ABB IRB 6650S - 125/3.5 Product Manual Download

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4 Repair

4.3.5. Replacement of complete arm system

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3HAC020993-001 Revision: G

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4.3.5. Replacement of complete arm system

Location of arm system

The complete arm system is defined as the complete robot except for the base and gearbox

axis 1. This is shown in the figure below.

A more detailed view of the component and its position may be found in chapter

Exploded

views on page 423

in part 2 of the Product manual.

xx0300000465

Upper arm

Lower arm

Frame

Gearbox, axis 1

Base attachment screws

Balancing device

Block for calibration

Motor axis 1

Continues on next page

Summary of Contents for IRB 6650S - 125/3.5

Page 1: ...Product manual Articulated robot IRB 6650S 200 3 0 IRB 6650S 125 3 5 IRB 6650S 90 3 9 M2000 M2000A M2004 ...

Page 2: ......

Page 4: ...sons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this 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 Contravent...

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

Page 6: ... 3 3 8 Inspection cable harness 135 3 3 9 Inspection information labels 139 3 3 10 Inspection mechanical stop axis 1 141 3 3 11 Inspection additional mechanical stops 143 3 3 12 Inspection damper axes 2 5 146 3 3 13 Inspection position switch axes 1 2 and 3 148 3 3 14 Inspection signal lamp 150 3 3 15 Inspection of air hoses Foundry Prime 152 3 4 Replacement changing activities 153 3 4 1 Type of o...

Page 7: ...269 4 5 Frame and base 273 4 5 1 Replacement of SMB unit 273 4 5 2 Replacement of brake release unit 277 4 5 3 Replacement of spherical roller bearing balancing device 281 4 5 4 Replacement of balancing device 286 4 5 5 Unloading the balancing device 295 4 5 6 Restoring the balancing device 298 4 6 Motors 300 4 6 1 Replacement of motor axis 1 300 4 6 2 Replacement of motor axis 2 306 4 6 3 Replace...

Page 8: ...l frame ax 1 402 8 3 5 Axis 3 4 403 8 3 6 Axis 3 4 Foundry 407 8 3 7 Axis 3 4 Foundry Prime 408 8 3 8 Wrist type 2 standard 409 8 3 9 Wrist type 2 Foundry 413 8 3 10 Wrist type 2 insulated 414 8 3 11 Wrist type 2 Foundry Prime 415 8 3 12 Material set manipulator 3HAC 13263 1 416 8 3 13 Material set axis 1 2 3HAC 13264 1 417 8 3 14 Material set balancing device 3HAC 13265 1 420 8 3 15 Arm extension...

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

Page 12: ... manual Additional axes and stand alone controller 3HAC021395 001 M2004 Application manual External axes 3HAC9299 1 M2000 M2000A Document name Document ID CalibWare 2 0 User s guide M2000 3HAC16090 1 Revision Description First edition A Model M2004 implemented Product manual divided into two parts Product manual procedures and Product manual reference information New foldouts Frame lower arm 1 on ...

Page 13: ...e undivided cabling from axis 1 to axis 6 is added to the spare parts in Spare part list on page 395 New procedure Replacement of cable harness axes 1 6 on page 204 Also a new circuit diagram is added to the manual due to the new cabling IRB 6650S included in section Rebuilding parts on page 399 E New variant IRB 6650S 90 3 9 is implemented throughout the manual F Foundry Prime Option included G C...

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

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

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

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

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

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

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

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

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

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

Page 25: ...rried out professionally and in accordance with the applicable safety regulations Care must be taken at all times Qualified personnel Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts Extraordinary risks If the working process is interrupted extra care must be taken d...

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

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

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

Page 29: ...xtinguishing 27 3HAC020993 001 Revision G Copyright 2004 2008 ABB All rights reserved 1 2 3 2 Fire extinguishing NOTE Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the robot system manipulator or controller ...

Page 30: ...eased manually by pushing the brake release buttons on the robot How to release the brakes is detailed in section Manually releasing the brakes on page 61 The robot arm may be moved manually on smaller robot models but larger models may require using an overhead crane or similar Increased injury Before releasing the brakes make sure that the weight of the arms does not increase the pressure on the...

Page 31: ...ction How to test The function of the holding brake of each axis motor may be checked as detailed below 1 Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized max static load 2 Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller 3 Check that the axis maintains its position If the manipulator do...

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

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

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

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

Page 36: ...age 139 Translation possibilities The labels fitted to the product contain space for adding a fourth language underneath the three standard languages English German and French Add a local language to the label by Using a transparent sticker over the standard label with text added in a fourth language Drawings detailing the design text figure dimensions of the standard labels can be ordered from AB...

Page 37: ...h for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc warning WARNING Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high volt...

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

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

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

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

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

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

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

Page 46: ...eight of the robot as specified in Weight robot on page 44 4 If the robot is not installed directly it must be stored as described in Storage conditions robot on page 45 5 Make sure the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 45 6 Before taking the robot to its installation site make sure the site conforms to Loa...

Page 47: ...the robot Operating conditions robot The table below shows the allowed operating conditions for the robot Force Endurance load operation Max load emergency stop Force xy 9 kN 20 kN Force z 29 7 kN 30 14 kN Torque xy 29 kNm 31 kNm 43 kNm 55 6 kNm Torque z 8 kNm 15 kNm Requirement Value Note Min levelity 0 5 mm Max tilt 5 The limit for the maximum load on the robot is reduced if the robot is tilted ...

Page 48: ...tallation procedure 3HAC020993 001 Revision G 46 Copyright 2004 2008 ABB All rights reserved Protection classes robot The table below shows the protection class of the robot Equipment Protection class Robot IP 67 Cooling fans option IP 54 Continued ...

Page 49: ...ved 2 2 2 Working range and type of motion Working range Following figures show the working ranges of the robot models The extreme positions of the robot arm are specified at the wrist center dimensions in mm IRB 6650S 200 3 0 The illustration below shows the unrestricted working range of IRB 6650S 200 3 0 xx0300000562 Continues on next page ...

Page 50: ...ng range and type of motion 3HAC020993 001 Revision G 48 Copyright 2004 2008 ABB All rights reserved IRB 6650S 125 3 5 The illustration below shows the unrestricted working range of IRB 6650S 125 3 5 xx0300000563 Continued Continues on next page ...

Page 51: ...pe of motion 49 3HAC020993 001 Revision G Copyright 2004 2008 ABB All rights reserved IRB 6650S 90 3 9 The illustration below shows the unrestricted working range of IRB 6650S 90 3 9 xx0600002739 A Marked area max payload 50 kg Continued Continues on next page ...

Page 52: ...w is specified for the different robot models below the figure xx0600002740 Type of motion IRB 6650S 200 3 0 3039 mm IRB 6650S 125 3 5 3485 mm IRB 6650S 90 3 9 3932 mm Axis Type of motion Range of movement Note 1 Rotation motion 180º to 180º 220º to 220º option 561 1 2 Arm motion 160º to 40º 3 Arm motion 70º to 180º 4 Wrist motion 300º to 300º 5 Bend motion 120º to 120º 6 Turn motion 300º to 300º ...

Page 53: ...d standing still the robot is not stable in the whole working area Moving the arms will displace the center of gravity which may cause the robot to tip over Do not change the robot position before securing it to the foundation Stabililty The figure below shows the robot in its shipping position which also is its most stable position xx0300000632 WARNING The robot is likely to be mechanically unsta...

Page 54: ...cribes how to attach the fork lift equipment to the robot Attachment points The attachment points for the fork lift equipment are shown in the figure below Notice the length of the IRB 6650S balancing device when planning to lift with a fork lift shown in the figure below xx0300000463 A Attachment points spacer and horizontal attachment screws B Attachment points horizontal attachment screws C Att...

Page 55: ...000379 Equipment etc Art no Note Fork lift set incl all required hardware 3HAC 0604 1 See the figure Fork lift set 3HAC 0604 1 on page 53 Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual A Fork lift pocket 2 pcs different from each other B Spacer 2 pcs C Horizontal attachment screws 4 pcs fork lift pocket D Vertical attachment screws...

Page 56: ...y releasing the brakes on page 61 xx0300000632 3 Fit the two spacers to the robot and secure Attachment points on the robot are shown in the figure Attachment points on page 52 4 CAUTION The fork lift pocket weighs 60 kg 5 Secure the longer fork lift pocket to the spacers with four of the horizontal attachment screws and washers Note The vertically and the horizontally attached screws are identica...

Page 57: ...ened with different torques xx0300000464 A vertical attachment screws 2 pcs M16x60 Tightening torque 270 Nm Make sure the original screws are always used or replacements of equivalent quality M16 quality 12 9 Attachment points on the robot are shown in the figure Attachment points on page 52 8 CAUTION The fork lift pocket weighs 22 kg 9 Secure the shorter fork lift pocket on the other side of the ...

Page 58: ...fork lift forks into the pockets xx0200000380 Reposition the harness if any before using a fork lift 11 CAUTION The robot weighs 2275 kg All lifting equipment 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 Action Note Il...

Page 59: ...gs General The robot may be lifted with roundslings according to the illustration below The illustration is identical with the label attached to the robot s lower arm Attachment points The figure below shows how to attach the roundslings to the robot xx0400000679 A Chain sling with shortener B Roundsling robot C Roundsling used to secure against rotation Continues on next page ...

Page 60: ...acity Length Note Chain sling with shortener 4 pcs 4 250 kg 0 43 m 0 605 m 0 75 m 0 785 m Roundsling robot 4 pcs 2 000 kg 2 m 2 5 m Action Note 1 Attach the roundslings to the robot according to the figure Attachment points on page 57 2 CAUTION The robot weighs 2275 kg All lifting equipment must be sized accordingly 3 WARNING Personnel must not under any circumstances be present under the suspende...

Page 61: ...lete robot with lifting slings Note the recommended robot position shown in the figure below and in the instruction Attempting to lift a robot in any other position may result in the robot tipping over causing severe damage or injury xx0400000722 Required equipment Slings attached directly onto robot The section below details how to lift and move the robot using lifting slings when these are attac...

Page 62: ...2 3 Fit the lifting device manipulator to the robot as described in the enclosed instruction Art no is specified in Required equipment on page 59 4 CAUTION The robot weighs 2275 kg All lifting equipment must be sized accordingly 5 WARNING Personnel must not under any circum stances be present under the suspended load 6 Raise the overhead crane to lift the robot Make sure all hooks and attachments ...

Page 63: ...ration 1 The internal brake release unit is equipped with six buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes If the robot is not connected to the controller power must be supplied to the connector R1 MP according to section Supplying power to connector R1 MP on page 62 The buttons are shown in the figure Location of brake release unit on page ...

Page 64: ... If the robot is not connected to the controller power must be supplied to connector R1 MP in the robot base in order to enable the brake release buttons on the robot Action Note Illustration 1 DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 2 Supply 0V on pin 12 and 24V on pin 11 xx0300000565 Continued ...

Page 65: ...fting base plate Equipment Art no Note Lifting eye M16 3HAC 14457 4 3 pcs Lifting slings 3 pcs Length approx 2 m A Attachment holes for lifting eyes x3 Action Note 1 CAUTION The base plate weighs 353 kg All lifting equipment used must be sized accordingly 2 Fit the lifting eyes in the three lifting holes Shown in the figure Hole con figuration on page 63 3 Fit the lifting slings to the eyes and to...

Page 66: ...ecuring the base plate 3HAC020993 001 Revision G 64 Copyright 2004 2008 ABB All rights reserved 2 3 6 Securing the base plate General This section details how to secure the base plate Base plate dimensions xx0100000105 Continues on next page ...

Page 67: ...ion and commissioning 2 3 6 Securing the base plate 65 3HAC020993 001 Revision G Copyright 2004 2008 ABB All rights reserved xx0400000715 Note1 Four holes for alternative clamping Continued Continues on next page ...

Page 68: ...pcs Equipment Art no Note Base plate 3HAC 12937 8 Includes guide sleeves 3HAC 12937 3 levelling screws 9ADA 120 79 attachment screws and washers for securing the manipulator to the base plate A drawing of the base plate itself may be ordered from ABB Robotics Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual Other tools and procedures...

Page 69: ...lation to the robot work location using the three grooves in the base plate Shown in the figure Base plate grooves and holes on page 66 4 Lift the base plate to its mounting position Detailed in section Lifting the base plate on page 63 5 Use the base plate as a template and drill 16 attachment holes as required by the selected bolt dimension If possible observe the recommenda tions specified in s...

Page 70: ...bot fitted to base plate The illustration below shows the robot 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 ...

Page 71: ...o the vicinity of its installation location 3 Fit two guide sleeves to the guide sleeve holes in the base plate Shown in the figure Base plate grooves and holes on page 66 Note that one of the guide sleeve holes is elongated 4 Guide the robot gently using two M24 screws while lowering it into its mounting position Make sure the robot base is correctly fitted onto the guide sleeves 5 Fit the bolts ...

Page 72: ...3 7 Orienting and securing the robot 3HAC020993 001 Revision G 70 Copyright 2004 2008 ABB All rights reserved Cross section guide sleeve hole The illustration below shows the cross section of the guide sleeve holes xx0600002629 Continued ...

Page 73: ... obstructed by any additional cabling equipment etc fitted by the robot user Make sure the required mounting holes are accessible when planning the robot cell 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...

Page 74: ...2 Installation and commissioning 2 3 8 Fitting equipment on robot 3HAC020993 001 Revision G 72 Copyright 2004 2008 ABB All rights reserved xx0300000569 xx0300000570 Continued Continues on next page ...

Page 75: ...993 001 Revision G Copyright 2004 2008 ABB All rights reserved xx0600003407 Illustration fitting of extra equipment on upper arm The illustration below shows the mounting holes available for fitting extra equipment on the upper arm xx0300000574 Continued Continues on next page ...

Page 76: ...0993 001 Revision G 74 Copyright 2004 2008 ABB All rights reserved xx0200000196 Illustration fitting of extra equipment on frame The illustration below shows the mounting holes available for fitting extra equipment on the frame xx0300000575 Continued Continues on next page ...

Page 77: ...lustration fitting on turning disk The illustration below shows the mounting holes available for fitting equipment on the turning disk xx0200000197 Fastener quality When fitting tools on the turning disk see the figures above use only screws with quality 12 9 When fitting other equipment standard screws with quality 8 8 can be used Continued ...

Page 78: ...tion of base spacers xx0500001570 Required equipment A Base spacer 4 pcs B Guide sleeve 4 pcs C Attachment screws and washers 8 pcs Equipment Art no Note Base spacers 3HAC 021899 002 Includes mounting set with attachment screws and mounting instruction Base plate 3HAC 12937 8 Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual Continues...

Page 79: ...y with lifting slings Make sure the robot is positioned in the most stable position the transport position Detailed in section Lifting robot with lifting slings on page 59 3 Install the base plate to the foundation if not used previously Detailed in section Securing the base plate on page 64 4 Fit the four base spacers and guiding sleeves to the base plate Shown in the figure Illustration instal l...

Page 80: ...and 3 Installation of this complete cabling is detailed in section Installation of cable harness for position switches and fans on page 97 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 82 If both cooling fans and position switches are installed...

Page 81: ...15374 1 Cabling position switches and cooling fans axes 1 2 and 3 3HAC16659 1 Choose this cabling if equipping the robot with both position switches and cooling fans or with cooling fans on axis 3 Cabling cooling fans axes 1 or 2 3HAC023599 001 Choose this cabling if only equipping the robot with cooling fans on axis 1 or 2 not on axis 3 and not with position switches Plate for customer connection...

Page 82: ... 102 Locking liquid Loctite Used for the three tightening screws Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual Circuit diagram See chapter Circuit diagram in the Product manual reference information Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures...

Page 83: ...rfaces of the motor when fitting the fanbox turn the connector to the correct position axis 1 groove pointing inwards as shown in the figure Cooling fan on page 79 Positions for axis 2 and 3 are shown in the figure Location of cooling fans on page 78 Shown in the figure Cooling fan on page 79 3 Temporarily lift the motor cabling out of the way of the current motor to make room for the fanbox 4 Fit...

Page 84: ... from the robot base Shown in the figure Location of cooling fans on page 78 4 Fit the plate for customer connections if not already fitted to the connection plate of the robot base Shown in the figure Plate for customer connections at base on page 80 Art no is specified in Required equipment on page 79 5 Run the cabling through the base and frame up beneath the balancing device 6 Secure the cable...

Page 85: ...er plate to the robot base 10 Install additional cabling to and inside the controller Also make adjustments in RobotWare as described in the following procedure Cabling is specified in section Position switch and fan cables robot base to controller option on page 102 Action Note Illustration Action Note 1 Modify the settings in RobotWare to include the cooling fans RobotWare 4 0 modify the setting...

Page 86: ...nts and overloading the motors CAUTION Incorrect defined loads may result in operational stops or major damage in bearings References Load diagrams permitted extra loads equipment and their positions are specified in the Product Specification The loads must also be defined in the software as detailed in User s Guide RobotWare 4 0 Operating manual RobotWare 5 0 Stop time and braking distances Robot...

Page 87: ...ace should be limited The working range of the following axes may be restricted Axis 1 hardware mechanical stop and software signal from adjustable position switch Axis 2 hardware mechanical stop and software signal from adjustable position switch Axis 3 hardware mechanical stop and software signal from adjustable position switch This section describes how to install hardware that restricts the wo...

Page 88: ...135 in both directions Mechanical stops axis 1 The illustration below shows the mounting position of the stop pin and one of the additional mechanical stops available for axis 1 xx0300000049 Required equipment A Additional mechanical stop B Stop pin Equipment etc Art no Note Mechanical stop for axis 1 7 5 3HAC 11076 1 Includes attachment screws and an assembly drawing Mechanical stop for axis 1 15...

Page 89: ... pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Fit the additional mechanical stop to the frame according to the figure Mechanical stops axis 1 on page 86 Tightening torque 120 Nm 3 Note The software working range limitations must be re defined to correspond to the changes in the mechanical limitations of the working range How to define...

Page 90: ...hanical stops axis 2 The illustration below shows the mounting position of the mechanical stops on axis 2 xx0300000047 Required equipment A Additional mechanical stops B Fixed mechanical stop Equipment etc Art no Note Mechanical stop set axis 2 3HAC 020885 001 Includes six stops attachment screws washers and assembly drawings Standard toolkit The contents are defined in section Standard toolkit on...

Page 91: ...tors and SMB 2 Fit and tighten the additional stops in a row starting from the fixed stop Tightening torque 115 Nm Shown in the figure Mechanical stops axis 2 on page 88 3 The software working range limitations must be re defined to correspond to the changes in the mechanical limitations of the working range How to define the range of movement in RobotWare 4 0 is detailed in User s guide S4Cplus c...

Page 92: ...n below shows the mounting position of the mechanical stops on axis 3 xx0300000048 Required equipment A Additional mechanical stops B Fixed mechanical stop Equipment etc Art no Note Mechanical stop set axis 3 3HAC 13128 1 Includes six stops one with 80 restriction 3HAC 12708 3 use when limitation angle 80 and five with 20 3HAC 12708 1 attachment screws Standard toolkit The contents are defined in ...

Page 93: ...ure to motors and SMB 2 Mount and tighten the additional stops in a row starting from the fixed stop Shown in the figure Mechanical stops axis 3 on page 90 3 Note The software working range limitations must be re defined to correspond to the changes in the mechanical limitations of the working range How to define the range of movement in RobotWare 4 0 is detailed in User s guide S4Cplus chapter Sy...

Page 94: ...ed equipment Description Art no Note Position switch axis 1 3HAC 15715 1 Includes position swtich and plate for customer connections Position switch axis 2 3HAC 021884 001 Includes only the position switch Position switch axis 3 3HAC 16417 2 Includes only the position switch Cabling position switches and cooling fans axes 1 2 and 3 3HAC 16659 1 Cabling to be installed on the robot Plate for custom...

Page 95: ...es are connected to different points on the robot system XT8 screw terminal in the controller cabinet when position switch cables are used R1 SW1 at the robot base Customer connection kit is recommended art no is specified in Required equipment on page 92 R1 SW2 3 at the robot base Customer connection kit is recommended art no is specified in Required equipment on page 92 Further information about...

Page 96: ...on switch unit 4 Refit the cable protection to the lower arm with two screws Action Note 1 Cut the cam to a suitable length Use a 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 95 If the angle is larger this may damage the position switch 3 Cut the part of the cam running in the profile to 90 Also see Illustration cut...

Page 97: ...ation adjust and secure cams The illustration below show how to adjust and secure the position switch cams and profiles xx0100000113 Illustration cutting the cam The illustration below show how to cut the position switch cam xx0100000114 A Cam stop M5 nut and M5 x 6 set screw B Adjustable cam C Profile A Remove the gray section Continued Continues on next page ...

Page 98: ...r customer connections at base xx0500002301 Cable harness for position switches and fans axes 1 3 xx0500002305 A Plate for customer connections B Attachment screws 3 pcs M6x16 A Cable bracket frame B Cable bracket lower arm C Cable bracket upper arm R1 SW2 3 Connected to the robot base R3 FAN2 Connected to the fan of axis 1 or 2 Continued Continues on next page ...

Page 99: ... SW3 Connected to the position switch of axis 3 Action Note Illustration 1 Move the robot to its calibration position 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Remove the rear cover A from the robot base and replace the protection B with a plate for customer connections i...

Page 100: ...xisting velcro strap B attached around the robot cabling Connect the connector R2 SW2 to the position switch of axis 2 Note There is a risk of the balancing device damaging the fan cable if it is not protected by correct routing underneath the robot cabling xx0500002309 A Cable bracket frame Also shown in the figure Cable harness for position switches and fans axes 1 3 on page 96 B Velcro strap C ...

Page 101: ...an of axis 3 together with the robot cabling with a velcro strap xx0500002313 A Bracket lower arm Also shown in the figure Cable harness for position switches and fans axes 1 3 on page 96 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 96 9 Connec...

Page 102: ...he base of the robot Make sure that the cabling run through the base frame and lower arm is not twisted and is running free from the robot cabling 11 Refit the rear cover to the robot base 12 Install additional cabling to and inside the control cabinet Cabling is specified in section Position switch and fan cables robot base to controller option on page 102 Action Note Illustration Continued ...

Page 103: ...tion switch and 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 102 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 pr...

Page 104: ...re only used for position switches Cabling for the cooling fans is specified in the table Cabling between robot base and controller cooling fans M2004 on page 103 Cable Art no Robot cable power 7 m 3HAC 11818 1 Robot cable power 15 m 3HAC 11818 2 Robot cable power 22 m 3HAC 11818 3 Robot cable power 30 m 3HAC 11818 4 Cable Art no Robot cable signal shielded 7 m 3HAC 7998 1 Robot cable signal shiel...

Page 105: ...robot base to the inside of the cabinet and the additional cabling specified below is therefor not needed Cable Art no Connection point Distributing cable 3HAC 022708 001 Robot base R1 SW2 3 Harness cooling 7 m 3HAC 022723 001 Distributing cable R1 FAN SW2 3 Inside cabinet A43 X10 and A43 X11 Harness cooling 15 m 3HAC 022723 004 Distributing cable R1 FAN SW2 3 Inside cabinet A43 X10 and A43 X11 Ha...

Page 106: ...followed and documented Commissioning Never switch off the overpressure in motors and serial measurement compartment during cooling down of robot after it has been switched off When turning off an cleaning cell we recommend that the humid air inside a cell is ventilated out to avoid that the humid air is sucked into e g gearboxes due to the raised vacuum when cooled down Environmental conditions A...

Page 107: ... serial measurement board cavity The robots are prepared with hoses to the motors and the serial measurement board cavity to enable pressurizing of them WARNING The robot must be pressurized also when it is switch off to avoid that the humid environmental air is sucked into the motors when cooling down Action Note Illustration 1 Connect a compressed air hose to air connector on robot base see illu...

Page 108: ...hould be exposed to direct high pressure jet of water The sealings between the moving parts on the wrist should not be exposed to direct or rebounding high pressure jet of water Protecting point at the wrist joints The illustration below show points that are particular sensitive to water spray xx0600002792 A Axis 5 bearing support side B Axis 5 bearing gear side C Axis 6 mounting flange gear house...

Page 109: ...n motors and serial measurement 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 an cleaning cell we recommend that the humid air is...

Page 111: ...uding intervals and refers to procedures for the activities Each procedure contains all information required to perform the activity that is required tools and materials The procedures are gathered in different sections divided according to the maintenance activity Safety information Before any service work is commenced it is extremely important that all safety information is observed There are ge...

Page 112: ...tivity to be carried out and the working conditions of the robot Calendar time specified in months regardless of whether the robot system is run or not Operating time specified in operating hours More frequent running of the robot means more frequent maintenance activities SIS specified by the robot s SIS Service Information System A typical value is given for a typical work cycle but the value wi...

Page 113: ... axis 2 on page 119 Inspection Axis 3 gear oil level 12 mths 1 Inspection oil level gearbox axis 3 on page 121 Inspection Axis 4 gear oil level 12 mths Inspection oil level gearbox axis 4 on page 123 Inspection Axis 5 gear oil level 12 mths Inspection oil level gearbox axis 5 on page 125 Inspection Axis 6 gear oil level 12 mths 1 Inspection oil level gearbox axis 6 on page 127 Inspection Balancing...

Page 114: ...lly 96 mths Replacement of gearbox axis 1 on page 339 Replacement Axis 2 gearbox As specified by the SIS or typically 96 mths Replacement of gearbox axis 2 on page 346 Replacement Axis 3 gearbox As specified by the SIS or typically 96 mths Replacement of gearbox axis 3 on page 354 Replacement Axis 4 gearbox 5 96 mths 2 Replacement of upper arm on page 250 Replacement Axis 5 gearbox 6 96 mths 2 Rep...

Page 115: ...place when damage is detected or when approaching life limit as specified in Expected component life on page 116 4 The interval is the same as the interval for changing axis 2 gear oil because of the similarity of the type and degree of operation Always lubricate the front eye bearing after refitting the balancing device shaft 5 It is recommended to replace the complete upper arm house instead of ...

Page 116: ...ed Inspection cable harness on page 135 Inspection Air hoses 6 mths Inspection of air hoses Foundry Prime on page 152 Inspection Balancing device 12 mths Inspection balancing device on page 130 Inspection Information labels 12 mths Inspection information labels on page 139 Inspection Damper axes 2 5 12 mths Inspection damper axes 2 5 on page 146 Inspection Mechanical stop axis 1 12 mths Inspection...

Page 117: ...d Replacement of cable harness axes 1 6 on page 204 Replacement SMB Battery pack 36 mths Replacement of SMB battery on page 175 Replacement Axis 1 gearbox As specified by the SIS or typically 96 mths Replacement of gearbox axis 1 on page 339 Replacement Axis 2 gearbox As specified by the SIS or typically 96 mths Replacement of gearbox axis 2 on page 346 Replacement Axis 3 gearbox As specified by t...

Page 118: ...s cycle will result in differences in expected life 3 The robot is dimensioned for a life of 8 years 350 000 cycles per year in a normal spot welding application Depending on the actual application the life of individual gearboxes may vary greatly from this specification The Service Information System SIS integrated in the robot software keeps track of the gearbox life in each individual case and ...

Page 119: ...ame and base The oil plugs are shown in the figure below xx0300000583 Required equipment A Oil plug inspection B Oil plug filling Equipment Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 152 Standard toolkit The contents are defined...

Page 120: ...RNING Safety risks during work with gearbox oil on page 41 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Open the oil plug inspection Shown in the figure Location of gearbox on page 117 4 Required oil level max 10 mm below the oil plug hole 5 Add oil if required Art no is spe...

Page 121: ... Oil plug draining C Vent hole gearbox axis 2 Equipment etc Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 152 Standard toolkit The contents are defined in section Standard toolkit on page 388 Other tools and procedures may be requi...

Page 122: ...pplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Open the oil plug filling Shown in the figure Location of gearbox on page 119 4 Measure the oil level at the oil plug filling Required oil level max 5 mm below the oil plug hole Shown in the figure Location of gearbox on page 119 5 Add oil if required Art no is specified in Required equipment on page ...

Page 123: ...r as shown in the figure below xx0200000230 Required equipment A Gearbox axis 3 B Oil plug filling C Oil plug draining Equipment etc Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 152 Standard toolkit The contents are defined in sec...

Page 124: ...ge 41 2 Move the robot to the calibration position Detailed in section Calibration scales and correct axis position on page 368 3 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 4 Open the oil plug filling Shown in the figure Location of gearbox on page 121 5 Required oil level max...

Page 125: ...Required equipment A Oil plug filling B Oil plug draining Equipment etc Art no Note Lubricating oil 11712016 604 Mobilgear 600 XP320 This is a common oil that can be replaced with an equivalent oil from another manufacturer Standard toolkit The contents are defined in section Standard toolkit on page 388 Other tools and procedures may be required See references to these procedures in the step by s...

Page 126: ...t axis position on page 368 3 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 4 Open the oil plug filling Shown in the figure Location of gearbox on page 123 5 Required oil level max 10 mm below the oil plug hole 6 Add oil if required Art no is specified in Required equipment on pa...

Page 127: ...quipment A Oil plug filling B Oil plug draining Equipment etc Art no Note Lubricating oil 11712016 604 Mobilgear 600 XP320 This is a common oil that can be replaced with an equivalent oil from another manufacturer Standard toolkit The contents are defined in section Standard toolkit on page 388 Other tools and procedures may be required See references to these procedures in the step by step instru...

Page 128: ...t For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Turn the wrist unit so that the both oil plugs face upwards 4 Open the oil plug filling Shown in the figure Location of gearbox on page 125 5 Measure the oil level Required oil level to the upper edge of the oil plug hole a 30mm xx0500002222 6 Add oil if required Art no is specified in Required equipment on page 125 Fu...

Page 129: ...Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 152 Standard toolkit The contents are defined in section Standard toolkit on page 388 Other tools and procedures may be required See references to these procedures in the step by step instructions ...

Page 130: ...of gearbox on page 127 4 Measure the oil level Required oil level to the upper edge of the oil plug hole for filling a 55 mm 5 mm xx0500002222 5 Add oil if required Art no is specified in Required equipment on page 127 Further information about how to fill the oil may be found in section Filling oil axis 6 on page 173 6 Refit the oil plug filling Tightening torque 24 Nm 7 WARNING Do not mix the oi...

Page 131: ...e is a risk for corrosion in the gearbox and reduced viscosity in the oil replacement of gearbox axis 6 is required each second year xx0600003155 A Water content in oil from gearbox axis 6 B Months or hours in operation C Replacement of gearbox axis 6 2 Less than 2 water in oil normal replacement interval as specified by SIS or typically 96 months for gearbox axis 6 is required xx0600003156 A Wate...

Page 132: ...arding dissonance damage leakage contamination lack of free space Inspection points balancing device The balancing device is located at the top rear of the frame as shown in the figure below The figure also shows the inspection points further detailed in the instructions xx0400001025 A Balancing device B Piston rod inside C Shaft including securing screw D Ear bearing and o rings E Label with arti...

Page 133: ...for mainte nance Securing screw Securing screw in the shaft M16 x 180 Locking liquid must be used when fitting the screw Loctite 245 Toolkit for maintenance Puller for separator 4552 2 Bahco Used for removing the spherical roller bearings Separator 4551 C Bahco Used for removing the spherical roller bearings Standard toolkit The contents are defined in section Standard toolkit on page 388 Other to...

Page 134: ... page 131 2 cylinder a tapping sound caused by the springs inside the cylinder replace the balancing device or consult ABB Robotics How to replace the device is detailed in section Replacement of balancing device on page 286 This section also specifies the spare part number 3 piston rod squeaking may indicate worn plain bearings internal contamination or insuffi cient lubrication perform maintenan...

Page 135: ...from the ear Leaks at the o rings however are not acceptable and must be attended to immediately in order to avoid any damage to the bearing Check the o rings in the front ear of the balancing device for leaks as shown and detailed below xx0400001026 A Shaft B O ring C Sealing spacer D Sealing ring in sealing spacer E Correct way out for excessive grease from inside the front ear F Incorrect leaka...

Page 136: ...gs and seals already assembled with sealing spacers and sealing rings Art no for the kit is specified in Required equipment on page 131 The replacement of the complete bearing is also detailed in section Replacement of spherical roller bearing balancing device on page 281 Incorrect leakage is shown in the previous figure Action Note Action 1 DANGER Turn off all electric power hydraulic and pneumat...

Page 137: ...me for the harness that runs undivided from axis 1 to axis 6 xx0200000097 Required equipment A Lower arm B Cables attached with velcro straps and mounting plate C Connectors at cable harness division point R2 M5 6 D Connectors at base Equipment etc Art no Note Standard toolkit The contents are defined in section Standard toolkit on page 388 Other tools and procedures may be required See references...

Page 138: ... at the division point and at the base Shown in the figure Location of cable harness axes 1 4 on page 135 4 note If the manipulator is used in a Foundry Prime application check the cables for cracks in insulation 5 Check that velcro straps and the mounting plate are properly attached to the frame Also check the cabling leading into the lower arm Make sure it is attached by the straps and not damag...

Page 139: ...t of the inspection points are the same for the harness that runs undivided from axis 1 to axis 6 xx0200000234 Inspection cable harness axes 5 6 The procedure below details how to inspect the cable harness of axes 5 6 A Connectors at cable harness division point R2 M5 6 B Cable attachment rear of upper arm C Cable attachment upper arm tube Action Note 1 DANGER Turn off all electric power hydraulic...

Page 140: ... connectors at the cable harness division Make sure the attachment plate is not bent or in other way damaged Shown in the figure Location of cabling axes 5 6 on page 137 4 note If the manipulator is used in a Foundry Prime application check the cables for cracks in insulation Shown in the figure Location of cable harness axes 1 4 on page 135 5 Replace the cable harness if wear cracks or damage is ...

Page 141: ...arning label High temperature 3HAC4431 1 4 pcs B Warning sign symbol of a flash located on motor cover 3HAC1589 1 5 pcs C Instruction label Safety instructions 3HAC4591 1 D Warning label Brake release 3HAC9508 1 I Warning label tools are not allowed around the balancing device during operation 3HAC020611 001 J Warning label Shut off power 3HAC17804 1 Information labels at gearboxes and at robot ba...

Page 142: ...l labels specified in the two previous figures The labels are in english Label set oil labels 3HAC021670 002 Includes only the oil labels at the gearboxes and at the robot base Are fitted to the robot if the gearboxes include Kyodo Yushi TMO 150 Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air p...

Page 143: ...he mechanical stop axis 1 A Mechanical stop stop pin Equipment etc Art no Note Mechanical stop ax 1 3HAC 10499 3 To be replaced when damaged Standard toolkit The contents are defined in section Standard toolkit on page 388 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 S...

Page 144: ...142 Copyright 2004 2008 ABB All rights reserved 4 If the stop pin is bent or damaged it must be replaced Note The expected life of gearboxes can be reduced as a result of collissions with the mechanical stop Art no is specified in Required equipment on page 141 Action Note Continued ...

Page 145: ... Copyright 2004 2008 ABB All rights reserved 3 3 11 Inspection additional mechanical stops Location of mechanical stops The figure below shows the location of the additional mechanical stops on axes 1 2 and 3 IRB 7600 shown xx0200000150 A Additional stop B Fixed stop Continues on next page ...

Page 146: ...e by 15 Mechanical stop axis 2 3HAC020885 001 Includes Mechanical stop pin Attachment screw and washer Document for mechanical stop pin Mechanical stop set axis 3 3HAC13128 1 Includes Mechanical stop pin Attachment screw and washer Document for mechanical stop pin Standard toolkit The contents are defined in section Standard toolkit on page 388 Action Note 1 DANGER Turn off all electric power hydr...

Page 147: ...e sure the stops are properly attached Correct tightening torque mechanical stop axis 1 120 Nm 4 If any damage is detected the mechanical stops must be replaced Correct attachment screws lubricated with Molycote 1000 Axis 1 M16 x 35 Axis 2 M16 x 50 Axis 3 M16 x 60 Art no is specified in Required equipment on page 144 Action Note Continued ...

Page 148: ...n of all the dampers to be inspected xx0400001024 Required equipment A damper must be replaced if damaged A Damper axis 2 2 pcs B Damper axis 3 2 pcs C Damper axis 4 1 pc D Damper axis 5 2 pcs Equipment Spare part art no Note Damper axis 2 3HAC 12991 1 Damper axis 3 3HAC 12320 1 Damper axis 4 3HAC 13564 1 Standard toolkit The contents are defined in section Standard toolkit on page 388 Continues o...

Page 149: ...supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Check all dampers for damage and for cracks or existing impressions larger than 1 mm To inspect the damper axis 4 remove the two covers on top of the upper arm Shown in the figure Location of dampers on page 146 3 Check attachment screws for deformation 4 If any damage is detected the damper must be...

Page 150: ... Instal lation of position switches option on page 92 Standard toolkit The contents are defined in section Standard toolkit on page 388 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 supplie...

Page 151: ...n axis 1 Check that the three sheets are in position and not damaged Deformation can result in rubbing against the cams Check that the area inside of the sheets is clean enough not to interfere the function of the position switch 6 If any damage is detected the position switch must be replaced Art no is specified in Required equipment on page 148 Action Note Continued ...

Page 152: ...rrent harness for alternative positioning xx0200000240 Required equipment A Signal lamp B Clamp C Position for cable gland D Warning label on motor cover E Warning sign on motor cover Equipment etc Art no Note Signal lamp 3HAC 10830 1 To be replaced in case of detected damage Standard toolkit The contents are defined in section Standard toolkit on page 388 Other tools and procedures may be require...

Page 153: ...ration MOTORS ON 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 If the lamp is not lit trace the fault by Checking whether the signal lamp is broken If so replace it Checking the cable connections Measuring the voltage in connectors motor axis 3 24V Checking the cabling Replac...

Page 154: ...etc Art no Note Leak detection spray Pressure gauge Cut off valve Action Note 1 Apply compressed air to the air connector on robot base and raise the pressure with the knob until the correct value is shown on the pressure gauge Recommended pressure 0 2 0 3 bar 2 Close the cut off valve It should take at least 5 sec for the pressure to reach 0 bar 3 The time 5 sec Test it completely step 4 The time...

Page 155: ...ts reserved 3 4 Replacement changing activities 3 4 1 Type of oil in gearboxes Location of gearboxes The figure show the location of the gearboxes on the robot xx0800000247 A Gearbox axis 1 B Gearbox axis 2 C Gearbox axis 3 D Gearbox axis 4 E Gearbox axis 5 F Gearbox axis 6 A B C D F E Continues on next page ...

Page 156: ... oil is used in gearboxes 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 xx0800000230 xx0800000234 Gearbox Type of oil Art no Amount Axis 1 Kyodo Yushi TMO 150 3HAC032140 001 7 300 ml Axis 2 Kyodo Yushi TMO 150 3HAC032140 001 5 800 ml Axis 3 Kyodo Yushi TMO 150 3HAC032140 001 2 5...

Page 157: ...h type of oil shall be filled in the gearbox after rinsing use the appropiate procedure The same applies if the type of oil shall be changed in the gearbox NOTE What is said about Kyodo Yushi TMO 150 also applies to Shell Tivela S 150 What is said about Mobilgear 600 XP320 also applies to Mobil Gearlube X320 Kyodo Yushi TMO 150 mixed with Optimol Optigear RMO 150 Use this procedure to rinse the co...

Page 158: ...nance 3 4 1 Type of oil in gearboxes 3HAC020993 001 Revision G 156 Copyright 2004 2008 ABB All rights reserved Oil change equipment 3HAC021745 001 Includes pump with outlet pipe Equipment Art no Note Continued ...

Page 159: ...ble in the rear of the robot base not shown in the figure xx0300000583 Required equipment A Oil plug inspection B Oil plug filling Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 7 300 ml Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 152 Oil collecting vesse...

Page 160: ... 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 3 Remove the rear cover on the base by unscrewing its attachment screws 4 Pull the oil draining hose out of the rear of the base xx0200000237 The hose is located beneath the base as shown in the figure with a v...

Page 161: ...s several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 3 Open the oil plug filling Shown in the figure Location of oil plugs on page 157 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in section ...

Page 162: ... Oil plug draining C Vent hole Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 5 800 ml Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 152 Oil collecting vessel Capacity 6 000 ml Oil exchange equipment 3HAC 021745 001 The contents are defined in section Speci...

Page 163: ...2 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 3 Remove the plug of the vent hole Shown in the figure Location of oil plugs on page 160 4 Remove the oil plug draining and drain the gearbox oil using a hose with nipple and an oil collecting vessel Remove the ...

Page 164: ...s Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 3 Remove the oil plug filling and the plug from the vent hole Shown in the figure Location of oil plugs on page 160 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detaile...

Page 165: ...uired equipment A Gearbox axis 3 B Oil plug filling C Oil plug draining Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 2 500 ml Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 152 Oil exchange equipment 3HAC 021745 001 The contents are defined in section Spec...

Page 166: ...ssure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 3 Remove the oil plug draining and drain the gearbox oil using a hose with nipple and an oil collecting ves...

Page 167: ...ase observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 3 Remove the oil plug filling Shown in the figure Location of gearbox on page 163 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in section Inspection oil level gearbox axis 3 on page ...

Page 168: ...equired equipment A Oil plug filling B Oil plug draining Equipment etc Art no Amount Note Lubricating oil 11712016 604 8 100 ml Mobilgear 600 XP320 This is a common oil that can be replaced with an equivalent oil from another manufacturer Oil exchange equipment 3HAC 021745 001 The contents are defined in section Special tools on page 389 Oil collecting vessel Capacity 9 000 ml Standard toolkit The...

Page 169: ...ots Do not turn off the air pressure to motors and SMB 3 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 4 Drain the oil from the gearbox into an vessel by opening theoil plug draining Remove the oil plug filling in order to drain the oil quicker Shown in the f...

Page 170: ... involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 3 Refill the gearbox with lubricating oil through the oil plug filling The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in section Inspection oil level gearbox axis 4 on page 1...

Page 171: ...osed with the kit Art no for the kit is specified in Required equipment on page 169 A Oil plug filling B Oil plug draining Equipment etc Art no Amount Note Lubricating oil 11712016 604 6 700 ml Mobilgear 600 XP320 This is a common oil that can be replaced with an equivalent oil from another manufacturer Oil exchange equipment 3HAC021745 001 The contents are defined in section Special tools on page...

Page 172: ...ction WARNING Safety risks during work with gearbox oil on page 41 4 Drain the oil from the gearbox by opening the oil plug draining Remove the oil plug filling in order to drain the oil quicker Shown in the figure Location of gearbox on page 169 Vessel capacity is specified in Required equipment on page 169 5 Refit the oil plug draining Tightening torque 24 Nm Action Note Action Note 1 Run axis 5...

Page 173: ...ed The correct oil level is detailed in section Inspection oil level gearbox axis 5 on page 125 Shown in the figure Location of gearbox on page 169 Art no and total amount are specified in Required equipment on page 169 5 WARNING Do not mix the oil types If wrong oil is refilled the gearbox must be rinsed as detailed in section WARNING Mixed oils may cause severe damage to gearbox on page 40 6 Ref...

Page 174: ...filling C Oil plug draining Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 450 ml Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 152 Oil exchange equipment 3HAC 021745 001 The contents are defined in section Special tools on page 389 Oil collecting vessel Ve...

Page 175: ...n of gearbox on page 172 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 41 4 Drain the oil fr...

Page 176: ...ned The correct oil level is detailed in section Inspection oil level gearbox axis 6 on page 127 Art no and the total amount are specified in Required equipment on page 172 5 WARNING Do not mix the oil types If wrong oil is refilled the gearbox must be rinsed as detailed in section WARNING Mixed oils may cause severe damage to gearbox on page 40 6 Note Don t mix Kyodo Yushi TMO 150 with other oil ...

Page 177: ...gure below xx0300000559 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 given spare part no or an ABB approved eqvivalent Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual Circuit Diagram See ch...

Page 178: ...e air pressure to motors and SMB 3 esd WARNING The unit is sensitive to ESD before handling the unit please observe the safety information in section WARNING The unit is sensitive to ESD on page 40 4 Remove the SMB battery cover by unscrewing its attachment screws Shown in the figure Location of SMB battery on page 175 5 Pull out the battery and disconnect the battery cable Shown in the figure Loc...

Page 179: ...rmation in section WARNING The unit is sensitive to ESD on page 40 3 Reconnect the battery cable to the SMB battery pack and fit it to the frame Art no is specified in Required equipment on page 175 Shown in the figure Location of SMB battery on page 175 4 Secure the SMB battery cover with its attachment screws Shown in the figure Location of SMB battery on page 175 5 Update the revolution counter...

Page 180: ...ing is located at the front ear of the balancing device as shown in the figure below Note The balancing device must be mounted on the robot when lubricating the bearing xx0400000721 Required equipment A Ear spherical roller bearing located inside B Lubrication nipple C Sealing spacer D Hole through which the shaft is pressed Equipment etc Art no Note Grease 3HAA 1001 294 Optimol PDO 150 ml Lubrica...

Page 181: ...ricate 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 178 Shown in the figure Location of bearing on page 178 The balancing device must be mounted on the robot when lubricating the bearing 3 Clean the area from any exces...

Page 182: ...n View from above xx0600002866 Required equipment A Plastic ring bearing cover A Equipment Art no Note Brush Rust preventive 3HAC026621 001 Equivalent Mercasol 3106 Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual Other tools and procedures may be required See references to these procedures in the step by step instructions below Thes...

Page 183: ...axis 1 Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Remove the plastic ring xx0600002866 A plastic ring 3 Wipe the surface under the ring 4 Apply the rust preventive on the bearing with the brush xx0600002867 A bearing 5 Refit the plastic ring A A Co...

Page 184: ...low xx0500002869 Required equipment A Plastic cover B Plastic ring Equipment Art no Note Brush Rust preventive 3HAC026621 001 Equivalent Mercasol 3106 Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures i...

Page 185: ...pulator in a suitable position 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Remove the plastic cover at the rear end of the upper arm xx0600002872 A plastic cover B plastic ring 4 Remove the plastic ring that covers the bearing xx0600002871 A plastic ring 5 Wipe the surface ...

Page 186: ...dry Prime 3HAC020993 001 Revision G 184 Copyright 2004 2008 ABB All rights reserved 6 Apply the rust preventive on the bearing with the brush xx0600002868 A bearing axis 4 B plastic ring 7 Refit the plasitc ring and cover Action Note Illustration Continued ...

Page 187: ...n in the illustration xx0500002863 Required equipment A Bearing B Cable bracket C Cover Equipment Art no Note Brush Rust preventive 3HAC026621 001 Equivalent Mercasol 3106 Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual Other tools and procedures may be required See references to these procedures in the step by step instructions bel...

Page 188: ...lectric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Dismantle the air hose from motor axis 6 4 Tighten the hose clamp on motor axis 6 and remove the air hose 5 Remove thew cover according to the illustration xx0600002864 A cover 6 Apply the rust preventive on the bearing and cable bracket with the brush ...

Page 189: ...ruction specifies how to clean the robot Periodicity The periodicity of cleaning the robot varies a great deal depending on the actual environment and function of the robot Clean a contamined robot as required Special points Special points to be observed are shown in the figure below xx0200000239 A Spiral cables to motor 6 B Inside of upper arm tube C Rear of upper arm tube D Inside of lower arm E...

Page 190: ...th a high pressure cleaner onto the sealing cup at the bottom of the motor 6 spiral cable item A in the figure Special points Although the robot is watertight avoid spraying connectors and similar items with a high pressure cleaner Foundry versions In working environments e g foundries where the robot may be exposed to fluids that dry to make a crusty surface e g release agents clean the cable har...

Page 191: ...oduction environment Recommendations on how to define these are given in Defining the SIS input parametersSIS system parameters on page 192 Maintenance intervals recommended by ABB are specified in section Maintenance ScheduleMaintenance schedule on page 111 3 Enter these parameters in the system How to do this is detailed in Setting the SIS parametersSetting the SIS parameters on page 194 4 Run t...

Page 192: ...nterval 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...

Page 193: ...outine When resetting the counter variables are reset The variables are described in section Import export of SIS dataExporting the SIS data on page 198 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 disp...

Page 194: ...ce interval E g by setting the value 20 000 the SIS will save this as the nominal time for activating the alarm not counting the percentage described below Operation time warning A percentage of the Operation time limit specified above E g by setting the value 90 the SIS will alert the operator 18 000 hours after an operation time Reset was made the last time Calendar time limit service level The ...

Page 195: ...ing the value 90 the SIS will alert the operator after 90 of the expected service interval of each gearbox The robot system automatically detects and stores all required variables to calculate the expected service interval of each gearbox This is done by extrapolating data from earlier operation into a function of time using a formula including input and output torque gearbox spindle speed other v...

Page 196: ...the SIS system is to function properly a number of parameters must be set This is detailed below Procedure M2000 This is an instruction of how to enter SIS parameters to the M2000 robot system Action Note 1 Open System parameters using the TPU Detailed in the User s Guide 2 Go to System parameters Manipulator types 2 xx0200000045 en0200000046 Continues on next page ...

Page 197: ... and press Enter en0200000047 xx0100000200 4 Select the required system The parameter list is displayed en0200000048 en0200000049 5 Select the required parameters by stepping up and down through the parameter list Available parameters are described in section Defining the SIS input parametersSIS system parameters on page 192 Action Note Continued ...

Page 198: ...l the manually set calendar time limit expires How to set the value determining when the message is to be shown is detailed in section Setting the SIS parametersSetting the SIS parameters on page 194 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 parame...

Page 199: ... of the service interval has expired for gearbox x X percent of gearbox hours remain until the auto matically calculated gearbox time limit expires How to set the value determining when the message is to be shown is detailed in section Setting the SIS parametersSetting the SIS parameters on page 194 Available in SIS message in the log Meaning Continued ...

Page 200: ...hich the supervision was started reset last time sisCalendarT sec Calendar time The number of hours since start last reset sisTotRunT sec Operation time Total number of operation hours since the system was started Corresponds to the operating time counter on the control cabinet sisRunT sec Operation time The number of operation hours since start last reset of the operation time counter Corresponds...

Page 201: ...hered in sections divided according to the component location on the robot Required equipment All equipment required to perform a specific repair activity is listed together with the current procedure The equipment is also gathered in different lists in the Product manual reference information Safety information Before any service work is commenced it is extremely important that all safety informa...

Page 202: ...ay be required which are included in the leakdown tester kit Art no is specified above 3 Apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer Recommended value 0 2 0 25 bar 20 25 kPa 4 Disconnect the compressed air supply 5 Wait for approx 8 10 minutes No pressure loss must be detected If the compressed air is signifi cantly colder or warmer t...

Page 203: ...able the roller elements to adjust to the correct position against the race flange 1 Tension the bearing gradually until the recommended pre tension is achieved Note The roller elements must be rotated a specified number of turns before pre tensioning is carried out and also rotated during the pre tensioning sequence 2 Make sure the bearing is properly aligned as this will directly affect the life...

Page 204: ... to lubricate the seals Action Note 1 Check the seal to ensure that the seal is of the correct type provided with cutting edge there is no damage to the sealing edge feel with a fingernail 2 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced as it may result in future leakage 3 Lubricate the seal with grease just before fitting Not too early as t...

Page 205: ...ver the surface preferably with a brush 4 Tighten the screws evenly when fastening the flange joint Action Action Note 1 Ensure that the correct o ring size is used 2 Check the o ring for surface defects burrs shape accuracy etc Defective o rings may not be used 3 Check the o ring grooves The grooves must be geometrically correct and free from pores and contamination Defective o rings may not be u...

Page 206: ... axis 6 In case the cabling has a division point at the upper arm it should instead be replaced as detailed in sections Replacement of cable harness axes 1 4 on page 216 Replacement of cable harness axes 5 6 on page 225 Location of cable harness The cable harness of axes 1 6 is run throughout the robot as shown in the figure below xx0500002176 A Rear cover plate B Cable guide inside the frame C Ca...

Page 207: ...rcasol 3106 Gasket 3HAC3537 1 motor axes 1 5 Gasket 3HAC12877 1 motor axis 6 Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual Circuit diagram See chapter Circuit diagram in the Product manual reference information A Cable bracket wrist unit B Cable bracket upper arm tube C Cable attachment rear Action Note Illustration 1 In order to ...

Page 208: ...screws Two of the attachment screws are visibly located at the rear attachment and the third is located at the bottom of the cable bracket in the center Shown in the figure Cable brackets of the upper arm on page 205 xx0200000254 B Attachment screws rear of cable bracket 2 pcs C Attachment screw bottom of cable bracket 1 pc 7 Pick out the cabling from motor axis 6 8 Loosen the cable bracket in the...

Page 209: ...nnect the earth cable beneath 3 Disconnect connectors R1 MP and R1 SMB Shown in the figure Location of cable harness on page 204 4 Pull the cable and connectors up through the cable guide in the center of the frame 5 Disconnect all connectors at motor 1 and motor 2 6 Open the SMB cover carefully The cable between the battery and the SMB unit may stay connected in order to avoid an update of the re...

Page 210: ...removing the attachment screws and the velcro strap D Note Different robot versions are fitted with different versions of the attachment plate When replacing the cable harness make sure the correct one is used to avoid cable failure xx0300000560 A Cable gland B Attachment screws cable gland C Attachment plate D Velcro strap 9 Remove the cable gland securing the cables inside the lower arm Action N...

Page 211: ...reserved 10 Remove the cable gland securing the cables to the arm house xx0100000143 11 Remove the velcro strap from the harness at the cable fixing bracket at the arm house 12 Disconnect all connectors at motor 3 and motor 4 13 Gently pull the cable harness out Action Note Illustration Continued Continues on next page ...

Page 212: ... Make sure the cables are not twisted with each other or with eventual customer harnesses Make a note of the correct positions of the connectors 3 Reconnect connectors R1 MP and R1 SMB at the base Shown in the figure Location of cable harness on page 204 Make a note of the correct positions of the connectors 4 Reconnect the earth cable 5 Refit the rear cover plate to the robot with its attachment ...

Page 213: ...te C to the cable gland with its two attachment screws using locking liquid Refit the velcro strap D Note Different robot versions are fitted with different versions of the attachment plate Make sure the correct one is used to avoid cable failure Locking liquid is specified in Required equipment on page 205 xx0300000560 A Cable gland B Attachment screws cable gland C Attachment plate D Velcro stra...

Page 214: ...onnect R1 G if it has been disconnected xx0200000118 10 Secure the SMB cover with its attachment screws 11 WARNING Before continuing any service work please observe the safety information in section WARNING The brake release buttons may be jammed after service work on page 39 12 Pull the cable harness through the lower arm 13 Refit the cable gland securing the cables inside the lower arm xx0100000...

Page 215: ...insert the cable harness from the rear into the upper arm 18 Connect the two connectors inside the upper arm tube R3 FB5 and R3 MP5 and secure the cable bracket with the two attachment screws to the tube Shown in the figure Cable brackets of the upper arm on page 205 19 Place the cabling to motor axis 6 correctly on the upper arm and gently pull the connectors through the hole on top of wrist unit...

Page 216: ... B Attachment screws rear of cable bracket C Attachment screw bottom of cable bracket 21 Reconnect the connectors to motor axis 6 and refit the motor cover 22 Refit the cover upper arm B and the cover wrist unit A Make sure the cabling is placed correctly when refitting the covers and does not get jammed xx0200000214 23 If any cable straps have been removed refit them to the harness 24 Refit the c...

Page 217: ... mm Fix the strap by wrapping it two turns around the largest cable before wrapping around the complete harness xx0500002320 26 If the connection between the SMB battery and the SMB unit has been broken the revolution counters must now be updated Detailed in section Updating revolution counters on page 370 27 DANGER Make sure all safety requirements are met when performing the first test run These...

Page 218: ...is equipped with an undivided cable harness it is instead replaced as detailed in section Replacement of cable harness axes 1 6 on page 204 The divided cable for axes 1 4 is not applicable for robot model IRB 6650S 90 3 9 Location of cable harness The cable harness for axes 1 4 is run throughout the base frame and lower arm as shown in the figure below xx0300000589 A Rear cover plate B Attachment ...

Page 219: ...o Art no Note Cable harness axes 1 4 3HAC025504 001 Includes a cable protection that must be fitted to the lower arm and a velcro strap for the harness going up inside the lower arm Not applicable for IRB 6650S 90 3 9 Locking liquid Loctite 638 Used to secure the attachment screws for the attachment plate inside the frame Standard toolkit 3HAC 15571 1 The contents are defined in section Standard t...

Page 220: ...attachment screws Shown in the figure Location of cable harness on page 216 4 Disconnect the earth cable Attachment point is shown in the figure Location of cable harness on page 216 5 Disconnect connectors R1 MP and R1 SMB Attachment points are shown in the figure Location of cable harness on page 216 6 Pull the cable and connectors up through the cable guide in the center of the frame 7 Disconne...

Page 221: ... gland A by removing the four attachment screws from inside the SMB recess B the attachment plate C by removing the attachment screws and the velcro strap D Note Different robot versions are fitted with different versions of the attachment plate When replacing the cable harness make sure the correct one is used to avoid cable failure xx0400001069 A Cable gland B Attachment screws cable gland C Att...

Page 222: ...emove the velcro strap from the harness at the cable fixing bracket at the arm house Shown in the figure Location of cable harness on page 216 14 Disconnect connector R2 M5 6 at the cable division point Shown in the figure Location of cable harness on page 216 15 Disconnect all connectors at motor 3 and motor 4 Specified and shown in the figure Location of cable harness on page 216 16 Gently pull ...

Page 223: ...ted slightly to improve access 3 Pull the cable and connectors down through the cable guide in the center of the frame Make sure the cables are not twisted with each other or with eventual customer harnesses Make a note of the correct positions of the connectors 4 Reconnect connectors R1 MP and R1 SMB at the rear cover plate Make a note of the correct positions of the connectors Attachment point i...

Page 224: ...ent robot versions are fitted with different versions of the attachment plate Make sure the correct one is used to avoid cable failure Locking liquid is specified in Required equipment on page 217 xx0400001069 A Cable gland B Attachment screws cable gland C Attachment plate D Velcro strap 9 Reconnect connectors R2 SMB R1 SMB1 3 R1 SMB4 6 to the SMB unit Reconnect X8 X9 and X10 to the brake release...

Page 225: ...ecuring the cables to the arm house Make sure not to twist the harness xx0100000143 15 Reconnect all connectors at motor 3 and motor 4 Specified and shown in the figure Location of cable harness on page 216 16 Reconnect the connector R2 M5 6 gently at the cable division point Be careful not to bend the attachment plate when fastening the screws Shown in the figure Location of cable harness on page...

Page 226: ...wrapping around the complete harness Both the protection and the strap are included in the spare part no specified in Required equipment on page 217 xx0500002320 19 If the connection between the SMB battery and the SMB unit has been broken the revolution counters must now be updated Detailed in the Calibration chapter section Updating revolution counters on page 370 20 DANGER Make sure all safety ...

Page 227: ...the cable harness axes 5 6 is shown in the figure below xx0200000213 Required equipment A Cable bracket wrist unit B Cable bracket upper arm tube C Connectors at motor axis 5 R4 FB5 and R4 MP5 D Connectors in upper arm tube R3 FB5 and R3 MP5 F Cable attachment rear G Connector at cable harness division point R2 M5 6 H Connectors at motor axis 6 R3 FB6 and R3 MP6 Equipment etc Spare part no Note Ca...

Page 228: ...ences to these procedures in the step by step instructions below These procedures include references to the tools required Circuit Diagram See chapter Circuit diagram in the Product manual reference informa tion Equipment etc Spare part no Note Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn o...

Page 229: ... out the cabling from motor axis 6 7 Loosen the cable bracket in the upper arm tube by undoing the two screws on top of the tube Shown in the figure Location of cable harness ax 5 6 on page 225 8 Disconnect the two connectors R3 FB5 and R3 MP5 in the tube Shown in the figure Location of cable harness ax 5 6 on page 225 9 Remove eventual cable straps from the harness 10 Remove the cable attachment ...

Page 230: ...e 225 xx0200000254 B Attachment screws rear of cable bracket C Attachment screw bottom of cable bracket 6 Reconnect the connectors to motor axis 6 and refit the motor cover 7 Refit the cover upper arm and the cover wrist unit Make sure the cabling is placed correctly when refitting the covers and does not get jammed xx0200000214 A cover wrist unit B cover upper arm tube 8 If any cable straps have ...

Page 231: ...rs R3 FB5 and R3 MP5 Equipment Spare part no Note Cable harness axis 5 3HAC14139 1 Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Action Note 1 DANGER Turn of...

Page 232: ...oundry Prime robots Do not turn off the air pressure to motors and SMB 2 Reconnect all connectors at motor axis 5 3 Refit the cable gland cover at the cable exit with its two attachment screws 4 Refit the cover of motor axis 5 5 Refit the complete wrist unit Detailed in section Refitting wrist unit on page 247 6 Recalibrate the robot Calibration is detailed in a separate calibration manual enclose...

Page 233: ... is defined as the complete robot except for the base and gearbox axis 1 This is shown in the figure below A more detailed view of the component and its position may be found in chapter Exploded views on page 423 in part 2 of the Product manual xx0300000465 A Upper arm B Lower arm C Frame D Gearbox axis 1 E Base attachment screws F Balancing device G Block for calibration H Motor axis 1 Continues ...

Page 234: ...om the frame because lack of space after refitting Hoisting block Used to adjust the length of the lifting chain Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools require...

Page 235: ...alibration from the bottom of the frame Shown in the figure Location of arm system on page 231 9 Unfasten the arm system from the base by unscrewing its 24attachment screws Shown in the figure Location of arm system on page 231 1 0 Fit the two guide pins in two opposite screw holes 1 1 CAUTION The complete arm system weighs 1250 kg All lifting equipment used must be sized accordingly 1 2 Lift the ...

Page 236: ...ent holes as shown in the figure to the right Fit one guide pin next to the guiding hole for the spring pin in the gearbox and the other guide pin straight across the frame Dimension is specified in Required equipment on page 232 xx0600003441 The figure above shows the frame view from below A Attachment holes for the guide pins M12 B Guiding hole for the spring pin located in the gearbox axis 1 6 ...

Page 237: ... 1 Detailed in section Refitting motor axis 1 on page 302 Detailed in section Replacement of motor axis 1 on page 300 11 Refit the cabling in the base 12 Perform a leak down test of the gearbox axis 1 Detailed in section Performing a leak down test on page 200 13 Refill the gearbox axis 1 with lubricating oil Detailed in section Oil change gearbox axis 1 on page 157 14 Recalibrate the robot Calibr...

Page 238: ... 236 Copyright 2004 2008 ABB All rights reserved 4 3 6 Replacement of air nipple and hose Foundry Prime Location The illustration below shows the routing of the Foundry Prime air hose xx0500002176 Hose lengths xx0600003395 Pos Length in mm 1A 40 1B 40 1C 2080 1D 1130 Continues on next page ...

Page 239: ...290 1L 195 1M 40 1N 40 1P 1605 1Q 100 1R 1490 1S 570 Pos Length in mm Equipment Art no Pos in illustration Velcro strap 3HAC12625 1 9 Cable straps 21662055 3 8 Elbow fitting 40 6 Rubber clamp 3HAC026523 001 5 T plug connector 3HAC026515 001 4 Y plug connector 3HAC026514 001 3 Bulkhead plug connector 3HAC026513 001 2 Hose 3HAC026526 001 1 Action Note Illustration DANGER Turn off all electric power ...

Page 240: ...e and hose Foundry Prime 3HAC020993 001 Revision G 238 Copyright 2004 2008 ABB All rights reserved Connection at base xx0600003042 Axis 1 xx0600003043 Balancing cylinder xx0600003398 Action Note Illustration Continued Continues on next page ...

Page 241: ...ement of air nipple and hose Foundry Prime 239 3HAC020993 001 Revision G Copyright 2004 2008 ABB All rights reserved Axis 1 2 xx0600003417 xx0600003419 xx0600003045 Action Note Illustration Continued Continues on next page ...

Page 242: ...dry Prime 3HAC020993 001 Revision G 240 Copyright 2004 2008 ABB All rights reserved Upper arm housing xx0600003046 xx0600003047 Tube shaft xx0600003163 1K Lay the hose in a spiral in the tube shaft Action Note Illustration Continued Continues on next page ...

Page 243: ...nd hose Foundry Prime 241 3HAC020993 001 Revision G Copyright 2004 2008 ABB All rights reserved Wrist NOTE Make sure the cable length from 5a to the nipple of axis 6 S see Hose lengths on page 236 xx0600003097 Action Note Illustration Continued ...

Page 244: ...uipment A Turning disk B Wrist unit C Oil plug draining D Oil plug filling F Attachment screws 12 pcs Equipment etc Spare part no Art no Note Turning disk dia 200 3HAC13752 1 O rings are not included O ring 3HAB 3772 64 1 pc 3HAB 3772 61 12 pcs Must be replaced when replacing the turning disk Grease 3HAB 3537 1 Used to lubricate the o rings Standard toolkit The contents are defined in section Stan...

Page 245: ...ted to the turning disk 3 Run the robot to a position where the oil plug draining of axis 6 gearbox faces downwards Shown in the figure Location of turning disk on page 242 4 Drain the oil from gearbox 6 Detailed in section Oil change gearbox axis 6 on page 172 5 Remove the turning disk by unscrewing its attachment screws Shown in the figure Location of turning disk on page 242 Action Note Illustr...

Page 246: ...oints on page 384 before fitting 3 Perform a leak down test of the gearbox axis 6 Detailed in section Performing a leak down test on page 200 4 Refill the gearbox 6 with oil Detailed in section Oil change gearbox axis 6 on page 172 5 Refit any equipment removed during disassem bly to the turning disk 6 DANGER Make sure all safety requirements are met when performing the first test run These are fu...

Page 247: ...and its position may be found in chapter Exploded views in the Product manual reference information xx0200000184 Required equipment A Wrist unit B Turning disk C Cover wrist unit D Cover upper arm tube E Connectors upper arm tube with cable bracket R3 FB5 R3 MP5 F Cable bracket G Attachment point for lifting tool wrist unit H Wrist unit attachment screws and washers I Upper arm tube Equipment etc ...

Page 248: ... Product manual reference infor mation Equipment etc Spare part no Art no Note Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Remove all equipment fitted to the turning disk 3 Turn axis 4 to a position where the cover upper arm tube and wrist unit face...

Page 249: ...otor axis 5 by disconnecting the two connectors in the upper arm tube R3 FB5 R3 MP5 Shown in the figure Location of wrist unit on page 245 11 Fit the lifting tool to the wrist unit Art no is specified in Required equipment on page 245 12 CAUTION The complete wrist unit weighs 130 kg All lifting equipment used must be sized accordingly 13 Slightly raise the wrist unit to unload the screw joint faci...

Page 250: ...y be used providing they are lubricated as detailed in section Screw joints on page 384 before fitting 7 Remove the guide pins and secure the two remaining attachment screws as detailed above 8 Remove the lifting tool from the wrist unit 9 Reconnect the motor axis 5 by connecting the two connectors inside the upper arm tube R3 FB5 R3 MP5 and secure the cable bracket with the two attachment screws ...

Page 251: ...onnect the connectors to motor axis 6 and refit the motor cover 14 Refit the cover upper arm tube Shown in the figure Location of wrist unit on page 245 15 Refit the cover wrist unit Shown in the figure Location of wrist unit on page 245 16 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included ...

Page 252: ...er arm includes the wrist unit but this section also describes how to remove the upper arm when there is no wrist unit mounted Note The lifting device is attached differently depending on whether the wrist unit is mounted on the upper arm or not The attachment points are shown in the following figure A more detailed view of the component and its position may be found in chapter Exploded views in t...

Page 253: ... 1 For guiding Sealing axis 2 3 Guide pins sealing axis 2 3 100 mm 3HAC 14628 2 For guiding Sealing axis 2 3 Power supply 24 VDC max 1 5A For releasing the brakes Rotation tool 3HAC 17105 1 Used to rotate the motor shaft beneath the motor cover when brakes are released with 24 VDC power supply Lifting eye VLBG M12 3HAC16131 1 Lifting device upper arm 3HAC15994 1 Lifting tool chain 3HAC15556 1 To b...

Page 254: ...s 3 Detailed in section Oil change gearbox axis 3 on page 163 8 Disconnect connector R2 M5 6 at the cable harness division as well as all remaining connections between upper and lower arm Shown in the figure Location of upper arm on page 250 9 Remove the cover on top of the motors axis 3 and 4 and disconnect all connectors inside the motors 10 Remove all brackets securing the cabling to the upper ...

Page 255: ...pins sealing axis 2 3 B Holes for the upper arm attachment screws 33 pcs C Holes for the gearbox attachment screws not affected in this instruction 3 Upper arm including wrist unit Fit the lifting eye VLBG M12 to the attachment hole lifting eye on the wrist unit Art no is specified in Required equipment on page 251 Shown in the figure Location of upper arm on page 250 4 Upper arm including wrist u...

Page 256: ...pment on page 251 xx0200000165 The rotation tool is used beneath the motor cover directly on the motor shaft as shown in figure above A Rotation tool 10 Fit the three washers to be placed beneath the attachment screws Shown in the figure Location of upper arm on page 250 1 1 Insert 31 of the 33 attachment screws upper arm into the attachment holes in the lower arm Do not remove the guide pins unti...

Page 257: ... not to bend the attachment plate when fastening the screws 19 Perform a leakdown test Detailed in section Performing a leak down test on page 200 20 Refill the gearbox with oil Detailed in section Oil change gearbox axis 3 on page 163 21 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in...

Page 258: ...erence information xx0300000474 Internal components lower arm The internal components of the lower arm are located as shown in the figure below The figure 1 shows a cut between the lower arm and the gearbox axis 3 The location of the sealing axis 2 3 is identical between the lower arm and the axis 2 The figure 2 shows a cut through the lower arm pivot point in axis 2 item B in the figure above A L...

Page 259: ...served xx0300000475 A Gearbox B Cover axis 2 C O ring D Bearing E Thrust washer F Bushing G Retaining ring shaft H Shaft lower arm I Protection washer J Shaft balancing device K Grease L Securing screw and washer balancing device shaft M Protection plug N Attachment screws and washers Continued Continues on next page ...

Page 260: ...ust be used for guiding the sealing axis 2 3 Rotation tool 3HAC 17105 1 Used to rotate the motor pinion and gear if necessary when brakes are released Hydraulic pump 80 MPa 3HAC13086 1 Hydraulic pump 150 MPa Glycerin 3HAC021563 012 Puller device axis 2 shaft 3HAC021563 001 The use of the tool is detailed in section Replacement of lower arm shaft on page 263 Press device axis 2 shaft 3HAC021600 001...

Page 261: ...uired equipment on page 258 Attachment is shown in the figure Location of lower arm on page 256 5 Unload the balancing device in order to make the piston rod and front ear adjustable when pulling the front shaft out Detailed in sectionUnloading the balancing device on page 295 6 Remove the securing screw from the balancing device front shaft Shown in the figure Location of lower arm on page 256 7 ...

Page 262: ...al components as detailed in section Removal lower arm shaft on page 265 15 Remove the attachment screws and washers that attach the lower arm to the gearbox axis 2 Shown in the figure Internal components lower arm on page 256 16 Lift the lower arm and place it on a secure surface 17 Remove the bearing and thrust washer from the shaft hole in the lower arm Shown in the figure Internal components l...

Page 263: ...m Art no is specified in Required equipment on page 258 6 CAUTION The lower arm weighs 160 kg All lifting equipment used must be sized accordingly 7 Lift the lower arm and move it to its mounting position 8 In case the hole pattern of the lower arm and the gearbox axis 2 does not match use power supply to release the motor axis 2 brakes and rotate the pinion and gear with the rotational tool Conne...

Page 264: ... and restore the balancing device Detailed in section Refitting balancing device on page 290 15 Refit the upper arm Detailed in section Refitting upper arm on page 253 16 Perform a leak down test Detailed in section Performing a leak down test on page 200 17 Refill the gearbox with oil Detailed in section Oil change gearbox axis 2 on page 160 18 Refit and reconnect all cables inside the lower arm ...

Page 265: ...ons in section Replacement of complete lower arm on page 256 are followed These include removing the upper arm removing the cabling in the lower arm unloading the balancing device and removing the front eye shaft draining the oil in gearbox axis 2 unloading the lower arm with specific lifting equipment Components lower arm shaft The figure below shows the components fitted to the lower arm shaft T...

Page 266: ...a new bearing when reassembling Puller device axis 2 shaft 3HAC021563 001 Press device axis 2 shaft 3HAC021600 001 Hydraulic pump 80 MPa 3HAC13086 1 Hydraulic pump 150 MPa Glycerin 3HAC021563 012 Press tool axis 2 bearing 3HAC13527 1 Retaining ring plier Isopropanol 1177 1012 208 For cleaning the shaft Grease 3HAB 3537 1 For lubrication of the bearing Glycerin For lubrication of the shaft Rust pre...

Page 267: ... shaft contact ABB Robotics A Nipple for the hydraulic pump B Nipple for the glycerin pump C Indicator Action Note Illustration 1 WARNING This procedure is a step in the complete procedure of removing the lower arm Make sure all the preceding steps specified in Prerequisites on page 263 are made before removing the lower arm shaft 2 Remove the protection plug Shown in the figure Components lower a...

Page 268: ... page 264 The attachments on the tool are shown in figure Puller device for removal of axis 2 shaft on page 264 6 Increase the pressure of the glycerin pump and at the same time pull out the shaft with the puller tool by increasing the pressure of the hydraulic pump Note Do not exceed the limit of maximum pressure classified for the pumps 7 Remove the bearing and thrust washer from the shaft hole ...

Page 269: ...ten the M16 nut Tightening torque 20 Nm 7 Fit both the hydraulic pump and the glycerin pump to the press device Art no is specified in Required equipment on page 264 The attachments on the tool are shown in the figure Press device for refitting of axis 2 shaft on page 265 8 Set the indicator on the press device to zero Shown in the figure Press device for refitting of axis 2 shaft on page 265 9 Pr...

Page 270: ...ing with the press tool axis 2 bearing Always use a new bearing when reassembling Art no is specified in Required equipment on page 264 15 Refit the protection washer and the retaining ring Shown in the figure Components lower arm shaft on page 263 16 Refit the protection plug Shown in the figure Components lower arm shaft on page 263 17 Proceed with the refitting procedure of the lower arm detail...

Page 271: ...oints robot The special equipment used to secure the lower arm is fitted to the attachment points shown in the figure below xx0300000608 Required equipment A Attachment hole securing screw B Holes for M12 bolts C Holes for M16 bolts Equipment etc Art no Note Fixture lower arm 3HAC020729 001 Includes the locking screw for securing the lower arm Standard toolkit 3HAC 15571 1 The contents are defined...

Page 272: ...holder Securing the lower arm The procedure below details how to secure the lower arm by fitting the fixture to the robot A Locking screw B Adjusters 2 pcs C M16 bolts 4 pcs D Ring nuts 2 pcs E M12 bolts and washers 2 pcs Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to ...

Page 273: ...chanical stops on axis 2 not stock equipment these must be removed at this point The attachment holes of the mechanical stops are used to attach the fixture 5 Remove the locking screw from the fixture where it is attached Shown in the figure Fixture lower arm on page 270 Art no of the fixture is specified in Required equipment on page 269 6 Secure the lower arm to the frame by inserting the lockin...

Page 274: ...ghten by hand 6 Lock using the two ring nuts 7 Fit and tighten the two M12 bolts in the attachment holes on the lower arm with tightening torque 91 Nm C Art no is specified in Required equipment on page 269 Attachment holes on the frame and on the lower arm are shown in the figure Attachment points robot on page 269 The adjusters bolts and ring nuts are shown in the figure Fixture lower arm on pag...

Page 275: ...of the frame as shown in the figure below xx0300000557 Required equipment A SMB cover B SMB unit C Battery cable Equipment etc Spare part no Art no Note SMB unit 3HAC16014 1 Brush Rust preventive 3HAC026621 001 Equivalent Mercasol 3106 Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual Circuit Diagram See chapter Circuit diagram in the...

Page 276: ...WARNING The unit is sensitive to ESD on page 40 4 Remove the SMB cover by unscrewing its attachment screws Shown in the figure Location of SMB unit on page 273 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 273 7 Gently disconnect the connectors ...

Page 277: ...to the pins Art no is specified in Required equipment on page 273 Shown in the figure Location of SMB unit on page 273 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 273 8 U...

Page 278: ...to ESD on page 40 3 Remove the SMB unit according to step 4 8 in Removal SMB unit on page 274 4 Refit the new SMB unit according to step 3 6 in Refitting SMB unit on page 274 5 NOTE Make sure that the gasket under the SMB cover is not damaged 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 hose...

Page 279: ... xx0300000558 Required equipment A Brake release unit B SMB cover C Bracket D Push button guard Equipment etc Art no Note Brake release unit with buttons 3HAC 16035 1 Located together with the SMB unit at the left hand side of the frame Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual Other tools and procedures may be required See re...

Page 280: ... button guardfrom the SMB cover Shown in the figure Location of brake release unit on page 277 The guard must be removed to ensure a correct refitting of the brake release unit 4 Open the SMB cover by unscrewing the attachment screws Let the battery stay connected to avoid the need of synchronization of the robot Shown in the figure Location of brake release unit on page 277 5 Remove the complete ...

Page 281: ...ressure to motors and SMB 2 esd WARNING The unit is sensitive to ESD before handling the unit please observe the safety information in section WARNING The unit is sensitive to ESD on page 40 3 Fasten the brake release unit on the bracket with the attachment screws Make sure the unit is positioned as straight as possible on the bracket The push buttons can otherwise get jammed when the SMB cover is...

Page 282: ...7 WARNING Before continuing any service work please observe the safety information in section WARNING The brake release buttons may be jammed after service work on page 39 8 Refit the push button guardto the SMB cover Shown in the figure Location of brake release unit on page 277 9 If the battery has been disconnected the revolution counter must be updated Detailed in the Calibration chapter secti...

Page 283: ... front ear of the balancing device as shown in the figure below xx0500002249 Required equipment A Spherical roller bearing B Sealing ring C O ring D Sealing spacer E Front ear of balancing device Equipment Spare part no Art no Note Spherical roller bearing 3HAA2167 17 Sealing spacer 3HAC12988 1 2 pcs required O ring 3HAB3772 76 2 pcs required Sealing ring 3HAC11581 6 2 pcs required Grease 3HAB 353...

Page 284: ... tool 3HAC15941 1 Press tool 3HAC15846 1 Hexagon nut M12 9ADA267 9 Plain washer 9ADA312 9 The tools in the set are shown in the figure Tool set on page 282 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Equipment Spare part no Art no Note A Threaded bar B Dolly C Press to...

Page 285: ...ove the balancing device from the robot Detailed in section Removal balancing device on page 289 3 Remove the both sealing spacers with a screwdriver or any equal tool Shown in the figure Location of bearing on page 281 4 Insert the threaded bar through the bearing 5 Fit the press tool and dolly to the threaded bar Secure with the nut and washer at each end xx0500002255 A Threaded bar 3HAC15945 1 ...

Page 286: ...acers Spare part no s are specified in Required equipment on page 281 6 Press in the sealing spacers with the press tools as shown in the figure to the right Secure the press tool and dolly with nuts and washers Note Fit the sealing spacers one at a time xx0500002258 A Threaded bar 3HAC15945 1 B Dolly 3HAC15948 1 C Press tool 3HAC15846 1 7 Refit the balancing device to the robot Detailed in sectio...

Page 287: ...0993 001 Revision G Copyright 2004 2008 ABB All rights reserved 10 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 38 Action Note Illustration Continued ...

Page 288: ...lancing device The balancing device is located on rear top of the frame as shown in the figure below xx0300000533 A Balancing device B Rear cover C Support shaft inside D Attachment screws rear cover E Balancing device shaft including securing screw F Bearing attachment G Parallel pin inside bearing attachment H Attachment screws bearing attachments Continues on next page ...

Page 289: ...ing equipment C Securing screw attachment hole secures the bearing attachment to the balancing device remove the protection plug D Hole in the frame to access the balancing device shaft with the puller press tool E Locking screw attachment hole secures the lower arm to the frame Equipment Spare part no Art no Note Balancing device 3HAC021031 002 Includes balancing device 3HAC 020040 001 Includes o...

Page 290: ...r bearing Guide pins M16 x 300 3HAC13120 5 Always use guide pins in pairs Lifting eye M12 3HAC14457 3 Shackle balancing device 3HAC 020997 1 Lifting tool chain 3HAC15556 1 Press tool balancing device 3HAC020902 001 Puller tool balancing device shaft 3HAC12475 1 Press tool balancing device shaft 3HAC17129 1 Hydraulic cylinder 3HAC11731 1 To be used with the press and puller tools 2 pcs required Hyd...

Page 291: ... equipment on page 287 Attachments are shown in the figure Attachment points balancing device on page 287 6 Unload the balancing device with the press tool in order to make the piston rod and front ear adjustable when pulling the shaft out Art no is specified in Required equipment on page 287 Detailed in section Unloading the balancing device on page 295 7 Remove the securing screw from the balanc...

Page 292: ...e frame Art no is specified in Required equipment on page 287 13 Lift the balancing device gently backwards to a secure area allowing the bearing attachments to slide on the guide pins Note Make sure not to burden the guide pins with the weight of the balancing device Action Note Illustration Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Fo...

Page 293: ...e protection plugs 12 Raise the balancing device to a position where the balancing device shaft may be inserted through the piston shaft front eye 13 Unload the balancing device with the press tool Detailed in section Unloading the balancing device on page 295 Art no is specified in Required equipment on page 287 For an easier reassembling of the shaft the piston rod may be pressed out more than n...

Page 294: ...ancing device on page 178 18 Restore the balancing device Detailed in section Restoring the balancing device on page 298 19 DANGER The rear cover of the balancing device is a safety device for the piston rod during operation Make sure the cover is properly secured before commissioning of the robot 20 Remove the locking screw that secures the lower arm to the frame xx0300000484 A Attachment hole fo...

Page 295: ...ual with the following additions Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Pull out the sealing spacers out they shall still remain on the ear Apply rust preventive abundantly in the gap press the sealing back in place wipe off surplus material xx...

Page 296: ...n G 294 Copyright 2004 2008 ABB All rights reserved 4 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 38 Action Note Illustration Continued ...

Page 297: ...ncing device How to secure the lower arm is detailed in the current repair activity e g removal of the balancing device Press tool and hydraulic cylinder The figure below shows the hydraulic cylinder mounted on the press tool The press tool includes two press devices that are used to different models of the balancing device xx0200000174 A Press block B Hydraulic cylinder C Press device D Bolt pres...

Page 298: ... Equipment etc Art no Note Press tool balancing device 3HAC020902 001 Includes press device 3HAC 15767 2 press device 3HAC 18100 1 Choose the correct device depending on model of balancing device Hydraulic cylinder 3HAC11731 1 To be used with the press tool 2 pcs required Hydraulic valve with hose 3HAC022643 001 Hydraulic pump 80 MPa 3HAC13086 1 To be used with the hydraulic cylinder Standard tool...

Page 299: ...nd hydraulic cylinder on page 295 6 Fit the hydraulic cylinder to the press tool Art no is specified in Required equipment on page 296 See the figure Press tool and hydraulic cylinder on page 295 7 Connect the hydraulic pump to the hydraulic valve and connect one of the hoses to the hydraulic cylinder on the press tool 8 Open the tap to the connected hose Check that the other tap is closed Note On...

Page 300: ...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 Required equipment A Press block B Hydraulic cylinder C Press device D Bolt press device E Moving pin with marking F Bolt 4 pcs G Pin attached to the fix plate Equipment etc Art no Note Hydraulic valve with hose 3HAC022643 001 Hydraulic cylin...

Page 301: ...tool has returned to its starting position 3 Remove the hydraulic cylinder 4 Remove the press tool by unscrewing the bolts Shown in the figure Press tool and hydraulic cylinder on page 298 5 Lubricate and refit the o ring at the end of the balancing device Make sure the o ring is seated properly Replace if damaged 6 Make sure the damper is properly fitted to the support shaft and refit them both t...

Page 302: ...c Spare part no Art no Note Motor including pinion 3HAC15879 2 3HAC15879 3 Foundry Prime 3HAC027316 001 Foundry Prime Includes motor pinion o ring 2152 2012 430 O ring 2152 2012 430 Must be replaced when reassembling motor Sikaflex 251FC 3HAC026620 001 Option Foundry Prime Mercasol 3106 3HAC026621 001 Option Foundry Prime Gasket 3HAC3438 1 Option Foundry Prime Must be replaced if the cabling is di...

Page 303: ...ures in the step by step instruc tions below These proceduresinclude references to the tools required Circuit Diagram See chapter Circuit diagram in the Product manual reference infor mation Equipment etc Spare part no Art no Note Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pre...

Page 304: ...CAUTION The motor weighs 25 kg All lifting equipment used must be sized accordingly 10 Lift the motor to get the pinion away from the gear and disconnect the brake release voltage 11 Remove the motor by gently lifting it straight up Action Note Illustration Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn o...

Page 305: ...0 Nm 8 Disconnect the brake release voltage 9 Reconnect all connectors beneath the motor cover 10 Refit the cable gland cover at the cable exit with its two attachment screws Make sure the cover is tightly sealed 11 Refit the motor cover with its four attachment screws Make sure the cover is tightly sealed 12 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed w...

Page 306: ...motor unit 3 note NOTE Keep the old top cover with the air nipple mounted 4 Remove the motor unit according to step 5 to 12 in Removal motor axis 1 on page 301 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 refitt the new motor according to Refitting motor axis 1 ...

Page 307: ...ts reserved 7 After mounting the motor on the manipulator the surface between the motor and the base frame must be protected with Mercasol 3106 xx0600002877 A base frame B motor unit 8 Perform a leak test according to Inspection of air hoses Foundry Prime on page 152 Action Note Illustration A B Continued ...

Page 308: ...he motor D Motor attachment holes 4 pcs Equipment etc Spare part no Art no Note Motor including pinion 3HAC021030 001 Includes motor pinion o ring 2152 2012 430 O ring 2152 2012 430 Must be replaced when reassembling motor Sikaflex 251FC 3HAC026620 001 Option Foundry Prime Gasket 3HAC3438 1 Option Foundry Prime Must be replaced if the cablling is dismantled from the motor Grease 3HAB 3537 1 For lu...

Page 309: ...ating manual Other tools and procedures may be required See references to these procedures in the step by step instruc tions below These procedures include references to the tools required Circuit diagram See chapter Circuit diagram in the Product manual reference informa tion Equipment etc Spare part no Art no Note Action Note 1 Move the robot to a position close enough to its calibration positio...

Page 310: ...e motor by unscrewing its four attachment screws and plain washers 11 Fit the two guide pins in two of the motor attachment holes Art no is specified in Required equipment on page 306 Shown in the figure Location of motor on page 306 12 If required press the motor out of position by fitting the removal tool motor to the remaining motor attachment holes Art no is specified in Required equipment on ...

Page 311: ... cover on top of the motor and connect the 24 VDC power supply Connect to connector R2 MP2 pin 2 pin5 4 Fit the lifting tool motor axis 2 3 4 to the motor Art no is specified in Required equipment on page 306 5 Fit the two guide pins in the two lower motor attachment holes Art no is specified in Required equipment on page 306 Shown in the figure Location of motor on page 306 6 CAUTION The motor we...

Page 312: ...nectors beneath the motor cover Connect in accordance with markings on connectors 14 Refit the cable gland cover at the cable exit with its two attachment screws Shown in the figure Location of motor on page 306 15 Refit the cover on top of the motor with its four attachment screws Make sure the cover is tightly sealed 16 Remove the lock screw from the hole for lock screw Shown in the figure Locat...

Page 313: ...screw to be inserted into the hole for lock screw Shown in the figure Location of motor on page 306 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 Lock the lower arm by inserting the lock screw into the hole Art no and dimension is specified in Required equipment on page 306 4 Drain the oil from gearbox axis 2 Detailed in section Oil change gearbox ax...

Page 314: ...movable and may fall down 9 Continue to remove the motor unit according to step 9 to 17 in Removal motor on page 307 10 Fill the four screw recesses on the new motor with Sikaflex After hardening Sikaflex can be formed with a knife xx0600002875 A motor unit B Sikaflex in screw recesses 11 Continue to refitt the new motor according to Refitting motor on page 309 12 Perform a leak test according to ...

Page 315: ...t of motor axis 3 Location of motor The motor axis 3 is located on the left hand side of the robot as shown in the figure below xx0200000186 xx0600003051 A Motor axis 3 B Cable gland cover motor axis 3 C Motor attachment holes 4 pcs A Cable gland cover motor axis 3 B Motor attachment holes 4 pcs C Motor axis 3 Continues on next page ...

Page 316: ...ing Removal tool motor M12x 3HAC 14631 1 Always use the removal tools in pairs Lifting tool motor ax 2 3 4 3HAC 15534 1 Mech stop ax 3 3HAC 12708 1 May be used to fix axis 3 Use attachment screws 3HAB 3409 86 M16 x 60 Washers for mech stop axis 3 3HAA 1001 186 Guide pins M10 x 100 3HAC 15521 1 For guiding the motor Guide pins M10 x 150 3HAC 15521 2 For guiding the motor Rotation tool 3HAC 17105 1 ...

Page 317: ... either Use a fork lift to rest the upper arm onto Use lifting slings and an overhead crane to rest the upper arm Use a mechanical stop to rest the upper arm Fit the mechanical stop in the attachment hole A with tightening torque 115 Nm The upper arm must be positioned as horizontal as possible xx0300000051 Fit the mechanical stop to the third and final attachment hole A below the fixed stop B in ...

Page 318: ...screw holes Art no is specified in Required equipment on page 314 Always use the removal tools in pairs 13 Apply the lifting tool motor axis 2 3 4 to the motor Art no is specified in Required equipment on page 314 14 CAUTION The motor weighs 27 kg All lifting equipment used must be sized accordingly 15 Lift the motor to get the pinion away from the gear 16 Remove the motor by gently lifting it str...

Page 319: ...r pinion when mating it to the gear Fit the motor making sure the motor pinion is properly mated to the gear of gearbox axis 3 Art no is specified in Required equipment on page 314 Make sure the motor pinion does not get damaged Make sure the motor is turned the right direction i e the cables facing forwards xx0200000165 The rotation tool is used beneath the motor cover directly on the motor shaft...

Page 320: ...forming a leak down test on page 200 18 Refill the gearbox with oil Detailed in section Oil change gearbox axis 3 on page 163 19 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 365 20 DANGER Make sure all safety requirements are met when performi...

Page 321: ...e old top cover with the air nipple mounted 5 Continue to remove the motor unit according to step 6 to 17 in Removal motor on page 315 6 Fill the four screw recesses on the new motor with Sikaflex After hardening Sikaflex can be formed with a knife xx0600002875 A motor unit B sikaflex in screw recesses 7 Continue to refitt the new motor according to Refitting motor on page 316 8 Perform a leak tes...

Page 322: ...of motor axis 4 Location of motor The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below xx0200000202 xx0500003050 A Motor axis 4 B Cable gland cover motor axis 4 C Motor attachment holes 4 pcs A Cable gland cover motor axis 4 B Motor axis 4 C Motor attachment holes 4 pcs Continues on next page ...

Page 323: ...14972 1 Always use the removal tools in pairs Guide pins M8 x 100 3HAC 15520 1 For guiding the motor Guide pins M8 x 150 3HAC 15520 2 For guiding the motor Rotation tool 3HAC 17105 1 Used to rotate the motor pinion when mating it to the gear when brakes are released with 24 VDC power supply Power supply 24 VDC max 1 5 A For releasing the brakes Standard toolkit The contents are defined in section ...

Page 324: ... by unscrewing its two attachment screws Shown in the figure Location of motor on page 320 Make sure the gasket is not damaged 4 Remove the cover on top of the motor by unscrewing its four attachment screws 5 Disconnect all connectors beneath the motor cover 6 In order to release the brake connect the 24 VDC power supply Connect to connector R2 MP4 pin 2 pin 5 7 Unscrew the motors four attachment ...

Page 325: ... specified in Required equipment on page 321 4 In order to release the brakes connect the 24 VDC power supply Connect to connector R2 MP4 pin 2 pin 5 5 Fit the two guide pins in two of themotor attachment holes Art no is specified in Required equipment on page 321 Shown in the figure Location of motor on page 320 6 Fit the motor with guidance of the pins making sure the motor pinion is properly ma...

Page 326: ...e cable gland cover at the cable exit with its two attachment screws Shown in the figure Location of motor on page 320 14 Perform a leak down test if gearbox has been drained Detailed in section Performing a leak down test on page 200 15 Refill the gearbox with oil if drained Detailed in section Filling oil on page 168 16 Recalibrate the robot Calibration is detailed in a separate calibration manu...

Page 327: ... old top cover with the air nipple mounted 4 Remove the motor unit according to step 4 to 12 in Removal motor axis 4 on page 322 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 refitt the new motor according to Refitting motor axis 4 on page 323 7 Perform a leak te...

Page 328: ... upper arm tube but attached to the wrist unit as shown in the figure below A more detailed view of the component and its position may be found in chapter Exploded views in the Product manual reference information xx0200000204 Required equipment A Motor axis 5 B Upper arm tube C Wrist unit Equipment etc Spare part no Art no Note 3HAC026982 001 Foundry Prime 3HAC027319 001 Foundry Prime Motor 3HAC1...

Page 329: ...val tools in pairs Oil injector max 500 MPa 3HAC021590 001 For pressing out the pinion motor 5 Motor press pinion 3HAC021883 001 For pressing the pinion on to the new motor Measuring tool 6896134 GN Guide pins M8 x 100 3HAC 15520 1 For guiding the motor Guide pins M8 x 150 3HAC 15520 2 For guiding the motor Power supply 24 VDC 1 5 A For releasing the brakes Standard toolkit The contents are define...

Page 330: ...se the brake connect the 24 VDC power supply Connect to either connector R4 MP5 in the motor pin 2 pin 5 connector R3 MP5 on the separate cable if not removed pin C pin D 9 Remove the motor by unscrewing its four attachment screws and plain washers 10 Fit the two guide pins in two of the motor attachment screw holes Art no is specified in Required equipment on page 326 11 If required press the mot...

Page 331: ...page 326 Replacing the complete wrist unit is detailed in section Replacement of complete wrist unit on page 245 4 Apply a thin film of mineral oil to the pinion shaft and the pinion hole in order to make the pinion run smoothly and to achieve an even friction torque when assembling the pinion Art no is specified in Required equipment on page 326 5 Place the motor and pinion in the press fixture A...

Page 332: ...gland cover at the cable exit with its two attachment screws 15 Refit the cover on top of the motor with its four attachment screws Make sure the cover is tightly sealed 16 Perform a leak down test Detailed in section Performing a leak down test on page 200 17 Refit the wrist unit Detailed in section Refitting wrist unit on page 247 18 Refill the gear with oil Detailed in section Oil change gearbo...

Page 333: ...ns Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Perform step 2 4 in Removal motor axis 5 on page 328 3 Remove the cover for connector access on top of the motor by unscrewing its four attachment screws xx0600002904 A attachment screw B air hose C top...

Page 334: ...med with a knife xx0600002880 A air hose B motor unit C sikaflex in screw recesses 8 Continue to refitt the new motor according to Refitting motor axis 1 on page 302 9 After mounting the motor in the wrist the surface between the motor and the wrist must be protected with Mercasol 3106 xx0600002879 A wrist unit B attachment screw 4 pcs C surface to protect with Mercasol D motor unit 10 Perform a l...

Page 335: ...in the center of the wrist unit as shown in the figure below A more detailed view of the component and its position may be found in chapter Exploded views in the Product manual reference information xx0200000222 Required equipment A Wrist unit B Motor axis 6 Equipment etc Spare part no Art no Note Motor including pinion 3HAC15991 4 Includes motor pinion o ring 2152 2012 430 Continues on next page ...

Page 336: ...ring Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Circuit Diagram ...

Page 337: ...is not damaged 9 Remove the motor by gently lifting it straight out Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Make sure the o ring on the circumference of the motor is seated properly Lightly lubricate the o ring with grease Art no is specified in ...

Page 338: ... with the calibration tools General calibration information is included in section Calibration information on page 365 13 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 38 Action Note Action Note Illustration 1 Move the robot to a position where the motor in axis 6 is...

Page 339: ...n horizontal position drain the oil from the axis 6 gearbox Detailed in section Draining oil axis 6 on page 173 5 Remove the rear motor cover by unscrewing the five attachment screws xx0600002885 A motor unit 3106 B attachment screw 5pcs C air nipple D rear motor cover E gasket 6 Continue to remove the motor unit according to step 6 to 11 in Removal motor on page 334 7 note NOTE Keep the old rear ...

Page 340: ...02884 A mercasol B motor unit C attachment screw 4pcs D sikaflex in screw recesses E loctite 570 F tilt house 9 Apply mercasol 3106 on the surface between tilt house and motor pinion side and Loctite 570 between gasket and tilt house 10 Continue to refitt the new motor according to step2 14 Refitting motor on page 335 11 Perform a leak test according to Inspection of air hoses Foundry Prime on pag...

Page 341: ...t and its position may be found in chapter Exploded views in the Product manual reference information xx0300000538 Required equipment A Gearbox axis 1 B Attachment screws gearbox axis 1 18 pcs Equipment etc Spare part no Art no Note Gearbox 3HAC10828 1 Includes gearbox all o rings and sealing rings O ring 3HAB 3772 54 Replace only when damaged O ring 3HAB 3772 55 Replace only when damaged Sealing ...

Page 342: ...ions below These procedures include references to the tools required Equipment etc Spare part no Art no Note Action Note Illustration 1 Move the robot to its most stable position shown in the figure to the right xx0300000632 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Drain...

Page 343: ...gear 1 on each sides of the base Art no is specified in Required equipment on page 339 11 Fit the support base Make sure the base remains in a stable position before performing any work underneath the base 12 Remove the bottom plate from underneath the base in order to get access to the attachment screws It may be necessary to also remove the rear connector plate xx0300000612 A Bottom plate B Rear...

Page 344: ...e gearbox away with the already mounted lifting tools Action Note Illustration Action Note Illustration 1 If the base is not supported with support base and gear 1 this should be done first Mounting of the support base and gear 1 is detailed in section Removal gearbox axis 1 on page 340 2 Make sure the two o rings C D on the cir cumference of the gearbox are seated properly in their grooves respec...

Page 345: ...t used must be sized accordingly 6 Lift the gearbox to its mounting position in the center of the base 7 Make sure the guide pin in the bottom face of the gearbox is properly aligned with the base Shown in the figure xx0200000055 above 8 Secure the gearbox and the three washers with the 18 attachment screws gearbox axis 1 18 pcs M16 x 90 12 9 quality UNBRAKO tightening torque 300 Nm Reused screws ...

Page 346: ...he base to the mounting site Detailed in section Orienting and securing the robot on page 68 13 Refit the complete arm system Detailed in section Refitting arm system on page 233 This is a complex task to be performed with utmost care in order to avoid injury or damage 14 Refit the cable support plate inside of the base and reconnect the cabling in the rear of the robot base 15 Perform a leak down...

Page 347: ...performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 38 Action Note Illustration Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Apply Mercasol 3106 on unpainted areas xx0600003132 ...

Page 348: ...und in chapter Exploded views in the Product manual reference information xx0300000546 Required equipment A Gearbox axis 2 inside the frame B Attachment hole for the locking screw lower arm C Attachment holes inside of frame for the fixture lower arm D Attachment holes for the fixture lower arm E Motor axis 2 F Rear attachment screws gearbox G Cover axis 2 H Attachment screws cover Equipment Spare...

Page 349: ...cing device 3HAC020902 001 Hydraulic cylinder 3HAC11731 1 To be used with the press tool and the hydraulic pump when unloading the balancing device Hydraulic pump 80 MPa 3HAC13086 1 To be used with the press tool and the hydraulic cylinder when unloading the balancing device Guide pins sealing ax 2 3 80mm 3HAC14628 1 For guiding the sealing Guide pins sealing ax 2 3 100mm 3HAC14628 2 For guiding t...

Page 350: ...age 346 4 Drain the gearbox axis 2 Notice Time consuming activity Detailed in section Oil change gearbox axis 2 on page 160 5 Remove the motor axis 2 Detailed in section Removal motor on page 307 6 Remove the rear attachment screws gearbox from inside of the lower arm Shown in the figure Location of gearbox on page 346 7 Remove the cover axis 2 by unscrewing its 14 attachment screws Shown in the f...

Page 351: ...r similar with guidance from the mounted guide pins 14 Remove the sealing from the lower arm Action Note Illustration Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Make sure the o ring is fitted to the gearbox as shown in the figure to the right Light...

Page 352: ...is 2 3 on to the guide pins on the gearbox Note Do not remove the guide pins for the sealing until the rear attachment screws are secured Art no is specified in Required equipment on page 346 6 Fit two guide pins M12 in 180 relation to each other in the frame in the screw holes for the gearboxes front attachment screws Art no is specified in Required equipment on page 346 xx0300000554 A Attachment...

Page 353: ...e it if damaged Art no is specified in Required equipment on page 346 14 Refit the cover axis 2 to the frame with the attachment screws cover Shown in the figure Location of gearbox on page 346 15 Insert and secure 16 of the 18rear attachment screws gearbox on the inside of the lower arm Shown in the figure Location of gearbox on page 346 18 pcs M16 x 50 tightening torque 300 Nm Reused screws may ...

Page 354: ...enclosed with the calibration tools General calibration information is included in section Calibration information on page 365 26 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 38 Action Note Illustration Action Note Illustration 1 DANGER Turn off all electric power h...

Page 355: ...sembly xx0600003134 A Mercasol 3106 on surfaces 4 Apply Mercasol 3106 on the lower arm according to the illustration to the roght before assembly xx0600003135 A Mercasol 3106 on surfaces 5 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 38 Action Note Illustration A Co...

Page 356: ...the figure below A more detailed view of the component and its position may be found in chapter Exploded views in the Product manual reference information xx0200000194 Required equipment A Gearbox axis 3 B Motor axis 3 C Upper arm D Attachment screws gearbox 24 pcs Equipment etc Spare part no Art no Note Gearbox 3HAC021127 001 Includes gearbox o ring Does not include the sealing axis 2 3 O ring 3H...

Page 357: ...r guiding the gearbox Use guides in pairs Guide pins sealing ax 2 3 80mm 3HAC14628 1 For guiding the sealing axis 2 3 Use guides in pairs Guide pins sealing ax 2 3 100mm 3HAC14628 2 For guiding the sealing axis 2 3 Use guides in pairs Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual Calibration Pendulum toolkit 3HAC15716 1 Complete k...

Page 358: ...tween the gearbox and lower arm On reassembly a new sealing must be used Art no is specified in Required equipment on page 354 6 Place the upper arm safely on a workbench in a fixture or similar 7 Remove the attachment screws gearbox Shown in the figure Location of gearbox on page 354 8 Fit the two guide pins in 180 relation to each other in the gearbox attachment screw holes Art no is specified i...

Page 359: ...DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Turn the upper arm in such a position that the gear mating surface faces upwards 3 Fit two guide pins in 180 relation to each other in the holes in the upper arm used for the gearbox attachment screws Art no is specified in Required...

Page 360: ...operly and the gearbox correctly oriented 10 Remove the lifting tool 11 Secure the gearbox with 22 of the 24 gearbox attachment screws Remove the guide pins and tighten the remaining two screws 24 pcs M12 x 60 Tightening torque 115 Nm Reused screws may be used providing they are lubricated as detailed in section Screw joints on page 384 before fitting 12 Refit the upper arm with a new sealing axis...

Page 361: ...re met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 38 Action Note Illustration Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Apply Mercasol on surfaces on lower arm ...

Page 362: ... A Gearbox axis 6 B Attachment screws and washers gearbox 18 pcs C Oil plug draining D Oil plug filling O ring not shown in figure Equipment etc Spare part no Art no Note Gearbox 3HAC10828 13 Includes o ring 3HAB 3772 57 Washers 3HAA 1001 172 Not included in gearbox Replace only when damaged O ring 3HAB 3772 58 Must be replaced when reas sembling gearbox Grease 3HAB3537 1 For lubricating the o rin...

Page 363: ...lude references to the tools required Equipment etc Spare part no Art no Note Action Note Illustration 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Drain the oil from gearbox axis 6 Detailed in section Oil change gearbox axis 6 on page 172 3 Remove the turning disk Detailed ...

Page 364: ... the gearbox Lubricate the o ring with grease Art no is specified in Required equipment on page 360 xx0100000132 A O ring gearbox axis 6 3 Insert the gearbox axis 6 into the wrist unit Art no is specified in Required equipment on page 360 Shown in the figure Location of gearbox on page 360 Make sure the gears of the gearbox mate with those of the motor 4 Secure the gearbox with the attachment scre...

Page 365: ...d in section Performing a leak down test on page 200 8 Refill the gearbox with oil Detailed in section Oil change gearbox axis 6 on page 172 9 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 365 10 DANGER Make sure all safety requirements are met...

Page 367: ...obot has Absolute Accuracy calibration it is also recommended but not always needed to be calibrated for new Absolute Accuracy The resolver values will change when parts affecting the calibration position are replaced on the robot e g motors wrist or part of transmission Contents of the revolution counter memory are lost If the contents of the revolution counter memory are lost the counters must b...

Page 368: ...n Pendulum standard method or Levelmeter calibration alternative method Absolute Accuracy calibration optional Based on standard calibration and besides positioning the robot at home position the Absolute Accuracy calibration also compensates for mechanical tolerances in the robot structure deflection due to load Absolute Accuracy calibration focuses on positioning accuracy in the Cartesian coordi...

Page 369: ...to the toolkit parts as the standard method with Calibration Pendulum This method may after calibration require modifications in the robot program and is therefore not recommended The calibration equipment for Levelmeter Calibration is ordered as separate parts for each robot and the operating manual for Levelmeter Calibration is enclosed with the Levelmeter 2000 CalibWare Absloute Accuracy calibr...

Page 370: ...00 but the scales and their positions are the same for IRB 6650S and IRB 7600 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 with...

Page 371: ...ards the calibration position in the same direction in order to avoid position errors caused by backlash in gears etc Positive directions are shown in the figure below This is normally handled by the robot calibration software Calibration movement directions 6 axes Note The figure shows an IRB 7600 but the positive direction is the same for all 6 axis robots except the positive direction of axis 3...

Page 372: ...olution counter storing the revolution counter setting with the TPU RobotWare 4 0 Action Note 1 Select axis by axis motion mode 2 Jog the robot to place the calibration marks within the tolerance zone Shown in section Calibration scales and correct axis position on page 368 3 When all axes are positioned store the revolution counter settings Detailed in section Step 2 Storing the revolution counte...

Page 373: ...es 5 Press OK when all axes that are to be updated are marked with an x CANCEL returns to the Calibration window 6 Press OK again to confirm and start the update CANCEL returns to the Revolution Counter Update window 7 At this point it is recommended that the revolution counter values are saved to a diskette Not required 8 CAUTION If a revolution counter is incorrectly updated it will cause incorr...

Page 374: ...lect the axis to have its revolution counter updated by Ticking in the box to the left Tapping Select all to update all axes Then tap Update 5 A dialog box is displayed warning that the updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the ticked revolution counters and remove...

Page 375: ...am MoveAbsJ 0 0 0 0 0 0 9E9 9E9 9E9 9E9 9E9 9E9 NoEOffs v1000 z50 Tool0 4 Run the program in manual mode 5 Check that the calibration marks for the axes align correctly If they do not update the revolution counters The calibration marks are shown in section Calibration scales and correct axis position on page 368 How to update the revolution counters is detailed in section Updating revolution coun...

Page 376: ...alibration marks for the axes align correctly If they do not update the revolution counters The calibration marks are shown in section Calibration scales and correct axis position on page 368 Detailed in section Updating revolution counters on page 370 Action Note 1 Tap Jogging in the ABB menu 2 Tap Motion mode to choose group of axes to jog 3 Tap axes 1 3 to jog axes 1 2 or 3 4 Manually run the r...

Page 377: ...ight 2004 2008 ABB All rights reserved 5 7 Additional calibration instruction IRB4400 Instrauction Before updating the revolution counters coarse calibration on IRB 4400 the stainless steel metal ring on axis 4 need to be removed Illustration xx0600003124 A Upper arm B Stainless steel ring C hose clamp A B C ...

Page 379: ...ce with local regulations Do no dispose of oil and grease near lakes ponds ditches down drains or on to soil Incineration must be carried out under controlled conditions in accordance with local regulations Also note that Spills may form a film on water surfaces causing damage to organisms Oxygen transfer could also be impaired Spillage may penetrate the soil causing ground water contamination Mat...

Page 380: ...ssioning The procedure below details the actions to perform on field when the balancing device is to be decommissioned Equipment Art no Note Standard toolkit The contents are defined in section Standard toolkit on page 388 in part 2 of the Product manual Cutting torch For opening housing and cutting coils Other tools and procedures may be required See references to these procedures in the step by ...

Page 381: ...e the balancing device The device also contains some grease 2 Place the device on a workbench or similar Make sure it is clamped in position with a vice or similar 3 Open a hole in the side of the housing as shown in the figure Use a cutting torch The measurements shown below are maximum values xx0400000698 4 Cut the coils of the three springs inside the housing as specified below Outer spring cut...

Page 383: ...HAC020993 001 Revision G Copyright 2004 2008 ABB All rights reserved 7 Reference information 7 1 Introduction General This chapter includes general information complementing the more specific information in the Product manual part 1 of 2 procedures ...

Page 384: ...t of machines Part 1 General requirements EN 1050 Principles for risk assessment ANSI RIA 15 06 1999 Industrial robots safety requirements DIN 19258 Interbus S International Standard Standards robot cell The following standards are applicable when the robot is part of a robot cell EN 953 Fixed and moveable guards EN 811 Safety distances to prevent danger zones being reached by the lower limbs EN 3...

Page 385: ...04 2008 ABB All rights reserved 7 3 Unit conversion Converter table Use the table below to convert units used in this manual Quantity Units Length 1 m 3 28 ft 39 37 in Weight 1 kg 2 21 lb Pressure 1 bar 100 kPa 14 5 psi Force 1 N 0 738 lbf Moment 1 Nm 0 738 lbf tn Volume 1 L 0 264 US gal ...

Page 386: ...Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint Screws treated with Gleitmo may be reused 3 4 times before the coating disappears After this the screw must be discarded and replaced with a new one When handling screws treated with Gleitmo protective gloves of nitrile rubber type should be used Screws lubricated in other ways Screws lubricated with Moly...

Page 387: ... specified overrides the standard value Use the correct tightening torque for each type of screw joint Only use correctly calibrated torque keys Always tighten the joint by hand and never use pneumatical tools Use the correct tightening technique that is do not jerk Tighten the screw in a slow flowing motion Maximum allowed total deviation from the specified value is 10 The table below specifies t...

Page 388: ...r and air connectors when one or both connectors are made of brass Dimension Tightening torque Nm Class 8 8 oil lubri cated Tightening torque Nm Class 10 9 oil lubri cated Tightening torque Nm Class 12 9 oil lubri cated M5 6 M6 10 M8 24 34 40 M10 47 67 80 M12 82 115 140 M16 200 290 340 M24 725 960 1150 Dimension Tightening torque Nm Class 10 9 Molycote lubricated Tightening torque Nm Class 12 9 Mo...

Page 389: ...cified All components exceeding 22 kg 50 lbs are high lighted in this way To avoid injury ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg A wide range of lifting tools and devices are available for each manipulator model Example Below is an example of how a weight specification is presented inside a procedure table Action Note CAUTION The motor we...

Page 390: ...olkit and defined in the table below This way the tools required are the sum of the Standard Toolkit and any tools listed in the instruction Contents standard toolkit Qty Tool Rem 1 Ring open end spanner 8 19 mm 1 Socket head cap 5 17 mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 10 100 Nm 1 Torque wrench 75 400 Nm 1 Ratchet head for torque wrench 1 2 2 Hexagon headed screw M10x100 1...

Page 391: ...ified directly in concerned instructions in the Product manual procedures Description Qty Art no Bolts M16 x 60 for Mech stop ax 3 2 3HAB 3409 86 Guide pins M8 x 100 2 3HAC 15520 1 Guide pins M8 x 150 2 3HAC 15520 2 Guide pins M10 x 100 2 3HAC 15521 1 Guide pins M10 x 150 2 3HAC 15521 2 Lifting tool wrist unit 1 3HAC 13605 1 Lifting tool motor ax 1 4 5 1 3HAC 14459 1 Lifting tool motor ax 2 3 4 1 ...

Page 392: ...fting device base 1 3HAC15560 1 Lifting device manipulator 1 3HAC15607 1 Lifting device upper arm 1 3HAC15994 1 Lifting eye VLBG M12 1 3HAC16131 1 Lifting eye M12 2 3HAC14457 3 Lifting eye M16 2 3HAC14457 4 Lifting tool chain 1 3HAC15556 1 Lifting tool gearbox axis 2 1 3HAC020386 001 Measuring tool 1 6896134 GN Motor press pinion 1 3HAC021883 001 Oil injector max 500 MPa 1 3HAC021590 001 Press too...

Page 393: ...ool ax1 3HAC 13908 4 Levelmeter 2000 kit 6369901 347 Includes one sensor Measuring pin 3HAC 13908 5 Sensor fixture 68080011 GM Sensor plate 3HAC 0392 1 Sync adapter 3HAC 13908 1 Turn disk fixture 3HAC 68080011 GU Description Art no Note Description Art no Note Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Description Art no Note Oil exchange equipment 3H...

Page 394: ...General Many repair and maintenance activities require different pieces of lifting equipment which are specified in each procedure The use of each piece of lifting equipment is not detailed in the activity procedure but in the instruction delivered with each piece of lifting equipment This implies that the instructions delivered with the lifting equipment should be stored for later reference ...

Page 395: ...st 8 1 Introduction 393 3HAC020993 001 Revision G Copyright 2004 2008 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 ...

Page 396: ...right 2004 2008 ABB All rights reserved 8 2 Spare part list 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 ...

Page 397: ...ion spare parts The figure below shows the spare parts of the robot xx0400001023 Parts The table below specifies all the recommended spare parts for the robot Item Description Spare part no Note A Motor including pinion Motor including pinion 3HAC15879 2 3HAC15879 3 Axis 1 Foundry Prime B Gearbox 3HAC10828 1 Axis 1 C Motor including pinion Motor including pinion 3HAC021030 001 3HAC026975 001 Axis ...

Page 398: ...ing device 3HAC021031 002 3HAC028431 001 Foundry Prime U Cover with gasket 3HAC025899 001 V Cable cover 3HAC022172 003 Cable harness axes 1 4 3HAC025504 001 3HAC026981 001 Foundry Prime Cable harness axes 1 6 3HAC024386 001 Cable harness axis 5 3HAC14139 1 Motor 3HAC17484 10 3HAC026982 001 Axis 5 Foundry Prime VK Cover VK 120x12 3HAA2166 23 Gearbox 3HAC10828 13 Axis 6 Motor including pinion 3HAC15...

Page 399: ...f the Product manual Option no Equipment Installation is detailed in 25 3 Position switch axis 1 Installation of position switches option on page 92 30 1 Position switch axis 2 33 1 Position switch axis 3 37 1 Base plate Securing the base plate on page 64 87 1 Cooling fan axis 1 Installation of cooling fan for motors axes 1 3 option on page 78 88 1 Cooling fan axis 2 89 1 Cooling fan axis 3 159 1 ...

Page 400: ...08 ABB All rights 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 ...

Page 401: ... 003 Lower arm type B X X 105 3HAC026574 001 Lower arm type B Foundry Prime X X 105 3HAC020505 003 Lower arm X X X 105 3HAC17212 1 Sealing axis 2 3 typeA X X X X X 108 201 3HAC020123 001 Sealing axis 2 3 typeB X X X X X X X 108 201 3HAB3409 84 Screw M16x50 18X 18X 108 202 3HAA1001 186 Washer 7x25x3 18X 18X 108 204 3HAC020958 001 Cable protection typeA X X X X X 108 235 3HAC021071 001 Cable protect...

Page 402: ... 109 302 3HAC020098 001 Guiding plate ax2 X X X 109 336 3HAC020745 001 Attachment plate X X X 109 336 3HAC020122 001 Attachment plate typeB X X 109 336 3HAC14792 1 Bracket X X X X X 109 338 3HAC15882 2 Motor axis 3 X 102 3 5 3HAC15885 2 Motor axis 3 X X X X X X X 102 3 5 3HAB3409 71 Screw M12x50 8X 8X 8X 8X 8X 8X 8X 109 304 3HAA1001 134 Washer 13x19x1 5 8X 8X 8X 8X 8X 8X 8X 109 305 3HAB3772 69 O r...

Page 403: ... insulated See section Wrist type 2 insulated on page 414 104 1 3HAC 021204 001 Balancing device 105 1 3HAC 020505 003 Lower arm 106 1 3HAC 16331 1 Cable harness man ax 1 4 106 1 3HAC024386 001 Cable harness man ax 1 6 108 1 3HAC 13263 1 Material set manipulator See section Material set manipulator 3HAC 13263 1 on page 416 109 1 3HAC 13264 1 Material set ax 1 2 See section Material set axis 1 2 3H...

Page 404: ...t head cap screw M16 x 90 101 5 1 3HAC 11529 1 Rubber lined clip D 28 101 6 1 3HAC 14453 1 Hose with flange 101 7 1 3HAC 14453 2 Plug 101 8 1 3HAC 4428 2 Hose Clip D 23 27 101 9 1 9ADA 618 56 Torx pan head screw M6 x 16 Item Qty Art number Description Dimension 101 1 1 1 3HAC 10044 2 Base casting 101 1 2 5 3HAC 4836 7 Protection plug 16 x 12 3 x 9 x 7 101 1 3 1 3HAC 1383 2 Protection Cover compl 1...

Page 405: ... sub block Wheel unit ax 4 225 kg 3HAC 12259 1 on page 404 102 1 6 3 3HAA 1001 99 Wedge 102 1 7 3 3HAC 12560 1 Stud bolt M8 x 65 102 1 8 12 9ADA 334 7 Spring washer conical 8 4 x 18 x 2 102 1 9 3 9ADA 267 7 Hexagon nut M8 102 1 10 3 3HAB 3409 63 Hex socket head cap screw M10 x 110 102 1 11 3 9ADA 334 8 Spring washer conical 10 5 x 23 x 2 5 102 1 12 1 3HAC 13564 1 Damper axis 4 See sub block Damper...

Page 406: ... 3HAB 7116 1 Locking liquid 102 1 33 1 ml 3HAB 7116 2 Locking liquid 102 1 34 1 3HAC 16721 1 Magnetic plug R 1 2 Item Qty Art number Description Dimension Note Item Qty Art number Description Dimenstion Note 102 1 5 1 1 3HAC 11742 1 Intermediate hub machine 102 1 5 2 1 3HAC 12259 2 Gear unit Z2 3 4 See sub block below 102 1 5 3 1 2126 2851 104 Lock nut M20 X 1 102 1 5 4 1 2213 3802 11 Taper roller...

Page 407: ...133 1 Axis 4 housing 102 3 1 1 3HAC026577 001 Axis 4 housing Foundry Prime 102 3 2 1 3HAC 021127 001 RV 410F 270 176 assembly See sub block RV 410F 270 176 assembly 3HAC 021127 001 on page 405 102 3 3 24 3HAB 3409 71 Hex socket head cap screw M12 x 60 102 3 4 24 3HAA 1001 134 Washer 13 x 19 x 1 5 102 3 5 1 3HAC 14750 1 Rot ac motor incl pinion See sub block Rot ac motor incl pinion 3HAC 14750 1 on...

Page 408: ...put gear 102 3 5 3 1 2152 2012 430 O ring 89 5 x 3 102 3 5 4 1 9ADA 183 444 Hex socket head cap screw M8 x 130 102 3 5 5 3 ml 3HAB 7116 1 Locking liquid Item Qty Art number Description Dimension Item Qty Art number Description Dimension 102 4 1 1 3HAC 17484 10 Rotational ac motor M10 102 4 2 1 3HAC 12260 1 Pinion Z1 4 102 4 3 1 2152 2012 430 O ring 89 5x3 Continued ...

Page 409: ...rview Item Qty Art number Description Note 102 1 1 3HAC 13350 1 Material set ax 4 See block Material set ax 4 3HAC 13350 1 on page 403 102 2 1 3HAC 020053 001 Tube shaft 2 55 foundry 102 3 1 3HAC 13351 1 Axis 3 See block Axis 3 3HAC 13351 1 on page 405 102 4 1 3HAC 14752 1 Rot ac motor incl gearbox See block Rot ac motor incl gearbox on page 406 ...

Page 410: ...ights reserved 8 3 7 Axis 3 4 Foundry Prime Overview Item Qty Art number Description Note 102 1 1 3HAC 13350 1 Material set ax 4 102 2 1 3HAC 020053 001 Tube shaft 2 55 foundry 102 3 1 3HAC 13351 1 Axis 3 102 4 1 3HAC 14753 1 Rot ac motor incl gearbox 6600 175 2 55 102 4 1 3HAC 14752 1 Rot ac motor incl gearbox ...

Page 411: ...5 8 9ADA 312 7 Plain washer 8 4 x 16 x 1 6 103 1 6 1 3HAA 2166 11 VK Cover D 80 B 10 103 1 7 1 3HAC 4334 3 Cylindrical roll bearing 50 x 90 x 20 103 1 8 4 3HAC 12560 1 Stud bolt M8 x 65 103 1 9 1 ml 3HAB 7116 2 Locking liquid 103 1 10 16 9ADA 334 7 Spring washer conical 8 4 x 18 x 2 103 1 11 4 9ADA 267 7 Hexagon nut M8 103 1 12 4 3HAA 1001 99 Wedge 103 1 13 1 3HAB 7299 1 Sealing Di 115 Dy 140 B 12...

Page 412: ...1171 2016 618 Lubricant paste Item Qty Art number Description Dimension Note Item Qty Art number Description Dimension 103 1 15 1 1 3HAC 14731 1 Shaft 103 1 15 2 1 3HAB 3643 11 Groove ball bearing 130 x 165 x 18 103 1 15 3 3 9ADA 618 56 Torx pan head screw M6 x 16 103 1 15 4 1 ml 3HAB 7116 1 Locking liquid Item Qty Art number Description Dimension Note 103 1 26 1 1 3HAC 7946 1 Hub ax5 machining 10...

Page 413: ...54 1 Rot ac motor incl pinion See sub block Rot ac motor incl pinion 3HAC 14754 1 on page 412 103 4 5 4 9ADA 312 7 Plain washer 8 4 x 16 x 1 6 103 4 6 4 9ADA 183 37 Hex socket head cap screw M8 x 25 103 4 7 18 3HAA 1001 172 Washer 8 4 x 13 x 1 5 103 4 8 2 2522 122 1 Magnetic plug R1 4 103 4 9 450 ml 3HAC 032140 001 Lubricating oil Kyodo Yushi TMO150 Do not mix different types of oil 103 4 10 2 ml ...

Page 414: ...cl pinion 3HAC 14754 1 Item Qty Art number Description Dimension 103 4 4 1 1 3HAC 17484 8 Rotational ac motor M8 103 4 4 2 1 3HAC 11173 3 Pinion RV 70F 125 8 103 4 4 3 1 2152 2012 430 O ring 89 5 x 3 103 4 4 4 1 9ADA 183 415 Hex socket head cap screw M5 x 55 103 4 4 5 2 ml 3HAB 7116 1 Locking liquid 103 4 4 6 1 3HAC 12877 1 Gasket Continued ...

Page 415: ...Description Dimension 103 1 1 3HAC 8114 4 Material set See block Material set 3HAC 8114 4 on page 409 103 2 1 3HAC 7941 30 Rot ac motor incl gearbox See block Rot ac motor incl gearbox on page 411 103 3 10 3HAB 3409 89 Hex socket head cap screw M16 x 80 103 4 1 3HAC 13890 2 Axis 6 complete Foundry See block Axis 6 complete 3HAC 13890 1 2 on page 411 103 5 1 3HAC 020566 001 Label ...

Page 416: ...e 414 Item Qty Art no Description Note Dimension 103 4 1 1 3HAC 17196 1 Axis 6 insulated 103 4 2 1 3HAC 14754 1 Rot ac motor incl pinion See sub block Rot ac motor incl pinon 3HAC 14754 1 on page 414 103 4 3 4 9ADA 312 7 Plain washer M8 103 4 4 4 9ADA 183 37 Hex socket head cap screw 103 4 5 450 ml 3HAC 032140 001 Lubricating oil Kyodo Yushi TMO150 103 4 5 450 ml 3HAC 16843 1 Lubricating oil TMO15...

Page 417: ...BB All rights reserved 8 3 11 Wrist type 2 Foundry Prime Overview Item Qty Art number Description Dimension 103 1 1 3HAC 8114 4 Material set 103 2 1 3HAC 7941 30 Rot ac motor incl gearbox 103 3 10 3HAB 3409 89 Hex socket head cap screw 103 4 1 3HAC 13890 2 Axis 6 complete Foundry 103 5 1 3HAC 020566 001 Label ...

Page 418: ...C 13960 1 Connection plate ax3 t 4 mm 108 214 2 3HAC 12320 1 Damper axis 3 108 215 2 3HAC 12991 1 Damper axis 2 108 216 2 9ADA 624 65 Torx counters head screw M6 x 60 108 217 2 9ADA 334 7 Spring washer conical 8 4 x 18 x 2 108 218 2 9ADA 618 57 Torx pan head screw M6 x 20 108 220 2 3HAC 9953 1 Syncplate with vernier T 1 5 108 222 1 3HAC 12719 1 Syncplate with vernier ax3 T 1 5 108 223 2 9ADA 183 4...

Page 419: ...11 1 3HAC 14131 1 Connection plate base t 3 mm 109 311 1 3HAC026186 001 Connection plate base Foundry Prime t 3 mm 109 312 1 3HAC 11774 3 Adapter complete See block Adapter complete 3HAC 11774 3 on page 419 109 313 1 3HAC 11769 1 Cable guide ax 1 109 315 14 9ADA 183 39 Hex socket head cap screw M8 x 35 109 316 14 9ADA 312 7 Plain washer 8 4 x 16 x 1 6 109 318 1 3HAB 3772 73 O ring 410 x 4 109 320 ...

Page 420: ...09 345 2 9ADA 267 6 Hexagon nut M6 109 346 1 3HAC 16035 1 BU w buttons DSQC 563 109 347 1 3HAC 6499 1 Push button guard 109 348 4 9ADA 629 56 Torx pan head roll screw M6 x 16 109 349 2 9ADA 618 58 Torx pan head screw M6 x 25 109 350 1 3HAC 4813 1 Cover push button guard 109 350 1 3HAC026331 001 Cover push button guard Foundry Prime 109 351 14 9ADA 618 44 Torx pan head screw M5 x 12 109 355 1 3HAC ...

Page 421: ...09 307 4 1 2152 2012 430 O ring 89 5 x 3 109 307 5 1 ml 3HAB 7116 1 Locking liquid Item Qty Art number Description Dimension 109 312 1 1 3HAC 11774 1 Adapter machined 109 312 2 2 2152 2012 428 O ring 79 5 x 3 109 312 3 1 ml 1234 0011 125 Acrylate adhesive Item Qty Art number Description Dimension 109 322 1 1 3HAC 13582 1 Protection screw 109 322 2 1 3HAB 3772 32 O ring 17 x 3 Item Qty Art number D...

Page 422: ...ushing 110 404 1 9ABA 135 31 Retaining ring shaft 65 110 405 1 3HAC 12480 1 Shaft 110 406 1 3HAC 4836 7 Protection plug 16 x 12 3 x 9 x 7 110 407 4 3HAB 7700 5 Hex socket head cap screw M16 x 70 110 408 2 9ABA 107 56 Parallel pin 10 x 20 110 409 1 3HAC 12548 1 Protection washer T 1 110 410 1 3HAC 11427 1 Shaft balancing device 110 411 4 3HAA 1001 186 Washer 17 x 25 x 3 110 412 50 ml 3HAA 1001 294 ...

Page 423: ...1 5 Overview Item Qty Art number Description Dimension 111 501 1 3HAC 9760 7 Arm extender 450mm 111 501 1 3HAC 15859 3 Arm extender 450mm Foundry 111 503 12 3HAB 7700 69 Hex socket head cap screw M12 x 50 111 504 12 3HAA 1001 134 Washer 13 x 19 x 1 5 111 505 1 9ABA 107 56 Parallel pin 10 x 20 111 506 1 3HAC 9760 10 Cable cover 450mm 111 507 6 9ADA 618 56 Torx pan head screw M6 x 16 ...

Page 425: ...ved 9 Exploded views 9 1 Introduction Definitions This chapter contains detailed views of the components on the manipulator The numbered details are specified with item numbers in the Part List The exploded views are divided into Base incl frame Frame Lower arm 1 Frame Lower arm 2 Upper arm Wrist complete ...

Page 431: ...for the robot Use the correct circuit diagram IRB 6600 IRB 6650 and IRB 6650S The cable harness of the robot is available in two different designs Either the cabling is divided between the upper and lower arm or not Accordingly there are also two different versions of the circuit diagram Determine which circuit diagram that is valid for the robot by checking the article number for the cable harnes...

Page 432: ...alid for your robot The validity of the circuit diagram depends on which cable harness is fitted to the robot Check the article number of the cable harness fitted to the robot and see page 3 of the circuit diagram in order to determine if the diagram is valid for the harness or not Where to find the article number Action Label on the cable harness The label is located at the connectors in the base...

Page 433: ...rs that may appear in this document Except as may be expressly stated anywhere in this document nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses damages to persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this document This document and parts thereof mus...

Page 434: ...ge Page description ABB Contents1 1 COPYRIGHT page 2 Table of contents 1 150 3 Valid For 4 Connection point location IRB 6600 6640 6650 7600 5 Connection point location IRB 6660 9 Legend IRB 66XX 7600 10 Brake Release Unit IRB 66XX 7600 20 Serial Measuring Board IRB 66XX 7600 30 Axis 1 IRB 66XX 7600 40 Axis 2 IRB 66XX 7600 50 Axis 3 Incl optional signal lamp IRB 66XX 76 60 Axis 4 IRB 66XX 7600 70 ...

Page 435: ...1 Manipulator harness axis 5 IRB 6600 6640 6650 6650S 3HAC11440 1 Manipulator harness axis 5 6 IRB 7600 3HAC023717 001 Manipulator harness axis 5 6 IRB 6600 ID 6640 ID 6650 ID 3HAC15930 1 UL signal lamp IRB 6600 6640 6650 6600 ID 6640 ID 6650 ID 6650S 7600 3HAC12498 1 Pos SW 3 functions IRB 6600 6640 6650 6600 ID 6640 ID 6650 ID 6650S 7600 3HAC12587 1 Pos SW 2 functions IRB 6600 6650 6600 ID 6650 ...

Page 436: ...7 8 R1 G R1 SMB1 7 R3 FAN2 R2 FB7 R2 G R2 SMB R1 SMB1 3 R1 SMB4 6 R2 SW2 X8 X9 X10 R2 MP2 R2 FB2 R2 MP4 R2 FB4 R3 FAN3 R2 FB3 R2 MP3 R2 H1 R2 H2 R2 M5 6 IRB7600 6600 ID 6640 ID 6650 ID R2 MP1 R2 FB1 R3 MP5 IRB 7600 6600 ID 6640 ID 6650 ID R3 FB5 IRB 7600 6600 ID 6640 ID 6650 ID R3 MP6 R3 FB6 R3 MP5 IRB 6600 6640 6650 6650S R3 FB5 IRB 6600 6640 6650 6650S R4 MP5 IRB 6600 6640 6650 6650S R4 FB5 IRB ...

Page 437: ...opyright 2003 ABB Page 5 21 Total IRB 6660 3HAC025744 001 Latest revision Approved by date Connection point location Location Plant Sublocation IRB6660 Manipulator Document no Next Rev Ind 02 Lab Office Status APPROVED 1 2 3 4 5 6 7 8 R3 MP6 R3 FB6 R3 MP5 R3 FB5 R2 MP3 R2 FB3 R2 H1 R2 H2 R2 MP1 R2 FB1 R1 MP R1 SMB R1 CP CS R2 MP4 R2 FB4 R2 MP2 R2 FB2 R1 SMB1 3 R1 SMB4 6 R2 SMB X8 X9 X10 R2 CP CS ...

Page 438: ...revision Approved by date Legend Location Plant Sublocation IRB66XX 7600 Manipulator Document no Next Rev Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 M B PTC R G BU FB SMB FAN SW Keypin Motor Brake Temp sensor PTC resistor Resolver Battery Pack Brake Release Unit Feedback unit Serial Measurment Board Fan Position switch Location pin to avoid mismatch Protective Earth Twisted wires...

Page 439: ... Circuit Brake Bleed Circuit Brake Bleed Circuit Brake Bleed Circuit Brake Bleed Circuit Brake Bleed Circuit 9 1 Key Pin Key Pin BU Brake Release Simplified R1 MP 13 4 3 5 2 X8 1 X8 1 5 3 11 12 X10 1 3 5 X9 4 8 10 X10 1 3 5 X9 4 8 10 Brake Release Brake PB 2 1 R1 MP R1 MP R1 MP R1 MP R1 MP R1 MP 5 6 7 8 9 10 0V 4 BU M1 Axis 1 30 2 BU M2 Axis 2 40 2 BU M3 Axis 3 50 2 BU M4 Axis 4 60 2 BU M5 7600 Ax...

Page 440: ...otal IRB 66XX 7600 3HAC025744 001 Latest revision Approved by date Serial Measuring Board Location Plant Sublocation 66XX 7600 SMB Document no Next Rev Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 A B C D E F L KEYPIN M R1 SMB 9 5 8 4 3 7 R2 SMB SDI SDI N SDO SDO N 0V 24V BK WHBK BN WHBN RD WHRD OG SMB 9 5 8 4 3 7 2 1 R2 SMB 2 1 R1 G X3 R1 G X3 G 0V Axis 3 50 3 0V EXT LAMP Axis 3 5...

Page 441: ...xt Rev Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 M 3 S V T W R U PE R2 MP1 1 6 7 9 2 5 Brake MU1 RD WH BK GNYE BU BU R2 MP1 1 6 7 9 12 2 17 18 19 R1 MP M1R M1S M1T BU M1 BU 0V M1 1 3 5 GNYE 9 10 R2 FB1 6 1 7 2 8 3 Resolver FB1 RD BK BU YE WHBK WHYE WHRD R2 FB1 6 1 7 2 8 3 2 14 3 15 6 18 R1 SMB1 3 BK WHBK BN WHBN RD WHRD X1 0V X1 Y1 0V Y1 0V EXC1 EXC1 2 14 3 15 6 18 R1 SMB1 3 SMB...

Page 442: ...02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 SMB R1 SMB1 3 4 16 5 17 7 19 R1 MP 32 31 30 4 16 5 17 7 19 R1 SMB1 3 BK WHBK BN WHBN RD WHRD M2R M2S M2T BU M2 BU 0V M2 1 2 4 GNYE 9 10 X2 0V X2 Y2 0V Y2 0V EXC1 EXC1 R2 MP2 1 6 7 9 2 5 R2 FB2 6 1 7 2 8 3 FB2 MU2 R2 MP2 1 6 7 9 2 5 R2 FB2 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver 4 3 10 12 R...

Page 443: ...4 5 6 7 8 SMB R1 SMB1 3 9 21 10 22 8 20 R1 MP 3 5 7 9 21 10 22 8 20 R1 SMB1 3 BK WHBK BN WHBN RD WHRD M3R M3S M3T PE PE BU M3 1 2 3 GNYE GNYE 9 X3 0V X3 Y3 0V Y3 0V EXC1 EXC1 R2 MP3 1 6 7 9 12 2 R2 FB3 6 1 7 2 8 3 FB3 MU3 R2 MP3 1 6 7 9 2 5 R2 FB3 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver KEYPIN B KEYPIN A A K 1 2 R2 H1 R2 H2 R2 H1 R2 H2 OG R3 H S...

Page 444: ...v Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 SMB R1 SMB4 6 2 14 3 15 6 18 R1 MP 1 2 10 2 14 3 15 6 18 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M4R M4S M4T PE BU M4 BU 0V M4 1 2 3 GNYE 6 7 X4 0V X4 Y4 0V Y4 0V EXC2 EXC2 R2 MP4 1 3 7 9 2 5 R2 FB4 6 1 7 2 8 3 FB4 MU4 R2 MP4 1 3 7 9 2 5 R2 FB4 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver PTC4 ...

Page 445: ...5 17 7 19 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M5R M5S M5T PE BU M5 BU 0V M5 1 2 3 GNYE 6 7 X5 0V X5 Y5 0V Y5 0V EXC2 EXC2 R3 MP5 1 3 7 9 2 5 R3 FB5 6 1 7 2 8 3 FB5 MU5 R3 MP5 1 3 7 9 2 5 R3 FB5 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver C1 C2 C3 GND B9 B1 B7 B8 8 11 C1 C2 C3 GND B9 B1 B7 8 11 PTC5 1 2 BU BK M5R M5S M5T PE BU M5 BU 0V M5 1 2 3 GNYE 6 ...

Page 446: ... 16 5 17 7 19 20 28 29 R1 SMB4 6 R1 MP BK WHBK BN WHBN RD WHRD M5R M5S M5T PE BU M5 BU 0V M5 PTC M5 5 1 2 3 GNYE 6 7 4 X5 0V X5 Y5 0V Y5 0V EXC2 EXC2 A B C D E F A B C D E F R3 FB5 R3 MP5 1 2 3 GND C D A B BK WHBK BN WHBN RD WHRD 1 2 3 GND C D A B M5R M5S M5T PE BU M5 BU 0V M5 PTC M5 PTC M6 X5 0V X5 Y5 0V Y5 0V EXC2 EXC2 1 2 3 GNYE 6 7 4 5 R4 FB5 6 1 7 2 8 3 R4 MP5 1 3 7 9 2 5 8 11 FB5 R4 FB5 6 1 ...

Page 447: ...6XX 7600 BU 10 2 BU 0V M5 66XX 7600 Axis 4 60 2 PTC M5 20 28 29 15 4 16 5 17 7 19 PTC 0V R1 SMB4 6 5 BK WHBK BN WHBN RD WHRD M5R M5S M5T PE BU M5 BU 0V M5 PTC M5 X5 0V X5 Y5 0V Y5 0V EXC2 EXC2 1 2 3 GNYE 6 7 4 R2 M5 6 C1 C2 C3 GND B9 B1 B7 A1 A7 A2 A8 A3 A9 C1 C2 C3 GND B9 B1 B7 A1 A7 A2 A8 A3 A9 R2 M5 6 BN WHBN RD WHRD OG WHOG M5R M5S M5T PE BU M5 BU 0V M5 PTC M5 PTC M6 1 2 3 GNYE 9 11 7 X5 0V X5...

Page 448: ... 20 R1 MP 9 8 16 9 21 10 22 8 20 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M6R M6S M6T PE BU M6 BU 0V M6 1 2 3 GNYE 6 7 X6 0V X6 Y6 0V Y6 0V EXC2 EXC2 R3 MP6 1 3 7 9 2 5 R3 FB6 6 1 7 2 8 3 FB6 MU6 R3 MP6 1 3 7 9 2 5 R3 FB6 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver 8 11 BU BK PTC6 1 2 8 11 R2 M5 6 C4 C5 C6 GND B11 B12 B10 C4 C5 C6 GND B11 B12 B10 M6R M6S M...

Page 449: ... 6 Document no Next Rev Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 SMB R1 SMB4 6 9 21 10 22 8 20 R1 MP 9 8 16 9 21 10 22 8 20 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M6R M6S M6T PE BU M6 BU 0V M6 1 2 3 GNYE 6 7 X6 0V X6 Y6 0V Y6 0V EXC2 EXC2 R3 MP6 1 3 7 9 2 5 R3 FB6 6 1 7 2 8 3 FB6 MU6 R3 MP6 1 3 7 9 2 5 R3 FB6 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U...

Page 450: ...9 21 10 22 8 20 9 21 10 22 8 20 R1 MP 66XX 7600 BU 10 7 BU M6 9 8 16 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M6R M6S M6T PE BU M6 X6 0V X6 Y6 0V Y6 0V EXC2 EXC2 1 2 3 GNYE 6 R2 M5 6 C4 C5 C6 GND B11 B10 R2 M5 6 A4 A10 A5 A11 A6 A12 C4 C5 C6 GND B11 B10 A4 A10 A5 A11 A6 A12 M6R M6S M6T PE BU M6 BU 0V M6 PTC 0V BK WHBK BN WHBN RD WHRD 1 2 3 GNYE 6 7 5 X6 0V X6 Y6 0V Y6 0V EXC2 EXC2 PTC M6 4 R3 FB6 6 1 7 2...

Page 451: ...0 17 1 2 3 4 5 6 7 8 SW1 1 22 21 14 13 SW1 2 22 21 14 13 SW1 3 22 21 14 13 SW1 4 22 21 14 13 SW1 5 22 21 14 13 SW1 6 22 21 14 13 A B D C E F H G J K M L N P S R T U W V X Y a Z Position switches Axis 1 Power 1 1 1 Power 1 1 2 Signal 1 1 1 Signal 1 1 2 Power 1 2 1 Power 1 2 2 Signal 1 2 2 Signal 1 2 1 Power 1 3 1 Power 1 3 2 Signal 1 3 2 Signal 1 3 1 Power 1 4 1 Power 1 4 2 Signal 1 4 2 Signal 1 4 ...

Page 452: ... A B D C E F H G J K M L Power 2 1 1 Power 2 1 2 Signal 2 1 2 Signal 2 1 1 Power 2 2 1 Power 2 2 2 Signal 2 2 2 Signal 2 2 1 Power 2 3 1 Power 2 3 2 Signal 2 3 2 Signal 2 3 1 1 2 4 3 5 6 8 7 9 10 12 11 SW2 1 22 21 14 13 SW2 2 22 21 14 13 SW2 3 22 21 14 13 Position switches Axis 2 R1 SW2 3 A B D C E F H G J K M L A B D C E F H G J K M L R2 SW2 Power 2 1 1 Power 2 1 2 Signal 2 1 2 Signal 2 1 1 Power...

Page 453: ...8 T U W V X Y a Z b c e d f h g R1 SW2 3 Power 3 1 1 Power 3 1 2 Signal 3 1 2 Signal 3 1 1 Power 3 2 1 Power 3 2 2 Signal 3 2 2 Signal 3 2 1 Power 3 3 1 Power 3 3 2 Signal 3 3 2 Signal 3 3 1 1 2 4 3 5 6 8 7 9 10 12 11 13 15 14 A B D C E F H G J K M L A B D C E F H G J K M L R2 SW3 Power 3 1 1 Power 3 1 2 Signal 3 1 2 Signal 3 1 1 Power 3 2 1 Power 3 2 2 Signal 3 2 2 Signal 3 2 1 Power 3 3 1 Power ...

Page 454: ... to the robot Check the article number of the cable harness fitted to the robot This circuit diagram is valid for the following cable harness assemblies For remaining cable harness assemblies see section Circuit diagram 3HAC 025744 001 on page 430 Where to find the article number Action Label on the cable harness The label is located at the connectors in the base Remove the rear cover plate to see...

Page 455: ...nnection Point Location 102 Legend 103 Brake Release Unit 104 Serial Measurement Board 105 Axis 1 106 Axis 2 107 Axis 3 108 Axis 4 109 Axis 5 IRB 7600 110 Axis 6 111 Switches axis 1 113 Switches Fan axis 2 114 Switches Fan axis 3 115 Axis 5 IRB 6600 901 Design changes note 1 1 905 Design changes note 2 1 2 7 906 ...

Page 474: ...nnection point 40 explanation safety symbols 35 F FlexPendant jogging to calibration position 374 MoveAbsJ instruction 373 updating revolution counters 371 fork lift 52 foundation loads 45 requirements 45 G gearbox axis 1 replacement 339 gearbox axis 2 replacement 346 gearbox axis 3 replacement 354 gearbox axis 6 replacement 360 I installation mechanical stop axis 1 86 mechanical stop axis 2 88 me...

Page 475: ...5 scales on robot 368 securing the robot to foundation attachment screws 68 securing base plate 64 securing lower arm 269 securing robot 68 securing upper arm 315 serial measurement board unit replacement 273 special tools 389 stability 51 storage conditions robot 45 symbols safety 35 sync marks 368 T testing brakes 29 tightening torque mechanical stop axis 1 87 mechanical stop axis 2 89 tool set ...

Page 476: ......

Page 477: ...ABB AB Robotics Products S 721 68 VÄSTERÅS SWEDEN Telephone 46 0 21 344000 Telefax 46 0 21 132592 3HAC020993 001 Revision G en ...

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