velcro strap D Note Different robot versions are fitted with different versions of the attachment plate Make sure the correct one is used to avoid cable failure Locking liquid is specified in Required equipment on page 229 xx0300000560 A Cable gland B Attachment screws cable gland C Attachment plate D Velcro stra...

Page 238: ...onnect R1 G if it has been disconnected xx0200000118 10 Secure the SMB cover with its attachment screws 11 WARNING Before continuing any service work please observe the safety information in section WARNING The brake release buttons may be jammed after service work on page 39 12 Pull the cable harness through the lower arm 13 Refit the cable gland securing the cables inside the lower arm xx0100000...

Page 239: ...insert the cable harness from the rear into the upper arm 18 Connect the two connectors inside the upper arm tube R3 FB5 and R3 MP5 and secure the cable bracket with the two attachment screws to the tube Shown in the figure Cable brackets of the upper arm on page 229 19 Place the cabling to motor axis 6 correctly on the upper arm and gently pull the connectors through the hole on top of wrist unit...

Page 240: ... B Attachment screws rear of cable bracket C Attachment screw bottom of cable bracket 21 Reconnect the connectors to motor axis 6 and refit the motor cover 22 Refit the cover upper arm B and the cover wrist unit A Make sure the cabling is placed correctly when refitting the covers and does not get jammed xx0200000214 23 If any cable straps have been removed refit them to the harness 24 Refit the c...

Page 241: ... mm Fix the strap by wrapping it two turns around the largest cable before wrapping around the complete harness xx0500002320 26 If the connection between the SMB battery and the SMB unit has been broken the revolution counters must now be updated Detailed in section Updating revolution counters on page 415 27 DANGER Make sure all safety requirements are met when performing the first test run These...

Page 242: ... axis 4 If the robot is equipped with an undivided cable harness it is instead replaced as detailed in section Replacement of cable harness axes 1 6 on page 228 Location of cable harness The cable harness for axes 1 4 is run throughout the base frame and lower arm as shown in the figure below xx0300000561 A Rear cover plate B Attachment point for earth lug C Connector R1 MP D Connector R1 SMB E Ca...

Page 243: ...ust be fitted to the lower arm and a velcro strap for the harness going up inside the lower arm Cable harness axes 1 4 IRB 6650 6650ID 3HAC 025504 001 Includes a cable protection that must be fitted to the lower arm and a velcro strap for the harness going up inside the lower arm Locking liquid Loctite 638 Used to secure the attachment screws for the attachment plate inside the frame Standard tool...

Page 244: ...attachment screws Shown in the figure Location of cable harness on page 240 4 Disconnect the earth cable Attachment point is shown in the figure Location of cable harness on page 240 5 Disconnect connectors R1 MP and R1 SMB Attachment points are shown in the figure Location of cable harness on page 240 6 Pull the cable and connectors up through the cable guide in the center of the frame 7 Disconne...

Page 245: ... gland A by removing the four attachment screws from inside the SMB recess B the attachment plate C by removing the attachment screws and the velcro strap D Note Different robot versions are fitted with different versions of the attachment plate When replacing the cable harness make sure the correct one is used to avoid cable failure xx0300000560 A Cable gland B Attachment screws cable gland C Att...

Page 246: ... at the cable division point Shown in the figure Location of cable harness on page 240 15 Disconnect all connectors at motor 3 and motor 4 Specified and shown in the figure Location of cable harness on page 240 16 Gently pull the cable harness out Action Note Illustration Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundr...

Page 247: ...1 MP and R1 SMB at the rear cover plate Make a note of the correct positions of the connectors Attachment point is shown in the figure Location of cable harness on page 240 5 Reconnect the earth cable Attachment point is shown in the figure Location of cable harness on page 240 6 Refit the rear cover plate to the robot with its attachment screws Shown in the figure Location of cable harness on pag...

Page 248: ...ent robot versions are fitted with different versions of the attachment plate Make sure the correct one is used to avoid cable failure Locking liquid is specified in Required equipment on page 241 xx0300000560 A Cable gland B Attachment screws cable gland C Attachment plate D Velcro strap 9 Reconnect connectors R2 SMB R1 SMB1 3 R1 SMB4 6 to the SMB unit Reconnect X8 X9 and X10 to the brake release...

Page 249: ...ecuring the cables to the arm house Make sure not to twist the harness xx0100000143 15 Reconnect all connectors at motor 3 and motor 4 Specified and shown in the figure Location of cable harness on page 240 16 Reconnect the connector R2 M5 6 gently at the cable division point Be careful not to bend the attachment plate when fastening the screws Shown in the figure Location of cable harness on page...

Page 250: ...wrapping around the complete harness Both the protection and the strap are included in the spare part no specified in Required equipment on page 241 xx0500002320 19 If the connection between the SMB battery and the SMB unit has been broken the revolution counters must now be updated Detailed in the Calibration chapter section Updating revolution counters on page 415 20 DANGER Make sure all safety ...

Page 251: ...red equipment A Cable bracket wrist unit B Cable bracket upper arm tube C Connectors at motor axis 5 R4 FB5 and R4 MP5 D Connectors in upper arm tube R3 FB5 and R3 MP5 F Cable attachment rear G Connector at cable harness division point R2 M5 6 H Connectors at motor axis 6 R3 FB6 and R3 MP6 Equipment etc Spare part no Note Cable harness axes 5 6 3HAC 14140 1 Standard toolkit The contents are define...

Page 252: ...s below These procedures include references to the tools required Circuit Diagram See chapter Circuit diagram in the Product manual reference informa tion Equipment etc Spare part no Note Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Remove the cover ...

Page 253: ... out the cabling from motor axis 6 7 Loosen the cable bracket in the upper arm tube by undoing the two screws on top of the tube Shown in the figure Location of cable harness ax 5 6 on page 249 8 Disconnect the two connectors R3 FB5 and R3 MP5 in the tube Shown in the figure Location of cable harness ax 5 6 on page 249 9 Remove eventual cable straps from the harness 10 Remove the cable attachment ...

Page 254: ...e 249 xx0200000254 B Attachment screws rear of cable bracket C Attachment screw bottom of cable bracket 6 Reconnect the connectors to motor axis 6 and refit the motor cover 7 Refit the cover upper arm and the cover wrist unit Make sure the cabling is placed correctly when refitting the covers and does not get jammed xx0200000214 A cover wrist unit B cover upper arm tube 8 If any cable straps have ...

Page 255: ...5 6 is run inside the upper arm as shown in the figure below xx0500001896 Required equipment A Cover upper arm tube B Hood upper arm housing C Attachment screws and washers 3 pcs hood upper arm housing D Connectors at motor axis 5 R3 FB5 and R3 MP5 E Connectors at motor axis 6 R3 FB6 and R3 MP6 F Connector at cable harness division point R2 M5 6 Equipment Spare part no Art no Note Cable harness ax...

Page 256: ...412 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Remove the process cabling from the upper arm if any How to remove the DressPack harness from the upper arm wrist unit is detailed in the Product manual SpotPack DressPack OrangeLine 4 Remove the cover from the upper arm tube ...

Page 257: ... removing the three attachment screws B Leave the cabling fitted to the bracket xx0500001905 8 Loosen the cable clamp C inside of the upper arm tube xx0500001904 9 Remove all velcro straps and cable ties holding the cabling inside the wrist unit 10 Pull out the cabling from the wrist unit and the upper arm tube Be careful not to damage the connectors Action Note Illustration Continued Continues on...

Page 258: ... arm A Location inside the wrist unit where to strap the cabling next to the axis 5 motor Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Make sure all the cable clamps and brackets are attached properly to the new cable harness Spare part no is specifi...

Page 259: ... cable clamps should be positioned approximately 1 m from the connector R2 M5 6 Note Adjust the clamps to make the bend of the fifth turn equal with the others creating a symmetrical spiral xx0500001909 A Attachment point for the power cable R3 MP B Attachment point for the signal cable R3 FB 7 Grease the cabling with cable grease Art no is specified in Required equipment on page 253 8 Refit the c...

Page 260: ...3082 001 Revision E 258 Copyright 2004 2008 ABB All rights reserved 11 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 38 Action Note Illustration Continued ...

Page 261: ...3 MP5 Equipment Spare part no Note Cable harness axis 5 3HAC 14139 1 Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Action Note 1 DANGER Turn off all electric...

Page 262: ...bots Do not turn off the air pressure to motors and SMB 2 Reconnect all connectors at motor axis 5 3 Refit the cable gland cover at the cable exit with its two attachment screws 4 Refit the cover of motor axis 5 5 Refit the complete wrist unit Detailed in section IRB 6600 6650 Refitting wrist unit on page 279 IRB 6600ID 6650ID Refitting wrist unit on page 284 6 Recalibrate the robot Calibration is...

Page 263: ... is defined as the complete robot except for the base and gearbox axis 1 This is shown in the figure below A more detailed view of the component and its position may be found in chapter Exploded views on page 477 in part 2 of the Product manual xx0200000224 A Upper arm B Lower arm C Frame D Gearbox axis 1 E Base attachment screws F Balancing device G Block for calibration H Motor axis 1 Continues ...

Page 264: ... lengths Notice that longer guide pins than 140 mm will not be possible to remove from the frame because lack of space after refitting Hoisting block Used to adjust the length of the lifting chain Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Other tools and procedures may be required See references to these procedures in the step...

Page 265: ...e lift is described in the enclosed instruction to the lifting device Follow the instructions before lifting 8 Remove the block for calibration from the bottom of the frame Shown in the figure Location of arm system on page 261 9 Unfasten the arm system from the base by unscrewing its 24attachment screws Shown in the figure Location of arm system on page 261 1 0 Fit the two guide pins in two oppos...

Page 266: ...e arm system weighs 1250 kg All lifting equipment used must be sized accordingly 4 Lift the complete arm system and move it at very low speed making sure it does not tip Make sure the lift is done completely level Adjust the length of the chains as detailed in enclosed instruction or with a hoisting block Make sure all the hooks and attachments stay in the correct position while lifting the robot ...

Page 267: ...screws and washers Shown in the figure Location of arm system on page 261 M12 x 70 tightening torque 115 Nm Reused screws may be used providing they are lubricated as detailed in section Screw joints on page 432 before fitting 9 Refit the block for calibrationat the bottom of the frame Shown in the figure Location of arm system on page 261 10 Refit the motor axis 1 Detailed in section Refitting mo...

Page 268: ...on E 266 Copyright 2004 2008 ABB All rights reserved 15 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 38 Action Note Illustration Continued ...

Page 269: ...ndry Prime 267 3HAC023082 001 Revision E Copyright 2004 2008 ABB All rights reserved 4 3 7 Replacement of air nipple and hose Foundry Prime Location The illustration below shows the routing of the Foundry Prime air hose xx0500002176 Continues on next page ...

Page 270: ...1D 1090 1E 310 1F 35 1G 250 1H 540 1K 4020 1L 195 1M 40 1N 40 1P 1605 1Q 100 for option 2 8m 175kg 350 1R 149 for option 2 8m 175kg 1740 1S 570 Equipment Art no Pos in illustration Elbow fitting 100 6 Rubber clamp 3HAC026523 001 5 T plugg connector 3HAC026515 001 4 Y plugg connector 3HAC026514 001 3 Bulkhead plugg connector 3HAC026513 001 2 Hose 3HAC026526 001 1 Cable strap 21662055 3 8 Continued ...

Page 271: ...g procedures correspond to the illustration in Hose lenghts on page 268 and the table in Required equipment on page 268 Action Note Illustration DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Localise the damaged hose or air connector and Continue to replace the damaged hose route the hose according to the following illustrations Connection at base xx0600...

Page 272: ... 7 Replacement of air nipple and hose Foundry Prime 3HAC023082 001 Revision E 270 Copyright 2004 2008 ABB All rights reserved Balancing device xx0600003397 Action Note Illustration Continued Continues on next page ...

Page 273: ...ement of air nipple and hose Foundry Prime 271 3HAC023082 001 Revision E Copyright 2004 2008 ABB All rights reserved Axis 1 2 xx0600003044 xx0600003162 xx0600003045 Action Note Illustration Continued Continues on next page ...

Page 274: ...dry Prime 3HAC023082 001 Revision E 272 Copyright 2004 2008 ABB All rights reserved Upper arm housing xx0600003046 xx0600003047 Tube shaft xx0600003163 1P Lay the hose in a spiral in the tube shaft Action Note Illustration Continued Continues on next page ...

Page 275: ...4 Repair 4 3 7 Replacement of air nipple and hose Foundry Prime 273 3HAC023082 001 Revision E Copyright 2004 2008 ABB All rights reserved Wrist xx0600003097 Action Note Illustration Continued ...

Page 276: ...200000217 Required equipment A Turning disk B Wrist unit C Oil plug draining D Oil plug filling F Attachment screws 12 pcs Equipment etc Spare part no Art no Note Turning disk dia 200 3HAC 13752 1 O rings are not included O ring 3HAB 3772 64 1 pc 3HAB 3772 61 12 pcs Must be replaced when replacing the turning disk Grease 3HAB 3537 1 Used to lubricate the o rings Standard toolkit The contents are d...

Page 277: ...uipment fitted to the turning disk 3 Run the robot to a position where the oil plug draining of axis 6 gearbox faces downwards Shown in the figure Location of turning disk on page 274 4 Drain the oil from gearbox 6 Detailed in section Oil change gearbox axis 6 on page 197 5 Remove the turning disk by unscrewing its attachment screws Shown in the figure Location of turning disk on page 274 Action N...

Page 278: ...ion Screw joints on page 432 before fitting 3 Perform a leak down test of the gearbox axis 6 Detailed in section Performing a leak down test on page 224 4 Refill the gearbox 6 with oil Detailed in section Oil change gearbox axis 6 on page 197 5 Refit any equipment removed during disassem bly to the turning disk 6 DANGER Make sure all safety requirements are met when performing the first test run T...

Page 279: ...acement of complete wrist unit IRB 6600ID and IRB 6650ID on page 282 Location of wrist unit The wrist unit is located in the frontmost part of the upper arm as shown in the figure below A more detailed view of the component and its position may be found in chapter Exploded views in the Product manual reference information xx0200000184 A Wrist unit B Turning disk C Cover wrist unit D Cover upper ar...

Page 280: ...edures include references to the tools required Circuit diagram See chapter Circuit diagram in the Product manual reference infor mation Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Remove all equipment fitted to the turning disk 3 Turn axis 4 to a p...

Page 281: ...nnect the motor axis 5 by disconnecting the two connectors in the upper arm tube R3 FB5 R3 MP5 Shown in the figure Location of wrist unit on page 277 11 Fit the lifting tool to the wrist unit Art no is specified in Required equipment on page 278 12 CAUTION The complete wrist unit weighs 130 kg All lifting equipment used must be sized accordingly 13 Slightly raise the wrist unit to unload the screw...

Page 282: ...d screws may be used providing they are lubricated as detailed in section Screw joints on page 432 before fitting 7 Remove the guide pins and secure the two remaining attachment screws as detailed above 8 Remove the lifting tool from the wrist unit 9 Reconnect the motor axis 5 by connecting the two connectors inside the upper arm tube R3 FB5 R3 MP5 and secure the cable bracket with the two attachm...

Page 283: ...cket 13 Reconnect the connectors to motor axis 6 and refit the motor cover 14 Refit the cover upper arm tube Shown in the figure Location of wrist unit on page 277 15 Refit the cover wrist unit Shown in the figure Location of wrist unit on page 277 16 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information i...

Page 284: ...e figure below A more detailed view of the component and its position may be found in chapter Exploded views on page 477 in part 2 of the Product manual xx0500001567 Required equipment A Wrist unit B Attachment screws and washers wrist unit C Upper arm tube Equipment Spare part no Art no Note Wrist process 3HAC 024793 001 Guide pins M12 x 200 3HAC13056 3 Always use guide pins in pairs Lifting slin...

Page 285: ...ning disk 3 Remove the integrated spotpack cabling How to remove the DressPack harness from the upper arm wrist unit is detailed in the Product manual SpotPack DressPack OrangeLine 4 Disconnect the connectors from motors axes 5 and 6 Loosen the cabling from the wrist unit 5 Support the weight of the wrist unit with lifting slings 6 CAUTION The complete wrist unit weighs 187 kg All lifting equipmen...

Page 286: ...ng and connectors through the wrist unit and match the wrist against the upper arm tube with guidance from the guide pins 6 Secure the wrist unit with 10 of the 12 attachment screws and washers Shown in the figure Location of wrist unit on page 282 12 pcs M12 x 50 12 9 quality UNBRAKO Tightening torque 115 Nm Reused screws may be used providing they are lubricated as detailed in section Screw join...

Page 287: ...85 3HAC023082 001 Revision E Copyright 2004 2008 ABB All rights reserved 11 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 38 Action Note Continued ...

Page 288: ...er arm includes the wrist unit but this section also describes how to remove the upper arm when there is no wrist unit mounted Note The lifting device is attached differently depending on whether the wrist unit is mounted on the upper arm or not The attachment points are shown in the following figure A more detailed view of the component and its position may be found in chapter Exploded views in t...

Page 289: ... 1 For guiding Sealing axis 2 3 Guide pins sealing axis 2 3 100 mm 3HAC 14628 2 For guiding Sealing axis 2 3 Power supply 24 VDC max 1 5A For releasing the brakes Rotation tool 3HAC 17105 1 Used to rotate the motor shaft beneath the motor cover when brakes are released with 24 VDC power supply Lifting eye VLBG M12 3HAC16131 1 Lifting device upper arm 3HAC15994 1 Lifting tool chain 3HAC15556 1 To b...

Page 290: ...ain the oil from gearbox axis 3 Detailed in section Oil change gearbox axis 3 on page 188 8 Disconnect connector R2 M5 6 at the cable harness division as well as all remaining connections between upper and lower arm Shown in the figure Location of upper arm on page 286 9 Remove the cover on top of the motors axis 3 and 4 and disconnect all connectors inside the motors 10 Remove all brackets securi...

Page 291: ...ide pins sealing axis 2 3 in two of the attachment screw holes on gearbox 3 see figure to the right Guide the new sealing axis 2 3 into position on gearbox 3 using the guide pins Always use a new sealing when reas sembling Art no is specified in Required equipment on page 287 xx0200000166 A Holes for the guide pins sealing axis 2 3 B Holes for the upper arm attachment screws 33 pcs C Holes for the...

Page 292: ...ool chain onto the lifting eye the lifting device and an overhead crane Art no is specified in Required equipment on page 287 7 CAUTION The complete upper arm weighs 380 kg IRB6600 IRB 6650 without any additional equipment fitted robot model IRB 66X0ID 437 kg Use a suitable lifting device to avoid injury to personnel 8 Lift the upper arm and move to its mounting position Make sure the lift is done...

Page 293: ...chment screws Tighten them as detailed above 14 Disconnect the brake release voltage and remove the rotation tool from the motor 15 Remove the lifting devices 16 Refit any cabling removed during the removal process 17 Reconnect all connectors inside motors axis 3 and 4 Refit the motor covers 18 Reconnect connector R2 M5 6 gently at the cable harness division point with 2 screws M6 Be careful not t...

Page 294: ...erence information xx0200000255 Internal components lower arm The internal components of the lower arm are located as shown in the figure below The figure 1 shows a cut between the lower arm and the gearbox axis 3 The location of the sealing axis 2 3 is identical between the lower arm and the axis 2 The figure 2 shows a cut through the lower arm pivot point in axis 2 item B in the figure above A L...

Page 295: ...aft hole 201 Sealing axis 2 3 202 Attachment screw 204 Washer 401 Bearing 402 Thrust washer 403 Bushing 404 Retaining ring 405 Shaft lower arm 406 Protection plug 409 Protection washer Equipment etc Art no Note Bearing 3HAC 12441 2 Always use a new bearing when reas sembling Sealing axis 2 3 3HAC 020123 001 Always use a new sealing when reas sembling Shackle balancing device 3HAC 020997 1 Continue...

Page 296: ...ft 3HAC021600 001 Press tool axis 2 bearing 3HAC13527 1 Retaining ring plier Grease 3HAB 3537 1 For lubrication of the shaft hole Isopropanol 1177 1012 208 For cleaning of the shaft Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Other tools and procedures may be required See references to these procedures in the step by step instru...

Page 297: ...a M20 thread diameter as shown in the figure to the right Pull the shaft out using the puller tool and the hydraulic pump xx0300000056 Note The dimension of the shaft puller tool is M20 Do not mix up with the shaft press tool used when mounting the shaft Art no is specified in Required equipment on page 293 8 Lower the balancing device until it rests safely against the bottom of the frame 9 Move t...

Page 298: ...he sealing axis 2 3 from the lower arm Shown in the figure Internal components lower arm on page 292 On reassembly new sealings must be used Action Note Illustration Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Fit two guidings in the attachment hole...

Page 299: ... the power supply if used 9 Secure the lower arm with 16 of the 18attachment screws and washers in gearbox axis 2 18 pcs M16 x 50 tightening torque 300 Nm Reused screws may be used providing they are lubricated as detailed in section Screw joints on page 432 before fitting Shown in the figure Internal components lower arm on page 292 10 Remove the guidings and secure the two remaining screws as de...

Page 300: ...ts Detailed in section Refitting cable harness axes 1 4 on page 244 18 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 409 19 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in sectio...

Page 301: ... that the preceding instructions in section Replacement of complete lower arm on page 292 are followed These include removing the upper arm removing the cabling in the lower arm unloading the balancing device and removing the front eye shaft draining the oil in gearbox axis 2 unloading the lower arm with specific lifting equipment Components lower arm shaft The figure below shows the components fi...

Page 302: ...a new bearing when reassembling Puller device axis 2 shaft 3HAC021563 001 Press device axis 2 shaft 3HAC021600 001 Hydraulic pump 80 MPa 3HAC13086 1 Hydraulic pump 150 MPa Glycerin 3HAC021563 012 Press tool axis 2 bearing 3HAC13527 1 Retaining ring plier Isopropanol 1177 1012 208 For cleaning the shaft Grease 3HAB 3537 1 For lubrication of the bearing Glycerin For lubrication of the shaft Rust pre...

Page 303: ... shaft contact ABB Robotics A Nipple for the hydraulic pump B Nipple for the glycerin pump C Indicator Action Note Illustration 1 WARNING This procedure is a step in the complete procedure of removing the lower arm Make sure all the preceding steps specified in Prerequisites on page 299 are made before removing the lower arm shaft 2 Remove the protection plug Shown in the figure Components lower a...

Page 304: ... page 300 The attachments on the tool are shown in figure Puller device for removal of axis 2 shaft on page 300 6 Increase the pressure of the glycerin pump and at the same time pull out the shaft with the puller tool by increasing the pressure of the hydraulic pump Note Do not exceed the limit of maximum pressure classified for the pumps 7 Remove the bearing and thrust washer from the shaft hole ...

Page 305: ...ten the M16 nut Tightening torque 20 Nm 7 Fit both the hydraulic pump and the glycerin pump to the press device Art no is specified in Required equipment on page 300 The attachments on the tool are shown in the figure Press device for refitting of axis 2 shaft on page 301 8 Set the indicator on the press device to zero Shown in the figure Press device for refitting of axis 2 shaft on page 301 9 Pr...

Page 306: ...ing with the press tool axis 2 bearing Always use a new bearing when reassembling Art no is specified in Required equipment on page 300 15 Refit the protection washer and the retaining ring Shown in the figure Components lower arm shaft on page 299 16 Refit the protection plug Shown in the figure Components lower arm shaft on page 299 17 Proceed with the refitting procedure of the lower arm detail...

Page 307: ...tails how to secure the lower arm with a specific fixture prior to performing certain service activities to the robot Attachment points robot The special equipment used to secure the lower arm is fitted to the attachment points shown in the figure below xx0400000708 A Attachment hole securing screw B Holes for M12 bolts C Holes for M16 bolts Continues on next page ...

Page 308: ... figure below Move them to the attachment points shown in the instruction Placeholder Equipment etc Art no Note Fixture lower arm 3HAC020729 001 Includes the locking screw for securing the lower arm Standard toolkit 3HAC 15571 1 The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual A Locking screw B Adjusters 2 pcs C M16 bolts 4 pcs D Ring nuts 2 pcs E M1...

Page 309: ... in three different ways shown in the figure to the right The lowered position as in figure A is recommended as it gives the least load on the tool xx0200000260 4 If the robot is fitted with moveable mechanical stops on axis 2 not stock equipment these must be removed at this point The attachment holes of the mechanical stops are used to attach the fixture 5 Remove the locking screw from the fixtu...

Page 310: ...ghten by hand 6 Lock using the two ring nuts 7 Fit and tighten the two M12 bolts in the attachment holes on the lower arm with tightening torque 91 Nm C Art no is specified in Required equipment on page 306 Attachment holes on the frame and on the lower arm are shown in the figure Attachment points robot on page 305 The adjusters bolts and ring nuts are shown in the figure Fixture lower arm on pag...

Page 311: ...he frame as shown in the figure below xx0200000203 Required equipment A SMB cover B SMB unit C Pins D Battery cable Equipment etc Spare part no Art no Note SMB unit 3HAC 16014 1 Brush Rust preventive 3HAC026621 001 Equivalent Mercasol 3106 Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Circuit Diagram See chapter Circuit diagram in...

Page 312: ...unit please observe the safety information in section WARNING The unit is sensitive to ESD on page 40 4 Remove the SMB cover by unscrewing its attachment screws Shown in the figure Location of SMB unit on page 309 5 Remove the connectors X8 X9 and X10 from the brake release board if need of more space 6 Remove the nuts and washers from the pins securing the board Shown in the figure Location of SM...

Page 313: ...B unit on page 309 4 Connect all connectors to the SMB board and fit the SMB unit onto the pins Art no is specified in Required equipment on page 309 Shown in the figure Location of SMB unit on page 309 R1 SMB1 3 R1 SMB4 6 and R2 SMB 5 Secure the SMB unit to the pins with the nuts and washers 6 If disconnected reconnect the connectors X8 X9 and X10 to the brake release board 7 Secure the SMB cover...

Page 314: ...ressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 esd WARNING The unit is sensitive to ESD before handling the unit please observe the safety information in section WARNING The unit is sensitive to ESD on page 40 3 Remove the SMB unit according to step 4 8 in Removal SMB unit on page 310 4 Refit the new SMB unit according to step 3 6 in Ref...

Page 315: ... equipment A Brake release unit B Attachment screws brake release unit 4 pcs C Buttons D SMB cover E Push button guard Equipment etc Art no Note Brake release unit with buttons 3HAC 16035 1 Located together with the SMB unit at the left hand side of the frame Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Other tools and procedures...

Page 316: ... button guardfrom the SMB cover Shown in the figure Location of brake release unit on page 313 The guard must be removed to ensure a correct refitting of the brake release unit 4 Open the SMB cover by unscrewing the attachment screws Let the battery stay connected to avoid the need of synchronization of the robot Shown in the figure Location of brake release unit on page 313 5 Remove the complete ...

Page 317: ...ressure to motors and SMB 2 esd WARNING The unit is sensitive to ESD before handling the unit please observe the safety information in section WARNING The unit is sensitive to ESD on page 40 3 Fasten the brake release unit on the bracket with the attachment screws Make sure the unit is positioned as straight as possible on the bracket The push buttons can otherwise get jammed when the SMB cover is...

Page 318: ...7 WARNING Before continuing any service work please observe the safety information in section WARNING The brake release buttons may be jammed after service work on page 39 8 Refit the push button guardto the SMB cover Shown in the figure Location of brake release unit on page 313 9 If the battery has been disconnected the revolution counter must be updated Detailed in the Calibration chapter secti...

Page 319: ...ront ear of the balancing device as shown in the figure below xx0500002249 Required equipment A Spherical roller bearing B Sealing ring C O ring D Sealing spacer E Front ear of balancing device Equipment Spare part no Art no Note Spherical roller bearing 3HAA 2167 18 Sealing spacer 3HAC 12649 1 2 pcs required O ring 3HAB 3772 75 2 pcs required Sealing ring 3HAC 11581 5 2 pcs required Grease 3HAB 3...

Page 320: ...ss tool 3HAC15941 2 Press tool 3HAC15846 2 Hexagon nut M12 9ADA267 9 Plain washer 9ADA312 9 The tools in the set are shown in the figure Tool set on page 318 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Equipment Spare part no Art no Note A Threaded bar B Dolly C Press ...

Page 321: ...ove the balancing device from the robot Detailed in section Removal balancing device on page 325 3 Remove the both sealing spacers with a screwdriver or any equal tool Shown in the figure Location of bearing on page 317 4 Insert the threaded bar through the bearing 5 Fit the press tool and dolly to the threaded bar Secure with the nut and washer at each end xx0500002255 A Threaded bar 3HAC15945 1 ...

Page 322: ...acers Spare part no s are specified in Required equipment on page 317 6 Press in the sealing spacers with the press tools as shown in the figure to the right Secure the press tool and dolly with nuts and washers Note Fit the sealing spacers one at a time xx0500002258 A Threaded bar 3HAC15945 1 B Dolly 3HAC15948 2 C Press tool 3HAC15846 2 7 Refit the balancing device to the robot Detailed in sectio...

Page 323: ...3082 001 Revision E Copyright 2004 2008 ABB All rights reserved 10 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 38 Action Note Illustration Continued ...

Page 324: ...lancing device The balancing device is located on rear top of the frame as shown in the figure below xx0200000223 A Balancing device B Rear cover C Support shaft inside D Attachment screws rear cover E Balancing device shaft including securing screw F Bearing attachment G Parallel pin inside bearing attachment H Attachment screws bearing attachments Continues on next page ...

Page 325: ... attachment to the balancing device remove the protection plug D Hole in the frame to access the balancing device shaft with the puller press tool E Locking screw attachment hole secures the lower arm to the frame Equipment Spare part no Art no Note Balancing device IRB 6600 and IRB 6600ID 3HAC 020691 001 IRB 6600 Includes balancing device 3HAC 17117 2 Includes end cover gasket 3HAC 17188 1 Balanc...

Page 326: ...e securing screw in the shaft Grease pump To lubricate spherical roller bearing Guide pins M16 x 300 3HAC13120 5 Always use guide pins in pairs Shackle balancing device 3HAC 020997 1 Lifting tool chain 3HAC15556 1 Press tool balancing device 3HAC020902 001 Puller tool balancing device shaft 3HAC12475 1 Press tool balancing device shaft 3HAC17129 1 Hydraulic cylinder 3HAC11731 1 To be used with the...

Page 327: ... and raise to unload the weight Art no is specified in Required equipment on page 323 Attachments are shown in the figure Attachment points balancing device on page 323 6 Unload the balancing device with the press tool in order to make the piston rod and front ear adjustable when pulling the shaft out Art no is specified in Required equipment on page 323 Detailed in section Unloading the balancing...

Page 328: ...e frame Art no is specified in Required equipment on page 323 13 Lift the balancing device gently backwards to a secure area allowing the bearing attachments to slide on the guide pins Note Make sure not to burden the guide pins with the weight of the balancing device Action Note Illustration Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Fo...

Page 329: ...e screws from outside of the bearing attachments and refit the protection plugs 12 Raise the balancing device to a position where the balancing device shaft may be inserted through the piston shaft front eye 13 Unload the balancing device with the press tool Detailed in section Unloading the balancing device on page 331 Art no is specified in Required equipment on page 323 For an easier reassembli...

Page 330: ...ancing device on page 203 18 Restore the balancing device Detailed in section Restoring the balancing device on page 334 19 DANGER The rear cover of the balancing device is a safety device for the piston rod during operation Make sure the cover is properly secured before commissioning of the robot 20 Remove the locking screw that secures the lower arm to the frame xx0300000483 A Attachment hole fo...

Page 331: ...ual with the following additions Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Pull out the sealing spacers out they shall still remain on the ear Apply rust preventive abundantly in the gap press the sealing back in place wipe off surplus material xx...

Page 332: ...n E 330 Copyright 2004 2008 ABB All rights reserved 4 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 38 Action Note Illustration Continued ...

Page 333: ...ncing device How to secure the lower arm is detailed in the current repair activity e g removal of the balancing device Press tool and hydraulic cylinder The figure below shows the hydraulic cylinder mounted on the press tool The press tool includes two press devices that are used to different models of the balancing device xx0200000174 A Press block B Hydraulic cylinder C Press device D Bolt pres...

Page 334: ...e 3HAC 15767 2 press device 3HAC 18100 1 Choose the correct device depending on model of balancing device Hydraulic cylinder 3HAC11731 1 To be used with the press tool Hydraulic pump 80 MPa 3HAC13086 1 To be used with the hydraulic cylinder Standard toolkit 3HAC 15571 1 The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Balancing device Press device Ar...

Page 335: ...pecified in Required equipment on page 332 See the figure Press tool and hydraulic cylinder on page 331 7 Connect the hydraulic pump to the cylinder Art no is specified in Required equipment on page 332 8 Increase the pressure and press until the marking on the moving pin indicates the correct position in level with the pressure block See the figure Press tool and hydraulic cylinder on page 331 Do...

Page 336: ...tool The press tool includes two press devices that are used to different models of the balancing device xx0200000174 Required equipment The different designs of the balancing device are sealed in different ways beneath the rear cover of the balancing device A Press block B Hydraulic cylinder C Press device D Bolt press device E Moving pin with marking F Bolt 4 pcs G Pin attached to the fix plate ...

Page 337: ...n rod and ear See illustration above 3 Press with the cylinder and the hydraulic pump until the fix plate is movable again Turn the pin on the fix plate to position Open Shown in the figure Press tool and hydraulic cylinder on page 334 Do not apply more pressure than necessary it could damage bearings and sealings at the shaft 4 Unload the cylinder and make sure the moving pin indicates that the t...

Page 338: ...sion E 336 Copyright 2004 2008 ABB All rights reserved 9 DANGER The rear cover of the balancing device is a safety device for the piston rod during operation Make sure the cover is properly secured before com missioning of the robot Action Note Illustration Continued ...

Page 339: ...tor axis 1 B Motor attachment screws and washers Equipment etc Spare part no Art no Note Motor including pinion 3HAC 15879 2 3HAC15879 3 Foundry Prime 3HAC027316 001 Foundry Prime Includes motor pinion o ring 2152 2012 430 O ring 2152 2012 430 Must be replaced when reassembling motor Sikaflex 251FC 3HAC026620 001 Option Foundry Prime Mercasol 3106 3HAC026621 001 Option Foundry Prime Gasket 3HAC343...

Page 340: ...al Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Other tools and procedures may be required See references to these procedures in the step by step instruc tions below These procedures include references to the tools required Circuit Diagram See chapter Circuit diagram in the Product manual reference infor mation Equipment etc Spare part no Art no Note Ac...

Page 341: ...own in the figure Location of motor on page 337 8 If required press the motor out of position by fitting removal tool motor to the motor attachment screw holes Art no is specified in Required equipment on page 337 Always use the removal tools in pairs 9 CAUTION The motor weighs 25 kg All lifting equipment used must be sized accordingly 10 Lift the motor to get the pinion away from the gear and dis...

Page 342: ...ure the motor with its four attachment screws and plain washers M10 x 40 tightening torque 50 Nm 8 Disconnect the brake release voltage 9 Reconnect all connectors beneath the motor cover 10 Refit the cable gland cover at the cable exit with its two attachment screws Make sure the cover is tightly sealed 11 Refit the motor cover with its four attachment screws Make sure the cover is tightly sealed ...

Page 343: ...t Manual with the following additions Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Remove the cover for connector access on top of the motor by unscrewing its four attachment screws xx0600002874 A attachment screw B air hose C top cover D motor unit ...

Page 344: ...xx0600002875 A motor unit B Sikaflex in screw recesses 6 Continue to refitt the new motor according to Refitting motor axis 1 on page 339 7 After mounting the motor on the manipulator the surface between the motor and the base frame must be protected with Mercasol 3106 xx0600002877 A base frame B motor unit 8 Perform a leak test according to Inspection of air hoses Foundry Prime on page 176 Action...

Page 345: ...n in the figure below xx0400001067 Required equipment A Motor axis 2 B Hole for locking screw C Cable gland cover located on the lower side of the motor D Motor attachment holes 4 pcs Equipment etc Spare part no Art no Note Motor including pinion 3HAC 021030 001 Includes motor pinion o ring 2152 2012 430 O ring 2152 2012 430 Must be replaced when reassembling motor Sikaflex 251FC 3HAC026620 001 Op...

Page 346: ...g the brakes Rotation tool 3HAC 17105 1 Used to rotate the motor pinion when mating it to the gear when brakes are released with 24VDC power supply Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Other tools and procedures may be required See r...

Page 347: ...re the weight of the lower arm properly before releasing the brakes of motor axis 2 When releasing the holding brakes of the motor the lower arm will be movable and may fall down Use the lock screw to lock the lower arm as detailed above 9 In order to release the brake connect the 24 VDC power supply Connect to connector R2 MP2 pin 2 pin 5 10 Remove the motor by unscrewing its four attachment scre...

Page 348: ... motor is seated properly Lightly lubricate the o ring with grease Art no is specified in Required equipment on page 343 3 In order to release the brake remove the cover on top of the motor and connect the 24 VDC power supply Connect to connector R2 MP2 pin 2 pin5 4 Fit the lifting tool motor axis 2 3 4 to the motor Art no is specified in Required equipment on page 343 5 Fit the two guide pins in ...

Page 349: ...nectors beneath the motor cover Connect in accordance with markings on connectors 14 Refit the cable gland cover at the cable exit with its two attachment screws Shown in the figure Location of motor on page 343 15 Refit the cover on top of the motor with its four attachment screws Make sure the cover is tightly sealed 16 Remove the lock screw from the hole for lock screw Shown in the figure Locat...

Page 350: ...screw to be inserted into the hole for lock screw Shown in the figure Location of motor on page 343 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 Lock the lower arm by inserting the lock screw into the hole Art no and dimension is specified in Required equipment on page 343 4 Drain the oil from gearbox axis 2 Detailed in section Oil change gearbox ax...

Page 351: ...movable and may fall down 9 Continue to remove the motor unit according to step 9 to 17 in Removal motor on page 344 10 Fill the four screw recesses on the new motor with Sikaflex After hardening Sikaflex can be formed with a knife xx0600002875 A motor unit B Sikaflex in screw recesses 11 Continue to refitt the new motor according to Refitting motor on page 346 12 Perform a leak test according to ...

Page 352: ...t of motor axis 3 Location of motor The motor axis 3 is located on the left hand side of the robot as shown in the figure below xx0200000186 xx0600003051 A Motor axis 3 B Cable gland cover motor axis 3 C Motor attachment holes 4 pcs A Cable gland cover motor axis 3 B Motor attachment holes 4 pcs C Motor axis 3 Continues on next page ...

Page 353: ...ing Removal tool motor M12x 3HAC 14631 1 Always use the removal tools in pairs Lifting tool motor ax 2 3 4 3HAC 15534 1 Mech stop ax 3 3HAC 12708 1 May be used to fix axis 3 Use attachment screws 3HAB 3409 86 M16 x 60 Washers for mech stop axis 3 3HAA 1001 186 Guide pins M10 x 100 3HAC 15521 1 For guiding the motor Guide pins M10 x 150 3HAC 15521 2 For guiding the motor Rotation tool 3HAC 17105 1 ...

Page 354: ... either Use a fork lift to rest the upper arm onto Use lifting slings and an overhead crane to rest the upper arm Use a mechanical stop to rest the upper arm Fit the mechanical stop in the attachment hole A with tightening torque 115 Nm The upper arm must be positioned as horizontal as possible xx0300000051 Fit the mechanical stop to the third and final attachment hole A below the fixed stop B in ...

Page 355: ...screw holes Art no is specified in Required equipment on page 351 Always use the removal tools in pairs 13 Apply the lifting tool motor axis 2 3 4 to the motor Art no is specified in Required equipment on page 351 14 CAUTION The motor weighs 27 kg All lifting equipment used must be sized accordingly 15 Lift the motor to get the pinion away from the gear 16 Remove the motor by gently lifting it str...

Page 356: ...r pinion when mating it to the gear Fit the motor making sure the motor pinion is properly mated to the gear of gearbox axis 3 Art no is specified in Required equipment on page 351 Make sure the motor pinion does not get damaged Make sure the motor is turned the right direction i e the cables facing forwards xx0200000165 The rotation tool is used beneath the motor cover directly on the motor shaft...

Page 357: ...forming a leak down test on page 224 18 Refill the gearbox with oil Detailed in section Oil change gearbox axis 3 on page 188 19 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 409 20 DANGER Make sure all safety requirements are met when performi...

Page 358: ...e old top cover with the air nipple mounted 5 Continue to remove the motor unit according to step 6 to 17 in Removal motor on page 352 6 Fill the four screw recesses on the new motor with Sikaflex After hardening Sikaflex can be formed with a knife xx0600002875 A motor unit B sikaflex in screw recesses 7 Continue to refitt the new motor according to Refitting motor on page 353 8 Perform a leak tes...

Page 359: ...of motor axis 4 Location of motor The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below xx0200000202 xx0500003050 A Motor axis 4 B Cable gland cover motor axis 4 C Motor attachment holes 4 pcs A Cable gland cover motor axis 4 B Motor axis 4 C Motor attachment holes 4 pcs Continues on next page ...

Page 360: ... 14972 1 Always use the removal tools in pairs Guide pins M8 x 100 3HAC 15520 1 For guiding the motor Guide pins M8 x 150 3HAC 15520 2 For guiding the motor Rotation tool 3HAC 17105 1 Used to rotate the motor pinion when mating it to the gear when brakes are released with 24 VDC power supply Power supply 24 VDC max 1 5 A For releasing the brakes Standard toolkit The contents are defined in section...

Page 361: ... by unscrewing its two attachment screws Shown in the figure Location of motor on page 357 Make sure the gasket is not damaged 4 Remove the cover on top of the motor by unscrewing its four attachment screws 5 Disconnect all connectors beneath the motor cover 6 In order to release the brake connect the 24 VDC power supply Connect to connector R2 MP4 pin 2 pin 5 7 Unscrew the motors four attachment ...

Page 362: ...page 358 3 Fit the lifting tool to the motor Choose the correct lifting tool lifting tool motor axis 1 4 and 5 if the upper arm is positioned vertically lifting tool motor axis 2 3 and 4 if the upper arm is positioned hori zontally Art no is specified in Required equipment on page 358 4 In order to release the brakes connect the 24 VDC power supply Connect to connector R2 MP4 pin 2 pin 5 5 Fit the...

Page 363: ...ase voltage 11 Reconnect all connectors beneath the motor cover 12 Refit the cover on top of the motor with its four attachment screws Make sure the cover is tightly sealed 13 Refit the cable gland cover at the cable exit with its two attachment screws Shown in the figure Location of motor on page 357 14 Perform a leak down test if gearbox has been drained Detailed in section Performing a leak dow...

Page 364: ...t Manual with the following additions Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Remove the cover for connector access on top of the motor by unscrewing its four attachment screws xx0600002874 A attachment screw B air hose C top cover D motor unit ...

Page 365: ...sses on the new motor with Sikaflex After hardening Sikaflex can be formed with a knife xx0600002875 A motor unit B sikaflex in screw recesses 6 Continue to refitt the new motor according to Refitting motor axis 4 on page 360 7 Perform a leak test according to Inspection of air hoses Foundry Prime on page 176 Action Note Illustration Continued ...

Page 366: ... is located inside the upper arm tube but attached to the wrist unit as shown in the figure below A more detailed view of the component and its position may be found in chapter Exploded views in the Product manual reference information xx0200000204 Required equipment A Motor axis 5 B Upper arm tube C Wrist unit Equipment etc Spare part no Art no Note 3HAC026982 001 Foundry Prime 3HAC027319 001 Fou...

Page 367: ...se the removal tools in pairs Oil injector max 500 MPa 3HAC021590 001 For pressing out the pinion motor 5 Motor press pinion 3HAC021883 001 For pressing the pinion on to the new motor Measuring tool 6896134 GN Guide pins M8 x 100 3HAC 15520 1 For guiding the motor Guide pins M8 x 150 3HAC 15520 2 For guiding the motor Power supply 24 VDC 1 5 A For releasing the brakes Standard toolkit The contents...

Page 368: ...er to release the brake connect the 24 VDC power supply Connect to either connector R4 MP5 in the motor pin 2 pin 5 connector R3 MP5 on the separate cable if not removed pin C pin D 9 Remove the motor by unscrewing its four attachment screws and plain washers 10 Fit the two guide pins in two of the motor attachment screw holes Art no is specified in Required equipment on page 364 11 If required pr...

Page 369: ...e pinion is damaged the complete wrist unit must be replaced Art no is specified in Required equipment on page 364 Replacing the complete wrist unit is detailed in section Replacement of complete wrist unit IRB 6600 and IRB 6650 on page 277 4 Apply a thin film of mineral oil to the pinion shaft and the pinion hole in order to make the pinion run smoothly and to achieve an even friction torque when...

Page 370: ...eparate cable of the axis 5 motor and reconnect all connectors beneath the motor cover 14 Refit the cable gland cover at the cable exit with its two attachment screws 15 Refit the cover on top of the motor with its four attachment screws Make sure the cover is tightly sealed 16 Perform a leak down test Detailed in section Performing a leak down test on page 224 17 Refit the wrist unit Detailed in ...

Page 371: ...ing additions Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Perform step 2 4 in Removal motor axis 5 on page 366 3 Remove the cover for connector access on top of the motor by unscrewing its four attachment screws xx0600002904 A attachment screw B air...

Page 372: ... can be formed with a knife xx0600002880 A air hose B motor unit C sikaflex in screw recesses 8 Continue to refitt the new motor according to Refitting motor axis 1 on page 339 9 After mounting the motor in the wrist the surface between the motor and the wrist must be protected with Mercasol 3106 xx0600002879 A wrist unit B attachment screw 4 pcs C surface to protect with Mercasol D motor unit 10 ...

Page 373: ...23745 003 Includes o ring 3HAB 3772 22 Grease 3HAB 3537 1 For lubricating the o ring Power supply 24 VDC 1 5A For releasing the brakes Allen key and socket A specific length is required for accessing the attachment screws of the motor The dimensions are shown in the figure Removal tools motor attachment screws on page 372 Standard toolkit The contents are defined in section Standard toolkit on pag...

Page 374: ...r without draining the gearbox oil 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Disconnect the motor connectors from the axis 5 motor Shown in the figure Location of motor axis 5 on page 371 4 In order to release the brakes connect the 24 VDC power supply to the motor Connec...

Page 375: ... properly mated to the gear of axis 5 5 Secure the motor with the three attachment screws and washers 3 pcs M8x25 Tightening torque 24 Nm Dimensions of the tools are specified in the figure Removal tools motor attachment screws on page 372 6 Disconnect the brake release and reconnect the motor connectors Shown in the figure Location of motor axis 5 on page 371 7 Perform a leak down test Detailed i...

Page 376: ...or axis 6 is located in the center of the wrist unit as shown in the figure below A more detailed view of the component and its position may be found in chapter Exploded views in the Product manual reference information xx0200000222 Required equipment A Wrist unit B Motor axis 6 Equipment etc Spare part no Art no Note Motor including pinion 3HAC 15991 4 Includes motor pinion o ring 2152 2012 430 C...

Page 377: ...ting the o ring Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Circu...

Page 378: ...tor pinion is not damaged 9 Remove the motor by gently lifting it straight out Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Make sure the o ring on the circumference of the motor is seated properly Lightly lubricate the o ring with grease Art no is sp...

Page 379: ...al enclosed with the calibration tools General calibration information is included in section Calibration information on page 409 13 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 38 Action Note Action Note Illustration 1 Move the robot to a position where the motor i...

Page 380: ...and SMB 4 In horizontal position drain the oil from the axis 6 gearbox Detailed in section Draining oil axis 6 on page 198 5 Remove the rear motor cover by unscrewing the five attachment screws xx0600002885 A motor unit 3106 B attachment screw 5pcs C air nipple D rear motor cover E gasket 6 Continue to remove the motor unit according to step 6 to 11 in Removal motor on page 375 7 note NOTE Keep th...

Page 381: ...ife xx0600002884 A mercasol B motor unit C attachment screw 4pcs D sikaflex in screw recesses E loctite 570 F tilt house 9 Apply mercasol 3106 on the surface between tilt house and motor pinion side and Loctite 570 between gasket and tilt house 10 Continue to refitt the new motor according to step2 14 Refitting motor on page 376 11 Perform a leak test according to Inspection of air hoses Foundry P...

Page 382: ...rt no Note Motor including pinion 3HAC 023746 003 Includes o ring 3HAB 3772 22 Grease 3HAB 3537 1 For lubricating the o ring Power supply 24 VDC 1 5 A For releasing the brakes Allen key and socket A specific length is required for accessing the attachment screws of the motor The dimensions are shown in the figure Removal tools motor attachment screws on page 372 Standard toolkit The contents are d...

Page 383: ...re to motors and SMB 3 Disconnect the motor connectors Shown in the figure Location of motor axis 6 on page 380 4 In order to release the brakes connect the 24 VDC power supply to the motor Connect to connector R3 MP6 pin C pin D 5 Unfasten the motor by unscrewing its three attachment screws and washers Dimensions of the tools are specified in the figure Removal tools motor attachment screws on pa...

Page 384: ... 372 6 Disconnect the brake release voltage 7 Reconnect the motor connectors Shown in the figure Location of motor axis 6 on page 380 8 Perform a leak down test Detailed in section Performing a leak down test on page 224 9 Refill the axis 6 gearbox with oil if previously drained Detailed in section Filling oil axis 6 on page 199 10 Recalibrate the robot Calibration is detailed in a separate calibr...

Page 385: ...wn in the figure below A more detailed view of the component and its position may be found in chapter Exploded views in the Product manual reference information xx0300000015 Required equipment A Gearbox axis 1 B Frame C Base Attachment screws gearbox axis 1 not shown in figure Equipment etc Spare part no Art no Note Gearbox 3HAC 10828 8 Includes gearbox all o rings and sealing rings O ring 3HAB 37...

Page 386: ...he contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Other tools and procedures may be required See references to these procedures in the step by step instruc tions below These procedures include references to the tools required Equipment etc Spare part no Art no Note Action Note Illustration 1 Move the robot to its most stable position shown in the figur...

Page 387: ...o the gearbox Art no is specified in Required equipment on page 383 9 CAUTION The base and gearbox weighs 423 kg together All lifting equipment must be used accordingly 10 Lift the robot base to allow fitting the support base and gear 1 on each sides of the base Art no is specified in Required equipment on page 383 11 Fit the support base Make sure the base remains in a stable position before perf...

Page 388: ...14 Remove the cable guide in the center of gearbox 1 by unscrewing its attachment screws xx0200000256 A Location for attachment screws cable guide cable guide removed in the figure 15 CAUTION The gearbox weighs 160 kg All lifting equipment used must be sized accordingly 16 Lift the gearbox away with the already mounted lifting tools Action Note Illustration Action Note Illustration 1 If the base i...

Page 389: ...ng ring 3HAC 11581 4 3 Refit the cable guide in the center of gearbox 1 with its attachment screws xx0200000256 A Location for attachment screws cable guide cable guide removed in figure 4 Fit the lifting device base and the lifting tool chain to the gearbox Art no is specified in Required equipment on page 383 5 CAUTION The gearbox weighs 160 kg All lifting equipment used must be sized accordingl...

Page 390: ... 1 18 pcs C Washers 3 pcs 9 Refit the bottom plate underneath the robot base by pushing it into the groove and fitting the attachment screw Note Direct the bends on the plate downwards If removed also refit the rear connector plate 1 screw M6 x 8 xx0300000612 A Bottom plate B Rear connector plate C Attachment screw D Groove 10 CAUTION The base and gearbox weighs 423 kg together All lifting equipme...

Page 391: ...ect the cabling in the rear of the robot base 15 Perform a leak down test Detailed in section Performing a leak down test on page 224 16 Refill the gearbox with oil Detailed in section Filling oil axis 1 on page 184 17 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration...

Page 392: ...06 on unpainted areas xx0600003132 A surface on the underside of the frame B Radial sealing gear axis 1 against base 3 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 38 Action Note Illustration A B Continued ...

Page 393: ...box for axis 2 is located in the lower arm rotational center underneath the cover A more detailed view of the component and its position may be found in chapter Exploded views in the Product manual reference information xx0400001065 A Gearbox axis 2 behind cover not shown in figure B Attachment hole for locking screw lower arm C Attachment holes inside of frame for fixture lower arm D Attachment h...

Page 394: ...box Guide pins M12 x 200 3HAC13056 3 For guiding the gearbox Press tool balancing device 3HAC020902 001 Hydraulic cylinder 3HAC11731 1 To be used with the press tool and the hydraulic pump when unloading the balancing device Hydraulic pump 80 MPa 3HAC13086 1 To be used with the press tool and the hydraulic cylinder when unloading the balancing device Guide pins sealing ax 2 3 80mm 3HAC14627 2 For ...

Page 395: ...age 392 4 Drain the gearbox axis 2 Notice Time consuming activity Detailed in section Oil change gearbox axis 2 on page 185 5 Remove the motor axis 2 Detailed in section Removal motor on page 344 6 Remove the rear attachment screws gearbox from inside of the lower arm Shown in the figure Location of gearbox on page 391 7 Remove the cover axis 2 by unscrewing its 14 attachment screws Shown in the f...

Page 396: ...r similar with guidance from the mounted guide pins 14 Remove the sealing from the lower arm Action Note Illustration Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Make sure the o ring is fitted to the gearbox as shown in the figure to the right Light...

Page 397: ... screws Art no is specified in Required equipment on page 392 7 CAUTION The gearbox weighs 100 kg All lifting equipment used must be sized accordingly 8 Lift the gearbox to its mounting position and slide it onto the guiding pins attached in the frame through the front attachment screw holes 9 Align the gearbox attachment screw holes to the hole patterns in the lower arm with help from the guide p...

Page 398: ...and tighten the two remaining screws as detailed above 17 Refit the motor Detailed in section Refitting motor on page 346 18 Perform a leak down test Detailed in section Performing a leak down test on page 224 19 Refill the gearbox with oil Detailed in section Oil change gearbox axis 2 on page 185 20 Restore the balancing device Detailed in section Restoring the balancing device on page 334 21 Rem...

Page 399: ... chapter in the Product Manual with the following additions Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Lift the protection ring and apply Mercasol 3106 between gear and protection ring xx0600003135 A protection ring B Mercasol on surface 3 Apply Me...

Page 400: ...106 on the lower arm according to the illustration to the roght before assembly xx0600003135 A Mercasol 3106 on surfaces 5 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 38 Action Note Illustration Continued ...

Page 401: ...the figure below A more detailed view of the component and its position may be found in chapter Exploded views in the Product manual reference information xx0200000194 Required equipment A Gearbox axis 3 B Motor axis 3 C Upper arm D Attachment screws gearbox 24 pcs Equipment etc Spare part no Art no Note Gearbox 3HAC 021127 001 Includes gearbox o ring Does not include the sealing axis 2 3 O ring 3...

Page 402: ...r guiding the gearbox Use guides in pairs Guide pins sealing ax 2 3 80mm 3HAC14628 1 For guiding the sealing axis 2 3 Use guides in pairs Guide pins sealing ax 2 3 100mm 3HAC14628 2 For guiding the sealing axis 2 3 Use guides in pairs Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Calibration Pendulum toolkit 3HAC15716 1 Complete k...

Page 403: ...tween the gearbox and lower arm On reassembly a new sealing must be used Art no is specified in Required equipment on page 399 6 Place the upper arm safely on a workbench in a fixture or similar 7 Remove the attachment screws gearbox Shown in the figure Location of gearbox on page 399 8 Fit the two guide pins in 180 relation to each other in the gearbox attachment screw holes Art no is specified i...

Page 404: ...DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Turn the upper arm in such a position that the gear mating surface faces upwards 3 Fit two guide pins in 180 relation to each other in the holes in the upper arm used for the gearbox attachment screws Art no is specified in Required...

Page 405: ...operly and the gearbox correctly oriented 10 Remove the lifting tool 11 Secure the gearbox with 22 of the 24 gearbox attachment screws Remove the guide pins and tighten the remaining two screws 24 pcs M12 x 60 Tightening torque 115 Nm Reused screws may be used providing they are lubricated as detailed in section Screw joints on page 432 before fitting 12 Refit the upper arm with a new sealing axis...

Page 406: ...re met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 38 Action Note Illustration Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Apply Mercasol on surfaces on lower arm ...

Page 407: ...A Gearbox axis 6 B Attachment screws and washers gearbox 18 pcs C Oil plug draining D Oil plug filling O ring not shown in figure Equipment etc Spare part no Art no Note Gearbox 3HAC 10828 13 Includes o ring 3HAB 3772 57 Washers 3HAA 1001 172 Not included in gearbox Replace only when damaged O ring 3HAB 3772 58 Must be replaced when reas sembling gearbox Grease 3HAB3537 1 For lubricating the o rin...

Page 408: ...lude references to the tools required Equipment etc Spare part no Art no Note Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Drain the oil from gearbox axis 6 Detailed in section Oil change gearbox axis 6 on page 197 3 Remove the turning disk Detailed ...

Page 409: ... the gearbox Lubricate the o ring with grease Art no is specified in Required equipment on page 405 xx0100000132 A O ring gearbox axis 6 3 Insert the gearbox axis 6 into the wrist unit Art no is specified in Required equipment on page 405 Shown in the figure Location of gearbox on page 405 Make sure the gears of the gearbox mate with those of the motor 4 Secure the gearbox with the attachment scre...

Page 410: ...d in section Performing a leak down test on page 224 8 Refill the gearbox with oil Detailed in section Oil change gearbox axis 6 on page 197 9 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 409 10 DANGER Make sure all safety requirements are met...

Page 411: ...obot has Absolute Accuracy calibration it is also recommended but not always needed to be calibrated for new Absolute Accuracy The resolver values will change when parts affecting the calibration position are replaced on the robot e g motors wrist or part of transmission Contents of the revolution counter memory are lost If the contents of the revolution counter memory are lost the counters must b...

Page 412: ...n Pendulum standard method or Levelmeter calibration alternative method Absolute Accuracy calibration optional Based on standard calibration and besides positioning the robot at home position the Absolute Accuracy calibration also compensates for mechanical tolerances in the robot structure deflection due to load Absolute Accuracy calibration focuses on positioning accuracy in the Cartesian coordi...

Page 413: ...hanical tolerances to the toolkit parts as the standard method with Calibration Pendulum This method may after calibration require modifications in the robot program and is therefore not recommended The calibration equipment for Levelmeter Calibration is ordered as separate parts for each robot and the operating manual for Levelmeter Calibration is enclosed with the Levelmeter 2000 CalibWare Abslo...

Page 414: ...at axes 2 and 3 xx0200000176 Calibration marks at axes 2 and 3 The calibration marks at axes 2 3 and 6 shown in the figure above consist of two single marks that should be positioned opposite to one another when the robot is standing in its calibration position One of the marks is more narrow than the other and should be positioned within the limits of the wider mark A1 Calibration scale axis 1 ea...

Page 415: ...at axes 2 and 3 xx0500002016 Calibration marks at axes 2 and 3 The calibration marks at axes 2 3 and 6 shown in the figure above consist of two single marks that should be positioned opposite to one another when the robot is standing in its calibration position One of the marks is more narrow than the other and should be positioned within the limits of the wider mark A Calibration scale axis 1 B C...

Page 416: ...ards the calibration position in the same direction in order to avoid position errors caused by backlash in gears etc Positive directions are shown in the figure below This is normally handled by the robot calibration software Calibration movement directions 6 axes Note The figure shows an IRB 7600 but the positive direction is the same for all 6 axis robots except the positive direction of axis 3...

Page 417: ...ivery the robot 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 below mentioned axes are rotated one or more turns from its calibration position before updating the revolution counter the correct calibration position will be lost due to uneven gear ratio This affects the following robots If the calibration marks seem to be w...

Page 418: ...If there is more than one unit connected to the robot they will be listed in the window xx0100000201 3 Select the desired unit and choose Rev Counter Update from the Calib menu The Revolution Counter Update window appears xx0100000202 4 Select the desired axis and press Incl to include it it will be marked with an x or press All to select all axes 5 Press OK when all axes that are to be updated ar...

Page 419: ...he calibration position very carefully after each update How to perform the check is detailed in section Checking the calibration position on page 419 Action Note Action 1 On the ABB menu tap Calibration All mechanical units connected to the system are shown along with their calibration status 2 Tap the mechanical unit in question A screen is displayed tap Rev Counters en0400000771 3 Tap Update Re...

Page 420: ...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 6 CAUTION If a revolution counter is incorrectly updated it will cause incorrect robot positioning which in turn may cause damage or injury Check the cal...

Page 421: ...am MoveAbsJ 0 0 0 0 0 0 9E9 9E9 9E9 9E9 9E9 9E9 NoEOffs v1000 z50 Tool0 4 Run the program in manual mode 5 Check that the calibration marks for the axes align correctly If they do not update the revolution counters The calibration marks are shown in section Calibration scales and correct axis position on page 412 How to update the revolution counters is detailed in section Updating revolution coun...

Page 422: ...alibration marks for the axes align correctly If they do not update the revolution counters The calibration marks are shown in section Calibration scales and correct axis position on page 412 Detailed in section Updating revolution counters on page 415 Action Note 1 Tap Jogging in the ABB menu 2 Tap Motion mode to choose group of axes to jog 3 Tap axes 1 3 to jog axes 1 2 or 3 4 Manually run the r...

Page 423: ...ight 2004 2008 ABB All rights reserved 5 7 Additional calibration instruction IRB4400 Instrauction Before updating the revolution counters coarse calibration on IRB 4400 the stainless steel metal ring on axis 4 need to be removed Illustration xx0600003124 A Upper arm B Stainless steel ring C hose clamp A B C ...

Page 425: ...ce with local regulations Do no dispose of oil and grease near lakes ponds ditches down drains or on to soil Incineration must be carried out under controlled conditions in accordance with local regulations Also note that Spills may form a film on water surfaces causing damage to organisms Oxygen transfer could also be impaired Spillage may penetrate the soil causing ground water contamination Mat...

Page 426: ...ssioning The procedure below details the actions to perform on field when the balancing device is to be decommissioned Equipment Art no Note Standard toolkit The contents are defined in section Standard toolkit on page 436 in part 2 of the Product manual Cutting torch For opening housing and cutting coils Other tools and procedures may be required See references to these procedures in the step by ...

Page 427: ...e the balancing device The device also contains some grease 2 Place the device on a workbench or similar Make sure it is clamped in position with a vice or similar 3 Open a hole in the side of the housing as shown in the figure Use a cutting torch The measurements shown below are maximum values xx0400000700 4 Cut the coils of the three springs inside the housing as specified below Outer spring cut...

Page 429: ...this enlargement following main parts on the robot differ from type A frame lower arm motor axis 2 adjustable mechanical stop axis 2 limit switches axis 2 How to know which type the robot is The identification plate on the cabinet and the lower arm of the robot tells if the robot has the enlarged gear or not Those robots with the original gear are named IRB 6600 Type A IRB 6650 Type A or simply IR...

Page 431: ...HAC023082 001 Revision E Copyright 2004 2008 ABB All rights reserved 8 Reference information 8 1 Introduction General This chapter includes general information complementing the more specific information in the Product manual part 1 of 2 procedures ...

Page 432: ...t of machines Part 1 General requirements EN 1050 Principles for risk assessment ANSI RIA 15 06 1999 Industrial robots safety requirements DIN 19258 Interbus S International Standard Standards robot cell The following standards are applicable when the robot is part of a robot cell EN 953 Fixed and moveable guards EN 811 Safety distances to prevent danger zones being reached by the lower limbs EN 3...

Page 433: ...04 2008 ABB All rights reserved 8 3 Unit conversion Converter table Use the table below to convert units used in this manual Quantity Units Length 1 m 3 28 ft 39 37 in Weight 1 kg 2 21 lb Pressure 1 bar 100 kPa 14 5 psi Force 1 N 0 738 lbf Moment 1 Nm 0 738 lbf tn Volume 1 L 0 264 US gal ...

Page 434: ...Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint Screws treated with Gleitmo may be reused 3 4 times before the coating disappears After this the screw must be discarded and replaced with a new one When handling screws treated with Gleitmo protective gloves of nitrile rubber type should be used Screws lubricated in other ways Screws lubricated with Moly...

Page 435: ...ue specified overrides the standard value Use the correct tightening torque for each type of screw joint Only use correctly calibrated torque keys Always tighten the joint by hand and never use pneumatical tools Use the correct tightening technique i e do not jerk Tighten the screw in a slow flowing motion Maximum allowed total deviation from the specified value is 10 The table below specifies the...

Page 436: ...r and air connectors when one or both connectors are made of brass Dimension Tightening torque Nm Class 8 8 oil lubri cated Tightening torque Nm Class 10 9 oil lubri cated Tightening torque Nm Class 12 9 oil lubri cated M5 6 M6 10 M8 24 34 40 M10 47 67 80 M12 82 115 140 M16 200 290 340 M24 725 960 1150 Dimension Tightening torque Nm Class 10 9 Molycote lubricated Tightening torque Nm Class 12 9 Mo...

Page 437: ...cified All components exceeding 22 kg 50 lbs are high lighted in this way To avoid injury ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg A wide range of lifting tools and devices are available for each manipulator model Example Below is an example of how a weight specification is presented inside a procedure table Action Note CAUTION The motor we...

Page 438: ...olkit and defined in the table below This way the tools required are the sum of the Standard Toolkit and any tools listed in the instruction Contents standard toolkit Qty Tool Rem 1 Ring open end spanner 8 19 mm 1 Socket head cap 5 17 mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 10 100 Nm 1 Torque wrench 75 400 Nm 1 Ratchet head for torque wrench 1 2 2 Hexagon headed screw M10x100 1...

Page 439: ...also specified directly in concerned instructions in the Product manual procedures Description Qty Art no Bolts M16 x 60 for Mech stop ax 3 2 3HAB 3409 86 Guide pins M8 x 100 2 3HAC 15520 1 Guide pins M8 x 150 2 3HAC 15520 2 Guide pins M10 x 100 2 3HAC 15521 1 Guide pins M10 x 150 2 3HAC 15521 2 Lifting tool wrist unit 1 IRB6600 IRB 6650 3HAC 13605 1 Lifting tool motor ax 1 4 5 1 3HAC 14459 1 Lift...

Page 440: ...device base 1 3HAC15560 1 Lifting device manipulator 1 3HAC15607 1 Lifting device upper arm 1 3HAC15994 1 Lifting eye VLBG M12 1 3HAC16131 1 Lifting eye M16 2 3HAC14457 4 Lifting tool chain 1 3HAC15556 1 Lifting tool gearbox axis 2 1 3HAC020386 001 Measuring tool 1 6896134 GN Motor press pinion 1 3HAC021883 001 Oil injector max 500 MPa 1 3HAC021590 001 Press tool axis 2 bearing 1 3HAC13527 1 Pulle...

Page 441: ...nge Levelmeter 2000 kit 6369901 347 Includes one sensor Measuring pin 3HAC 13908 5 Sensor fixture 68080011 GM Sensor plate 3HAC 0392 1 Sync adapter 3HAC 13908 1 Turn disk fixture 3HAC 68080011 GU Description Art no Note Description Art no Note Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Description Art no Note Oil exchange equipment 3HAC 021745 001 Inc...

Page 442: ...General Many repair and maintenance activities require different pieces of lifting equipment which are specified in each procedure The use of each piece of lifting equipment is not detailed in the activity procedure but in the instruction delivered with each piece of lifting equipment This implies that the instructions delivered with the lifting equipment should be stored for later reference ...

Page 443: ...st 9 1 Introduction 441 3HAC023082 001 Revision E Copyright 2004 2008 ABB All rights reserved 9 Spare part part list 9 1 Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot ...

Page 444: ...right 2004 2008 ABB All rights reserved 9 2 Spare part list 9 2 1 Introduction Overview This section specifies all articles considered spare parts of the robot The spare parts are also specified as required equipment directly in the repair instruction of the current spare part ...

Page 445: ...s reserved 9 2 2 Spare part list Repair instructions Each spare part is replaced as described in corresponding repair instruction in the Product manual procedures Location spare parts IRB 6600 and IRB 6650 The figure below shows the spare parts of the IRB 6600 and IRB 6650 xx0400001022 Continues on next page ...

Page 446: ...ist 3HAC023082 001 Revision E 444 Copyright 2004 2008 ABB All rights reserved Location spare parts IRB 6600ID and IRB 6650ID The figure below shows the spare parts of the IRB 6600ID and IRB 6650ID xx0500001796 Continued Continues on next page ...

Page 447: ...001 Axis 4 Foundry Prime H SMB unit 3HAC 16014 1 I Battery pack 3HAC 16831 1 J Wrist type 2 IRB 6650 125 3 2 200 2 75 IRB 6600 175 2 8 225 2 55 Wrist type 2 3HAC 16626 2 3HAC026879 001 Foundry Prime J Wrist type 2 insulated turning disk IRB 6650 125 3 2 200 2 75 IRB 6600 175 2 8 225 2 55 3HAC 16626 3 J Wrist process IRB 6600ID and IRB 6650ID 3HAC 024793 001 K Turning disk diam 200 175 2 55 3HAC025...

Page 448: ...024385 001 Cable harness axes 1 6 IRB 6650 3HAC 024386 001 Cable harness axis 5 3HAC 14139 1 Motor 3HAC 17484 10 3HAC026982 001 Axis 5 Foundry Prime Gearbox 3HAC 10828 13 Axis 6 Motor including pinion 3HAC 15991 4 3HAC026983 001 Axis 6 Foundry Prime Cable harness axes 5 6 IRB 6600 and IRB 6650 3HAC 14140 1 Spherical roller bearing 3HAA 2167 18 At front ear of the balancing device Sealing spacer 3H...

Page 449: ...Installation is detailed in 25 3 Position switch axis 1 Installation of position switches option on page 111 30 1 Position switch axis 2 33 1 Position switch axis 3 37 1 Base plate Securing the base plate on page 74 87 1 Cooling fan axis 1 Installation of cooling fan for motors axes 1 3 option on page 97 88 1 Cooling fan axis 2 89 1 Cooling fan axis 3 159 1 Fork lift device Lifting robot with fork...

Page 450: ...08 ABB All rights reserved 9 3 Part list 9 3 1 Introduction Overview This section specifies all the replacement articles of the robot The parts are shown in exploded views or in foldouts either in this or in a separate chapter Specific spare parts are listed separately in a Spare part list ...

Page 451: ... 003 Lower arm type B X X 105 3HAC026574 001 Lower arm type B Foundry Prime X X 105 3HAC020505 003 Lower arm X X X 105 3HAC17212 1 Sealing axis 2 3 typeA X X X X X 108 201 3HAC020123 001 Sealing axis 2 3 typeB X X X X X X X 108 201 3HAB3409 84 Screw M16x50 18X 18X 108 202 3HAA1001 186 Washer 7x25x3 18X 18X 108 204 3HAC020958 001 Cable protection typeA X X X X X 108 235 3HAC021071 001 Cable protect...

Page 452: ... 109 302 3HAC020098 001 Guiding plate ax2 X X X 109 336 3HAC020745 001 Attachment plate X X X 109 336 3HAC020122 001 Attachment plate typeB X X 109 336 3HAC14792 1 Bracket X X X X X 109 338 3HAC15882 2 Motor axis 3 X 102 3 5 3HAC15885 2 Motor axis 3 X X X X X X X 102 3 5 3HAB3409 71 Screw M12x50 8X 8X 8X 8X 8X 8X 8X 109 304 3HAA1001 134 Washer 13x19x1 5 8X 8X 8X 8X 8X 8X 8X 109 305 3HAB3772 69 O r...

Page 453: ...e 466 103 1 3HAC 8114 8 Wrist type 2 insulated See section Wrist type 2 insulated on page 467 103 1 3HAC 023639 001 Wrist process IRB 6600ID 6650ID See section Wrist process IRB 6600ID and 6650ID on page 464 104 1 3HAC 17117 2 Balancing Device A 6600 225 2 55 6600 175 2 8 6600 175 2 55 6600ID 185 2 55 104 1 3HAC 17117 3 Balancing Device B 6650 125 3 2 6650 200 2 75 6650ID 170 2 75 105 1 3HAC 02012...

Page 454: ... Material set balancing device 3HAC 13265 1 on page 473 111 1 3HAC 12311 4 Arm extension set 250mm IRB 6600 175 2 8 See section Arm extension set 250 mm 3HAC 12311 4 on page 474 111 1 3HAC 12311 5 Arm extension set 450mm IRB 6650 125 3 2 See section Arm extension set 450 mm 3HAC 12311 5 on page 475 112 2 or 1 3HAC 12129 1 Cover plate t 1 5 mm 112 1 3HAC026188 001 Cover plate Foundry Prime t 1 5 mm...

Page 455: ...t head cap screw M16 x 70 101 5 1 3HAC 11529 1 Rubber lined clip D 28 101 6 1 3HAC 14453 1 Hose with flange 101 7 1 3HAC 14453 2 Plug 101 8 1 3HAC 4428 2 Hose Clip D 23 27 101 9 1 9ADA 618 56 Torx pan head screw M6 x 16 Item Qty Art number Description Dimension 101 1 1 1 3HAC 17224 2 Base casting 101 1 2 5 3HAC 4836 7 Protection plug 16 x 12 3 x 9 x 7 101 1 3 1 3HAC 1383 2 Protection Cover compl 1...

Page 456: ... sub block Wheel unit ax 4 225 kg 3HAC 12259 1 on page 455 102 1 6 3 3HAA 1001 99 Wedge 102 1 7 3 3HAC 12560 1 Stud bolt M8 x 65 102 1 8 12 9ADA 334 7 Spring washer conical 8 4 x 18 x 2 102 1 9 3 9ADA 267 7 Hexagon nut M8 102 1 10 3 3HAB 3409 63 Hex socket head cap screw M10 x 110 102 1 11 3 9ADA 334 8 Spring washer conical 10 5 x 23 x 2 5 102 1 12 1 3HAC 13564 1 Damper axis 4 See sub block Damper...

Page 457: ...d 102 1 33 1 ml 3HAB 7116 2 Locking liquid 102 1 34 1 3HAC 16721 1 Magnetic plug R 1 2 Item Qty Art number Description Dimension Note Item Qty Art number Description Dimenstion Note 102 1 5 1 1 3HAC 11742 1 Intermediate hub machine 102 1 5 2 1 3HAC 12259 2 Gear unit Z2 3 4 See sub block below 102 1 5 3 1 2126 2851 104 Lock nut M20 X 1 102 1 5 4 1 2213 3802 11 Taper roller bearing 40 x 68 x 19 102 ...

Page 458: ...V 410F 270 176 assembly See sub block RV 410F 270 176 assembly 3HAC 021127 001 on page 456 102 3 3 24 3HAB 3409 71 Hex socket head cap screw M12 x 60 102 3 4 24 3HAA 1001 134 Washer 13 x 19 x 1 5 102 3 5 1 3HAC 14750 1 Rot ac motor incl pinion See sub block Rot ac motor incl pinion 3HAC 14750 1 on page 456 102 3 6 4 3HAB 3409 50 Hex socket head cap screw M10 x 40 102 3 7 4 3HAB 4233 1 Washer 102 3...

Page 459: ... 1 2152 2012 430 O ring 89 5 x 3 102 3 5 4 1 9ADA 183 444 Hex socket head cap screw M8 x 130 102 3 5 5 3 ml 3HAB 7116 1 Locking liquid Item Qty Art number Description Dimension Item Qty Art number Description Dimension 102 4 1 1 3HAC 17484 10 Rotational ac motor M10 102 4 2 1 3HAC 12260 1 Pinion Z1 4 102 4 3 1 2152 2012 430 O ring 89 5x3 Continued ...

Page 460: ...rview Item Qty Art number Description Note 102 1 1 3HAC 13350 1 Material set ax 4 See block Material set ax 4 3HAC 13350 1 on page 454 102 2 1 3HAC 020053 001 Tube shaft 2 55 foundry 102 3 1 3HAC 13351 1 Axis 3 See block Axis 3 3HAC 13351 1 on page 456 102 4 1 3HAC 14752 1 Rot ac motor incl gearbox See block Rot ac motor incl gearbox on page 457 ...

Page 461: ...ights reserved 9 3 7 Axis 3 4 Foundry Prime Overview Item Qty Art number Description Note 102 1 1 3HAC 13350 1 Material set ax 4 102 2 1 3HAC 020053 001 Tube shaft 2 55 foundry 102 3 1 3HAC 13351 1 Axis 3 102 4 1 3HAC 14753 1 Rot ac motor incl gearbox 6600 175 2 55 102 4 1 3HAC 14752 1 Rot ac motor incl gearbox ...

Page 462: ...p screw M8 x 25 103 1 5 8 9ADA 312 7 Plain washer 8 4 x 16 x 1 6 103 1 6 1 3HAA 2166 11 VK Cover D 80 B 10 103 1 7 1 3HAC 4334 3 Cylindrical roll bearing 50 x 90 x 20 103 1 8 4 3HAC 12560 1 Stud bolt M8 x 65 103 1 9 1 ml 3HAB 7116 2 Locking liquid 103 1 10 16 9ADA 334 7 Spring washer conical 8 4 x 18 x 2 103 1 11 4 9ADA 267 7 Hexagon nut M8 103 1 12 4 3HAA 1001 99 Wedge 103 1 13 1 3HAB 7299 1 Seal...

Page 463: ... 1 34 5 ml 1171 2016 618 Lubricant paste Item Qty Art number Description Dimension Note Item Qty Art number Description Dimension 103 1 15 1 1 3HAC 14731 1 Shaft 103 1 15 2 1 3HAB 3643 11 Groove ball bearing 130 x 165 x 18 103 1 15 3 3 9ADA 618 56 Torx pan head screw M6 x 16 103 1 15 4 1 ml 3HAB 7116 1 Locking liquid Item Qty Art number Description Dimension Note 103 1 26 1 1 3HAC 7946 1 Hub ax5 m...

Page 464: ...e sub block Rot ac motor incl pinion 3HAC 14754 1 on page 463 103 4 5 4 9ADA 312 7 Plain washer 8 4 x 16 x 1 6 103 4 6 4 9ADA 183 37 Hex socket head cap screw M8 x 25 103 4 7 18 3HAA 1001 172 Washer 8 4 x 13 x 1 5 103 4 8 2 2522 122 1 Magnetic plug R1 4 103 4 9 450 ml 3HAC 16843 1 Lubricating oil RMO 150 Do not mix different types of oil 103 4 9 450 ml 3HAC 032140 001 Lubricating oil Kyodo Yushi T...

Page 465: ...ac motor incl pinion 3HAC 14754 1 Item Qty Art number Description Dimension 103 4 4 1 1 3HAC 17484 8 Rotational ac motor M8 103 4 4 2 1 3HAC 11173 3 Pinion RV 70F 125 8 103 4 4 3 1 2152 2012 430 O ring 89 5 x 3 103 4 4 4 1 9ADA 183 415 Hex socket head cap screw M5 x 55 103 4 4 5 2 ml 3HAB 7116 1 Locking liquid 103 4 4 6 1 3HAC 12877 1 Gasket Continued ...

Page 466: ...3HAC11409 6 Shoulder Screw 103 13 1 3HAC021044 001 Wrist Cover 103 14 1 3HAC021044 001 Wrist Cover 103 15 1 3HAB3701 30 Radial Seals w dust lip 103 16 3 ml 12690014 413 Locking liquid 103 17 3 ml 12690014 413 Locking liquid 103 18 1 3HAC021237 001 Adjust screw 103 19 1 3HAC021237 001 Adjust screw 103 20 3 3HAC16721 1 Magnetic plug 103 21 3 3HAC16721 1 Magnetic plug 103 22 1 3HAC18146 1 Bearing scr...

Page 467: ...16x70 103 40 1 3HAB3772 85 O ring 103 41 1 3HAC13142 1 Washer 103 42 4 3HAA1001 99 Wedge 103 43 4 3HAA1001 99 Wedge 103 44 4 3HAC12560 1 Stud bolt 103 45 4 3HAC12560 1 Stud bolt 103 46 16 9ADA334 7 Spring washer conical 103 47 16 9ADA334 7 Spring washer conical 103 48 4 9ADA267 7 Hexagon nut M8 103 49 4 9ADA267 7 Hexagon nut M8 103 50 1 3HAC022695 001 Screw 103 51 1 3HAC18246 1 Washer 103 52 1 3HA...

Page 468: ... Description Dimension 103 1 1 3HAC 8114 4 Material set See block Material set 3HAC 8114 4 on page 460 103 2 1 3HAC 7941 30 Rot ac motor incl gearbox See block Rot ac motor incl gearbox on page 462 103 3 10 3HAB 3409 89 Hex socket head cap screw M16 x 80 103 4 1 3HAC 13890 2 Axis 6 complete Foundry See block Axis 6 complete 3HAC 13890 1 2 on page 462 103 5 1 3HAC 020566 001 Label ...

Page 469: ... 467 Item Qty Art no Description Note Dimension 103 4 1 1 3HAC 17196 1 Axis 6 insulated 103 4 2 1 3HAC 14754 1 Rot ac motor incl pinion See sub block Rot ac motor incl pinon 3HAC 14754 1 on page 467 103 4 3 4 9ADA 312 7 Plain washer M8 103 4 4 4 9ADA 183 37 Hex socket head cap screw 103 4 5 450 ml 3HAC 032140 001 Lubricating oil Kyodo Yushi TMO150 103 4 5 450 ml 3HAC 16843 1 Lubricating oil RMO 15...

Page 470: ...BB All rights reserved 9 3 12 Wrist type 2 Foundry Prime Overview Item Qty Art number Description Dimension 103 1 1 3HAC 8114 4 Material set 103 2 1 3HAC 7941 30 Rot ac motor incl gearbox 103 3 10 3HAB 3409 89 Hex socket head cap screw 103 4 1 3HAC 13890 2 Axis 6 complete Foundry 103 5 1 3HAC 020566 001 Label ...

Page 471: ...e protection IRB6600 and IRB 6600ID 108 212 1 3HAC 11771 1 Cable guide end part 108 213 1 3HAC 13960 1 Connection plate ax3 t 4 mm 108 214 2 3HAC 12320 1 Damper axis 3 108 215 2 3HAC 12991 1 Damper axis 2 108 216 2 9ADA 624 65 Torx counters head screw M6 x 60 108 217 2 9ADA 334 7 Spring washer conical 8 4 x 18 x 2 108 218 2 9ADA 618 57 Torx pan head screw M6 x 20 108 220 2 3HAC 9953 1 Syncplate wi...

Page 472: ...Bottom plate Foundry Prime T 2 109 311 1 3HAC 14131 1 Connection plate base t 3 mm 109 311 1 3HAC026186 001 Connection plate base Foundry Prime t 3 mm 109 312 1 3HAC 11774 3 Adapter complete See block Adapter complete 3HAC 11774 3 on page 472 109 313 1 3HAC 11769 1 Cable guide ax 1 109 315 14 9ADA 183 39 Hex socket head cap screw M8 x 35 109 316 14 9ADA 312 7 Plain washer 8 4 x 16 x 1 6 109 318 1 ...

Page 473: ...3 1 Lubricating oil RMO 150 Do not mix the types of oil 109 342 5 800 ml 3HAC 032140 001 Lubricating oil Kyodo Yushi TMO150 Do not mix the types of oil 109 344 1 ml 3HAB 7116 1 Locking liquid 109 345 2 9ADA 267 6 Hexagon nut M6 109 346 1 3HAC 16035 1 BU w buttons DSQC 563 109 347 1 3HAC 6499 1 Push button guard 109 348 4 9ADA 629 56 Torx pan head roll screw M6 x 16 109 349 2 9ADA 618 58 Torx pan h...

Page 474: ...gon socket head screw M8 x 150 109 307 4 1 2152 2012 430 O ring 89 5 x 3 109 307 5 1 ml 3HAB 7116 1 Locking liquid Item Qty Art number Description Dimension 109 312 1 1 3HAC 11774 1 Adapter machined 109 312 2 2 2152 2012 428 O ring 79 5 x 3 109 312 3 1 ml 1234 0011 125 Acrylate adhesive Item Qty Art number Description Dimension 109 322 1 1 3HAC 13582 1 Protection screw 109 322 2 1 3HAB 3772 32 O r...

Page 475: ...ushing 110 404 1 9ABA 135 31 Retaining ring shaft 65 110 405 1 3HAC 12480 1 Shaft 110 406 1 3HAC 4836 7 Protection plug 16 x 12 3 x 9 x 7 110 407 4 3HAB 7700 5 Hex socket head cap screw M16 x 70 110 408 2 9ABA 107 56 Parallel pin 10 x 20 110 409 1 3HAC 12548 1 Protection washer T 1 110 410 1 3HAC 12534 1 Shaft balancing device 110 411 4 3HAA 1001 186 Washer 17 x 25 x 3 110 412 50 ml 3HAA 1001 294 ...

Page 476: ...11 4 Overview Item Qty Art number Description Dimension 111 501 1 3HAC 9760 3 Arm extender 250mm 111 501 1 3HAC 15859 2 Arm extender 250mm Foundry 111 503 12 3HAB 7700 69 Hex socket head cap screw M12 x 50 111 504 12 3HAA 1001 134 Washer 13 x 19 x 1 5 111 505 1 9ABA 107 56 Parallel pin 10 x 20 111 506 1 3HAC 9760 9 Cable cover 250mm 111 507 4 9ADA 618 56 Torx pan head screw M6 x 16 ...

Page 477: ...1 5 Overview Item Qty Art number Description Dimension 111 501 1 3HAC 9760 7 Arm extender 450mm 111 501 1 3HAC 15859 3 Arm extender 450mm Foundry 111 503 12 3HAB 7700 69 Hex socket head cap screw M12 x 50 111 504 12 3HAA 1001 134 Washer 13 x 19 x 1 5 111 505 1 9ABA 107 56 Parallel pin 10 x 20 111 506 1 3HAC 9760 10 Cable cover 450mm 111 507 6 9ADA 618 56 Torx pan head screw M6 x 16 ...

Page 479: ...ved 10 Exploded views 10 1 Introduction Definitions This chapter contains detailed views of the components on the manipulator The numbered details are specified with item numbers in the Part List The exploded views are divided into Base incl frame Frame Lower arm 1 Frame Lower arm 2 Upper arm Wrist complete ...

Page 484: ...10 Exploded views 10 6 Wrist complete IRB 6600 and IRB 6650 3HAC023082 001 Revision E 482 Copyright 2004 2008 ABB All rights reserved 10 6 Wrist complete IRB 6600 and IRB 6650 Exploded view xx0200000336 ...

Page 485: ...xploded views 10 7 Wrist complete IRB 6600ID and IRB 6650ID 483 3HAC023082 001 Revision E Copyright 2004 2008 ABB All rights reserved 10 7 Wrist complete IRB 6600ID and IRB 6650ID Exploded view xx0500002407 ...

Page 487: ...for the robot Use the correct circuit diagram IRB 6600 IRB 6650 and IRB 6650S The cable harness of the robot is available in two different designs Either the cabling is divided between the upper and lower arm or not Accordingly there are also two different versions of the circuit diagram Determine which circuit diagram that is valid for the robot by checking the article number for the cable harnes...

Page 488: ...alid for your robot The validity of the circuit diagram depends on which cable harness is fitted to the robot Check the article number of the cable harness fitted to the robot and see page 3 of the circuit diagram in order to determine if the diagram is valid for the harness or not Where to find the article number Action Label on the cable harness The label is located at the connectors in the base...

Page 489: ...rs that may appear in this document Except as may be expressly stated anywhere in this document nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses damages to persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this document This document and parts thereof mus...

Page 490: ...ge Page description ABB Contents1 1 COPYRIGHT page 2 Table of contents 1 150 3 Valid For 4 Connection point location IRB 6600 6640 6650 7600 5 Connection point location IRB 6660 9 Legend IRB 66XX 7600 10 Brake Release Unit IRB 66XX 7600 20 Serial Measuring Board IRB 66XX 7600 30 Axis 1 IRB 66XX 7600 40 Axis 2 IRB 66XX 7600 50 Axis 3 Incl optional signal lamp IRB 66XX 76 60 Axis 4 IRB 66XX 7600 70 ...

Page 491: ...1 Manipulator harness axis 5 IRB 6600 6640 6650 6650S 3HAC11440 1 Manipulator harness axis 5 6 IRB 7600 3HAC023717 001 Manipulator harness axis 5 6 IRB 6600 ID 6640 ID 6650 ID 3HAC15930 1 UL signal lamp IRB 6600 6640 6650 6600 ID 6640 ID 6650 ID 6650S 7600 3HAC12498 1 Pos SW 3 functions IRB 6600 6640 6650 6600 ID 6640 ID 6650 ID 6650S 7600 3HAC12587 1 Pos SW 2 functions IRB 6600 6650 6600 ID 6650 ...

Page 492: ...7 8 R1 G R1 SMB1 7 R3 FAN2 R2 FB7 R2 G R2 SMB R1 SMB1 3 R1 SMB4 6 R2 SW2 X8 X9 X10 R2 MP2 R2 FB2 R2 MP4 R2 FB4 R3 FAN3 R2 FB3 R2 MP3 R2 H1 R2 H2 R2 M5 6 IRB7600 6600 ID 6640 ID 6650 ID R2 MP1 R2 FB1 R3 MP5 IRB 7600 6600 ID 6640 ID 6650 ID R3 FB5 IRB 7600 6600 ID 6640 ID 6650 ID R3 MP6 R3 FB6 R3 MP5 IRB 6600 6640 6650 6650S R3 FB5 IRB 6600 6640 6650 6650S R4 MP5 IRB 6600 6640 6650 6650S R4 FB5 IRB ...

Page 493: ...opyright 2003 ABB Page 5 21 Total IRB 6660 3HAC025744 001 Latest revision Approved by date Connection point location Location Plant Sublocation IRB6660 Manipulator Document no Next Rev Ind 02 Lab Office Status APPROVED 1 2 3 4 5 6 7 8 R3 MP6 R3 FB6 R3 MP5 R3 FB5 R2 MP3 R2 FB3 R2 H1 R2 H2 R2 MP1 R2 FB1 R1 MP R1 SMB R1 CP CS R2 MP4 R2 FB4 R2 MP2 R2 FB2 R1 SMB1 3 R1 SMB4 6 R2 SMB X8 X9 X10 R2 CP CS ...

Page 494: ...revision Approved by date Legend Location Plant Sublocation IRB66XX 7600 Manipulator Document no Next Rev Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 M B PTC R G BU FB SMB FAN SW Keypin Motor Brake Temp sensor PTC resistor Resolver Battery Pack Brake Release Unit Feedback unit Serial Measurment Board Fan Position switch Location pin to avoid mismatch Protective Earth Twisted wires...

Page 495: ... Circuit Brake Bleed Circuit Brake Bleed Circuit Brake Bleed Circuit Brake Bleed Circuit Brake Bleed Circuit 9 1 Key Pin Key Pin BU Brake Release Simplified R1 MP 13 4 3 5 2 X8 1 X8 1 5 3 11 12 X10 1 3 5 X9 4 8 10 X10 1 3 5 X9 4 8 10 Brake Release Brake PB 2 1 R1 MP R1 MP R1 MP R1 MP R1 MP R1 MP 5 6 7 8 9 10 0V 4 BU M1 Axis 1 30 2 BU M2 Axis 2 40 2 BU M3 Axis 3 50 2 BU M4 Axis 4 60 2 BU M5 7600 Ax...

Page 496: ...otal IRB 66XX 7600 3HAC025744 001 Latest revision Approved by date Serial Measuring Board Location Plant Sublocation 66XX 7600 SMB Document no Next Rev Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 A B C D E F L KEYPIN M R1 SMB 9 5 8 4 3 7 R2 SMB SDI SDI N SDO SDO N 0V 24V BK WHBK BN WHBN RD WHRD OG SMB 9 5 8 4 3 7 2 1 R2 SMB 2 1 R1 G X3 R1 G X3 G 0V Axis 3 50 3 0V EXT LAMP Axis 3 5...

Page 497: ...xt Rev Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 M 3 S V T W R U PE R2 MP1 1 6 7 9 2 5 Brake MU1 RD WH BK GNYE BU BU R2 MP1 1 6 7 9 12 2 17 18 19 R1 MP M1R M1S M1T BU M1 BU 0V M1 1 3 5 GNYE 9 10 R2 FB1 6 1 7 2 8 3 Resolver FB1 RD BK BU YE WHBK WHYE WHRD R2 FB1 6 1 7 2 8 3 2 14 3 15 6 18 R1 SMB1 3 BK WHBK BN WHBN RD WHRD X1 0V X1 Y1 0V Y1 0V EXC1 EXC1 2 14 3 15 6 18 R1 SMB1 3 SMB...

Page 498: ...02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 SMB R1 SMB1 3 4 16 5 17 7 19 R1 MP 32 31 30 4 16 5 17 7 19 R1 SMB1 3 BK WHBK BN WHBN RD WHRD M2R M2S M2T BU M2 BU 0V M2 1 2 4 GNYE 9 10 X2 0V X2 Y2 0V Y2 0V EXC1 EXC1 R2 MP2 1 6 7 9 2 5 R2 FB2 6 1 7 2 8 3 FB2 MU2 R2 MP2 1 6 7 9 2 5 R2 FB2 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver 4 3 10 12 R...

Page 499: ...4 5 6 7 8 SMB R1 SMB1 3 9 21 10 22 8 20 R1 MP 3 5 7 9 21 10 22 8 20 R1 SMB1 3 BK WHBK BN WHBN RD WHRD M3R M3S M3T PE PE BU M3 1 2 3 GNYE GNYE 9 X3 0V X3 Y3 0V Y3 0V EXC1 EXC1 R2 MP3 1 6 7 9 12 2 R2 FB3 6 1 7 2 8 3 FB3 MU3 R2 MP3 1 6 7 9 2 5 R2 FB3 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver KEYPIN B KEYPIN A A K 1 2 R2 H1 R2 H2 R2 H1 R2 H2 OG R3 H S...

Page 500: ...v Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 SMB R1 SMB4 6 2 14 3 15 6 18 R1 MP 1 2 10 2 14 3 15 6 18 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M4R M4S M4T PE BU M4 BU 0V M4 1 2 3 GNYE 6 7 X4 0V X4 Y4 0V Y4 0V EXC2 EXC2 R2 MP4 1 3 7 9 2 5 R2 FB4 6 1 7 2 8 3 FB4 MU4 R2 MP4 1 3 7 9 2 5 R2 FB4 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver PTC4 ...

Page 501: ...5 17 7 19 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M5R M5S M5T PE BU M5 BU 0V M5 1 2 3 GNYE 6 7 X5 0V X5 Y5 0V Y5 0V EXC2 EXC2 R3 MP5 1 3 7 9 2 5 R3 FB5 6 1 7 2 8 3 FB5 MU5 R3 MP5 1 3 7 9 2 5 R3 FB5 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver C1 C2 C3 GND B9 B1 B7 B8 8 11 C1 C2 C3 GND B9 B1 B7 8 11 PTC5 1 2 BU BK M5R M5S M5T PE BU M5 BU 0V M5 1 2 3 GNYE 6 ...

Page 502: ... 16 5 17 7 19 20 28 29 R1 SMB4 6 R1 MP BK WHBK BN WHBN RD WHRD M5R M5S M5T PE BU M5 BU 0V M5 PTC M5 5 1 2 3 GNYE 6 7 4 X5 0V X5 Y5 0V Y5 0V EXC2 EXC2 A B C D E F A B C D E F R3 FB5 R3 MP5 1 2 3 GND C D A B BK WHBK BN WHBN RD WHRD 1 2 3 GND C D A B M5R M5S M5T PE BU M5 BU 0V M5 PTC M5 PTC M6 X5 0V X5 Y5 0V Y5 0V EXC2 EXC2 1 2 3 GNYE 6 7 4 5 R4 FB5 6 1 7 2 8 3 R4 MP5 1 3 7 9 2 5 8 11 FB5 R4 FB5 6 1 ...

Page 503: ...6XX 7600 BU 10 2 BU 0V M5 66XX 7600 Axis 4 60 2 PTC M5 20 28 29 15 4 16 5 17 7 19 PTC 0V R1 SMB4 6 5 BK WHBK BN WHBN RD WHRD M5R M5S M5T PE BU M5 BU 0V M5 PTC M5 X5 0V X5 Y5 0V Y5 0V EXC2 EXC2 1 2 3 GNYE 6 7 4 R2 M5 6 C1 C2 C3 GND B9 B1 B7 A1 A7 A2 A8 A3 A9 C1 C2 C3 GND B9 B1 B7 A1 A7 A2 A8 A3 A9 R2 M5 6 BN WHBN RD WHRD OG WHOG M5R M5S M5T PE BU M5 BU 0V M5 PTC M5 PTC M6 1 2 3 GNYE 9 11 7 X5 0V X5...

Page 504: ... 20 R1 MP 9 8 16 9 21 10 22 8 20 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M6R M6S M6T PE BU M6 BU 0V M6 1 2 3 GNYE 6 7 X6 0V X6 Y6 0V Y6 0V EXC2 EXC2 R3 MP6 1 3 7 9 2 5 R3 FB6 6 1 7 2 8 3 FB6 MU6 R3 MP6 1 3 7 9 2 5 R3 FB6 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver 8 11 BU BK PTC6 1 2 8 11 R2 M5 6 C4 C5 C6 GND B11 B12 B10 C4 C5 C6 GND B11 B12 B10 M6R M6S M...

Page 505: ... 6 Document no Next Rev Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 SMB R1 SMB4 6 9 21 10 22 8 20 R1 MP 9 8 16 9 21 10 22 8 20 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M6R M6S M6T PE BU M6 BU 0V M6 1 2 3 GNYE 6 7 X6 0V X6 Y6 0V Y6 0V EXC2 EXC2 R3 MP6 1 3 7 9 2 5 R3 FB6 6 1 7 2 8 3 FB6 MU6 R3 MP6 1 3 7 9 2 5 R3 FB6 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U...

Page 506: ...9 21 10 22 8 20 9 21 10 22 8 20 R1 MP 66XX 7600 BU 10 7 BU M6 9 8 16 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M6R M6S M6T PE BU M6 X6 0V X6 Y6 0V Y6 0V EXC2 EXC2 1 2 3 GNYE 6 R2 M5 6 C4 C5 C6 GND B11 B10 R2 M5 6 A4 A10 A5 A11 A6 A12 C4 C5 C6 GND B11 B10 A4 A10 A5 A11 A6 A12 M6R M6S M6T PE BU M6 BU 0V M6 PTC 0V BK WHBK BN WHBN RD WHRD 1 2 3 GNYE 6 7 5 X6 0V X6 Y6 0V Y6 0V EXC2 EXC2 PTC M6 4 R3 FB6 6 1 7 2...

Page 507: ...0 17 1 2 3 4 5 6 7 8 SW1 1 22 21 14 13 SW1 2 22 21 14 13 SW1 3 22 21 14 13 SW1 4 22 21 14 13 SW1 5 22 21 14 13 SW1 6 22 21 14 13 A B D C E F H G J K M L N P S R T U W V X Y a Z Position switches Axis 1 Power 1 1 1 Power 1 1 2 Signal 1 1 1 Signal 1 1 2 Power 1 2 1 Power 1 2 2 Signal 1 2 2 Signal 1 2 1 Power 1 3 1 Power 1 3 2 Signal 1 3 2 Signal 1 3 1 Power 1 4 1 Power 1 4 2 Signal 1 4 2 Signal 1 4 ...

Page 508: ... A B D C E F H G J K M L Power 2 1 1 Power 2 1 2 Signal 2 1 2 Signal 2 1 1 Power 2 2 1 Power 2 2 2 Signal 2 2 2 Signal 2 2 1 Power 2 3 1 Power 2 3 2 Signal 2 3 2 Signal 2 3 1 1 2 4 3 5 6 8 7 9 10 12 11 SW2 1 22 21 14 13 SW2 2 22 21 14 13 SW2 3 22 21 14 13 Position switches Axis 2 R1 SW2 3 A B D C E F H G J K M L A B D C E F H G J K M L R2 SW2 Power 2 1 1 Power 2 1 2 Signal 2 1 2 Signal 2 1 1 Power...

Page 509: ...8 T U W V X Y a Z b c e d f h g R1 SW2 3 Power 3 1 1 Power 3 1 2 Signal 3 1 2 Signal 3 1 1 Power 3 2 1 Power 3 2 2 Signal 3 2 2 Signal 3 2 1 Power 3 3 1 Power 3 3 2 Signal 3 3 2 Signal 3 3 1 1 2 4 3 5 6 8 7 9 10 12 11 13 15 14 A B D C E F H G J K M L A B D C E F H G J K M L R2 SW3 Power 3 1 1 Power 3 1 2 Signal 3 1 2 Signal 3 1 1 Power 3 2 1 Power 3 2 2 Signal 3 2 2 Signal 3 2 1 Power 3 3 1 Power ...

Page 510: ... to the robot Check the article number of the cable harness fitted to the robot This circuit diagram is valid for the following cable harness assemblies For remaining cable harness assemblies see section Circuit diagram 3HAC 025744 001 on page 486 Where to find the article number Action Label on the cable harness The label is located at the connectors in the base Remove the rear cover plate to see...

Page 511: ...nnection Point Location 102 Legend 103 Brake Release Unit 104 Serial Measurement Board 105 Axis 1 106 Axis 2 107 Axis 3 108 Axis 4 109 Axis 5 IRB 7600 110 Axis 6 111 Switches axis 1 113 Switches Fan axis 2 114 Switches Fan axis 3 115 Axis 5 IRB 6600 901 Design changes note 1 1 905 Design changes note 2 1 2 7 906 ...

Page 530: ...ent 40 wrist strap connection point 40 explanation safety symbols 35 F FlexPendant jogging to calibration position 420 MoveAbsJ instruction 419 updating revolution counters 417 fork lift 61 foundation loads 54 requirements 54 G gearbox axis 1 replacement 383 gearbox axis 2 replacement 391 gearbox axis 3 replacement 399 gearbox axis 6 replacement 405 I identification 427 installation mechanical sto...

Page 531: ...ty symbols 35 scales on robot 412 securing the robot to foundation attachment screws 78 securing base plate 74 securing lower arm 305 securing robot 78 securing upper arm 352 serial measurement board unit replacement 309 special tools 437 stability 60 storage conditions robot 54 symbols safety 35 sync marks 412 T testing brakes 29 tightening torque mechanical stop axis 1 106 mechanical stop axis 2...

Page 532: ......

Page 533: ...ABB AB Robotics Products S 721 68 VÄSTERÅS SWEDEN Telephone 46 0 21 344000 Telefax 46 0 21 132592 3HAC023082 001 Revision E en ...

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