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4 Repair

4.2.1. Performing a leak-down test

3HAC022033-001 Revision: K

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4.2 General procedures

4.2.1. Performing a leak-down test

General

After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox oil must

be tested. This is done in a leak-down test.

Required equipment

Procedure

Equipment, etc.

Art. no.

Note

Leakdown tester

3HAC0207-1

Leak detection spray

-

Action

Note

1. Finish the refitting procedure of the motor or gear in

question.

2. Remove the topmost oil plug on the gear in question

and replace it with the

leakdown tester

.

Adapters, which are included in the leakdown tester
kit, may be required.

Art. no. is specified in

equipment on page 246

.

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 may

be detected.

If the compressed air is signifi-
cantly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
may occur. This is quite normal.

6. Was any pressure drop evident?

Localize the leak as detailed below.

Remove the leakdown tester and refit the oil plug.

The test is complete.

7. Spray suspected leak areas with

leak detection spray

.

Bubbles indicate a leak.

8. When the leak has been localized, take the necessary

measures to correct the leak.

工控帮助教小舒QQ2823408167

长沙工控帮教育科技有限公司

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Summary of Contents for IRB 7600 Series

Page 1: ...ABB Robotics Product manual IRB 7600 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 2: ...工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 3: ...l rights reserved Product manual IRB 7600 500 2 55 IRB 7600 500 2 3 IRB 7600 400 2 55 IRB 7600 340 2 8 IRB 7600 325 3 1 IRB 7600 150 3 5 M2000 M2000A M2004 Document ID 3HAC022033 001 Revision K 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 4: ...itness 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 prosec...

Page 5: ... 1 2 3 8 Signal lamp optional 36 1 2 4 Safety stops 37 1 2 4 1 What is an emergency stop 37 1 3 Safety related instructions 39 1 3 1 Safety signals in the manual 39 1 3 2 Safety symbols on manipulator labels 41 1 3 3 DANGER Moving manipulators are potentially lethal 46 1 3 4 DANGER First test run may cause injury or damage 47 1 3 5 WARNING The brake release buttons may be jammed after service work...

Page 6: ...Maintenance schedule 143 3 2 3 Expected component life 149 3 3 Inspection activities 150 3 3 1 Inspection oil level gearbox axis 1 150 3 3 2 Inspection oil level gearbox axis 2 153 3 3 3 Inspection oil level gearbox axis 3 156 3 3 4 Inspection oil level gearbox axis 4 158 3 3 5 Inspection oil level gearbox axis 5 161 3 3 6 Inspection oil level gearbox axis 6 164 3 3 7 Inspection balancing device 1...

Page 7: ...63 4 3 4 Replacement of air nipple and hose Foundry Prime 268 4 4 Upper and lower arm 275 4 4 1 Replacing turning disk 275 4 4 2 Replacement of complete wrist unit 279 4 4 3 Replacement of complete upper arm 283 4 4 4 Replacement of complete lower arm 288 4 5 Frame and base 297 4 5 1 Replacement of SMB unit 297 4 5 2 Replacement of brake release unit 301 4 5 3 Replacement of balancing device 307 4...

Page 8: ...n 434 8 2 2 Spare part list 435 8 3 Part list 437 8 3 1 Introduction 437 8 3 2 Rebuilding parts 438 8 3 3 Part list overview 439 8 3 4 Mechanical stop axis 1 3HAC12812 2 441 8 3 5 Base incl frame axis 1 3HAC12304 1 442 8 3 6 Axis 3 4 3HAC13063 1 IRB 7600 150 3 5 325 3 1 340 2 8 400 2 55 500 2 55 443 8 3 7 Axis 3 4 3HAC13063 2 IRB 7600 500 2 3 446 8 3 8 Axis 3 4 Foundry 3HAC13063 4 IRB 7600 150 3 5...

Page 9: ...ved 10 Circuit Diagram 469 10 1 About circuit diagrams 469 10 2 Circuit diagram 3HAC 025744 001 471 10 2 1 Validity of circuit diagram 3HAC 025744 1 471 10 3 Circuit diagram 3HAC 13347 1 472 10 3 1 Validity of circuit diagram 3HAC 13347 1 472 Index 473 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 10: ...Table of Contents 8 3HAC022033 001 Revision K Copyright 2004 2011 ABB All rights reserved 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 11: ... and electrical installation 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 the robot Contains general safety aspects as well as more specific information on how to avoid personal injuries and damage to the product Installati...

Page 12: ...ification IRB 7600 3HAC023934 001 Product specification IRB 7600 M2000 M2000A 3HAC13491 1 Circuit diagrams IRB 7600 3HAC13347 1 3HAC025744 001 Product manual IRC5 3HAC021313 001 Product manual S4Cplus M2000 3HAC021333 001 Product manual S4Cplus M2000A 3HAC022419 001 Operating manual IRC5 with FlexPendant 3HAC16590 1 User s guide S4Cplus 3HAC7793 1 Operating manual Calibration Pendulum 3HAC16578 1 ...

Page 13: ...ing oil in the gearboxes Changes made in the chapter Maintenance and Part list C New variant of the robot IRB 7600 500 2 55 implemented throughout the manual Wrist unit updated new spare part number is specified in Replacement of complete wrist unit on page 279 and Spare part list on page 435 Insulated wrist unit implemented new spare part number is specified in Replacement of complete wrist unit ...

Page 14: ...Shell Tivela S150 in gearboxes 1 2 3 and 6 has been replaced by Kyodo Yushi TMO 150 Changes made in chapters Maintenance and Spare Parts The section Type of oil in gearboxes in chapter Maintenance has been updated according to changes made in oil types and intervals for oil change Sections Robot transportation precaution and Securing the robot are added to the Installation chapter Modified mainten...

Page 15: ...AC16628 4 3HAC16628 3 on page 449 Corrected exploded view see Wrist complete on page 468 Added inspection of oil level in gearboxes and inspection of surface treatment in maintenance schedule for Foundry Prime See section Activities and intervals Foundry Prime on page 146 Text in maintenance schedules concering lubrication of balancing device bearing changed into concerning all bearings of the bal...

Page 16: ...recommended repair procedures including spare parts Calibration Decommissioning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with exploded views or references to separate spare parts lists Circuit diagrams or references to circuit diagrams Software manuals The software documentation consists of a wide range of manuals ranging from manuals for...

Page 17: ...tions of all required preventive maintenance procedures including intervals and expected life time of parts Repair descriptions of all recommended repair procedures including spare parts Calibration Decommissioning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with exploded views or references to separate spare parts lists Circuit diagrams or ...

Page 18: ... system parameters DVD with PC software How to install included or required hardware How to use the application Examples of how to use the application Operating manuals The operating manuals describe hands on handling of the products The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and trouble shooters The group of ...

Page 19: ... 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 that is article number and dimensions The designation in the procedure for the component or attachment point corresponds to the designation in the referenc...

Page 20: ...How to read the product manual 3HAC022033 001 Revision K 18 Copyright 2004 2011 ABB All rights reserved 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 21: ...eneral safety aspects important to attend to before performing any service work on the robot These are applicable for all service work and are found in General safety information on page 20 Specific safety information pointed out in the procedures How to avoid and eliminate the danger is either described directly in the procedure or in specific instructions in the section Safety related instructio...

Page 22: ...or as described in the applicable documents for example User s guide S4Cplus M2000 Operating manual IRC5 with FlexPendant Product manual Connection of external safety devices Apart from the built in safety functions the manipulator is also supplied with an interface for the connection of external safety devices An external safety function can interact with other machines and peripheral equipment v...

Page 23: ... be set up in front of the manipulator 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 manipulator 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 manipulator parts there is a risk of being crushed by the parallel arm if ...

Page 24: ...t collapse as parts are removed e g secure the lower arm according to repair instruction 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 ...

Page 25: ...Touching these may cause burns of various severity Because of a higher environment temperature more surfaces on the manipulator get hot and may result in burns Elimination The instructions below detail how to avoid the dangers specified above Action Info 1 Always use your hand at some distance to feel if heat is radiating from the potentially hot component before actually touching it 2 Wait until ...

Page 26: ...ols 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 work pieces in the event of a power failure or a disturbance to the controller CAUTION Ensure that a gripper is prevented from dropping a work piece if such is us...

Page 27: ...hydraulic systems Residual energy Residual energy can 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 prevent tools etc f...

Page 28: ...sionally 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 due to risks othe...

Page 29: ... outside the robot s working space Voltage related risks controller S4Cplus A danger of high voltage is associated with the following parts Controller Be aware of stored electrical energy DC link Units inside the controller e g I O modules can be supplied with power from an external source Mains supply mains switch Power unit Power supply unit for the computer system 230 VAC Rectifier unit 400 480...

Page 30: ...5 230 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 manipulator A danger of high voltage is associated with the manipulator in The power supply for the...

Page 31: ...ure to enable it to withstand the force created if the load being handled by the manipulator is dropped or released at maximum speed Determine the maximum speed from the maximum velocities of the manipulator axes and from the position at which the manipulator is working in the work cell see the section Robot motion in the Product specification Also consider the maximum possible impact caused by a ...

Page 32: ...33 001 Revision K 30 Copyright 2004 2011 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 manipulator system manipulator or controller 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 33: ... the brake release buttons on the manipulator How to release the brakes is detailed in the section Manually releasing the brakes on page 83 The manipulator arm may be moved manually on smaller manipulator models but larger models may require using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the arms does not increase the pressure...

Page 34: ...he function of the holding brake of each axis motor may be checked as described 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 does not change posi...

Page 35: ...opyright 2004 2011 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 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 36: ...the manipulator s working space This is to prevent anyone else from taking control of the manipulator without the programmer s knowledge Enabling device The enabling device is a manually operated constant pressure push button which when continuously activated in one position only allows potentially hazardous functions but does not initiate them In any other position hazardous functions are stopped...

Page 37: ... 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 Manual mode with full speed 100 is not available in USA or Canada Pay attention to the rotating axes of the manipulator Keep away from axes to not get entangled with hair or clothing Also be aware of any danger that may be caused by rotati...

Page 38: ...amp optional Description A signal lamp with a yellow fixed light can be mounted on the manipulator as a safety device Function The lamp is active in MOTORS ON mode Further information Further information about the MOTORS ON MOTORS OFF mode may be found in the product manual for the controller 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 39: ...o the motors so that the manipulator path can be maintained When completed power is disconnected from the motors The default setting is an uncontrolled stop However controlled stops are preferred since they minimize extra unnecessary wear on the manipulator and the actions needed to return the manipulator system back to production Please consult your plant or cell documentation to see how your man...

Page 40: ...that can be operated in order to achieve an emergency stop There are emergency stop buttons available on the FlexPendant and on the controller cabinet on the Control Module on a Dual Cabinet Controller There can also be other types of emergency stops on your manipulator Consult your plant or cell documentation to see how your manipulator system is configured Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科...

Page 41: ...le contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height and so on 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 voltage e...

Page 42: ... ESD ELECTROSTATIC DISCHARGE ESD Warns for electrostatic hazards which could result in severe damage to the product Note NOTE Describes important facts and conditions Tip TIP Describes where to find additional information or how to do an operation in an easier way Symbol Designation Significance Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 43: ...nch The labels are identified and located on the product as shown in the section Inspection information labels on page 187 Symbols on safety labels Symbol Description xx0900000812 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...

Page 44: ...g see product manual xx0900000815 Do not dismantle Dismantling this part can cause injury xx0900000814 Extended rotation This axis has extended rotation working area compared to standard xx0900000808 Brake release Pressing this button will release the brakes This means that the manipulator arm can fall down xx0900000810 Tip risk when loosening bolts The manipulator can tip over if the bolts are no...

Page 45: ... All rights reserved xx0900000818 Heat Risk of heat that can cause burns xx0900000819 xx1000001141 Moving robot The robot can move unexpectedly xx0900000820 xx1000001140 Brake release buttons xx0900000821 Lifting bolt Symbol Description Continued Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 46: ...00822 Lifting of robot xx0900000823 Oil Can be used in combination with prohibition if oil is not allowed xx0900000824 Mechanical stop xx1000001144 No mechanical stop xx0900000825 Stored energy Warns that this part contains stored energy Used in combination with Do not dismantle symbol Symbol Description Continued Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 47: ...ht 2004 2011 ABB All rights reserved xx0900000826 Pressure Warns that this part is pressurized Usually contains additional text with the pressure level xx0900000827 Shut off with handle Use the power switch on the controller Symbol Description Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 48: ...ure all emergency stop equipment is correctly installed and connected Emergency stop equipment such as gates tread mats light curtains etc 2 Usually the hold to run function is active only in manual full speed mode To increase safety it is also possible to activate hold to run for manual reduced speed with a system parameter The hold to run function is used in manual mode not in automatic mode How...

Page 49: ...en performing the first test run after a service activity such as repair installation or maintenance Collision risks CAUTION When programming the movements of the manipulator always check potential collision risks before the first test run 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 ...

Page 50: ...rned 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 manipulator 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 Check the p...

Page 51: ... This discharge may destroy sensitive electronics Elimination Location of wrist strap button The location of the wrist strap button is shown in the following illustration IRC5 The wrist strap button is located in the top right corner 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 prote...

Page 52: ...ved Assemble the wrist strap The picture illustrates how the ESD wrist strap is assembled in the controller xx0400001055 A The strap is fastened to a button on the side of the control module B When not used the wrist strap is placed on the power supply unit C Power supply unit Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 53: ... like goggles and gloves are always worn Possible pressure build up in gearbox When opening the oil or grease plug there may be pressure present in the gearbox causing lubricant to spray from the opening Open the plug carefully and keep away from the opening Do not overfill the gearbox when filling Do not overfill Overfilling of gearbox lubricant can lead to internal over pressure inside the gearb...

Page 54: ...nds on drained volume The specified amount of oil or grease is based on the total volume of the gearbox When changing the lubricant the amount refilled may differ from the specified amount depending on how much has previously been drained from the gearbox After refilling check the lubricant level Warning Description Elimination Action Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 55: ...xtra loads equipment Safety information Before any installation work is commenced it is extremely important that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 19 before performing any installation work ...

Page 56: ...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 Always remove the tool be...

Page 57: ...read and follow the instructions in section Securing the robot on page 61 Always place the robot in the ABB recommended transport position for robot with tool detailed in sub section Transport position with a transport support on page 57 Always use the recommended transport support detailed in sub section Recommended transport support on page 59 IRB7600 IRB66XX xx0800000037 A Transport Support B H...

Page 58: ...s 3HAC022033 001 Revision K 56 Copyright 2004 2011 ABB All rights reserved IRB6620 Foundry Plus xx0800000036 A Transport Support B Hexagon socket head cap screw M10x50 C Threaded bar M10x280 D Nut M10 Continued Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 59: ...2033 001 Revision K Copyright 2004 2011 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 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 60: ...missioning 2 2 Robot transportation precautions 3HAC022033 001 Revision K 58 Copyright 2004 2011 ABB All rights reserved IRB 6620 Foundy Plus xx0800000041 Continued Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 61: ...C022033 001 Revision K Copyright 2004 2011 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 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 62: ...stallation and commissioning 2 2 Robot transportation precautions 3HAC022033 001 Revision K 60 Copyright 2004 2011 ABB All rights reserved IRB 6620 xx0800000038 Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 63: ... 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 Action Note 1 Mount the transport support s lower end to the robot using the recommended screw joint A in figure Do not tighten the screw See attachment point for the specific robot in the section Transport position with a transport support ...

Page 64: ...n the transport support see the section Manually releasing the brakes on page 83 See attachment point for the specific robot in the section Transport position with a transport support on page 57 4 Tighten all the attachment screws A and B in the figure with the brake release for axis 3 still activated starting with the lower attachment screw CAUTION Do not attempt to tighten any attachment screws ...

Page 65: ...e the lifting device used is dimensioned to handle the weight of the robot Specified in Weight robot on page 63 4 If the robot is not to be installed directly it must be stored Specified in Storage conditions robot on page 64 5 Make sure the appointed operating environment of the robot conforms to the specifications Specified in Operating conditions robot on page 64 6 Before taking the robot to it...

Page 66: ...ating conditions robot The table below shows the allowed operating conditions for the robot Force Endurance load operation Max load emergency stop Force xy 14000 N 31000 N Force z 32000 10000 N 39000 16000 N Torque xy 42000 Nm 72000 Nm Torque z 11000 Nm 19500 Nm Requirement Value Note Min levelness 0 5 mm Max tilt 5 The limit for the maximum payload on the robot is reduced if the robot is tilted f...

Page 67: ...procedure 65 3HAC022033 001 Revision K Copyright 2004 2011 ABB All rights reserved Protection classes robot The table below shows the protection class of the robot Equipment Protection class Robot IRB 7600 IP 67 Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 68: ...0 150 3 5 3HAC022033 001 Revision K 66 Copyright 2004 2011 ABB All rights reserved 2 4 2 Working range IRB 7600 150 3 5 Illustration The illustration below shows the unrestricted working range of IRB 7600 150 3 5 xx0100000101 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 69: ...0 340 2 8 67 3HAC022033 001 Revision K Copyright 2004 2011 ABB All rights reserved 2 4 3 Working range IRB 7600 340 2 8 Illustration The illustration below shows the unrestricted working range of IRB 7600 340 2 8 xx0300000296 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 70: ...HAC022033 001 Revision K 68 Copyright 2004 2011 ABB All rights reserved 2 4 4 Working range IRB 7600 400 2 55 IRB 7600 500 2 55 Illustration The illustration below shows the unrestricted working range of IRB 7600 400 2 55 and IRB 7600 500 2 55 xx0100000100 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 71: ...0 500 2 3 69 3HAC022033 001 Revision K Copyright 2004 2011 ABB All rights reserved 2 4 5 Working range IRB 7600 500 2 3 Illustration The illustration below shows the unrestricted working range of IRB 7600 500 2 3 en0100000099 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 72: ... 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 Shipping and transport position This figure shows the robot in its shipping position which also is a recommended transport position xx0100000103 WARNING The robot is likely to be mechanically unstable i...

Page 73: ...the figure below Determine which fork lift set fits the current robot Note The distance between the attachment holes for the fork lift pockets shown in the figure below are different depending on the design of the frame This means that the fork lift sets are unique for one type of frame and not compatible Except for the shorter distance between the attachment holes the later design of the frame al...

Page 74: ...ee the section Different designs on page 71 A Attachment points spacer and horizontal attachment screws B Attachment points horizontal attachment screws C Attachment points vertical attachment screws D Attachment points horizontal attachment screws Equipment etc Art no Note Fork lift set incl all required hardware 3HAC0604 2 See figure Fork lift set 3HAC0604 2 on page 73 Standard toolkit Content i...

Page 75: ...4 2011 ABB All rights reserved Fork lift set 3HAC0604 2 The fork lift set 3HAC0604 2 is fitted to the robot as shown in the figure below xx0100000102 A Vertical attachment screws 4 pcs fork lift pocket B Fork lift pockets 2 pcs C Spacer 2 pcs Continued Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 76: ...ection details how to secure the fork lift set to the robot in order to lift and move the robot using the fork lift ONLY 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 2 pcs E Securing screw used for IRB 6650S Action Note 1 If a cooling fan for the axis 1 motor is used it must be removed in order ...

Page 77: ...t 3HAC0604 2 is used Release the brakes if required as detailed in section Manually releasing the brakes on page 83 xx0200000079 When using fork lift set 3HAC0604 2 no load is permitted on the robot xx0200000387 3 Fit the two spacers to the robot and secure Attachment points are shown in figure Attachment points on robot on page 72 4 CAUTION The fork lift pocket weighs 60 kg Action Note Continued ...

Page 78: ...tened with different torques Always use original screws or replace ments of equivalent quality M16 quality 12 9 Attachment points on robot are shown in figure Attachment points on robot on page 72 xx0400001068 A Horizontal attachment screws 4 pcs M16 x 60 Tightening torque 60 Nm B Spacers 2 pcs 6 Make sure the securing screw is removed from the fork lift pocket It is only used for robot model IRB ...

Page 79: ...M16 quality 12 9 Attachment points on robot are shown in figure Attachment points on robot on page 72 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 attachment screws 4 pcs M16x60 Tightening torque 60 Nm Always use original screws or replace ments of equivalent quality M16 quality 12 9 Attachment p...

Page 80: ...g 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 Installation of cooling fan for motors axes 1 3 option on page 104 Action Note Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 81: ...with the equipment NOTE Move the robot to the recommended position shown in the figure and in the instruction Attempting to lift a robot in any other position may result in the robot tipping over causing severe damage or injury Illustration lifting slings The figure below shows how to lift the complete robot with lifting slings xx0200000153 A Load hook B Swivelling lifting eyes 4 pcs C Shortening ...

Page 82: ...hown 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 83 xx0100000103 3 Fit lifting device robot to the robot as described in enclosed instruction Art no is specified in Required equipment on page 80 4 CAUTION The robot weighs 2550 kg All lifting equipment used must be sized accordingly 5 WARNIN...

Page 83: ...ce the recommended robot position shown in the figure below Roundslings attached to the robot xx0200000315 Required equipment A Chain sling with shortener 4250 kg 3 pcs 0 5 m 0 5 m 0 265 m B Roundsling 1000 kg 2 pcs C Roundsling 2000 kg 3 pcs 4 m Equipment Note Chain sling with shortener 4250 kg 3 pcs Lengths 0 5 m 2 pcs 0 265 m 1 pc Roundslings 1000 kg 2 pcs Roundslings 2000 kg 3 pcs Lengths 4 m ...

Page 84: ...position above the robot 4 Attach the three chain slings with shorteners to the overhead crane hook Shown in the figure Roundslings attached to the robot on page 81 Lengths are specified in Required equipment on page 81 5 Fit the three roundslings 2000 kg to the robot Attach the roundslings to the chain slings hanging from the overhead crane Shown in the figure Roundslings attached to the robot on...

Page 85: ...ower to connector R1 MP on page 85 External brake release unit using push buttons on an external brake release unit This does NOT require the controller to be connected The external unit is used when there are no push buttons on the robot Read about how to use the external brake release unit in the section Manually releasing the brakes external brake release unit on page 86 Location of brake relea...

Page 86: ...or 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 the section Supplying power to connector R1 MP on page 85 Buttons are shown in figure Location of brake release unit at base on page 83 or Location of brake release unit at frame on page 84 2 DANGER W...

Page 87: ...f the robot is not connected to the controller power must be supplied to connector R1 MP on the robot in order to enable the brake release buttons Action Note 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 xx0600002937 Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 88: ...ernal brake release unit must only be used when the robot does not have an internal brake release unit when there are no push buttons on the robot Internal brake release unit How to use the internal brake release unit if available is detailed in section Manually releasing the brakes on page 83 Required equipment Connections robot The illustration below shows where to connect the external brake rel...

Page 89: ...nnector plate B Connector R1 MP C Connector R1 BU D External brake release unit E Connect to R1 BU Action Note 1 Remove the rear cover plate from the base of the robot by unscrewing its attachment screws and plain washers Shown in the figure Connec tions robot on page 86 2 Locate the free connector connected to the rear of connector R1 MP behind the rear connector plate Make sure it is designated ...

Page 90: ...brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the robot arm 5 Release the holding brake of each robot axis by pressing the respective button on the external brake release unit 6 Disconnect the external brake release unit 7 Refit the rear cover plate with its attachment screws Action Note Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育...

Page 91: ...se plate Equipment Art no Note Lifting eye M16 3HAC14457 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 lifting eyes in specified holes Shown in figure Hole configu ration on page 89 3 Fit lifting slings to the eyes and to the lifting device 工控帮助教小舒QQ...

Page 92: ...ing 2 5 7 Securing the base plate 3HAC022033 001 Revision K 90 Copyright 2004 2011 ABB All rights reserved 2 5 7 Securing the base plate Base plate dimensions xx1000001053 Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 93: ...ng 2 5 7 Securing the base plate 91 3HAC022033 001 Revision K Copyright 2004 2011 ABB All rights reserved xx0400000715 A Four holes for alternative clamping 4x Ø18 Continued Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 94: ...es 4 pcs Equipment Art no Note Base plate 3HAC 12937 7 Includes guide sleeves 3HAC12937 3 levelling screws 9ADA120 79 attachment screws and washers for securing the robot to the base plate A drawing of the base plate itself may be ordered from ABB Robotics Standard toolkit Content is defined in section Standard toolkit on page 427 Other tools and procedures may be required See references to these ...

Page 95: ...work location using the three grooves in the base plate Shown in figure Base plate grooves and holes on page 92 4 Lift the base plate to its mounting position Detailed in section Lifting the base plate on page 89 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 section Recommenda tions ...

Page 96: ...base fitted to the base plate xx0100000107 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 12 pcs M24 x 140 B Orienting grooves in the robot base and in the base plate C Levelling screws D Base plate attachment screws Suitable screws lightly lubricated M24 x 140 Q...

Page 97: ...eves to the guide sleeve holes in the base plate Shown in figure Base plate grooves and holes on page 92 NOTE 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 and washers in the base attachment holes Specified in Attachment screws ...

Page 98: ...ght 2004 2011 ABB All rights reserved Hole configuration base This illustration shows the hole configuration used when securing the robot xx0300000046 Cross section guide sleeve hole This illustration shows the cross section of the guide sleeve holes xx0100000109 Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 99: ...unting holes are accessible when planning the robot cell 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 of the lower arm when fitting extra equipment Always use appropriate attachment screws xx0700000722 Robot variant A IRB 7600 500 2 ...

Page 100: ... Copyright 2004 2011 ABB All rights reserved xx0100000120 Illustration fitting of extra equipment on upper arm The illustration below shows the mounting holes available for fitting extra equipment on the upper arm xx0100000116 Continued Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 101: ...of extra equipment on frame The illustration below shows the mounting holes available for fitting extra equipment on the frame xx0100000117 Robot variant A IRB 7600 500 2 55 1056 mm IRB 7600 500 2 3 806 mm IRB 7600 400 2 55 1056 mm IRB 7600 340 2 8 1306 mm IRB 7600 325 3 1 1556 mm IRB 7600 150 3 5 2012 mm Continued Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 102: ...sion K 100 Copyright 2004 2011 ABB All rights reserved xx0100000118 Illustration fitting on turning disk The illustration below shows the mounting holes available for fitting equipment on the turning disk xx0100000119 Continued Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 103: ...K Copyright 2004 2011 ABB All rights reserved Fastener quality When fitting tools on the turning disk see the figures above only use screws with quality 12 9 When fitting other equipment to mounting holes standard screws with quality 8 8 may be used Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 104: ...lation of base spacers xx0500001570 Required equipment A Base spacer 4 pcs B Guide sleeve 4 pcs C Attachment screws and washers 12 pcs Equipment Art no Note Base spacers 3HAC 021899 002 Includes mounting set with attachment screws and mounting instruction Base plate 3HAC 12937 7 Standard toolkit Content is defined in section Standard toolkit on page 427 Continues on next page 工控帮助教小舒QQ2823408167 长...

Page 105: ...ifting 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 79 3 Install the base plate to the foundation if not used previously Detailed in section Securing the base plate on page 90 4 Fit the four base spacers and guiding sleeves to the base plate Shown in the figure Illustration instal lation of...

Page 106: ...his complete cabling is detailed in section Installation of cable harness for position switches and fans on page 129 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 109 If both cooling fans and position switches are installed on the robot the com...

Page 107: ... rights reserved xx0700000671 Cooling fan The details of the cooling fan are shown in the figure below xx0500002158 A Cooling fan axis 2 B Cooling fan axis 1 C Rear cover plate A Fanbox B Attachment screws fanbox plates 9 pcs C Groove in the connector D Tightening screws fanbox 3 pcs Continued Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 108: ...s 1 or 2 3HAC023599 001 Choose this cabling if only equipping the robot with cooling fans on axis 1 or 2 not on axis 3and not with position switches Plate for customer connections 3HAC025778 001 An additional connection plate must be fitted to the robot base if not already installed The plate is shown in the figure Plate for customer connections at base on page 107 Additional cabling to and inside...

Page 109: ...ng screws Standard toolkit Content is defined in section Standard toolkit on page 427 Circuit diagram See chapter Circuit diagram 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 Art no Note A Plate for customer connections B Attachment screws 3 pcs M6x16 quality ...

Page 110: ...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 105 Positions for axis 2 and 3 are shown in the figureLocation of cooling fans on page 104 Shown in the figure Cooling fan on page 105 3 Temporarily lift the motor cabling out of the way of the current motor to make room for the fanbox 4 Fit the ...

Page 111: ...pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 3 Remove the rear cover plate from the robot base Shown in the figure Location of cooling fans on page 104 4 Remove the cable bracket A Shown in the figure Separate cabling for axis 1 or 2 on page 108 5 Fit the plate for customer connections if not already fitted to the...

Page 112: ...acket Also shown in the figure Separate cabling for axis 1 or 2 on page 108 8 Connect the connector R3 FAN2 to the fan of axis 1or 2 NOTE Fans on both axis 1 and 2 can not be used at the same time 9 Connect the connector R1 SW2 3 to the base of the robot Make sure that the cabling run through the frame and base is not twisted and runs freely from the robot cabling 10 Refit the rear cover plate to ...

Page 113: ...ttings in RobotWare to include the cooling fans RobotWare 4 0 modify the settings in RobInstall RobotWare 4 063 and older must be updated with a newer release RobotWare 5 0 change the settings in the Modifying options dialogue by using the Modify Controller System Wizard in the System Builder of RobotStudio Read more about modifying the system in Operating manual RobotStudio Continued 工控帮助教小舒QQ282...

Page 114: ...s Cable guard option no 908 1 Introduction How to install the Foundry Plus Cable guard is described in the instruction delivered with the cable guard Separate instructions for IRB 140 4600 1600 6620 6640 6650S 6660 and 7600 are available in English German French Spanish and Italian and can be found on the DVD delivered with the Cable guard article number 3HAC035933 001 工控帮助教小舒QQ2823408167 长沙工控帮教育...

Page 115: ...structure CAUTION Incorrectly defined loads may result in operational stops or major damage to the robot References Load diagrams permitted extra loads equipment and their positions are specified in the Product Specification The loads must also be defined in the software as detailed in User s Guide RobotWare 4 0 Operating manual IRC5 with FlexPendant Stop time and braking distances Robot motor bra...

Page 116: ... 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 Note that this option also requires installation of a posit...

Page 117: ...nical stops axis 1 The illustration 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 3HAC11076 1 Includes attachment screws and an assembly drawing Mechanical stop for axis 1 15 3HAC11076 2 Includes attachment sc...

Page 118: ...o the frame according to the figure Mechanical stops axis 1 on page 115 Tightening torque 120 Nm 3 Adjust the software working range limitations system parameter configuration to correspond to the mechanical limitations How to define the range of movement in RobotWare 4 0 is detailed in User s guide S4Cplus chapter System Parameters topic Manipulator The system parameters that must be changed Uppe...

Page 119: ... 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 3HAC11077 1 Includes six stops 3HAC11407 1 each one restricting the working range by 15 Includes attachment screws Standard toolkit Content is defined in section ...

Page 120: ...starting from the fixed stop Tightening torque 115 Nm Shown in the figure Mechanical stops axis 2 on page 117 3 The software working range limitations must be redefined 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 System Parameters topic Manipulator The system paramet...

Page 121: ... limited by fixed mechanical stops and can be reduced by adding additional mechanical stops with 20 graduation in respective direction Mechanical stops axis 3 The illustration below shows the mounting position of the mechanical stops on axis 3 xx0300000048 The figure shows IRB 7600 but the principle is the same A Additional mechanical stops B Fixed mechanical stop C Attachment screw M16x60 quality...

Page 122: ...c Art no Note Mechanical stop set axis 3 3HAC13128 2 Includes six stops one with 80 restriction 3HAC12708 4 use when limitation angle 80 and five with 20 3HAC 12708 2 Includes attachment screws Standard toolkit Content is defined in section Standard toolkit on page 427 User s guide S4Cplus RobotWare 4 0 Technical reference manual System parameters Art no is specified in section References on page ...

Page 123: ...m the fixed stop Tightening torque 115 Nm Shown in the figure Mechanical stops axis 3 on page 119 3 NOTE The software working range limitations system parameters must be redefined 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 System Parameters topic Manipulator The sys...

Page 124: ...the user Required equipment Description Art no Note Position switch axis 1 3HAC15715 1 Includes position swtich and plate for customer connections Position switch axis 2 3HAC15715 2 Includes only the position switch Position switch axis 3 3HAC15715 3 Includes only the position switch Cabling position switches and cooling fans axes 1 2 and 3 3HAC15390 1 Cabling to be installed on the robot Plate fo...

Page 125: ...tion 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 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 126: ...hts 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 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 127: ...ion 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 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公...

Page 128: ...usting cams and stops The instruction below details how to fit and adjust the parts of the position switches Action Note 1 Cut the cam to a suitable length Use a sharp knife and rubber hammer or similar 2 Cut the edge of the cam edge to max 30 Shown in Illustration cutting the cam on page 127 If the angle is larger this may damage the position switch 3 Cut the part of the cam running in the profil...

Page 129: ...ecure 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 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 130: ...ions 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 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 131: ...osition switch of axis 3 Action Note 1 Move the robot to its calibration position 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 3 Remove the rear cover A from the robot base and replace the protection B with a plate for customer connections if not already...

Page 132: ...cro 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 128 B Velcro strap C Connector ...

Page 133: ... 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 128 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 128 9 Connect the conn...

Page 134: ...he 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 134 Action Note Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技...

Page 135: ...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 134 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 136: ...sed for position switches Cabling for the cooling fans is specified in the table Cabling between robot base and controller cooling fans M2004 on page 135 Cable Art no Robot cable power 7 m 3HAC11818 1 Robot cable power 15 m 3HAC11818 2 Robot cable power 22 m 3HAC11818 3 Robot cable power 30 m 3HAC11818 4 Cable Art no Robot cable signal shielded 7 m 3HAC7998 1 Robot cable signal shielded 15 m 3HAC7...

Page 137: ...o the inside of the cabinet and the additional cabling specified below is therefor not needed Cable Art no Connection point Distributing cable 3HAC022708 001 Robot base R1 SW2 3 Harness cooling 7 m 3HAC022723 001 Distributing cable R1 FAN SW2 3 Inside cabinet A43 X10 and A43 X11 Harness cooling 15 m 3HAC022723 004 Distributing cable R1 FAN SW2 3 Inside cabinet A43 X10 and A43 X11 Harness cooling 2...

Page 138: ...h off the overpressure in motors and serial measurement compartment during cooling down of robot after it has been switched off When turning off a cleaning cell we recommend that the humid air inside a cell is ventilated out to avoid that the humid air is sucked into gearboxes for example due to the raised vacuum when cooled down Environmental conditions The table below details the environmental c...

Page 139: ...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 Parameter Value Air pressure supplied to robot Max 0 2 0 3 bar 0 0 bar Action Note 1 Connect a compressed air hose t...

Page 140: ...d to direct high pressure jet of water The sealings between the moving parts on the wrist should not be exposed to direct or rebounding high pressure jet of water Protection points at the wrist joints The illustration below shows points that are particularly sensitive to water spray xx0600002792 A Axis 5 bearing support side B Axis 5 bearing gear side C Axis 6 mounting flange gear house Continued ...

Page 141: ...asurement compartment during cooling down of robot after it has been switched off 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 NOTE When turning off a cleaning cell we recommend that the humid air is ventilated out from th...

Page 142: ...2 Installation and commissioning 2 8 2 Commissioning Foundry Prime 3HAC022033 001 Revision K 140 Copyright 2004 2011 ABB All rights reserved 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 143: ... activity which is required tools and materials The procedures are gathered in different sections and 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 general safety aspects that must be read through as well as more specific safety information that describes the danger a...

Page 144: ...cified in months regardless of whether the manipulator system is running or not Operating time specified in operating hours More frequent running of the manipulator means more frequent maintenance activities SIS specified by the robot s SIS Service Information System A typical value is given for a typical work cycle but the value will differ depending on how hard each part is run The SIS is furthe...

Page 145: ... axis 2 on page 153 Inspection Axis 2 gearbox oil level Every 12 months Inspection oil level gearbox axis 2 on page 153 Inspection Axis 3 gearbox oil level Every 12 months Inspection oil level gearbox axis 3 on page 156 Inspection Axis 4 gearbox oil level Every 12 months Inspection oil level gearbox axis 4 on page 158 Inspection Axis 5 gearbox oil level Every 12 months Inspection oil level gearbox...

Page 146: ...es Every 24 000 hours Do not mix with other oils Oil change gearbox axis 2 on page 203 Changing Axis 3 gearbox oil Optomol Optigear RO 150 Every 12 000hours Oil change gearbox axis 3 on page 206 Changing Axis 3 gearbox oil Kyodo Yushi TMO 150 First change when DTC 1 reads 6 000 hours Second change when DTC 1 reads 24 000 hours Following changes Every 24 000 hours Do not mix with other oils Oil cha...

Page 147: ...hanges Every 24 000 hours Do not mix with other oils Oil change gearbox axis 5 on page 212 Changing Axis 5 secondary gearbox oil Mobil Gearlube X320 Every 12 000hours Oil change gearbox axis 5 on page 212 Changing Axis 5 secondary gearbox oil Kyodo Yushi TMO 150 First change when DTC 1 reads 6 000 hours Second change when DTC 1 reads 24 000 hours Following changes Every 24 000 hours Do not mix wit...

Page 148: ...r Foundry Prime Maintenance activity Equipment Interval Note Detailed in section Inspection Signal lamp Every 12 months Inspecting signal lamp option Inspection Mechanical stop axes 1 2 3 Every 12 months Mechanical stops in addition to the fixed stops Inspection mechanical stop axes 1 2 and 3 Inspection Position switches axes 1 2 3 Every 12 months Inspection position switch axes 1 2 and 3 Inspecti...

Page 149: ...1 2 and 3 on page 179 Analysis Oil gearbox axis 6 Every 3 000h or 6 months 2 Inspection oil level gearbox axis 6 Changing Axis 1 gearbox oil Kyodo Yushi TMO 150 Every 6 000 hours Oil change gearbox axis 1 Changing Axis 2 gearbox oil Kyodo Yushi TMO 150 Every 6 000 hours Oil change gearbox axis 2 on page 203 Changing Axis 3 gearbox oil Kyodo Yushi TMO 150 Every 6 000 hours Oil change gearbox axis 3...

Page 150: ...fetime can be extended approx 3 times for longer production breaks by a battery shutdown service routine See Operating manual IRC5 with FlexPendant for instructions 4 Damage to painted surfaces must be repaired as soon as possible to avoid corrosion 7 The warranty does not apply to effects or wear caused by environmental factors Overhaul Robot 40 000 hours Expected component life on page 149 Overh...

Page 151: ...box axes 4 and 5 is not calculated by SIS See the Operating manual Service Information System In some applications such as Foundry or Washing the robot can be exposed to chemicals high temperature or humidity which can have an effect on the lifetime of the gearboxes Contact the local ABB Robotics Service team for more information 5 The given life for the balancing device is based on a test cycle o...

Page 152: ...B Oil plug filling C Motor axis 1 D Oil plug inspection not available in all designs E Label specifies type of oil in the axis 1 gearbox Equipment etc Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 NOTE Do not mix with other oils Standard toolkit Content is defined in section Standard toolkit on page 427 Other tools and procedures may be required See references to these procedures ...

Page 153: ...ric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 3 Remove the motor axis 1 Detailed in section Removal motor axis 1 on page 328 4 Measure the oil level through the motor hole Required oil level 40 mm 5 mm to the motor hole 5 If necessary fill with lubricating oil or drain Art no is sp...

Page 154: ... lubricants oil or grease on page 51 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 3 Open the oil plug inspection Shown in the figure Location of gearbox on page 150 4 Required oil level max 10 mm below the oil plug hole 5 Add oil if required Art no is sp...

Page 155: ...he later design is located 33 mm below the original placement The measured distance to the oil level varies depending on the design of the cover Oil plug early design The axis 2 gearbox is located in the lower arm rotational center The figure below shows the early design of the gearbox cover xx0300000068 A Gearbox axis 2 behind motor attachment not shown in figure B Oil plug filling early design C...

Page 156: ...Gearbox axis 2 behind motor attachment not shown in figure B Oil plug filling later design C Oil plug draining D Label specifies the type of oil in axis 2 gearbox Equipment etc Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 NOTE Do not mix with other oils Standard toolkit Content is defined in section Standard toolkit on page 427 Other tools and procedures may be required See refer...

Page 157: ... hydraulic but not the air pressure to the gearboxes motors and SMB 3 Open the oil plug filling two different designs Read more about the differences in Oil change gearbox axis 2 on page 203 4 Measure the oil level Required oil level to oil plug early design 35 mm 5 mm Required oil level to oil plug later design max 10 mm below the oil plug hole Shown in the figures Oil plug early design on page 1...

Page 158: ...A Gearbox axis 3 B Oil plug filling C Oil plug draining D Label specifies the oil type of axis 3 gearbox Equipment Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 NOTE Do not mix with other oils Standard toolkit Content is defined in section Standard toolkit on page 427 Other tools and procedures may be required See references to these procedures in the step by step instructions bel...

Page 159: ...upplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 3 Run the robot to the calibration position Detailed in section Calibration scale and correct axis position on page 406 4 Open the oil plug filling Shown in the figure Location of gearbox on page 156 5 Required oil level max 10 mm below the oil plug hole 6 Add oil if required Art...

Page 160: ...x C Oil plug filling secondary gear D Oil plug draining secondary gear E Oil plug filling primary gearbox draining not shown in figure F Label specifies the type of oil in the secondary gear of axis 4 G Label specifies the type of oil in the primary gear of axis 4 Equipment etc Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 To be used in primary and secondary gearboxes NOTE Do not ...

Page 161: ... all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 3 Run the robot to the calibration position Shown in section Calibration scale and correct axis position on page 406 4 Open the oil plug filling in the primary gearbox Shown in the figure Location of gearbox on page 158 5 Measure the oil level Required oil level 35 mm 5 mm to the oil plug hole 6 Add oil if r...

Page 162: ...AC022033 001 Revision K 160 Copyright 2004 2011 ABB All rights reserved 11 WARNING Do not mix oil types If wrong oil is refilled the gearbox must be rinsed as detailed in section Type of oil on page 192 Action Note Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 163: ...ng secondary gear D Oil plug draining secondary gear E Oil plug filling primary gearbox draining on opposite side of wrist housing not shown in figure F Label specifies the type of oil in primary gear axis 5 G Label specifies the type of oil in secondary gear axis 5 Equipment etc Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 To be used for primary and secondary gearboxes NOTE Do n...

Page 164: ...ctric power and hydraulic but not the air pressure to the gearboxes motors and SMB 3 Run the robot to the calibration position Shown in section Calibration scale and correct axis position on page 406 4 Open the oil plug filling in the primary gearbox Shown in the figure Location of gearbox on page 161 5 Measure the oil level Required oil level 80 mm 5 mm to the oil plug hole 6 Add oil if required ...

Page 165: ...3 3HAC022033 001 Revision K Copyright 2004 2011 ABB All rights reserved 11 WARNING Do not mix oil types If wrong oil is refilled the gearbox must be rinsed as detailed in section Type of oil on page 192 Action Note Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 166: ...00114 Required equipment A Gearbox axis 6 B Oil plug filling notice the two possible locations B1 or B2 C Oil plug draining can be located on the turning disk instead D Label specifies the type of oil in gearbox axis 6 Equipment Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 NOTE Do not mix with other oils Standard toolkit Content is defined in section Standard toolkit on page 427 ...

Page 167: ...and tilthouse so that the oil plug for filling is facing upwards Shown in the figure Location of gearbox on page 164 3 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 4 Open the oil plug filling 5 Measure the oil level measurement a in the figure to the right...

Page 168: ...fit the oil plug filling Tightening torque 24 Nm 8 WARNING Do not mix oil types If wrong oil is refilled the gearbox must be rinsed as detailed in section Type of oil on page 192 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 Replacement of gearbox axis 6 is required every two years xx06000...

Page 169: ... ABB All rights reserved 2 Less than 2 water in oil Normal replacement interval is required for gearbox axis 6 See Activities and intervals Foundry Prime on page 146 xx0600003156 A Water content in oil from gearbox axis 6 B Months or hours in operation If Then Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 170: ... maintenance may be performed according to specific maintenance kits If the balancing device is an older model it must in some cases be upgraded instead The instruction for the current inspection details if a fault requires a maintenance upgrade and the table below specifies the different models and which of the two actions they require The article number of the balancing device is located on a la...

Page 171: ...ipment used if damage is detected on the balancing device See section Action at detected faults on page 168 to determine whether to perform maintenance or upgrade A Balancing device B Piston rod inside C Shaft including securing screw D Ear bearing and o rings E Label with article number F Inspect the surroundings G Bearing balancing device attachments Equipment etc Spare part no Art no Note Maint...

Page 172: ...required See references to these procedures in the step by step instructions below These procedures include references to the tools required Equipment etc Spare part no Art no Note Check for dissonance from If dissonance is detected 1 bearing at the link ear bearings at the balancing devices attachments perform maintenance or upgrade according to given instructions in Maintenance kit bearings and ...

Page 173: ... 169 To decide whether to perform maintenance or upgrade see section Action at detected faults on page 168 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 visible at the front of the balancing device perform maintenance or upgrade according to given instructions in Maintenance kit complete Upgrade kit Art...

Page 174: ...ur and must not be confused with incorrect leaks from the ear Leaks at the o rings and or sealings 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 xx0300000284 A Shaft B O ring C Sealing spacer D Sealing ring in sealing spacer E Correct way out for exc...

Page 175: ...ealing spacers and sealing rings Art no for the kit is specified in Required equipment on page 169 The replacement of the complete bearing is also detailed in section Replacement of spherical roller bearing balancing device on page 316 Incorrect leakage is shown in the previous figure Action 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all el...

Page 176: ...ables 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 Content is defined in section Standard toolkit on page 427 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 requi...

Page 177: ...ct wear and damage 3 Check the connectors at the division point and at the base Shown in the figure Location of cable harness axes 1 4 on page 174 4 NOTE If the robot is used in a Foundry Prime appli cation 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 ...

Page 178: ... and SMB 2 Make an overall visual inspection of the cable harness in order to detect wear and damage 3 Check the attachments at the rear of the 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 any other way damaged Shown in the figure Location of cabling axes 5 6 on page 175 4 NOTE If the robot is used in a Foun...

Page 179: ...is procedure to inspect the mechanical stop pin axis 1 A Mechanical stop pin Equipment etc Art no Note Mechanical stop pin axis 1 3HAC10499 3 To be replaced when damaged Standard toolkit Content is defined in section Standard toolkit on page 427 Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not ...

Page 180: ...1 ABB All rights reserved 4 If the mechanical stop pin is bent or damaged it must be replaced NOTE The expected life of gearboxes can be reduced as a result of collisions with the mechanical stop Art no is specified in Required equipment on page 177 Action Note Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 181: ...onal mechanical stops on axes 1 2 and 3 xx0200000150 Required equipment A Additional stop B Fixed stop Equipment etc Art no Note Mechanical stop ax 1 3HAC11076 1 Limits the robot working range to 7 5 Mechanical stop ax 1 3HAC11076 2 Limits the robot working range to 15 Mechanical stop ax 2 3HAC11077 1 Mechanical stop ax 3 3HAC13128 2 Standard toolkit Content is defined in section Standard toolkit ...

Page 182: ...to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 2 Check the additional stops on axes 1 2 and 3 for damage Shown in the figure Location of the mechanical stops on page 179 3 Make sure the stops are properly attached Correct tightening torque 115 Nm 4 If any damage is detected the mechanical stops must be replaced Correct attachment scr...

Page 183: ...00000099 Required equipment A Damper axis 2 2 pcs B Damper axis 3 2 pcs C Damper axis 4 2 pcs D Damper axis 5 2 pcs Equipment Art no Note Damper axis 2 3HAC12990 1 Replace if damaged Damper axis 3 3HAC11750 1 Replace if damaged Damper axis 4 3HAC13564 1 Replace if damaged Damper axis 5 3HAC10503 8 Replace if damaged Standard toolkit Content is defined in section Standard toolkit on page 427 Contin...

Page 184: ...l electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 2 Check all dampers for damage such as cracks or existing impressions larger than 1 mm In order to inspect dampers axis 4 the two covers on top of the upper arm must be removed Shown in the figure Location of dampers on page 181 3 Check attachment screws for deformation 4 If any damage is detected the damper mu...

Page 185: ...reserved 3 3 12 Inspection position switch axes 1 2 and 3 Location of position switches The position switches axes 1 2 and 3 are located as shown in the figures below xx0100000158 A Position switch axis 1 B Cam C Set screw cam D Protection sheet E Rail F Rail attachment Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 186: ...001 Revision K 184 Copyright 2004 2011 ABB All rights reserved The illustration below shows the position switch for axis 2 xx0100000159 A Position switch axis 2 B Cam C Set screw cam E Rail F Rail attachment Continued Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 187: ...B Cam C Set screw cam E Rail F Rail attachment Equipment etc Spare part no Note Position switch axis 1 3HAC15715 1 To be replaced in case of detected damage Position switch axis 2 3HAC15715 2 To be replaced in case of detected damage Position switch axis 3 3HAC15715 2 To be replaced in case of detected damage Standard toolkit Content is defined in section Standard toolkit on page 427 Continued Con...

Page 188: ...t Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 2 Check the position switch Check that the rollers are easy to push in and that they roll freely 3 Check the rail Check that the rail is firmly attached with the attachment screws 4 Check the cams Check that the rollers has not caused any impressions on the cams Check that the cams are clean Wipe t...

Page 189: ...00 A Warning label concerning high temperature B Warning sign symbol of a lightning flash located on motor cover C Instruction label D Warning label concerning brake release E Warning label tools are not allowed around the balancing device during operation F Warning label concerning shutting off power G Label type of oil in gearbox H Label type of oil in gearbox I Label type of grease in ear Infor...

Page 190: ...t See the chapter Spare parts Includes all labels specified in previous figures Label set oil labels See the chapter Spare parts 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 Turn off all electric power an...

Page 191: ...B Warning sign C Warning label D Position for cable gland Equipment etc Spare part no Note Signal lamp 3HAC10830 1 To be replaced in case of detected damage Includes UL signal lamp 3HAC 13097 1 Warning label 3HAC 4431 1 Warning sign 3HAC 1589 1 Standard toolkit Content is defined in section Standard toolkit on page 427 Other tools and procedures may be required See references to these procedures i...

Page 192: ... Note 1 Check that the UL lamp is lit when the motors are in operation motors ON 2 If the lamp is not lit trace the fault Check whether the UL lamp is broken If so replace it Check the cable connections Measure the voltage in connectors motor axis 3 24V Check the cabling Replace cabling if a fault is detected Part no is specified in Required equipment on page 189 Continued 工控帮助教小舒QQ2823408167 长沙工控...

Page 193: ...ly 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 3 bar xx0600002794 A Air Connection B Cut off valve C Pressure gauge 2 Close the cut off valve It should take at least 5 seconds for the pressure to reach 0 bar 3 The time is 5 seconds If the answer is YES Localize the leakage b...

Page 194: ...ge 193 Labels on the robot on page 195 Article numbers and volumes Alternative Optimol Optigear RMO 150 on page 196 Article numbers and volumes Alternative Kyodo Yushi TMO 150 on page 197 Mixed types of oil may cause severe damage on page 197 Rinsing gearbox on page 198 Equipment on page 198 Location of gearbox The figure shows the location of the gearboxes on the robot xx0400000798 A Axis 1 gearb...

Page 195: ... Read the section Which type of oil does the gearbox contain on page 193to find the type of oil 2 Use section Article numbers and volumes Alternative Optimol Optigear RMO 150 on page 196to get correct oil data Robot Serial number range Type of oil Note 1 on page 194 Axis 1 2 3 Axis 4 primary 5 primary 6 Axis 4 secondary 5 secondary IRB7600 M2000 76 20000 26999 Optimol Optigear RMO 150 Shell Tivela...

Page 196: ...ndary 5 primary and secondary and 6 IRB7600 M2000 A 76 34000 Shell Tivela S 150 Shell Tivela S 150 Kyodo Yushi TMO 150 Shell Tivela S 150 Kyodo Yushi TMO 150 Shell Tivela S 150 IRB7600 M2004 76 51000 Shell Tivela S 150 Shell Tivela S 150 Kyodo Yushi TMO 150 Shell Tivela S 150 Kyodo Yushi TMO 150 Shell Tivela S 150 Robot Serial number range Type of oil Note 3 on page 194 Axis 1 2 3 Axis 4 primary 4...

Page 197: ...ow the labels NOTE Robots delivered with Optimol Optigear RMO150 are not equipped with labels If the oil is changed to Tivela S150 TMO 150 after delivery the robot must be completed with these labels Labels next to oil plugs Labels located next to oil plugs of each gearbox show which type of oil it contains All gearboxes must have the correct label clearly visible xx0900000132 Labels located next ...

Page 198: ...r RO 150 Art No 3HAC031291 001 Gearbox Type of oil Art no Amount Axis 1 Optimol Optigear RO 150 3HAC031291 001 7 600 ml Axis 2 Optimol Optigear RO 150 3HAC031291 001 4 800 ml Axis 3 Optimol Optigear RO 150 3HAC031291 001 4 200 ml Axis 4 primary gear Kyodo Yushi TMO 150 3HAC032140 001 900 ml Axis 4 secondary gear Mobilgear 600 XP320 11712016 604 3 850 ml Axis 5 primary gear Kyodo Yushi TMO 150 3HAC...

Page 199: ...O 150 as well as Shell Tivela S 150 is not compatible with mineral oil contamination with other types of oil in the gearboxes is not accepted Equipment used in handling Kyodo Yushi as well as Shell Tivela S 150 must be carefully cleaned before use If the type of oil needs to be changed the gearbox must be thoroughly rinsed See Rinsing gearbox on page 198 Gearbox Type of oil Art no Amount Axis 1 Ky...

Page 200: ...ptigear RMO 150 Optigear RO 150 are mixed Flush the gearbox properly three times with the correct type of oil Use a service program when flushing Refill the gearbox with the correct type of oil Kyodo Yushi TMO 150 mixed with Mobilgear 600 XP320 Use this procedure to rinse the contaminated gearbox if the gearbox shall contain Kyodo Yushi TMO 150 and it is mixed with Mobilgear 600 XP320 Flush the ge...

Page 201: ... 1 gearbox is located between the frame and base as shown in the figure below The oil is drained with a hose that may be reached behind the rear cover of the robot base xx0200000111 A Gearbox axis 1 B Oil plug filling C Motor axis 1 D Oil plug inspection not in all designs E Label specifies the type of oil in the gearbox Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 202: ...ng on how much oil has previously been drained from the gearbox A Oil plug in the base Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 7 600 ml Kyodo Yushi TMO 150 NOTE Do not mix with other oils Oil collecting vessel Capacity 8 000 ml Oil exchange equipment 3HAC17313 1 Content is defined in section Special tools on page 428 Standard toolkit Content is defined in section Standard t...

Page 203: ...the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 3 Remove the rear cover on the base by unscrewing its attachment screws 4 Pull the oil hose out of the rear of the base Some early versions of the robot has the oil draining plug in the base as shown in the figure Oil plug in the base on page 200 instead of the hose 5 Place an oil vessel cl...

Page 204: ...ANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 3 Open the oil plug filling Shown in the figure Location of gearbox on page 199 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously being drained The correc...

Page 205: ...box axis 2 B Oil plug filling later design C Oil plug draining D Label specifies the type of oil in the gearbox Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 4 800 ml Kyodo Yushi TMO 150 Note Do not mix with other oil types Oil collecting vessel Capacity 5 000 ml Oil exchange equipment 3HAC021745 001 Content is defined in section Special tools on page 428 Standard toolkit Content...

Page 206: ...earboxes motors and SMB 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 51 3 Remove the oil plug draining and drain the gearbox oil using a hose with nipple and an oil collecting vessel Remove the oil plug filling in order to drain the oil ...

Page 207: ...several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 51 3 Remove the oil plug filling and the plug from the vent hole Shown in the figure Location of oil plugs on page 203 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously being...

Page 208: ...A Gearbox axis 3 B Oil plug filling C Oil plug draining D Label specifies the type of oil in gearbox Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 4 200 ml Kyodo Yushi TMO 150 Note Do not mix with other oil types Oil exchange equipment 3HAC021745 001 Content is defined in section Special tools on page 428 Oil collecting vessel Capacity 5 000 ml Standard toolkit Content is defined...

Page 209: ... gearboxes motors and SMB 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 51 3 Remove the oil plug draining and drain the gearbox oil using a hose with nipple and an oil collecting vessel Remove the oil plug filling in order to drain the oi...

Page 210: ...ing please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 51 3 Remove the oil plug filling Shown in the figure Location of gearbox on page 206 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously drained The correct oil level is detailed in the section Inspection oil le...

Page 211: ... contaminated gearbox on page 231 Location of gearbox The axis 4 gearbox is located at the rear of the upper arm as shown in the figure below xx0200000107 A Upper arm housing B Cover axis 4 gearbox C Oil plug filling secondary gear D Oil plug draining secondary gear E Oil plug filling primary gearbox draining not shown in figure located further down on the motor flange F Label specifies the type o...

Page 212: ...s defined in section Standard toolkit on page 427 Action Note 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 51 2 Open the oil plug draining secondary gear Shown in the figure Location of gearbox on page 209 3 Drain the oil from the second...

Page 213: ...motors and SMB 3 Refill the secondary gear with lubricating oil through the oil plug filling secondary gear Kyodo Yushi TMO 150 Art no and amount is specified in Required equipment on page 210 Shown in the figure Location of gearbox on page 209 4 Refill the primary gearbox with oil through the oil plug filling primary gear Make sure the air is ventilated through the oil plug during filling to avoi...

Page 214: ...tion Flushing a contaminated gearbox on page 231 Location of gearbox The axis 5 gearbox is located in the wrist unit as shown in the figure below xx0200000108 A Wrist housing B Cover axis 5 gearbox C Oil plug filling secondary gear D Oil plug draining secondary gear E Oil plug filling primary gearbox draining on opposite side of wrist housing not shown in figure F Label specifies the type of oil i...

Page 215: ... used in the secondary gearbox Oil collecting vessel Capacity 1 000 ml Oil collecting vessel Capacity 4 000 ml Oil exchange equipment 3HAC17313 1 Content is defined in section Special tools on page 428 Standard toolkit Content is defined in section Standard toolkit on page 427 Action Note 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety informat...

Page 216: ...ilated through the oil plug during filling to avoid overpres sure in the gearbox 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 5 on page 161 Kyodo Yushi TMO 150 Art no and total amount is specified in Required equipment on page 213 Shown in the figure Location of gearbox on page 212 4 R...

Page 217: ...locations of the plug shown as B1 and B2 C Oil plug draining can be located on the turning disk instead D Label specifies the type of oil in gearbox axis 6 Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 850 ml 750 ml with insulated turning disk Kyodo Yushi TMO 150 Oil collecting vessel Vessel capacity 1 000 ml Oil exchange equipment 3HAC17313 1 Content is defined in section Specia...

Page 218: ...RNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 51 2 Move the wrist so that the oil plug filling of axis 6 gearbox faces upwards If the oil plug draining is located on the turning disk rotate the disk so that the plug faces downwards Shown in t...

Page 219: ...d pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 4 Remove the oil plug filling Shown in the figure Location of gearbox on page 215 5 Refill the wrist with lubricating oil Make sure the air is ventilated through the oil plug during filling to avoid overpressure in the gearbox If the plug hole for draining i...

Page 220: ...ocation of SMB battery The SMB battery SMB serial measurement board is located on the left hand side of the frame as shown in the figure below xx0200000238 Required equipment A SMB battery cover B SMB battery pack C Battery cable Equipment etc Spare part no Note Battery pack 3HAC16831 1 Battery includes protection circuits Replace it only with a given spare part number or an ABB approved equivalen...

Page 221: ...e gearboxes motors and SMB 3 esd WARNING The unit is sensitive to ESD Before handling the unit please read the safety information in the section WARNING The unit is sensitive to ESD on page 49 4 Remove SMB battery cover by unscrewing its attachment screws Shown in figure Location of SMB battery on page 218 5 Pull out battery and disconnect battery cable Shown in figure Location of SMB battery on p...

Page 222: ...n the section WARNING The unit is sensitive to ESD on page 49 3 Reconnect battery cable to SMB battery pack and fit it to frame Art no is specified in Required equipment on page 218 Shown in figure Location of SMB battery on page 218 4 Secure the SMB battery cover with its attachment screws Shown in figure Location of SMB battery on page 218 5 Update revolution counter Detailed in chapter Calibrat...

Page 223: ...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 3HAA1001 294 Optimol PDO 150 ...

Page 224: ...the spherical roller 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 221 Shown in the figure Location of bearing on page 221 The balancing device must be mounted on the robot when lubricating the bearing 3 Clean the area from any excessive gr...

Page 225: ...llustration View from above xx0600002866 Required equipment A Plastic ring bearing cover A Equipment Art no Note Brush Rust preventive 3HAC034903 001 Equivalent Mercasol 3106 Standard toolkit Content is defined in section Standard toolkit on page 427 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include referen...

Page 226: ...rust preventive on bearing axis 1 Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 2 Remove the plastic ring xx0600002866 Parts A Plastic ring 3 Wipe the surface under the plastic ring A Continued Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教...

Page 227: ...s 1 Foundry Prime 225 3HAC022033 001 Revision K Copyright 2004 2011 ABB All rights reserved 4 Apply rust preventive on the bearing with a brush xx0600002867 Parts A Bearing 5 Refit the plastic ring Action Note A Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 228: ...e illustration xx0500002869 Required equipment A Cover B Cable guide Equipment Art no Note Brush Rust preventive 3HAC034903 001 Equivalent Mercasol 3106 Standard toolkit Content is defined in section Standard toolkit on page 427 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 requi...

Page 229: ...on 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 3 Remove the cover at the rear end of the upper arm xx0600002872 Parts A Cover B Cable guide 4 Remove the cable guide that covers the sealing xx0600002871 Parts A Cable guide 5 Wipe the surface under the ca...

Page 230: ...Copyright 2004 2011 ABB All rights reserved 6 Apply rust preventive on the radial sealing and the rear part of the tube with a brush xx0600002868 Parts A Radial sealing and rear part of tube B Cable guide 7 Refit the radial sealing and cable guide Action Note Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 231: ...racket C Cover Equipment Art no Note Brush Rust preventive 3HAC034903 001 Equivalent Mercasol 3106 Standard toolkit Content is defined in section Standard toolkit on page 427 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 Put the robot and the upper arm in a...

Page 232: ...om motor axis 6 4 Tighten the hose clamp on motor axis 6 and remove the air hose 5 Remove the cover xx0600002864 A Cover 6 Apply rust preventive on the bearing and cable bracket with the brush See Location of bearing on page 229 7 Refit the cover 8 Perform a leakdown test See Inspection of air hoses Foundry Prime on page 191 Action Note A Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 233: ... 4 6 maximum working range with regard to the installation limitation axis 4 and 5 90 degrees axis 6 180 degrees Draining the gearbox properly The contaminated gearbox must be drained properly before and during the flushing procedure Axis 4 gearbox open both oil plugs filling and draining and run axis 3 in different directions Draw out the last volume approx 40 60 ml by using a syringe with a prep...

Page 234: ...e the finger tips to measure the temperature Recommendedserviceprogram detailed in section above Service program 2 Drain the gearbox properly Described in section above Draining the gearbox properly on page 231 3 Fill the gearbox with 700 ml of lubricating oil Kyodo Yushi TMO 150 Art no is specified in Required equipment on page 231 4 Refit the oil plug Tightening torque 24 Nm 5 Run the Service pr...

Page 235: ... class 2 Perform according to section Cleaning with water and steam on page 234 Protection classes Cleaning method Vacuum cleaner Wipe with cloth Rinse with water High pressure water or steam Standard Yes Yes With light cleaning detergent Yes It is highly recommended that water contains a rust prevention solution and that the robot is dried afterwards No Foundry Plus Yes Yes With light cleaning de...

Page 236: ... may shorten the life of the robot Always check that all protective covers are fitted to the robot before cleaning Never Never point the water jet at connectors joints sealings or gaskets Never use compressed air to clean the robot Never use solvents that are not approved by ABB to clean the robot Never spray from a distance closer then 0 4m Never remove any covers or other protective devices befo...

Page 237: ... SIS on page 236 2 Define what 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 238 3 Enter these parameters in the system How to do this is detailed in Setting the SIS parameters on page 240 4 Run the robot in normal operation 5 Reset the counter if a repair is made or if a counte...

Page 238: ...al 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 has been exceeded by that...

Page 239: ...g the counter variables are reset The variables are described in section Exporting the SIS data on page 243 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 display the data Service...

Page 240: ... 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 number of calendar...

Page 241: ...rt 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 estimated remaining lifetime 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 varia...

Page 242: ...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 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 243: ...nd 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 238 Action Note Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 244: ...n section Setting the SIS parameters on page 240 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 240 Proceed with the required service as detailed in chapter Repair on page 245 or chapter Maintenance on page 141 depending on which type...

Page 245: ...on 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 to the operating ...

Page 246: ...3 Maintenance 3 7 6 Exporting the SIS data 3HAC022033 001 Revision K 244 Copyright 2004 2011 ABB All rights reserved 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 247: ... location on the robot Required equipment The details of the equipment required to perform a specific repair activity are listed in the respective procedures The details of equipment are also available in different lists in the chapter Reference information Safety information There are general safety information and specific safety information The specific safety information describes the danger a...

Page 248: ...akdown tester kit may be required Art no is specified in Required equipment on page 246 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 may be detected If the compressed air is signifi cantly colder or warmer t...

Page 249: ...3HAB3537 1 Used to grease the bearings if not specified otherwise Action Note 1 To avoid contamination let a new bearing remain in its wrapping until it is time for fitting 2 Ensure that the parts included in the bearing fitting are free from burrs grinding waste and other contamination Cast components must be free of foundry sand 3 Bearing rings inner rings and roller elements must not be subject...

Page 250: ...ring may be totally filled with grease when mounted as excessive grease will be pressed out from the bearing when the robot is started During operation the bearing should be filled to 70 80 of the available volume Ensure that grease is handled and stored properly to avoid contamination Grease the different types of bearings as following description Grooved ball bearings must be filled with grease ...

Page 251: ... keyways etc Equipment etc Art no Note Grease 3HAB3537 1 Used 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 since it may result in future leakage 3 Lubri...

Page 252: ...may not be used because leakage could occur 2 Clean the surfaces properly in accordance with the recommendations of ABB 3 Distribute the sealing compound evenly over the surface preferably with a brush 4 Tighten the screws evenly when fastening the flange joint Action Note 1 Ensure that the correct o ring size is used 2 Check the o ring for surface defects burrs shape accuracy and so on Defective ...

Page 253: ...ed some from each other Any differences are pointed out in the procedures xx0100000140 1 Alternative with brake release at frame 2 Alternative with brake release at base A Connector at robot base R1 MP and R1 SMB B Connectors at motor 1 R2 FB1 and R2 MP1 C Connectors at motor 2 R2 FB2 and R2 MP2 D Connectors at serial measurement board R1 SMB1 3 R1 SMB4 6 R1 SMB1 7 R2 FB7 and R2 SMB Battery connec...

Page 254: ...chment screws for the attachment plate inside the frame Standard toolkit Content is defined in section Standard toolkit on page 427 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 Circuit Diagram See chapter Circuit diagram Action Note 1 In order to facilitate refitting of...

Page 255: ...e guide in the center of the frame 7 Disconnect all connectors at motors 1 and 2 Specified and shown in the figure Location of cable harness on page 251 8 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 revolution counter Be careful not to let the weight of the cover strain the cable In order to remove the cover comp...

Page 256: ...e 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 11 Remove the cable gland securing the cables inside the lower arm Action Note Contin...

Page 257: ...ocation of cable harness on page 251 15 Disconnect all connectors at motor 3 and motor 4 Specified and shown in the figure Location of cable harness on page 251 16 Gently pull the cable harness out Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes mo...

Page 258: ...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 251 5 Reconnect the earth cable Attachment point is shown in the figure Location of cable harness on page 251 6 Refit the rear cover plate to the robot with its attachment screws Shown in the figure Location of cable harness on page 251 7 R...

Page 259: ...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 252 xx0300000560 A Cable gland B Attachment screws cable gland C Attachment plate D Velcro strap Action Note Cont...

Page 260: ...ntinuing any service work please observe the safety information in section WARNING The brake release buttons may be jammed after service work on page 48 12 Pull the cable harness through the lower arm 13 Refit the cable gland securing the cables inside the lower arm xx0100000142 14 Refit the cable gland securing the cables to the arm house Make sure not to twist the harness xx0100000143 15 Reconne...

Page 261: ...velcro straps B with a distance of approximately 180 mm Fix the strap by wrapping it two turns around the largest cable before wrapping around the complete harness xx0500002320 19 Refit the cable harness to the guide plate axis 2 Shown in the figure Location of cable harness on page 251 20 Refit the velcro strap at the guide plate axis 2 Shown in the figure Location of cable harness on page 251 21...

Page 262: ...division R2 M5 6 D Connectors at motor 5 R3 FB5 and R3 MP5 E Connectors at motor 6 R3 FB6 and R3 MP6 Equipment etc Spare part no Note Cable harness ax 5 6 3HAC11440 1 Gasket 3HAC033489 001 Recommended to be changed for Foundry Plus robots Standard toolkit Content is defined in section Standard toolkit on page 427 Other tools and procedures may be required See references to these procedures in the ...

Page 263: ...ct position 90º to allow the motor 6 cover to open 5 Disconnect all connectors at motor 5 and motor 6 Specified in the figure Location of cable harness ax 5 6 on page 260 6 Remove the plastic cover on the rear of the upper arm by removing the attachment screws 7 Remove the spiral plate by unscrewing the screw at the bottom of the spiral cup 8 Remove eventual cable straps from the harness 9 Disconn...

Page 264: ...m 7 Reconnect all connectors at motor 5 and motor 6 Specified in the figure Location of cable harness ax 5 6 on page 260 8 Secure the cable with the cable attachment inside the upper arm 9 Refit the left hand side wrist cover with its attachment screws 10 Reconnect connector R2 M5 6 gently at the cable harness division with two screws M6 Be careful not to bend the attachment plate when fastening t...

Page 265: ...em The complete arm system is defined as the complete robot except for the base and gearbox axis 1 that is the upper and lower arms balancing device and frame This is shown in the figure below xx0100000150 A Gearbox axis 1 B Motor axis 1 C Base attachment screws D Upper arm E Lower arm F Frame G Balancing device H Block for calibration Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 266: ...ep by step instructions below These procedures include references to the tools required Action Note 1 Position the robot in its most stable position as shown in the figure to the right If the brakes need to be released see section Manually releasing the brakes on page 83 xx0100000103 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric p...

Page 267: ...e Location of complete arm system on page 263 10 Lift the arm system and secure it in a safe area Make sure all hooks and attachments maintain in correct position while lifting the robot Always move the robot at very low speeds making sure it does not tip Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power ...

Page 268: ...f the 24 attachment screws before the arm system is completely lowered 8 Remove the guide pins and secure the arm system to the base with the 24 base attachment screws and washers Shown in the figure Location of complete arm system on page 263 24 pcs M12 x 110 12 9 quality UNBRAKO tightening torque 110 Nm Reused screws may be used providing they are lubricated as detailed in section Screw joints o...

Page 269: ...right 2004 2011 ABB All rights reserved 14 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 47 Action Note Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 270: ...ose Foundry Prime Location The illustration below shows the routing of the Foundry Prime air hose xx0500002176 Hose lengths xx0600003157 Pos 1A Hose length 40 mm Pos 1B Hose length 40 mm Pos 1C Hose length 1570 mm Pos 1D Hose length 1140 mm Pos 1E Hose length 310 mm Pos 1F Hose length 35 mm Pos 1G Hose length 260 mm Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 271: ...1 c Battery cover d Motor axis 2 e Length 805 mm f Motor axis 6 g Rubber clamp on washer on gear axis 6 h Rubber clamp on tilthouse j Rubber clamp on wrist cover k Motor axis 5 m Motor axis 3 n Motor axis 4 o Bulkhead plug connector Equipment Art no Pos in illustration Velcro strap 3HAC12625 1 9 only in illustrations below Cable straps 21662055 3 8 only in illustrations below Elbow fitting 3HAC026...

Page 272: ...8and the table in Required equipment on page 269 Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Locate the damaged hose or air connector and continue to replace the damaged hose Route the hose according to the illustrations in the procedure below 3 Connection at base xx0600003042 Items in illustration are detailed in Required equipment on ...

Page 273: ...ry Prime 271 3HAC022033 001 Revision K Copyright 2004 2011 ABB All rights reserved 5 Balancing device xx0600003397 Item in illustration is detailed in Hose lengths on page 268 Action Note Continued Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 274: ... nipple and hose Foundry Prime 3HAC022033 001 Revision K 272 Copyright 2004 2011 ABB All rights reserved 6 Axis 1 2 xx0600003418 xx0600003420 xx0600003045 Action Note Continued Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 275: ... 3HAC022033 001 Revision K Copyright 2004 2011 ABB All rights reserved 7 Upper arm housing xx0600003046 xx0600003047 8 Tube shaft xx0600003163 1P Lay the hose in a spiral in the tube shaft Action Note Continued Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 276: ...ry Prime 3HAC022033 001 Revision K 274 Copyright 2004 2011 ABB All rights reserved 9 Wrist NOTE Make sure the cable length from 5a to the nipple of axis 6 S see Hose lengths on page 268 xx0600003097 Action Note Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 277: ...ilthouse C Turning disk attachment screws 33 pcs Equipment etc Spare part no Art no Note Turning disk dia 250 3HAC13193 1 Does not include o ring Turning disk insulated 3HAC023124 002 O ring 21522012 433 Must be replaced when replacing the turning disk Grease 3HAB3537 1 Used to lubricate the o ring Standard toolkit Content is defined in section Standard toolkit on page 427 Other tools and procedur...

Page 278: ...ic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 2 Drain the oil from gearbox 6 Detailed in section Oil change gearbox axis 6 on page 215 3 Remove the attachment screws 33 pcs securing the turning disk Shown in the figure Location of turning disk on page 275 4 Remove the turning disk xx1000001135 Continued Continue...

Page 279: ... SMB 2 Lubricate the o ring with grease and fit it to the rear of the turning disk Art no is specified in Required equipment on page 275 xx0100000130 A O ring turning disk 3 Secure the turning disk with its attachment screws Attachment screws M10 x 25 12 9 quality UNBRAKO Tightening torque 50 Nm Reused screws may be used providing they are lubricated as detailed in section Screw joints on page 423...

Page 280: ...2004 2011 ABB All rights reserved 5 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 47 Action Info Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 281: ...eference information xx0100000147 Required equipment A Wrist unit B Wrist unit attachment screws and washers C Attachment cable harness axis 5 6 D Connectors at cable harness division R2 M5 6 E Turning disk F Cover axis 5 G Rear cover H View with cable harness mounted on robot Equipment etc Spare part no Art no Note Wrist type 3 3HAC16628 4 Wrist insulated 3HAC16628 3 Wrist Foundry Prime 3HAC02729...

Page 282: ...ted to the turning disk 3 Turn axis 4 to a position where the cover axis 5 faces upwards Shown in the figure Location of wrist unit on page 279 4 Remove the cover axis 5 by unscrewing its attachment screws 5 CAUTION The complete wrist unit weighs 200 kg All lifting equipment used must be sized accordingly 6 Fit the lifting tool wrist unit to the two holes on the sealing surface against the cover a...

Page 283: ...he cover axis 5 from the wrist unit to be fitted Fit the lifting tool wrist unit to the wrist unit Art no is specified in Required equipment on page 279 4 Lift the wrist unit and move it to its mounting position 5 Fit a new friction washer between the upper arm tube and the wrist unit Art no is specified in Required equipment on page 279 6 Gently pull the wrist unit cable harness through the upper...

Page 284: ...ns Inspection oil level gearbox axis 5 on page 161 Inspection oil level gearbox axis 6 on page 164 14 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 403 15 Refit any equipment previously removed from the turning disk 16 DANGER Make sure all safe...

Page 285: ...the component and its position may be found in chapter Exploded views in the Product manual reference information xx0100000148 A Upper arm B Attachment screws upper arm C Connectors at cable harness division R2 M5 6 D Rear cable attachment E Oil plug draining F Oil plug filling G Attachment hole M12 H Sealing between lower arm and gearbox 3 J Attachment holes for lifting device upper arm K Attachm...

Page 286: ...e procedures in the step by step instructions below These procedures include references to the tools required Action Note 1 Run the upper arm to a horizontal position 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 3 CAUTION The complete upper arm weighs 45...

Page 287: ...aining connections to the upper arm 10 Disconnect all connectors inside motors 3 and 4 11 Remove all brackets securing cabling to the upper arm by unscrewing their attachment screws respectively 12 Raise the lifting equipment to take the weight of the upper arm 13 Carefully remove the upper arm attachment screws Make sure that the upper arm is lifted in a completely level position in all planes in...

Page 288: ...84 5 Fit one of the pieces included in the lifting device upper arm to the attachment holes for lifting device upper arm using the included attachment screws Shown in the figure Location of upper arm on page 283 Art no is specified in Required equipment on page 284 6 Run the lifting chain from the rear lifting point through the overhead crane hook through the hoisting block to the lifting eye in t...

Page 289: ... fit the two remaining attachment screws Tighten them as detailed above 13 Refit any cabling removed during the removal process 14 Reconnect all connectors inside motors 3 and 4 15 Reconnect connector R2 M5 6 gently at the rear cable division point Be careful not to bend the attachment plate when fastening the screws 16 Refill the gearbox with oil Detailed in section Filling oil on page 208 17 Rec...

Page 290: ...al reference information xx0100000149 Attachment points lower arm The lower arm attachment points are located as shown in the figure below The figure 1 shows gearbox 3 but the location of sealing axis 2 3 in relation to the gearbox is identical for axis 3 The figure 2 shows a cut view through the lower arm pivot point in axis 2 item B in the figure above A Lower arm B Pivot point axis 2 C Front sh...

Page 291: ... Frame E Shaft hole 201 Sealing axis 2 3 202 Attachment screw 204 Washer 401 Bearing 402 Thrust washer 403 Bushing 404 Retaining ring 405 Shaft 406 Protection plug 409 Protection washer Equipment etc Spare part no Art no Note Bearing 3HAC4310 1 Always use a new bearing Sealing axis 2 3 3HAC11054 1 Always use a new sealing VK cover 3HAA2166 23 Continued Continues on next page 工控帮助教小舒QQ2823408167 长沙...

Page 292: ...in 3HAC021563 012 To be used together with the press tool axis 2 shaft and the puller tool Press device axis 2 shaft 3HAC021600 001 Press tool axis 2 bearing 3HAC13453 1 Power supply 24 VDC 1 5 A For releasing the brakes Retaining ring pliers Standard toolkit Content is defined in section Standard toolkit on page 427 Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operatin...

Page 293: ...using hydraulic press tool on page 320 6 Remove the securing screw from the balancing device front shaft Shown in the figure Location of lower arm on page 288 7 Apply the shaft puller tool to the shaft through the hole in the frame The shaft has a M20 thread diameter and a 40 mm depth of thread as shown in the figure to the right Pull the shaft out using the puller tool and the hydraulic pump Art ...

Page 294: ... to the right and mount both the hydraulic pump and the glycerin pump to it Art no is specified in Required equipment on page 289 xx0300000010 17 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 Do not exceed the limit of maximum pressure classified for the pumps 18 Remove the lower arm attachme...

Page 295: ... cover on new lower arm or replace existing if damaged Spare part no is specified in Required equipment on page 289 3 Fit the two guidings in the attachment holes of the lower arm Included in the lifting tool lower arm art no is specified in Required equipment on page 289 xx0200000262 A Attachment holes for the two guidings 4 Fit the new sealing axis 2 3 on the guidings Always use a new sealing wh...

Page 296: ...arm with 28 of the 30 attachment screws and washers in gearbox 2 30 pcs M16 x 50 tightening torque 300 Nm Shown in the figure Attachment points lower arm on page 288 10 Remove the guidings and secure the two remaining attachment screws as detailed above 11 Apply grease to the shaft hole Art no is specified in Required equipment on page 289 12 Push the shaft in by hand xx0300000014 A Retaining ring...

Page 297: ...2 Press the bearing in with the press tool axis 2 bearing Always use a new bearing when reas sembling Art no is specified in Required equipment on page 289 23 Refit the protection washer and the retaining ring Shown in the figure Attachment points lower arm on page 288 24 Refit the protection plug Shown in the figure Attachment points lower arm on page 288 25 Refit and restore the balancing device...

Page 298: ...ight 2004 2011 ABB All rights reserved 31 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 47 Action Note Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 299: ...ide of the 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 Brush Option Foundry prime Rust preventive 3HAC026621 001 Option Foundry prime Equivalent Mercasol 3106 Standard toolkit Content is defined in section Standard toolkit on page 427 Circuit Diagram See chapter Circuit diagram Con...

Page 300: ...to ESD on page 49 4 Remove the SMB cover by unscrewing its attachment screws Shown in the figure Location of SMB unit on page 297 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 SMB unit on page 297 7 Gently disconnect the connectors from the SMB unit when pulling...

Page 301: ...pins Art no is specified in Required equipment on page 297 Shown in the figure Location of SMB unit on page 297 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 with its attachment screws Shown in the figure Location of SMB unit on page 297 8 Update t...

Page 302: ...8 5 NOTE Make sure that the gasket under the SMB cover is not damaged Secure the SMB cover with its attachment screws 6 Apply rust preventive on the surface around the SMB cover and under on top of the screw heads 7 Perform a leakdown test according to Inspection of air hoses Foundry Prime on page 191 8 Update the revolution counter See Updating revolution counters on page 408 9 DANGER Make sure a...

Page 303: ...release unit with or without push buttons located at the base The later design instead includes a brake release unit with push buttons placed together with the SMB unit on the left hand side of the frame The different designs are not compatible Location of brake release unit base The early design includes a brake release unit with or without push buttons located at the base as shown in the figure ...

Page 304: ... release circuit without buttons at base 3HAC14219 1 Brake release at the base according to figure Location of brake release unit base on page 301 Includes brake release unit 3HAC14228 1 Brake release circuit with buttons at base 3HAC12989 1 Brake release at the base according to figure Location of brake release unit base on page 301 Includes brake release unit 3HAC16036 1 Brake release unit with ...

Page 305: ...t no Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 2 esd WARNING The unit is sensitive to ESD Before handling the unit please read the safety information in the section WARNING The unit is sensitive to ESD on page 49 3 Remove the cover at...

Page 306: ...fitting of the brake release unit 4 Remove 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 frame on page 302 5 Disconnect the connectors X8 X9 and X10 from the brake release unit xx0200000129 A Connector X8 B Connector X9 C Connector X10 D Push buttons for each axis...

Page 307: ... robot Spare part no is specified in Required equipment on page 302 Shown in the figure Location of brake release unit base on page 301 3 Reconnect the cable to the brake release circuit 4 Fasten the attachment screws brake release circuit on the outside of the rear of the base Shown in the figure Location of brake release unit base on page 301 5 Refit the cover of the rear of the base Action Note...

Page 308: ...lease observe the safety information in section WARNING The brake release buttons may be jammed after service work on page 48 6 Refit the push button guard on the SMB cover Shown in the figure Location of brake release unit frame on page 302 7 If the battery has been disconnected the revolution counters must be updated Detailed in section Updating revolution counters on page 408 8 DANGER Make sure...

Page 309: ...located on rear top of the frame as shown in the figure below xx0100000139 A Balancing device B Rear cover C Support shaft inside included in balancing device 3HAC14675 1 D Attachment screws rear cover E Balancing device shaft including screw and washer F Bearing attachment G Parallel pin inside bearing attachment H Attachment screws bearing attachment Continues on next page 工控帮助教小舒QQ2823408167 长沙...

Page 310: ...he figure below xx0600002653 A Attachment hole for lifting eye M12 B Attachment hole for securing screw that secures the bearing attachment to the balancing device protection plug fitted normally C Hole in frame to access the balancing device front eye shaft with the puller press tool D Attachment hole for locking screw that secures the lower arm to the frame Continued Continues on next page 工控帮助教...

Page 311: ...001 294 150 ml Optimol PDO For lubrication of spherical roller bearing in ear in case of new balancing device Brush Rust preventive 3HAC026621 001 Equivalent Mercasol 3106 Locking liquid Loctite 243 To apply to the 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 Lifting eye M12 3HAC14457 3 Lifting tool ch...

Page 312: ...ent hole in the frame Attachment hole for the locking screw is shown in the figure Attachment points balancing device on page 308 Art no is specified in Required equipment on page 309 4 CAUTION The balancing device weighs 300 kg All lifting equipment used must be sized accordingly 5 Fit the lifting eye M12 to the balancing device and raise to unload the weight Art no is specified in Required equip...

Page 313: ... to the balancing device by replacing the protection plug on the outside of each attachment with securing screws The protection plugs must be refitted after refitting the balancing device do not loose them Shown in the figure Attachment points balancing device on page 308 Dimensions for the securing screws are specified in Required equipment on page 309 11 Remove the two bearing attachments from t...

Page 314: ...chment points balancing device on page 308 Dimension of the securing screws is specified in Required equipment on page 309 4 Refit the two parallel pins in the frame Shown in the figure Location of balancing device on page 307 5 Fit two guide pins to the upper holes in the frame where the bearing attachments are to be attached 6 Fit the lifting eye to the balancing device Art no is specified in Re...

Page 315: ...ressed in when fitting the shaft 15 Lubricate the shaft with grease Art no is specified in Required equipment on page 309 16 Apply the shaft press tool to the lubricated shaft Fit the shaft to the piston shaft front eye through the hole in the frame using the shaft press tool and the hydraulic pump The hole in the frame is shown in the figure Attachment points balancing device on page 308 Art no i...

Page 316: ... the piston rod during operation Make sure the cover is properly secured before commissioning of the robot 21 Remove the locking screw that secures the lower arm to the frame xx0200000454 1 Attachment hole for the securing screw 22 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or ...

Page 317: ...back in place wipe off surplus material xx0600003131 A Sealing spacers 3 Apply Mercasol 3106 to the shaft and hole in frame xx0600003130 A Mercasol on shaft and in hole B Mercasol between piston rod and ear 4 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 47 Actio...

Page 318: ...re 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 3HAA2167 17 Sealing spacer 3HAC12988 1 2 pcs required O ring 3HAB3772 76 2 pcs required Sealing ring 3HAC11581 6 2 pcs required Grease 3HAB3537 1 For lubrication of the components Toolkit 3HAC15943 ...

Page 319: ...tools required Equipment Spare part no Art no Note A Threaded bar B Dolly C Press tool for removal of bearing D Press tool for refitting of bearing E Hexagon nut M12 2pcs F Plain washer 13x24x2 5 2pcs Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and ...

Page 320: ...on Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 2 Grease the inside walls of the front ear 3 Insert the threaded bar through the new bearing and place it at the front ear Fit also the press tool and the dolly to the bar as shown in the figure to the...

Page 321: ... B Dolly 3HAC15948 1 C Press tool 3HAC15846 1 7 Refit the balancing device to the robot Detailed in section Refitting balancing device on page 312 8 Lubricate the spherical roller bearing in the ear NOTE The balancing device must be mounted on the robot when lubrication is performed Detailed in section Lubrication of spherical roller bearing balancing device on page 221 9 Make sure no incorrect le...

Page 322: ... in the current repair activity for example removal of the balancing device DANGER There is a high tensioned spring inside the balancing device incorrect handling may cause injuries and damage property 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...

Page 323: ...ce Equipment etc Art no Note Press tool balancing device 3HAC020902 001 Includes press device 3HAC15767 2 press device 3HAC18100 1 Choose the correct device depending on model of balancing device Hydraulic cylinder 3HAC11731 1 To be used with the press tool Hydraulic pump 80 MPa 3HAC13086 1 To be used with the hydraulic cylinder Standard toolkit Content is defined in section Standard toolkit on pa...

Page 324: ...other screws then the rear cover attachment screws xx0200000175 E Rear cover attachment screws 4 pcs 4 Remove the o ring from the balancing device end 5 Remove the support shaft 6 Fit the press tool to the rear of the balancing device with enclosed bolts Tighten them properly Art no is specified in Required equipment on page 321 See the figure Press tool and hydraulic cylinder on page 320 7 Fit th...

Page 325: ...raulic press tool 323 3HAC022033 001 Revision K Copyright 2004 2011 ABB All rights reserved 11 Unload the hydraulic cylinder 12 The hydraulic cylinder may now be removed from the tool when necessary Action Note Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 326: ... There is a high tensioned spring inside the balancing device incorrect handling may cause injuries and damage property 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 327: ...he figure Press tool and hydraulic cylinder on page 324 2 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 324 Do not apply more pressure than necessary it could damage bearings and sealings at the shaft 3 Unload the cylinder and make sure the moving pin i...

Page 328: ...nt screws using locking liquid Apply sikaflex 521FX on the cover xx0200000175 E 4 pcs M10x30 tightening torque 50 Nm Locking liquid is specified in Required equipment on page 325 10 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 Action Note Continued 工控帮助教小舒QQ2823408167 长...

Page 329: ...tion of motor The motor axis 1 is located on the left hand side of the robotas shown in the figure below xx0100000123 Required equipment A Motor axis 1 B Cable gland cover motor axis C Cover for connector access D Motor attachment screws Equipment etc Spare part no Art no Note Motor axis 1 3HAC14207 1 Includes motor pinion o ring 21522012 430 O ring 21522012 430 Must be replaced when reassemling t...

Page 330: ...pply 24 VDC max 1 5 A For releasing the brakes Standard toolkit Content is defined in section Standard toolkit on page 427 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 Dia...

Page 331: ...ent screws and plain washers If required use the extension 300mm for bits 1 2 Shown in the figure Location of motor on page 327 Art no is specified in Required equipment on page 327 8 CAUTION The motor weighs 32 kg All lifting equipment used must be sized accordingly 9 Lift the motor to get the pinion away from the gear and disconnect the brake release voltage 10 Remove the motor by gently lifting...

Page 332: ... Secure the motor with its four attachment screws and plain washers M10 x 40 tightening torque 50 Nm 9 Disconnect the brake release voltage 10 Reconnect all connectors beneath the motor cover 11 Refit the cable gland cover at the cable exit with its two attachment screws Make sure the cover is tightly sealed 12 Refit the motor cover with its four attachment screws Make sure the cover is tightly se...

Page 333: ...ions Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 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 3 NOTE Keep the old top...

Page 334: ...75 A Motor unit B Sikaflex in screw recesses 6 Continue to refit the new motor according to section Refitting motor axis 1 on page 329 7 After mounting the motor on the robot 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 191 Action Note Con...

Page 335: ...tor axis 2 IRB 7600 500 2 3 IRB 7600 400 2 55 IRB 7600 340 2 8 IRB 7600 150 3 5 3HAC14209 2 Includes motor pinion o ring 2152 2012 430 Motor axis 2 IRB7600 500 2 55 IRB7600 325 3 1 3HAC025819 001 Includes motor pinion o ring 2152 2012 430 O ring 21522012 430 21522012 430 Must be replaced when reassembling motor Sikaflex 521FC 3HAC026759 001 Option Foundry Prime Gasket 3HAC3438 1 Option Foundry Pri...

Page 336: ... 3HAC12342 1 Extension bar 300 mm for bits 1 2 3HAC12342 1 Power supply 24 VDC 1 5 A For releasing the brakes Rotation tool 3HAC17105 1 Used to rotate the motor pinion when mating it to the gear when brakes are released with 24VDC power supply Standard toolkit Content is defined in section Standard toolkit on page 427 Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operati...

Page 337: ...xis 2 on page 203 5 Remove the cover on top of the motor by unscrewing its four attachment screws 6 Remove the cable gland cover at the cable exit by unscrewing its two attachment screws Shown in the figure Location of motor on page 333 Make sure the gasket is not damaged 7 Disconnect all connectors beneath the motor cover 8 DANGER Secure the weight of the lower arm properly before releasing the b...

Page 338: ...e the motor by gently lifting it straight out and place it on a secure surface Disconnect the brake release voltage Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 2 Make sure the o ring on the circumference of the motor is seated pr...

Page 339: ...or shaft as shown in the figure above A Rotation tool 10 Remove the guide pins 11 Secure the motor with four attachment screws and plain washers If required use the extension 300mm for bits 1 2 M10 x 40 tightening torque 50 Nm Reused screws may be used providing they are lubricated as detailed in section Screw joints on page 423 before fitting 12 Disconnect the brake release voltage 13 Reconnect a...

Page 340: ...mation on page 403 20 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 47 Action Note Action Note 1 Move the robot to a position close enough to its calibration position to allow the lock screw to be inserted into the hole for lock screw Shown in the figure Location...

Page 341: ...ectors beneath the motor cover 7 NOTE Keep the old top cover with the air nipple mounted 8 DANGER Secure the weight of the lower arm properly before releasing the brakes of motor axis 2 When releasing the holding brakes of the motor the lower arm will be movable and may fall down 9 After the weight of the lower arm is properly secured continue removal of the motor unit as detailed in section Remov...

Page 342: ...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 refit the new motor according to section Refitting motor on page 336 12 Perform a leak test according to Inspection of air hoses Foundry Prime on page 191 Action Note Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 343: ...o Art no Note Motor axis 3 3HAC14209 1 Includes motor pinion o ring 21522012 430 O ring 21522012 430 Must be replaced when reas sembling motor Sikaflex 521FC 3HAC026759 001 Option Foundry Prime Gasket 3HAC3438 1 Option Foundry Prime Mercasol 3106 3HAC0266621 001 Option Foundry Prime Loctite 574 Option Foundry Prime Mechanical stop axis 3 3HAC12708 2 May be used to fix axis 3 Use attachment screws ...

Page 344: ...ate 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 Content is defined in section Standard toolkit on page 427 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 ...

Page 345: ...otors and SMB 3 Drain the oil from gearbox axis 3 Detailed in section Oil change gearbox axis 3 on page 206 4 Remove any equipment hindering access to motor axis 3 5 Remove the cover on top of the motor by unscrewing its four attachment screws 6 Remove the cable gland cover at the cable exit by unscrewing its two securing screws Shown in the figure Location of motor on page 341 Make sure the gaske...

Page 346: ...e o ring on the circumference of the motor is seated properly Lightly lubricate it with grease Art no is specified in Required equipment on page 341 3 Fit the lifting tool motor axis 2 3 4 to the motor Art no is specified in Required equipment on page 341 4 Fit the two guide pins in the two lower motor attachment holes Art no is specified in Required equipment on page 341 Shown in the figure Locat...

Page 347: ... no is specified in Required equipment on page 341 12 Disconnect the brake release voltage 13 Reconnect all connectors 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 Make sure the cover is tightly sealed Shown in the figure Location of motor on page 341 15 Refit the cover on top of the motor ...

Page 348: ... when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 47 Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 2 Remove the motor according to step 2 4 in Rem...

Page 349: ...rwards in section Removal motor on page 343 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 section Refitting motor on page 344 8 Perform a leak test according to Inspection of air hoses Foundry Prime on page 191 Action Note Contin...

Page 350: ... pcs Equipment etc Spare part no Art no Note Motor axis 4 3HAC14210 1 Includes motor pinion o ring 21522012 430 O ring 21522012 430 Must be replaced when reas sembling motor Sikaflex 521FC 3HAC026759 001 Option Foundry Prime Mercasol 3106 3HAC026621 001 Option Foundry Prime Loctite 574 Option Foundry Prime Gasket 3HAC3438 1 Option Foundry Prime Lifting tool motor ax 1 4 5 3HAC14459 1 Lifting tool ...

Page 351: ...with 24 VDC power supply Power supply 24 VDC max 1 5 A For releasing the brakes Standard toolkit Content is defined in section Standard toolkit on page 427 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 t...

Page 352: ...at the cable exit of the motor by unscrewing its two attachment screws Shown in the figure Location of motor on page 348 Make sure the gasket is not damaged 6 Remove the cover on top of the motor by unscrewing its four attachment screws 7 Disconnect all connectors beneath the motor cover 8 In order to release the brake connect the 24 VDC power supply Connect to connector R2 MP4 pin 2 pin 5 9 CAUTI...

Page 353: ...NGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 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 specified in Required equipment on page 348 3 CAUTION The motor weighs 22 kg All lifti...

Page 354: ...ure above A Rotation tool 9 Remove the guide pins 10 Secure the motor with four attachment screws and plain washers If required use the extension 300mm for bits 1 2 4 pcs M10 x 80 tightening torque 50 Nm Art no is specified in Required equipment on page 348 11 Disconnect the brake release voltage 12 Reconnect all connectors beneath the motor cover 13 Refit the cover on top of the motor with its fo...

Page 355: ...re met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 47 Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 2 Remove the cover for connector access o...

Page 356: ...e 349 5 Fill the four screw recesses on the new motor with Sikaflex After hardening Sikaflex can be formed with a knife xx0600002875 A Motor unit B Sikaflex in screw recesses 6 Continue to refit the new motor according to section Refitting motor axis 4 on page 351 7 Perform a leak test according to Inspection of air hoses Foundry Prime on page 191 Action Note Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育...

Page 357: ...te Motor axis 5 3HAC14725 1 Includes motor pinion o ring 21522012 430 O ring 21522012 430 Must be replaced when replacing motor Grease 3HAB3537 1 For lubricating the o ring Standard toolkit Content is defined in section Standard toolkit on page 427 Guide pins M10 x 100 3HAC15521 1 For guiding the motor Guide pins M10 x 150 3HAC15521 2 For guiding the motor Lifting tool motor ax 1 4 5 3HAC14459 1 F...

Page 358: ...xes motors and SMB 3 Remove the left hand side cover of the wrist unit by unscrewing its six attachment screws The motor is accessible behind the rear part of the cover 4 Remove the heat protection plate by unscrewing its two attachment screws Shown in the figure Location of motor on page 355 5 Remove the cover on top of the motor by unscrewing its four attachment screws 6 Remove the cable gland c...

Page 359: ...d pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes 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 specified in Required equipment on page 355 3 CAUTION The motor weighs 22 kg All lifting equipment used must be sized accordingly 4...

Page 360: ...e cable exit with its two attachment screws Shown in the figure Location of motor on page 355 13 Refit the cover on top of the motor with its four attachment screws Make sure the cover is tightly sealed 14 Refit the heat protection plate with its two attachment screws Shown in the figure Location of motor on page 355 15 If cables are loose place them correctly and tie them up with cable ties 16 Re...

Page 361: ...ed views on page 463 xx0100000128 Required equipment A Motor axis 6 Equipment etc Spare part no Art no Note Motor axis 6 3HAC14211 1 Includes motor pinion o ring 21522012 430 O ring 21522012 430 Must be replaced when reas sembling motor Brush Option Foundry Prime Mercasol 3106 3HAC026621 001 Option Foundry Prime Sikaflex 521FC 3HAC026759 001 Option Foundry Prime Loctite 574 Option Foundry Prime Lo...

Page 362: ...l 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 Circuit Diagram See chapter Circuit diagram Equipment etc Spare part no Art no Note Action Note 1 Move the robot to one of the recommended positions to a position where the motor in axis 6 is pointed straight up This positi...

Page 363: ...ction Note Action Note 1 Make sure the o ring on the circumference of the motor is seated properly Lightly lubricate the o ring with grease Art no is specified in Required equipment on page 359 2 In order to release the brake connect the 24 VDC power supply Connect to connector R3 MP6 pin 2 pin 5 3 Fit the two guide pins in two of the motor attachment holes Art no is specified in Required equipmen...

Page 364: ...rforming the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 47 Action Note Action Note 1 Move the robot to one of the recommended positions to a position where the motor in axis 6 is pointed straight up This position enables the motor to be replaced without draining the gear oil which in turn saves time to a position where the moto...

Page 365: ...00002885 A Motor unit B Attachment screw 5 pcs C Air nipple D Rear motor cover E Gasket G Air nipple 5 Continue to remove the motor unit according to step 6 and forwards in Removal motor on page 360 6 NOTE Keep the old rear motor cover with the air nipple For Foundry Prime robots Replace the gasket on the cover Action Note Continued Continues on next page 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 366: ...2884 A Mercasol 3106 B Motor unit C Attachment screw 4pcs D Sikaflex in screw recesses E Loctite 570 F Tilt house G Grease J Sealing K Sealing 8 Apply Mercasol 3106 on the motor end cover and Loctite 570 on the tilt house on the surface facing the motor end cover 9 Apply grease on the o ring on the motor 10 Continue to refit the new motor according to section Refitting motor on page 361 11 Perform...

Page 367: ...detailed view of the component and its position may be found in chapter Exploded views on page 463 xx0100000133 Required equipment A Gearbox axis 1 B Oil plug filling C Attachment screws gearbox to frame D Frame E Base Attachment screws base to gearbox not shown in figure Equipment etc Spare part no Art no Note Gearbox 3HAC10828 1 Includes gearbox all o rings and sealing rings O ring 3HAB3772 54 R...

Page 368: ...0 1 Lifting tool chain 3HAC15556 1 Standard toolkit Content is defined in section Standard toolkit on page 427 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 1 Move the robot to its most stable position shown in the fig...

Page 369: ...nd gear 1 and the lifting tool chain to the gearbox Art no is specified in Required equipment on page 365 9 CAUTION The base and gearbox weighs 510 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 365 11 Fit the support base Make sure the base re...

Page 370: ...achment screws gearbox axis 1 18 pcs C Washers 3 pcs 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 200 kg All lifting equipment used must be sized accordingly 16 Lift the gearbox away with the already mounted lifting tools Action Note ...

Page 371: ...ase Make sure the small o ring around the oil hole is fitted properly Art no is specified in Required equipment on page 365 xx0200000055 A Guide pin C O ring 3HAB 3772 54 D O ring 3HAB 3772 55 E Sealing 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 lif...

Page 372: ...w A Oil drain hose B Attachment screws gearbox axis 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 If removed also refit the rear connector plate NOTE Direct the bends on the bottom plate downwards 1 screw M6 x 8 xx0300000612 A Bottom plate B Rear connector plate C Attachment screw D Groove 10 CAUTION The b...

Page 373: ... rear of the robot base 15 Perform a leak down test Detailed in section Performing a leak down test on page 246 16 Refill the gearbox with oil Detailed in section Filling oil gearbox axis 1 on page 202 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 information o...

Page 374: ...ed 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 the section DANGER First test run may cause injury or damage on page 47 Action Note A B Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 375: ...nformation xx0100000135 Required equipment A Gearbox axis 2 behind motor attachment not shown in figure B Motor axis 2 C Oil plug filling D Oil plug draining E Front gearbox attachment screws F Attachment holes fixture lower arm G Motor attachment H Sealing between gearbox and lower arm not shown in figure I Hole for locking screw lower arm M16 x 60 Equipment etc Spare part no Art no Note Gearbox ...

Page 376: ...aling ax 2 3 80mm 3HAC14627 2 For guiding the sealing axis 2 3 Guides are to be used in pairs Guide pins sealing ax 2 3 100mm 3HAC14627 3 For guiding the sealing axis 2 3 Guides are to be used in pairs 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 instructio...

Page 377: ...k Align the fixture with the frame and lower arm Tighten the four M16 bolts C on the inside of the frame in attachment holes with tightening torque 220 Nm Screw in the two adjusters B until they rest against the flats on the lower arm Tighten by hand Lock using the two ring nuts D Tighten the two M12 bolts E in the attachment holes fixture lower arm with tightening torque 91 Nm Art no is specified...

Page 378: ... in Required equipment on page 373 13 CAUTION The gearbox weighs 125 kg All lifting equipment used must be sized accordingly 14 Fit the lifting tool gearbox axis 2 to the gearbox Art no is specified in Required equipment on page 373 15 Fit two guide pins in 180 relation to each other instead of the removed front attachment screws Art no is specified in Required equipment on page 373 16 If required...

Page 379: ...ressure to the gearboxes motors and SMB 2 Fit the guide pins sealing axis 2 3 on gearbox axis 2 Only the holes showed in figure beside are allowed to be used to the guide pins xx0200000125 A Holes for guide pins sealing axis 2 3 on gearbox 2 Always use a new sealing when reassembling Art no is specified in Required equipment on page 373 3 Fit the new sealing axis 2 3 on gearbox axis 2 with guidanc...

Page 380: ...ed properly 9 Remove the lifting tool 10 In a similar way fit the lifting tool to the motor flange Lock the tool with the hook Lift it and slide it onto the guide pins Remove the lifting tool 11 Insert and secure 18 of the 20 attachment screws on the front of the motor attachment Remove the guide pins and tighten the remaining two screws Tightening torque 300 Nm Reused screws may be used providing...

Page 381: ...in section Filling oil on page 205 18 Restore the balancing device by removing the balancing device tools Detailed in section Restoring the balancing device on page 325 19 Remove the fixture lower arm 20 Remove the locking screw lower arm 21 Refit any mechanical stops if such were removed during disassembly 22 Refit any equipment to the turning disc if such was removed during assembly 23 Recalibra...

Page 382: ...s 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 xx0100000137 A Gearbox axis 3 B Attachment screws gearbox C Oil plug filling D Oil plug draining E Motor axis 3 F Attachment screws upper arm G Attachment screws motor H Sealing axis 2 3 between lower arm and gearbox 3 Continues on ne...

Page 383: ...for mechanical stop axis 3 3HAA1001 186 Bolt M16x60 for mechanical stop axis 3 3HAB3409 86 3HAC025333 005 Lifting eye M16 3HAC14457 4 Guide pins M16 x 250 3HAC13120 4 For guiding the gearbox Use guides in pairs Guide pins M16 x 300 3HAC13120 5 For guiding the gearbox Use guides in pairs Guide pins sealing ax 2 3 80mm 3HAC14627 2 For guiding the sealing axis 2 3 Use guides in pairs Guide pins seali...

Page 384: ...ection Removal motor on page 343 NOTE When removing the motor axis 3 the brake on axis 3 is released Make sure the upper arm is secured and disabled to move 4 Remove the upper arm Detailed in section Removal upper arm on page 284 5 Remove the sealing axis 2 3 between the gearbox and lower arm On reassembly a new sealing must be used Art no is specified in Required equipment on page 381 6 Place the...

Page 385: ... 10 CAUTION The gearbox weighs 125 kg All lifting equipment used must be sized accordingly 11 Remove the gearbox with guidance from the guide pins using an overhead crane or similar Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 2 T...

Page 386: ...ition Make sure the o rings are seated properly and the gearbox correctly oriented 10 Remove the lifting tool 11 Secure the gearbox with 18 of the 20 gearbox attachment screws Remove the guide pins and tighten the remaining two screws 20 pcs M16 x 90 12 9 quality UNBRAKO tightening torque 300 Nm Reused screws may be used providing they are lubricated as detailed in section Screw joints on page 423...

Page 387: ...These are further detailed in the section DANGER First test run may cause injury or damage on page 47 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 Apply Mercasol on surfaces on lower arm and gear before assembly Area where Mercasol shall be applied ga...

Page 388: ...of the component and its position may be found in chapter Exploded views in the Product manual reference information xx0100000144 A Upper arm housing B Gearbox axis 4 C Cover axis 4 gearbox D Attachment screws cover axis 4 E Oil plug filling secondary gearbox F Oil plug draining secondary gearbox G Gear Z3 H Gear attachment screws I Motor axis 4 J Motor flange K Oil plug filling primary gearbox dr...

Page 389: ... 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 Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to t...

Page 390: ...nd gearbox axis 4 out along with the friction washers If required insert screws into two holes in the gearbox to press it out M10 Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 2 Make sure the two o rings on the circumference of the...

Page 391: ...axis 4 Detailed in section Refitting motor axis 4 on page 351 10 Refit gear Z3 to the gearbox with its gear attachment screws Shown in the figure Location of gearbox on page 386 9 pcs M12 x 50 tightening torque 115 Nm 6 pcs M16 x 60 tightening torque 300 Nm 11 Replace the gasket cover axis 4 Art no is specified in Required equipment on page 387 12 Refit the cover axis 4 gearbox with its attachment...

Page 392: ...ht 2004 2011 ABB All rights reserved 17 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 47 Action Note Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 393: ...ay be found in chapter Exploded views in the Product manual reference information xx0100000146 A Wrist housing B Cover axis 5 gearbox C Attachment screws cover axis 5 D Oil plug secondary filling E Oil plug secondary draining F Gear Z3 G Wheel unit H Attachment screws gear Z3 K Gearbox axis 5 L Oil plug primary filling draining plug on the opposite side of the wrist housing not shown in figure N V...

Page 394: ...s required For lifting the gearbox Removal tool wheel unit 3HAC15814 1 For removing and lifting the wheel unit Guide pins M10 x 100 3HAC15521 1 Always use guide pins in pairs Guide pins M10 x 150 3HAC15521 2 Always use guide pins in pairs Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Other tools and procedures may be required See references to these proc...

Page 395: ...tion of gearbox on page 391 18 pcs M10 x 40 9 Apply two lifting eyes to the gearbox axis 5 in opposite positions Art no is specified in Required equipment on page 392 10 Remove the gearbox by gently lifting it straight out 11 Remove the friction washers located beneath the gearbox from the wrist housing Action Note Action Note 1 Drain the oil from the secondary gearbox Detailed in section Oil chan...

Page 396: ... electric power and hydraulic but not the air pressure to the gearboxes motors and SMB 2 Make sure the two o rings on the circumference of the gearbox are seated properly in their grooves respectively Lightly lubricate the o rings with grease Art no is specified in Required equipment on page 392 3 Fit two guide pins in the housing Art no is specified in Required equipment on page 392 4 Refit the t...

Page 397: ...quired equipment on page 392 12 Refit the cover axis 5 gearbox with its attachment screws and secure with locking liquid 14 pcs tightening torque 10 Nm Shown in the figure Location of gearbox on page 391 13 Refit the motor axis 5 Detailed in section Refitting motor axis 5 on page 357 14 Perform a leak down test Detailed in section Performing a leak down test on page 246 15 Refill the primary gearb...

Page 398: ...ng 6 Fasten the bearing washer with its attachment screws and secure with locking liquid Turn the gear Z4 in order to reach all the screws xx0200000068 A Gear Z4 B Surface beneath VK cover C VK cover D Attachment screws gear Z4 21 pcs M16 E Attachment screws bearing washer 7 pcs M6 7 Clean the surface beneath the VK cover with iso propanol 8 Secure the wheel unit with attachment screws gear Z4 21 ...

Page 399: ...ent screws gearbox C Washers D Oil plug filling E Oil plug draining can be located on the turning disk instead O ring not shown in the figure Equipment etc Spare part no Art no Note Gear axis 6 3HAC17811 1 Includes o ring 3HAB3772 49 Washers 3HAC10122 13 Not included in the gearbox Replace if damaged O ring 3HAB3772 49 3HAB3772 64 3HAB3772 61 Must be replaced when reassembling gearbox O ring type ...

Page 400: ...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 Equipment etc Spare part no Art no Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off al...

Page 401: ...ure to the right to press it free xx0200000220 A M10 holes for pressing out the gearbox 6 Remove the gearbox axis 6 by lifting it out carefully Be careful not to damage the motor pinion Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Turn off all electric power and hydraulic but not the air pressure to the gearboxes motors and SMB...

Page 402: ...ist unit Art no is specified in Required equipment on page 397 Shown in the figure Location of gearbox on page 397 Make sure the gears of the gearbox mate with the gears of the motor 5 Fit the both washers and secure the gearbox with the attachment screws Shown in the figure Location of gearbox on page 397 18 pcs M10 x 50 12 9 quality Gleitmo Tightening torque 65 Nm Reused screws may be used provi...

Page 403: ...ak down test Detailed in the section Performing a leak down test on page 246 9 Refill the gearbox with oil Detailed in the section Filling oil gearbox axis 6 on page 217 10 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 403 11 DANGER Make sure a...

Page 404: ...4 Repair 4 7 6 Replacement of gearbox axis 6 3HAC022033 001 Revision K 402 Copyright 2004 2011 ABB All rights reserved 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 405: ...ation manuals If the robot has absolute accuracy calibration it is also recommended but not always necessary to calibrate for new absolute accuracy The resolver values will change when parts affecting the calibration position are replaced on the robot for example motors or parts of the transmission The revolution counter memory is lost If the revolution counter memory is lost the counters must be ...

Page 406: ...ter 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 coordinate system for the robot Absolute ac...

Page 407: ...o 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 absolute accuracy calibra...

Page 408: ...d their positions are the same 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 ...

Page 409: ... position in the same direction in order to avoid position errors caused by backlash in gears and so on Positive directions are shown in the graphic below This is normally handled by the robot calibration software Calibration movement directions 6 axes Note The graphic shows an IRB 7600 The positive direction is the same for all 6 axis robots except the positive direction of axis 3 for IRB 6400R w...

Page 410: ... underneath the flange plate on the base At delivery 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 following 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 fol...

Page 411: ...he 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 are marked with an x CANCEL returns to the Cali...

Page 412: ...libration position on page 412 Action Note Action 1 On the ABB menu tap Calibration All mechanical units connected to the system are shown with their calibration status 2 Tap the mechanical unit in question A screen is displayed tap Rev Counters en0400000771 3 Tap Update Revolution Counters A dialog box is displayed warning that updating the revolution counters may change programmed robot position...

Page 413: ...rs 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 calibration position very carefully after each update See the section Checking the calibration p...

Page 414: ...te 1 Create the following program MoveAbsJ 0 0 0 0 0 0 9E9 9E9 9E9 9E9 9E9 9E9 NoEOffs v1000 z50 Tool0 2 Run the program in manual mode 3 Check that the calibration marks for the axes align correctly If they do not update the revolution counters See Calibration scale and correct axis position on page 406 and Updating revolution counters on page 408 Action Note 1 On ABB menu tap Program editor 2 Cr...

Page 415: ...equal to zero 4 Check that the calibration marks for the axes align correctly If they do not update the revolution counters See Calibration scale and correct axis position on page 406 and Updating revolution counters on page 408 Action Note 1 On the ABB menu tap Jogging 2 Tap Motion mode to select group of axes to jog 3 Tap to select the axis to jog axis 1 2 or 3 4 Manually run the robots axes to ...

Page 416: ...5 Calibration information 5 6 Checking the calibration position 3HAC022033 001 Revision K 414 Copyright 2004 2011 ABB All rights reserved 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 417: ...not dispose of oil and grease near lakes ponds ditches down drains or onto soil Incineration must be carried out under controlled conditions in accordance with local regulations Also note that Spills can form a film on water surfaces causing damage to organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination Material Example application Bat...

Page 418: ...commissioning The procedure below details the actions to perform on field when the balancing device is to be decommissioned Equipment Art no Note Standard toolkit Content is defined in section Standard toolkit on page 427 Cutting torch For opening housing and cutting coils Other tools and procedures may be required See references to these procedures in the step by step instructions below These pro...

Page 419: ...e 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 xx0200000082 4 Cut the coils of the three springs inside the housing as specified below Outer spring cut at least five coils Midd...

Page 420: ...6 Decommissioning 6 2 Decommissioning of balancing device 3HAC022033 001 Revision K 418 Copyright 2004 2011 ABB All rights reserved 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 421: ...ision K Copyright 2004 2011 ABB All rights reserved 7 Reference information 7 1 Introduction General This chapter includes general information complementing the more specific information in the different procedures in the manual 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 422: ...sign EN ISO 10218 11 Robots for industrial environments Safety requirements Part 1 Robot EN ISO 9787 Manipulating industrial robots coordinate systems and motion nomenclatures EN ISO 9283 Manipulating industrial robots performance criteria and related test methods EN ISO 14644 12 Classification of air cleanliness EN ISO 13732 1 Ergonomics of the thermal environment Part 1 EN IEC 61000 6 4 option 1...

Page 423: ...d Other standards Standard Description ANSI RIA R15 06 Safety requirements for industrial robots and robot systems ANSI UL 1740 option 429 1 Safety standard for robots and robotic equipment CAN CSA Z 434 03 option 429 1 Industrial robots and robot Systems General safety require ments Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 424: ...ts reserved 7 3 Unit conversion Converter table Use the following table 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 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 425: ...mo treated screws 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 lu...

Page 426: ...c tools Use the correct tightening technique which is do not jerk Tighten the screw in a slow flowing motion Maximum allowed total deviation from the specified value is 10 The following table specifies the recommended standard tightening torque for oil lubricated screws with slotted or cross recess head screws The following table specifies the recommended standard tightening torque for oil lubrica...

Page 427: ...mended standard tightening torque for water and air connectors when one or both connectors are made of brass Dimension Tightening torque Nm Class 10 9 Molycote lubricated Tightening torque Nm Class 12 9 Molycote lubricated M8 28 35 M10 55 70 M12 96 120 M16 235 280 M20 550 M24 790 950 Dimension Tightening torque Nm Nominal Tightening torque Nm Min Tightening torque Nm Max 1 8 12 8 15 1 4 15 10 20 3...

Page 428: ...components exceeding 22 kg 50 lbs are highlighted in this way To avoid injury ABB recommends the use of a lifting accessory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Action Note CAUTION The motor weighs 32 kg All lifting acce...

Page 429: ...lowing table 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 Bit for Socket head cap...

Page 430: ...ctions in the Product manual procedures Description Qty Art no Extension 300mm for bits 1 2 1 3HAC12342 1 Guide pins M8 x 100 2 3HAC15520 1 Guide pins M8 x 150 2 3HAC15520 2 Guide pins M10 x 100 2 3HAC15521 1 Guide pins M10 x 150 2 3HAC15521 2 Lifting tool wrist unit 1 3HAC12734 1 Lifting tool motor ax 1 4 5 1 3HAC14459 1 Lifting tool motor ax 2 3 4 1 3HAC15534 1 Removal tool motor M10x 2 3HAC1497...

Page 431: ...HAC15560 1 Lifting device robot 1 3HAC15607 1 Lifting device upper arm 1 3HAC15536 1 Lifting eye VLBG M12 1 3HAC16131 1 Lifting eye M12 2 3HAC14457 3 Lifting eye M16 2 3HAC14457 4 Lifting tool chain 1 3HAC15556 1 Lifting tool gearbox axis 2 1 3HAC12731 1 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 3HAC13453 1...

Page 432: ...s the recommended equipment for oil exchange Description Art no Note Angel bracket 68080011 LP Calibration bracket 3HAC13908 9 Calibration tool ax1 3HAC13908 4 Levelmeter 2000 kit 6369901 347 Includes one sensor Measuring pin 3HAC13908 5 Sensor fixture 68080011 GM Sensor plate 3HAC0392 1 Sync adapter 3HAC13908 1 Turn disk fixture 3HAC68080011 GU Description Art no Note Calibration Pendulum toolkit...

Page 433: ...and maintenance activities require different pieces of lifting accessories which are specified in each procedure The use of each piece of lifting accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference 工控帮助教小舒QQ28234081...

Page 434: ...7 Reference information 7 8 Lifting accessories and lifting instructions 3HAC022033 001 Revision K 432 Copyright 2004 2011 ABB All rights reserved 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 435: ...n 433 3HAC022033 001 Revision K Copyright 2004 2011 ABB All rights reserved 8 Spare part part list 8 1 Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 436: ...ABB All rights reserved 8 2 Spare parts 8 2 1 Introduction Overview This section specifies all articles considered spare parts of the robot The spare parts are also specified as required equipment directly in the repair instruction of the current spare part 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 437: ... axis 4 3HAC14210 2 3HAC027318 001 With pinion 102 1 2 Foundry Prime H Gear axis 4 3HAC17810 1 102 1 8 1 I Friction washer 3HAC10122 27 102 1 33 J SMB Unit 3HAC022286 001 109 326 K Battery pack 3HAC16831 1 109 328 Harness manipulator 1 4 3HAC12782 1 Brake release at base 106 Harness manipulator 1 4 3HAC14940 1 Brake release in frame 106 Cable harness ax 5 6 3HAC11440 1 103 40 Gasket motor axis 6 3...

Page 438: ...pare part is replaced as described in corresponding repair instruction in the chapter Repair on page 245 P Turning disk dia 250 3HAC13193 1 103 28 5 P Turning disk insulated 3HAC023124 002 103 28 3 R Balancing device 3HAC14214 1 104 Maintenance kit 3HAC15834 1 For balancing device Maintenance kit 3HAC14962 1 For balancing device Only bearings Item Description Spare part no Note Continued 工控帮助教小舒QQ...

Page 439: ...reserved 8 3 Part list 8 3 1 Introduction Overview This section specifies all the replacement articles of the robot The parts are shown in exploded views or in foldouts either in this or in a separate chapter Specific spare parts are listed separately in a Spare part list 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 440: ...d 3HAC15932 1 Tube shaft 2 55 X X X X X 102 2 Foundry 3HAC10509 5 Tube shaft 2 3 X 102 2 Standard 3HAC15932 2 Tube shaft 2 3 X 102 2 Foundry 3HAC9760 1 Arm extender 250mm X 2X 111 501 Standard 3HAC15932 3 Arm extender 250mm X 2X 111 501 Foundry 3HAC9760 5 Arm extender 956mm X 111 501 Standard 3HAC15932 4 Arm extender 956mm X 111 501 Foundry 3HAC11755 1 Friction washer X 2X X 111 502 3HAB7700 69 Sc...

Page 441: ...w Steel 8 8 A2F M6 x 20 10 2 3HAC10509 11 Cover 101 1 3HAC12304 1 Base incl frame ax 1 See section Base incl frame axis 1 3HAC12304 1 on page 442 102 1 3HAC13063 1 Axis 3 4 Standard protection IRB 7600 150 3 5 325 3 1 340 2 8 400 2 55 500 2 55 See section Axis 3 4 3HAC13063 1 IRB 7600 150 3 5 325 3 1 340 2 8 400 2 55 500 2 55 on page 443 3HAC13063 2 Axis 3 4 Standard protection IRB 7600 500 2 3 Se...

Page 442: ...HAC13079 1 on page 455 109 1 3HAC13077 1 Material set ax 1 2 See section Material set axis 1 2 3HAC13077 1 on page 456 110 1 3HAC13082 1 Mtrl set balancing device See section Material set balancing device 3HAC13082 1 on page 459 111 1 3HAC12311 1 Arm extension set 956mm IRB 7600 150 3 5 See section Arm extension set 956 mm 3HAC12311 1 IRB 7600 150 3 5 on page 460 1 3HAC12311 2 Arm extension set 25...

Page 443: ...C022033 001 Revision K Copyright 2004 2011 ABB All rights reserved 8 3 4 Mechanical stop axis 1 3HAC12812 2 Part list Item Qty Art number Description Dimension 5 1 1 3HAC12812 1 Mechanical stop 5 2 1 9ABA142 92 Spring pin slotted 10 x 30 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 444: ...KO 12 9 Gleitmo 610 M16x90 101 5 1 3HAC11529 1 Rubber lined clip D 28 101 6 1 3HAC14453 1 Hose with flange 101 7 1 3HAC14453 2 Plug 101 8 1 3HAC4428 2 Hose Clip 101 9 1 9ADA618 56 Torx pan head screw Steel 8 8 A2F M6x16 Item Qty Art number Description Note 101 1 1 1 3HAC10044 2 Base casting 101 1 2 5 3HAC4836 7 Protection plug 101 1 3 1 3HAC1383 2 Protection Cover compl 101 1 4 1 3HAC14024 1 Prote...

Page 445: ...1 3 4 3HAB3409 50 Hex socket head cap screw Steel 12 9 Gleitmo 610 M10x40 102 1 4 4 3HAB4233 1 Washer 102 1 5 1 3HAC11499 1 Motor flange machining 102 1 6 18 3HAB3409 60 Hex socket head cap screw Steel 12 9 Gleitmo 610 M10x80 102 1 7 2 3HAC10122 12 Washer RV 125 F axis4 5 T 3 102 1 8 1 3HAC17810 1 RV 125F 97 909 assembly See table RV 125F 97 909 assembly 3HAC17810 1 on page 444 102 1 9 1 3HAC12640...

Page 446: ...102 1 32 1 9ABA107 56 Parallel pin 10x20 102 1 33 2 3HAC10122 27 Friction washer 102 1 34 1 3HAB7116 1 Locking liquid 102 1 35 30 3HAB3537 1 Bearing grease 102 1 36 1 3HAC020486 001 Pinion Z3 4 5 102 1 37 1 3HAC020619 001 Set of shims Z3 4 5 102 1 38 9 3HAB7700 69 Hex socket head cap screw UNBRAKO 12 9 Gleitmo 610 M12x50 102 1 39 6 3HAB3409 86 Hex socket head cap screw Steel 12 9 Gleitmo 610 M16x6...

Page 447: ...xis 4 housing mach 102 3 2 1 3HAC12641 1 RV 700F incl gear See following table 102 3 3 20 3HAB7700 89 Hex socket head cap screw UNBRAKO 12 9 Gleitmo 610 M16x90 102 3 4 20 3HAC10264 1 Washer 17x30x3 102 3 5 1 3HAC14724 1 Rot ac motor incl pinion See following table 102 3 6 4 3HAB3409 50 Hex socket head cap screw Steel 12 9 Gleitmo 610 M10x40 102 3 7 4 3HAB4233 1 Washer 102 3 8 1 3HAC16721 1 Magneti...

Page 448: ...09 5 Item Qty Art number Description Note 102 1 1 3HAC022181 001 Material set ax 4 See table Material set axis 4 3HAC022181 001 on page 443 102 2 1 3HAC10509 5 Tube shaft 2 3 See table below 102 3 1 3HAC13062 1 Axis 3 See table Axis 3 3HAC13062 1 on page 445 Item Qty Art number Description Note 102 2 1 1 3HAC10509 6 Tube shaft 2 55 cast 102 2 2 1 3HAC1383 2 Protection Cover compl 工控帮助教小舒QQ28234081...

Page 449: ...55 Part list Tube shaft 2 55 Foundry 3HAC15932 1 Item Qty Art no Description Note 102 1 1 3HAC022181 001 Material set ax 4 See table Material set axis 4 3HAC022181 001 on page 443 102 2 1 3HAC15932 1 Tube shaft 2 55 Foundry See table below 102 3 1 3HAC13062 1 Axis 3 See table Axis 3 3HAC13062 1 on page 445 Item Qty Art number Description Note 102 2 1 1 3HAC10509 2 Tube shaft 2 55 cast 102 2 2 1 3H...

Page 450: ...oundry 3HAC15932 2 Item Qty Art no Description Note 102 1 1 3HAC022181 001 Material set ax 4 See table Material set axis 4 3HAC022181 001 on page 443 102 2 1 3HAC15932 2 Tube shaft 2 55 See table below 102 3 1 3HAC13062 1 Axis 3 See table Axis 3 3HAC13062 1 on page 445 Item Qty Art number Description Note 102 2 1 1 3HAC10509 6 Tube shaft 2 55 cast 102 2 2 1 3HAC1383 2 Protection Cover compl 工控帮助教小...

Page 451: ... 3HAC10503 3 Wrist housing machining 103 10 2 2522122 1 Magnetic plug R1 4 103 11 4 9ADA183 35 Hex socket head cap screw 103 12 2 3HAC10503 8 Damper ax 5 103 13 2 3HAC10122 27 Friction washer 103 14 4 3HAB3409 50 Hex socket head cap screw M10x40 103 15 4 3HAB4233 1 Washer 103 16 1 3HAC024853 001 Rot ac motor incl pinion See table Rot ac motor incl pinion 3HAC024853 001 on page 451 103 17 2 3HAC029...

Page 452: ...6 1 Locking liquid 103 38 1 3HAC11440 5 Heat protection plate 103 39 3 21662055 3 Cable straps outdoors 103 40 1 3HAC11440 1 Cable harness manip ax5 6 103 41 3 800 ml 3HAC032140 001 Lubricating oil TMO 150 NOTE Do not mix with other oils The different types of oils are further specified in section Oil in gearboxes 103 42 750 ml 3HAC032140 001 Lubricating oil Kyodo Yushi TMO 150 103 43 1 3HAC024760...

Page 453: ...scription Note Dimension Item Qty Art number Description Note 103 1 1 1 3HAC11409 1 Cover right machining 103 1 2 1 3HAC11409 5 Gasket Item Qty Art number Description Note 103 6 1 1 3HAC037194 002 RV 125F i 97 909 103 6 2 1 3HAB3772 50 O ring 103 6 3 1 3HAB3772 49 O ring Item Qty Art number Description Note 103 16 1 1 3HAC17484 2 Rotational ac motor M2 103 16 2 1 3HAC10122 17 Pinion RV 125F 97 909...

Page 454: ...3 28 3 2 3HAC10122 13 Washer RV 125 F T 3 103 28 4 18 3HAB3409 55 Hex socket head cap screw M10x50 103 28 5 1 3HAC13193 1 Turning disc 103 28 6 33 3HAB3409 53 Hex socket head cap screw M10x25 103 28 7 2 2522122 1 Magnetic plug R1 4 103 28 8 1 3HAC11471 1 Sync Plate 103 28 9 1 3HAB3772 83 O ring 104 5x3 103 28 10 2 9ADA618 32 Torx pan head screw M4x8 103 28 11 6 3HAB7116 1 Locking liquid 103 28 12 ...

Page 455: ... Cover plastic 103 28 8 33 3HAB3409 53 Hex socket head cap screw M10x25 103 28 9 33 ml 3HAC16151 1 UV hardening glue 103 28 10 1 3HAC024953 001 Axis 6 complete insulated See following table Item Qty Art number Description Note 103 28 10 1 1 3HAC10436 1 Tilthouse RV125F 103 28 10 2 1 3HAC037474 001 RV 125F 178 41 assembly See table RV 125F 178 41 assembly 3HAC037474 001 on page 452 103 28 10 13 2 3...

Page 456: ...03 51 4 750 ml 3HAC032140 001 Lubricating oil Kyodo Yushi TMO 150 103 51 10 1 3HAC14263 1 Protection Cover 103 51 11 1 9ADA624 69 Torx counters head screw M8x20 103 51 12 1 3HAC024842 001 Rot AC motor incl pinion 103 51 15 4 9ADA312 7 Plain washer M8 103 51 16 6 ml 3HAB7116 1 Locking liquid 103 51 17 4 9ADA183 37 Hex socket head cap screw Steel 8 8 A2F M8x25 Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科...

Page 457: ... 1 Cable guide end part 108 213 1 3HAC13960 1 Connection plate ax3 108 214 2 3HAC11750 1 Damper axis 3 108 215 2 3HAC12990 1 Damper axis 2 108 216 2 9ADA624 65 Torx counters head screw M6x60 108 217 2 9ADA334 7 Spring washer conical 8 4x18x2 108 218 2 9ADA618 57 Torx pan head screw M6x20 108 220 2 3HAC9953 1 Syncplate with nonie 108 222 1 3HAC14658 1 Syncplate with nonie ax 3 108 223 2 9ADA183 48 ...

Page 458: ...8 109 307 1 3HAC14724 1 Rot ac motor incl pinion IRB 7600 500 2 3 400 2 55 340 2 8 325 3 1 150 3 5 See table Rot ac motor incl pinion 3HAC14724 1 on page 458 109 308 8 3HAB3409 50 Hex socket head cap screw M10x40 109 309 8 3HAB4233 1 Washer 109 310 1 3HAC12252 1 Bottom plate 109 311 1 3HAC14131 1 Connection plate base 109 312 1 3HAC11774 3 Adapter complete 109 313 1 3HAC11769 1 Cable guide ax 1 10...

Page 459: ...do Yushi TMO 150 109 344 1 ml 3HAB7116 1 Locking liquid 109 345 2 9ADA267 6 Hexagon nut M6 109 346 1 3HAC16036 1 BU w buttons DSQC 561 3HAC14219 1 BU at the base Read more about the difference in section Replacement of brake release unit on page 301 3HAC12989 1 BU at the base 109 347 1 3HAC2744 1 Push button guard 109 348 4 9ADA629 56 Torx pan head roll screw M6x16 109 349 2 9ADA618 58 Torx pan he...

Page 460: ...9 306 2 1 3HAC11350 1 Pinion RV 500C RV 320C 109 306 3 1 21522012 430 O ring D 89 5x3 Item Qty Art number Description Note 109 307 1 1 3HAC025724 001 Rotational AC motor M13 109 307 2 1 3HAC11632 1 Pinion Z1 2 3 109 307 3 1 21502012 430 O ring D 89 5x3 Item Qty Art number Description Note 109 307 1 1 3HAC17484 1 Rotational ac motor M1 109 307 2 1 3HAC11632 1 Pinion Z1 2 3 109 307 3 1 21522012 430 ...

Page 461: ...3HAC13122 1 Bushing 110 404 1 9ABA135 32 Retaining ring shaft 110 405 1 3HAC13123 1 Shaft 110 406 1 3HAC4836 7 Protection plug 16x12 3x9x7 110 407 4 3HAB7700 89 Hex socket head cap screw M16x90 110 408 2 9ABA107 56 Parallel pin 10x20 110 409 1 3HAC12548 2 Protection washer 110 410 1 3HAC11427 1 Shaft Balancing device 110 411 4 3HAA1001 186 Washer 17x25x3 110 412 120 ml 3HAA1001 294 Grease 110 413 ...

Page 462: ...6 mm 3HAC12311 1 IRB 7600 150 3 5 Part list Item Qty Art number Description Dimension 111 501 1 3HAC9760 5 Arm extender 956 mm 111 501 1 3HAC15932 4 Arm extender 956 mm Foundry 111 502 1 3HAC11755 1 Friction washer 111 503 20 3HAB7700 69 Hex socket head cap screw M12x50 111 504 20 3HAA1001 134 Washer 13x19x1 5 111 505 1 9ABA107 56 Parallel pin 10x20 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 463: ...0 mm 3HAC12311 2 IRB 7600 340 2 8 Part list Item Qty Art number Description Dimension 111 501 1 3HAC9760 1 Arm extender 250 mm 111 501 1 3HAC15932 3 Arm extender 250 mm Foundry 111 502 1 3HAC11755 1 Friction washer 111 503 20 3HAB7700 69 Hex socket head cap screw M12x50 111 504 20 3HAA1001 134 Washer 13x19x1 5 111 505 1 9ABA107 56 Parallel pin 10x20 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 464: ...8 Spare part part list 8 3 15 Arm extension set 250 mm 3HAC12311 2 IRB 7600 340 2 8 3HAC022033 001 Revision K 462 Copyright 2004 2011 ABB All rights reserved 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 465: ...ws 9 1 Introduction Definitions This chapter contains detailed views of the components on the manipulator The numbered details are specified with item numbers in the Part List The exploded views are divided into Base incl frame Frame Lower arm 1 Frame Lower arm 2 Upper arm Wrist complete 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 466: ...9 Exploded views 9 2 Base incl Frame 3HAC022033 001 Revision K 464 Copyright 2004 2011 ABB All rights reserved 9 2 Base incl Frame Exploded view xx0200000329 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 467: ...9 Exploded views 9 3 Frame Lower arm 1 465 3HAC022033 001 Revision K Copyright 2004 2011 ABB All rights reserved 9 3 Frame Lower arm 1 Exploded view xx0200000330 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 468: ...9 Exploded views 9 4 Frame Lower arm 2 3HAC022033 001 Revision K 466 Copyright 2004 2011 ABB All rights reserved 9 4 Frame Lower arm 2 Exploded view xx0200000331 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 469: ...9 Exploded views 9 5 Upper arm 467 3HAC022033 001 Revision K Copyright 2004 2011 ABB All rights reserved 9 5 Upper arm Exploded view xx0200000333 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 470: ...9 Exploded views 9 6 Wrist complete 3HAC022033 001 Revision K 468 Copyright 2004 2011 ABB All rights reserved 9 6 Wrist complete Exploded view xx0200000332 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 471: ...004 Product Article numbers for circuit diagrams IRB 120 3HAC031408 003 IRB 140 type C 3HAC6816 3 IRB 260 3HAC025611 001 IRB 360 3HAC028647 009 IRB 460 3HAC036446 005 IRB 660 3HAC025691 001 IRB 760 3HAC025691 001 IRB 1410 3HAC2800 3 IRB 1600 type A 3HAC021351 003 IRB 2400 3HAC6670 3 IRB 2600 3HAC029570 007 IRB 4400 4450S 3HAC9821 1 IRB 4600 3HAC029038 003 IRB 4600 Foundry Prime 3HAC029038 003 IRB ...

Page 472: ... About circuit diagrams 3HAC022033 001 Revision K 470 Copyright 2004 2011 ABB All rights reserved IRB 7600 3HAC13347 1 3HAC025744 001 Product Article numbers for circuit diagrams Continued 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 473: ...t 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 Remove the rear c...

Page 474: ...k 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 471 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 the label WebConf...

Page 475: ...onditions operating robot 64 storing robot 64 connecting the robot and controller cabling 133 connection external safety devices 20 copper 415 D damage to mechanical stop 177 danger levels 39 dimensions frame 99 lower arm 97 turning disk 100 upper arm 98 direction of axes 407 E emergency stop definition 37 devices 38 enabling device 34 environmental information 415 equipment on robot 97 ESD damage...

Page 476: ...axis 2 replacement 333 motor axis 3 replacement 341 motor axis 4 replacement 348 motor axis 6 replacement 359 MoveAbsJ instruction 412 TPU 412 N negative directions axes 407 neodymium 415 NiCad 415 O oil disposal 415 oil change safety risks 51 oil in gearboxes 192 operating conditions robot 64 P plastic 415 position switches cabling on robot 122 installing 122 positive directions axes 407 protecti...

Page 477: ...bot 94 securing upper arm 343 serial measurement board unit replacement 297 signal lamp 36 signals safety 39 SMB battery extension of lifetime 218 replacement 218 special tools 428 stability 70 standards ANSI 421 CAN 421 EN 420 EN IEC 420 EN ISO 420 protection 420 safety 420 storage conditions robot 64 symbols safety 39 sync marks 406 T temperatures allowed operating robot 64 stored robot 64 testi...

Page 478: ...rights reserved working range IRB 7600 150 3 5 66 IRB 7600 340 2 8 67 IRB 7600 400 2 55 68 IRB 7600 500 2 3 69 IRB 7600 500 2 55 68 restricting axis 1 115 restricting axis 2 117 restricting axis 3 119 wrist unit insulated 279 435 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 479: ...工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

Page 480: ...3HAC022033 001 Rev K en Contact us ABB AB Discrete Automation and Motion Robotics S 721 68 VÄSTERÅS SWEDEN Telephone 46 0 21 344 400 www abb com 工控帮助教小舒QQ2823408167 长沙工控帮教育科技有限公司 ...

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