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4.2 General procedures

4.2.1 Performing a leak-down test

When to perform a leak-down test

After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox
oil must be tested. This is done in a leak-down test.

Required equipment

Note

Article number

Equipment, etc.

-

Leak-down tester

-

Leak detection spray

Performing a leak-down test

Note

Action

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

1

Remove the upper oil plug on the gear and replace
it with the leak-down tester.

2

Regulators, which are included in the leak-down test,
may be required.

Correct value:

Use caution, apply compressed air and raise the
pressure with the knob until the correct value is
shown on the manometer.

CAUTION

The pressure must under no circumstance be higher
than 0.25 bar (20-25 kPa). Also during the time when
the pressure is raised.

3

0.2-0.25 bar (20-25 kPa)

Disconnect the compressed air supply.

4

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

Wait for approximately 8-10 minutes and make sure
that no pressure loss occurs.

5

If any pressure drop occurred, then localize the leak
as described in step

6

If no pressure drop occurred, then remove the leak-
down tester and refit the oil plug. The test is complete.

Spray any suspected leak areas with the leak detec-
tion spray. Bubbles indicate a leak.

7

When the leak has been localized, take the necessary
measures to correct the leak.

8

146

Product manual - IRB 760

3HAC039838-001 Revision: M

© Copyright 2011-2018 ABB. All rights reserved.

4 Repair

4.2.1 Performing a leak-down test

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Summary of Contents for IRB 760 Series

Page 1: ...ROBOTICS Product manual IRB 760 ...

Page 2: ...Trace back information Workspace R18 2 version a18 Checked in 2018 11 20 Skribenta version 5 3 012 ...

Page 3: ...Product manual IRB 760 450 3 2 IRC5 Document ID 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ... 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 manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Keep for future reference Additional copies of this manual may be obtained from ABB Original instructions ...

Page 5: ... 4 Safety signals and symbols 38 1 4 1 Safety signals in the manual 40 1 4 2 Safety symbols on product labels 47 2 Installation and commissioning 47 2 1 Introduction 48 2 2 Unpacking 48 2 2 1 Pre installation procedure 52 2 2 2 Working range and type of motion 55 2 2 3 Risk of tipping stability 56 2 3 On site installation 56 2 3 1 Lifting robot with fork lift 62 2 3 2 Lifting robot with roundsling...

Page 6: ...the IRB 760 145 4 Repair 145 4 1 Introduction 146 4 2 General procedures 146 4 2 1 Performing a leak down test 147 4 2 2 Mounting instructions for bearings 149 4 2 3 Mounting instructions for seals 151 4 2 4 Cut the paint or surface on the robot before replacing parts 152 4 2 5 The brake release buttons may be jammed after service work 153 4 3 Complete robot 153 4 3 1 Replacing cable harness lower...

Page 7: ...is Calibration 364 5 4 3 Installation locations for the calibration tools 366 5 4 4 Axis Calibration Running the calibration procedure 372 5 5 Calibrating with Calibration Pendulum method 373 5 6 Verifying the calibration 374 5 7 Checking the synchronization position 375 6 Decommissioning 375 6 1 Environmental information 377 6 2 Scrapping of robot 378 6 3 Decommissioning of balancing device 381 7...

Page 8: ...This page is intentionally left blank ...

Page 9: ...pair maintenance work Product manual scope The manual covers covers all variants and designs of the IRB 760 Some variants and designs may have been removed from the business offer and are no longer available for purchase Organization of chapters The manual is organized in the following chapters Contents Chapter Safety information that must be read through before performing any installation or serv...

Page 10: ...760 3HAC039612 001 Product specification IRB 760 3HAC031045 001 Operating manual General safety information i 3HAC021313 001 Product manual IRC5 IRC5 with main computer DSQC 639 3HAC047136 001 Product manual IRC5 IRC5 with main computer DSQC1000 3HAC050941 001 Operating manual IRC5 with FlexPendant 3HAC050996 001 Application manual Electronic Position Switches 3HAC051016 001 Application manual Add...

Page 11: ...91 Changed the instruction so that the weight of axis 3 is unloaded when removing the axis 3 motor instead of securing the upper arm with roundslings see Replacing motors axes 2 and 3 on page 298 Other minor improvements also made Added information that the cable should be twisted one turn when refitting it in the upper arm tube see Replacing the cable harness upper end incl axis 6 on page 163 Cla...

Page 12: ...hase faulty information removed in Securing the base plate on page 70 Corrections due to updates in terminology New standard calibration method is introduced Axis Calibration See Calibration on page 349 Information about grounding point added See Robot cabling and connection points on page 94 Replacement procedure for the upper arm is updated see Replacing the upper arm on page 211 H Published in ...

Page 13: ...xis 3 gearbox o ring in repair procedures Note added to calibration chapter to emphasize the requirement of equally dressed robot when using previously created reference calib ration values Information about myABB Business Portal added K Published in release R18 2 The following updates are done in this revision Added locating hole position in tool flange view L Published in release R18 2 The follo...

Page 14: ...completed with a reference to the section where the equipment is listed with further information that is article number and dimensions The designation in the procedure for the component or attachment point corresponds to the designation in the referenced list The table below shows an example of a reference to a list of required equipment from a step in a procedure Note Illustration Action Art no i...

Page 15: ...sioning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists References to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Application...

Page 16: ...ts The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 16 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved Product documentation Continued ...

Page 17: ...arried out by in experienced or non qualified personnel Foreign objects Force majeure Nation region specific regulations To protect personnel the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed To be observed by the supplier of the complete system The integrator is respo...

Page 18: ...working in the work cell see the section Robot motion in the Product specification Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot Safe handling Users shall not be exposed to hazards including slipping tripping and falling hazards It must be possible to safely turn off tools such as milling cutters etc Make sure tha...

Page 19: ...view The protective stops and emergency stops are described in the product manual for the controller Product manual IRB 760 19 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 20: ...guishing Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator or controller 20 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 21: ...s may require using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the robot does not increase the pressure on the trapped person further increasing any injury DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the robot Product man...

Page 22: ... arrest burn injuries or other severe injuries To avoid these personal injuries switch off the main power on the controller before proceeding work Note Switch off all main power switches in a MultiMove system 22 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 1 Safety 1 2 3 Make sure that the main power has been switched off ...

Page 23: ...safety lock Make sure that no one else can turn on the power to the controller and robot while you are working with the system A good method is to remove the power cable to the controller If the robot is installed at a height hanging or other than standing directly on the floor there may be additional risks than those for a robot standing directly on the floor Energy stored in the robot for the pu...

Page 24: ...modifications to the robot 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 An external safety function can interact with other machines and peripheral equipment via this interface This means that control signals can act on safety signals received from the peripheral equipment a...

Page 25: ...y stop equipment is cor rectly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system parameter 2 The hold to...

Page 26: ...efore it is powered up 2 Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Install all safety equipment properly 5 Make sure all personnel are standing at a safe distance from the robot and is out of its reach behind safety fences or similar 6 If...

Page 27: ... in USA or Canada Pay attention to the rotating axes of the robot Keep away from axes to not get entangled with hair or clothing Also be aware of any danger that may be caused by rotating tools or other devices mounted on the robot or inside the cell Keep clear of moving parts so that limbs hands or fingers do not get trapped or crushed by the robot To prevent anyone else from taking control of th...

Page 28: ...manipulator switches to the MOTORS OFF state To ensure safe use of the teach pendant the following must be implemented The enabling device must never be rendered inoperational in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move Anyone entering the working space of the robot must always hold the teach pendant This is to pr...

Page 29: ... risks IRC5 controller A danger of high voltage is associated with for example the following parts Be aware of stored electrical energy DC link Ultracapacitor bank unit in the controller Units such as I O modules can be supplied with power from an external source The main supply main switch The transformers The power unit The control power supply 230 VAC The rectifier unit 262 400 480 VAC and 400 ...

Page 30: ...be live even if the robot system is in the OFF position Power supply cables which are in motion during the working process may be damaged 30 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 1 Safety 1 3 6 Risks associated with live electric parts Continued ...

Page 31: ...e Action Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Product manual IRC5 Panel Mounted Controller Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of ...

Page 32: ... your hand at some distance to feel if heat is radiating from the potentially hot component before actually touching it Wait until the potentially hot component has cooled if it is to be removed or handled in any other way Do not put anything on hot metal surfaces e g paper or plastic 32 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 1 Safety 1 3 8 Hot...

Page 33: ...ure must be released in the complete pneumatic or hydraulic systems before starting to repair them Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics All pipes hoses and connections have to be inspected regularly for leaks and damage Damage must be repaired immediately Splashed oil may cause injury or fire Safe design Gravity may cause ...

Page 34: ... as described below 1 Run each robot axis to a position where the combined weight of the robot arm and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the robot does not change position as the motors are switched off then the brake function is adequate 34 Product manual IRB 760 3HAC039838 001 Revision M Cop...

Page 35: ...losion fire may follow depending upon the circumstances Note Appropriate disposal regulations must be observed Safe handling Use safety glasses when handling the batteries In the event of leakage wear rubber gloves and chemical apron In the event of fire use self contained breathing apparatus Do not short circuit recharge puncture incinerate crush immerse force discharge or expose to temperatures ...

Page 36: ...tion Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling hot lubricant heated up to 90 C Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction Allergic r...

Page 37: ...a time to heat up the oil Warm oil drains quicker than cold oil Heat up the oil After filling verify that the level is correct The specified amount of oil or grease is based on the total volume of the gearbox When changing the lubricant the amount refilled may differ from the specified amount depending on how much has previously been drained from the gearbox Specified amount de pends on drained vo...

Page 38: ...he instructions are not followed that can lead to serious injury pos sibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc WARNING Warns for electrical hazards which could result in severe personal injury or dea...

Page 39: ...d conditions NOTE Describes where to find additional information or how to do an operation in an easier way TIP Product manual IRB 760 39 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 40: ...glish German and French Symbols on safety labels Description Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of ...

Page 41: ... Do not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page Product manual IRB 760 41 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights res...

Page 42: ...ip over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page 42 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 43: ...1 1 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page Product manual IRB 760 43 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 44: ...0001242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page 44 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 45: ...that this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts Product manual IRB 760 45 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Contin...

Page 46: ...This page is intentionally left blank ...

Page 47: ...portant that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page17 before performing any installation work Note If the IRB 760 is connected to power always make sure that the robot is connected to protective ...

Page 48: ...pecified in Weight robot on page 48 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 50 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 51 7 Before taking the robot to its installation site make sure that the site conforms to Loads on founda...

Page 49: ...e shows the various forces and torques working on the robot during different kinds of operation Note These forces and torques are extreme values that are rarely encountered during operation The values also never reach their maximum at the same time WARNING The robot installation is restricted to the mounting options given in following load table s Floor mounted Max load emergency stop Endurance lo...

Page 50: ... be interpreted as the frequency of the robot mass inertia robot assumed stiff when a foundation translational torsional elasticity is added i e the stiffness of the pedestal where the robot is mounted The minimum resonance frequency should not be interpreted as the resonance frequency of the building floor etc For example if the equivalent mass of the floor is very high it will not affect robot m...

Page 51: ...ure Maximum ambient humidity Protection classes robot The table shows the available protection types of the robot with the corresponding protection class Protection class Protection type IP 67 Manipulator protection type Standard Product manual IRB 760 51 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 2 1 Pre installation procedure Continue...

Page 52: ...stricted working range of IRB 760 450 3 2 xx1000001066 Mechanical stop H Maximum working range J Angles Position mm Position in figure Axis 3 Axis 2 Z X 0 0 1824 5 1940 A 20 42 1957 1002 B 28 42 862 925 C 120 50 198 896 D 120 85 513 1190 E 15 85 307 3169 F 20 50 1829 2839 G Continues on next page 52 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Inst...

Page 53: ...to 300 Turn motion 6 67 revolutions to 67 revolutions 1 1 The default working range for axis 6 can be extended by changing parameter values in the software Option 610 1 Independent axis can be used for resetting the revolution counter after the axis has been rotated no need for rewinding the axis Continues on next page Product manual IRB 760 53 3HAC039838 001 Revision M Copyright 2011 2018 ABB All...

Page 54: ...adius xx1000001068 Motor axis 3 A 54 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range and type of motion Continued ...

Page 55: ...is the most stable position Do not change the robot position before securing it to the foundation Shipping and transportation position This figure shows the robot in its shipping position and transportation position xx1000001161 WARNING The robot is likely to be mechanically unstable if not secured to the foundation Product manual IRB 760 55 3HAC039838 001 Revision M Copyright 2011 2018 ABB All ri...

Page 56: ...oints adapter A Attachment points fork lift pocket horizontal attachment screws B Attachment points fork lift pocket vertical attachment screws C Required equipment Note Art no Equipment etc See figure Fork lift set 3HAC023044 001 on page 57 3HAC023044 001 Fork lift set incl all required hardware Content is defined in section Standard tools on page 389 Standard toolkit Continues on next page 56 Pr...

Page 57: ...and one short A Adapter 2 pcs B Horizontal attachment screws 4 pcs fork lift pocket C Attachment screw for adapter 1 pc adapter D Vertical attachment screws 2 pcs E Continues on next page Product manual IRB 760 57 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting robot with fork lift Continued ...

Page 58: ...e tailed in section Manually releasing the brakes on page 67 xx1000001093 Position the robot as shown in the figure to the right 1 Attachment points are shown in figure Attachment points on robot on page56 Fit the two adapters to the robot and secure 2 Attachment screws 2 pcs M16 x 90 Tightening torque 270 Nm Continues on next page 58 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011...

Page 59: ...s and washers Note The screws which are attached horizontally and vertically are identical However they are tightened with different torque 5 Attachment points on the robot are shown in figure Attachment points on robot on page 56 xx0500002279 A Horizontal attachment screws 4 pcs M16 x 60 Tightening torque 60 Nm B Adapter Continues on next page Product manual IRB 760 59 3HAC039838 001 Revision M C...

Page 60: ...are shown in figure Attachment points on robot on page 56 CAUTION The fork lift pocket weighs 22 kg 8 4 pcs M16x60 Secure the shorter fork lift pocket on the other side of the robot with the four remaining hori zontal attachment screws 9 Tightening torque 60 Nm Always use original screws or replace ments of equivalent quality M16 qual ity 12 9 Attachment points on robot are shown in figure Attachm...

Page 61: ...move it to its install ation site 12 WARNING Personnel must not under any circumstances be present under the suspended load 13 Refit the cooling fan to the motor if any Product manual IRB 760 61 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 3 1 Lifting robot with fork lift Continued ...

Page 62: ...s Note Action xx1000001093 Position robot in a secure transport position 1 Attach roundslings to robot according to fig ure Attachment points on page 63 2 CAUTION The IRB 760 robot weighs 2300 kg All lifting accessories used must be sized accordingly 3 WARNING Personnel must not under any circum stances be present under the suspended load 4 Continues on next page 62 Product manual IRB 760 3HAC0398...

Page 63: ...y 2 000 kg A Chain slings with shortener 4 pcs Lifting capacity 4 000 kg B Roundsling 1 5 m Lifting capacity 2 000 kg C Roundsling 1 m Lifting capacity 2 000 kg D Roundsling 1 m Lifting capacity 2 000 kg E Note No sharp edges F Product manual IRB 760 63 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 3 2 Lifting robot with roundslings Contin...

Page 64: ...uipment Note Move the robot to the recommended position shown in the figure and in the instruction Attempting to lift a robot in any other position may result in the robot tipping over causing severe damage or injury Continues on next page 64 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 3 3 Lifting robot with liftin...

Page 65: ...ifting eyes and hooks C Note Make sure to run lifting sling between parallel stag and frame D Required equipment Note Article number Equipment Includes user instructions 3HAC15971 2 3HAC15607 1 Lifting accessory robot Continues on next page Product manual IRB 760 65 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 3 3 Lifting robot with lifti...

Page 66: ...kets it is necessary to remove these in order to reach the lower holes in the frame These are used to attach the hooks of the lifting slings 3 Article number is specified in Required equipment on page 65 Fit the lifting accessory to the robot as de scribed in the enclosed instruction 4 CAUTION The IRB 760 robot weighs 2300 kg All lifting accessories used must be sized ac cordingly 5 WARNING Person...

Page 67: ...nit on page 67 The internal brake release unit is equipped with buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes Note Axes 4 and 5 do not exist 1 If the robot is not connected to the controller power must be supplied to the connector R1 MP according to the section Supplying power to connector R1 MP on page 68 DANGER When releasing the holding br...

Page 68: ...e controller power must be supplied to connector R1 MP on the robot in order to enable the brake release buttons Note Action DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 1 xx0600002937 Supply 0V on pin 12 and 24V on pin 11 2 68 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 I...

Page 69: ...kg All lifting accessories used must be sized accordingly 1 Shown in figure Hole configur ation on page 69 Fit lifting eyes in specified holes 2 Fit lifting slings to the eyes and to the lifting accessory CAUTION Lift and move the base plate very slowly If the base plate starts to swing it is a risk for injuries or damage 3 Product manual IRB 760 69 3HAC039838 001 Revision M Copyright 2011 2018 AB...

Page 70: ...3x45º 0 3 Ø 45P7 A A Ø1 5 4x 6 3 4 8 2 1 6 3x45º B B 2 1 3 3x R1 3 x 4 3x 90º C C 4 5 K 7 0 5 0 47 0 25 c 2x R22 5 1 6 D 2 c 5 2 5 º Common Zone E F G H xx1000001053 Common tolerance zone accuracy all over the base plate from one contact surface to the other E F G H Continues on next page 70 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation...

Page 71: ...82 923 4x Ø16 5x Ø22 16x 861 2x 358 2x 18 0 905 813 475 137 45 0 0 37 2x 87 2x 293 2x 450 2x 630 2x 813 2x 947 2x 991 2x A xx1000001054 Four holes for alternative clamping 4x Ø18 Color RAL 9005 Thickness 80 100 µm A Continues on next page Product manual IRB 760 71 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Securing the base plate Co...

Page 72: ...for leveling bolts in the base plate A A A B B B B xx1500000312 Orienting grooves 3 pcs A Levelling bolts attachment holes 4 pcs B Continues on next page 72 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 3 6 Securing the base plate Continued ...

Page 73: ... Content is defined in section Standard tools on page 389 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Base plate This section details how to secure the base plate to the foundation Note Action Make sure the foundation is levelled 1 Continues on next pa...

Page 74: ... orienting grooves and leveling bolts on page 72 Fit the base plate and use the levelling bolts to level the base plate 6 If required fit strips of sheet metal underneath the base plate to fill any gaps 7 Secure the base plate to the foundation with screws and sleeves 8 Maximum allowed deviation all over the base plate from one contact surface to the other 0 3 mm Recheck the four contact surfaces ...

Page 75: ... the base plate B Levelling screws C Base plate attachment screws D 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 M24 x 140 Suitable screws lightly lubricated Quality 8 8 Quality Thickness 4 mm Suitable washer Outer diameter 44 mm Inner diameter 25 mm 725 Nm Tightening torque Continues on next page...

Page 76: ...base plate 3 Make sure the robot base is correctly fitted onto the guide sleeves Guide the robot gently using two M24 screws while lowering it into its mounting position 4 Specified in Attachment screws on page 75 Fit the bolts and washers in the base attach ment holes 5 Shown in figure Illustration robot fitted to base plate on page 75 Note Lightly lubricate screws before as sembly Tighten bolts ...

Page 77: ... configuration used when securing the robot xx1000001050 Continues on next page Product manual IRB 760 77 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Orienting and securing the robot Continued ...

Page 78: ...ation shows the cross section of the guide sleeve holes xx1000001051 78 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 3 7 Orienting and securing the robot Continued ...

Page 79: ...e the robot and or its parts Note No extra equipment may be fitted on the lower arm of the robot Illustration fitting of extra equipment on upper arm The illustration below shows the mounting holes available for fitting extra equipment on the upper arm Max extra weight on the upper arm IRB 760 450 3 2 35 kg Note The weight of the extra equipment on the upper arm must be deducted from the maximal h...

Page 80: ...0 35 415 kg xx1000001069 Mounting holes M10 Through 6 pcs A Mounting holes M8 Depth 12 mm 4 pcs B Continues on next page 80 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 3 8 Fitting equipment on robot Continued ...

Page 81: ... the mounting holes available for fitting extra equipment on the frame xx1000001070 Continues on next page Product manual IRB 760 81 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 3 8 Fitting equipment on robot Continued ...

Page 82: ...ng equipment on the turning disk xx1000001058 Mounting flange A A B Y X xx1800001403 Tool flange in bottom view Continues on next page 82 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 3 8 Fitting equipment on robot Continued ...

Page 83: ...gures above only use screws with quality 12 9 When fitting other equipment to mounting holes standard screws with quality 8 8 may be used Product manual IRB 760 83 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 3 8 Fitting equipment on robot Continued ...

Page 84: ...gure xx1000001030 Signal lamp A Motor cover B Required equipment Note Article number Equipment etc Complete kit with signal lamp cables adapter gasket screws etc Spare parts on page 393 Signal lamp kit Fitted between motor and cable gland replace if damaged 3HAC033206 001 Gasket Continues on next page 84 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2...

Page 85: ...IRB 760 x x x x A B C D G F E xx1000001064 Signal lamp bracket A Attachment screws for the bracket M8x12 2 pcs B Attachment screws for the signal lamp 2 pcs C Cable straps 2 pcs D Cable gland cover E Motor adapter including gasket F Attachment screw M6x40 1 pc G Continues on next page Product manual IRB 760 85 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation and...

Page 86: ...n page 85 Arrange the signal cable in a loop at the signal cable bracket with two cable straps 4 Electrical installation signal lamp Use this procedure to connect the signal lamp to the axis 6 motor The instruction requires that the signal lamp is already mounted to the tilthouse Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before...

Page 87: ...ckage to the motor Secure with attachment screw M6x40 enclosed with the signal lamp kit 6 In addtion to the enclosed gasket that is fitted to the adapter there is also a gasket located on the motor Make sure it does not get damaged Re place if damaged Push the signal cable through the hole in the adapter and connect it to the connector inside the motor 7 Loosen the motor cables at the glands and a...

Page 88: ... robot References Load diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must be defined in the software Operating manual IRC5 with FlexPendant Stopping time and braking distances The performance of the motor brake depends on if there are any loads attached to the robot For more information see product specification for the robot 88 P...

Page 89: ...ed to move 180 The working range may however be increased to 220 with option 561 1 Extended working range axis 1 Note that this option also requires installation of option 810 1 Electronic position switch This section describes how to install hardware that restricts the working range Note Adjustments must also be made in the robot configuration software system parameters References to relevant man...

Page 90: ...ops available for axis 1 xx0300000049 Additional mechanical stop A Stop pin B Required equipment Note Article number Equipment etc Includes attachment screws and an assembly drawing 3HAC11076 1 Mechanical stop for axis 1 7 5 Includes attachment screws and an assembly drawing 3HAC11076 2 Mechanical stop for axis 1 15 Standard toolkit Article number is specified in section References on page10 Techn...

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

Page 92: ...Electronic Position Switches The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters Redefine the software working range limit ations in the system parameters topic Motion The Arm parameters Upper Joint Boundand Lower Joint Bound must be changed to 3 84 respectively 3 84 The values are in radians that is 3 84 ...

Page 93: ...he speed can be regulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 1...

Page 94: ...as well as feedback from the servo system External axes cables option See the Application manual Additional axes and stand alone controller M2004 see document number in Refer ences on page 10 Robot cables These cables are included in the standard delivery They are completely pre manufactured and ready to plug in Connection point robot Connection point cabinet Description Cable sub category R1 MP X...

Page 95: ...es A B xx1600002016 Diameter A Diameter x10 B Grounding and bonding point on manipulator There is a grounding bonding point on the manipulator base The grounding bonding point is used for potential equalizing between control cabinet manipulator and any peripheral devices xx1600001005 Product manual IRB 760 95 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 2 Installation and ...

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Page 97: ...t sections and divided according to the maintenance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 17 before performing any service work Note If...

Page 98: ...rs More frequent running means more frequent maintenance activities Overhaul Depending on application and operational environment a complete overhaul may be necessary in average around 40000 hours ABB Connected Services and its Assessment tools can help you to identify the real stress level of your robot and define the optimal ABB support to maintain your robot working Contact your local ABB Custo...

Page 99: ...tenance activities and intervals Interval Equipment Maintenance activity Robot Cleaning Every 12 months Axis 1 gearbox oil level Inspection Every 12 months Axes 2 and 3 gearboxes oil level Inspection Every 12 months Axis 6 gearbox oil level Inspection Every 12 months Balancing device Inspection Every 12 monthsi Robot harness Inspection Every 12 months Information labels Inspection Every 12 months ...

Page 100: ...e low is displayed when the battery needs to be replaced The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced See the replacement instruction for more details iv The battery low alert 38213 Battery charge low is displayed when remaining backup capacity robot powered off is less than 2 months The typical lifetime of...

Page 101: ... movement most material handling applications ii Severe chemical or thermal environments or similar environments can result in shortened life expectancy iii Examples of extreme usage in regard to movement press tending very severe palletizing applications major use of axis 1 movement iv The given life for the balancing device is based on a test cycle of 4 000 000 cycles that starts from the initia...

Page 102: ...l plug filling C Motor axis 1 D Drain hose Behind cover E Required equipment Note Art no Equipment Note Do not mix with other oils See Type and amount of oil in gearboxes on page 124 Lubricating oil Content is defined in section Standard tools on page 389 Standard toolkit Continues on next page 102 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 3 Maint...

Page 103: ...g the robot working area 2 This is a precaution to reduce the temperature dependency of the measurement Make sure that the oil temperature is 25 C 10 C 3 Shown in figure Location of gear box on page 102 Open the oil plug inspection 4 A B C xx1400002785 A Oil plug hole B Required oil level C Gearbox oil Measure the oil level Required oil level max 10 mm below the oil plug hole 5 Where to find type ...

Page 104: ...tational center underneath the motor attachment xx0500002482 Gearbox axis 2 A Oil plug draining B Oil plug filling C Ventilation hole gearbox axis 2 D Continues on next page 104 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 2 Inspecting oil level gearbox axes 2 3 ...

Page 105: ...rocedures may be required See references to these procedures in the step by step instructions below Inspecting oil level gearbox 2 3 Use this procedure to inspect the oil level in gearbox axes 2 3 Note Action WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety inform ation in the section Safety risks during work with gearbox lubricants oil or grease ...

Page 106: ... level at the oil plug filling 4 Required oil level max 5 mm below oil plug hole Art no is specified in Required equipment on page 105 Add oil if required 5 Filling of oil is detailed further in section Changing oil gearbox axes 2 and 3 on page 129 Tightening torque 24 Nm Refit oil plug filling 6 106 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 3 Mai...

Page 107: ... required Other tools and procedures may be required See references to these procedures in the step by step instructions below Inspection oil level axis 6 gearbox Use this procedure to inspect the oil level in the axis 6 gearbox Note Action WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety informa tion in the section Safety risks during work with g...

Page 108: ...level max 2 mm below the oil plug hole 4 Art no is specified in Required equipment on page 107 Add oil if required 5 Further information about how to fill the oil may be found in the section Changing oil gearbox axis 6 on page 133 Tightening torque 24 Nm Refit oil plug filling 6 108 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 3 Ins...

Page 109: ...se Loctite 243 Locking liquid Content is defined in section Standard tools on page 389 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page Product manual IRB 760 109 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved ...

Page 110: ... suspected fault trace according to following step by step instruction Clean the area of old grease Run the robot for a few minutes in order to move the balancing device piston Check for leakage Leakage from the inner side of attachment signifies a damaged spacer ring while leakage from the outer side signifies a damaged lock nut Replace damaged component 2 A Spacer ring B Lock nut KM10 C Support ...

Page 111: ...evice is in a horizontal position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 xx0600002689 Check the guide ring for wear Replace if necessary 3 A Guide ring B Circlip Note If there is a risk of metallic contact between the piston rod and the end cover the guide ring must be replaced 4 Product manual...

Page 112: ...es 1 6 A Connectors at base B Motor cables 4 locations C Cable guide axis 2 D Cable guide axis 3 E Metal clamps with nuts F Required equipment Visual inspection no tools are needed Continues on next page 112 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 5 Inspecting cable harness ...

Page 113: ...e 112 Check the cable guide axis 2 Replace if damaged 5 Shown in figure Location of cable har ness axes 1 6 on page 112 Check the metal clamps on the lower arm 6 xx0500002498 Check the metal clamps holding the cable harness inside the upper arm as shown in figure to the right 7 A Metal clamp inside upper arm Shown in figure Location of cable har ness axes 1 6 on page 112 Check the metal clamp hold...

Page 114: ...AC1589 1 4 pcs B Combined warning label Moving robot Shut off with handle and Before dismantling see product manual 3HAC17804 1 C Combined warning label Brake release Brake release buttons and Moving robot 3HAC054583 001 D Combined warning label Extended rotation See user documentation and No mechanical stop 3HAC021761 001 E Continues on next page 114 Product manual IRB 760 3HAC039838 001 Revision...

Page 115: ...Label for marking of axis 7 3HAC028979 001 option P Required tools and equipment Visual inspection no tools are required Inspecting labels Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Inspect the labels located as shown in the figures 2 Article numbers for the labels and plate set is specif...

Page 116: ... the figure xx0600002695 Mechanical stop pin A Fixed stop B Required equipment Visual inspection no tools are required Inspecting mechanical stop pin Use this procedure to inspect the axis 1 mechanical stop pin Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page 116 Product ...

Page 117: ...te The expected life of gearboxes can be reduced after collision with the mechanical stop Make sure the mechanical stop pin can move in both directions 3 Product manual IRB 760 117 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting the axis 1 mechanical stop pin Continued ...

Page 118: ...rking range by 15 3HAC11076 2 Mechanical stop axis 1 Content is defined in section Standard tools on page 389 Standard toolkit Inspecting mechanical stops Use this procedure to inspect the additional mechanical stops Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page 118 Pr...

Page 119: ...tional mechanical stops Axis 1 120 Nm Article number is specified in Required equipment on page118 If any damage is detected the mechanical stops must be replaced Correct attachment screws Axis 1 M16 x 35 quality 12 9 4 Product manual IRB 760 119 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the additional mechanical stops Continued ...

Page 120: ...0001238 Damper lower arm upper 2 pcs A Damper lower arm lower 1 pc B Damper axis 2 2 pcs C Damper axis 3 2 pcs Not visible in this view Continues on next page 120 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 9 Inspection dampers ...

Page 121: ... supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 1 Shown in figure Location of dampers on page 120 Check all dampers for damage cracks or existing impressions larger than 1 mm 2 Check attachment screws for deformation 3 Art no is specified in Required equipment on page 121 If any damage is detected the damper must b...

Page 122: ...able gland D Required tools and equipment Note Article number Equipment To be replaced if damage is detected See Spare parts on page 393 Signal lamp kit Content is defined in section Stand ard tools on page 389 Standard toolkit Continues on next page 122 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting the signal lamp opti...

Page 123: ...ing area 2 Article number is specified in Re quired tools and equipment on page 122 If the lamp is not lit trace the fault by inspecting whether the signal lamp is broken If so replace it inspecting cable connections measuring the voltage in the connectors of motor axis 6 24V inspecting the cabling Replace the cabling if a fault is detected 3 Product manual IRB 760 123 3HAC039838 001 Revision M Co...

Page 124: ...al abb com Before starting any inspection maintenance or changing activities of lubrication always contact the local ABB Service organization for more information For ABB personnel Always check ABB Library for the latest revision of the manual Technical reference manual Lubrication in gearboxes in order to always get the latest information of updates about lubrication in gearboxes A new revision w...

Page 125: ...gested dispenser or a similar one Orion OriCan article number 22590 pneumatic Nipple for quick connect fitting with o ring Product manual IRB 760 125 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 4 1 Type of lubrication in gearboxes Continued ...

Page 126: ... A Gearbox axis 1 B Oil plug filling C Motor axis 1 D Drain hose E Required equipment Note Amount Art no Equipment etc Note Do not mix with other oils See Type and amount of oil in gear boxes on page 124 See Type and amount of oil in gearboxes on page 124 Lubricating oil Capacity 8 000 ml Oil collecting vessel Continues on next page 126 Product manual IRB 760 3HAC039838 001 Revision M Copyright 20...

Page 127: ... Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 36 2 Remove rear cover on the base by unscrewing its attachment screws 3 xx0200000237 Pull out the draining hose from the rear of the base 4 The hose is located beneath the base seen from below A Oil draining ...

Page 128: ...ore entering the robot working area 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 36 2 Shown in figure Location of oil plugs on page 126 Open the oil plug filling 3 Where to find type of oil and total amount is detailed in Type and amount of oil ...

Page 129: ...or attachment The figure shows the position of gearbox axis 2 xx0500002482 Gearbox axis 2 A Oil plug draining B Oil plug filling C Ventilation hole plug gearbox axis 2 D Continues on next page Product manual IRB 760 129 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 4 3 Changing oil gearbox axes 2 and 3 ...

Page 130: ...es on page 124 See Type and amount of oil in gearboxes on page 124 Lubricating oil Capacity 6 000 ml Oil collecting vessel Content is defined in section Special tools on page 390 3HAC021745 001 Oil exchange equip ment Content is defined in section Standard tools on page 389 Standard toolkit Continues on next page 130 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All righ...

Page 131: ... on page 129 Remove the oil plug draining and drain gear box using a hose with a nipple and an oil col lecting vessel 4 Vessel capacity is specified in Re quired equipment on page 130 Draining is time consuming Elapsed time varies depending on the temperature of the oil Tightening torque 24 Nm Refit the oil plug draining 5 Filling axes 2 and 3 Use this procedure to fill gearboxes of axes 2 and 3 w...

Page 132: ...ld also be removed 3 Tightening torque 24 Nm Art no and total amount are specified in Required equipment on page 130 Refill gearbox with lubricating oil The amount of oil to be filled depends on the amount that was previously drained 4 Shown in Location of oil plugs on page 129 Refit oil plug filling and ventilation hole plug 5 Tightening torque 24 Nm 132 Product manual IRB 760 3HAC039838 001 Revi...

Page 133: ...l types 3HAC021745 001 Oil exchange equipment Vessel capacity 900 ml Oil collecting vessel Content is defined in section Standard tools on page 389 Standard toolkit Draining oil Use this procedure to drain oil from gearbox axis 6 When using oil change equipment follow the instructions enclosed with kit Note Action Put tilt house in a suitable position 1 Continues on next page Product manual IRB 76...

Page 134: ...tions enclosed with kit Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Shown in figure Location of oil plugs on page 133 Remove the oil plug filling 2 Art no and the total amount are specified in Required equipment on page 133 Refill the gearbox with lubricating oil Amount of oil to be refill...

Page 135: ...red off 2 days week or 18 months if the robot is powered off 16 h day The lifetime can be extended for longer production breaks with a battery shutdown service routine See Operating manual IRC5 with FlexPendant for instructions WARNING See instructions for batteries Safety risks during handling of batteries on page35 Location of SMB battery The SMB battery SMB serial measurement board is located o...

Page 136: ... for the battery It is important that the SMB unit uses the correct battery Make sure to order the correct spare parts Do not exchange battery contacts Note Spare part no Equipment etc Battery includes protection circuits Only re place with a specified spare part or an ABB approved equivalent For spare part no see Spare parts on page 393 Battery unit Content is defined in section Standard tools on...

Page 137: ...over by unscrewing the attachment screws CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 4 Shown in figure Location of SMB battery on page 135 Pull out the battery and disconnect the battery cable 5 Shown in figure Location of SMB battery on page 135 Remove the SMB battery Battery includes protection circ...

Page 138: ... page 135 A B D C xx1300000307 A Battery pack RMU B Battery holder C Battery cable D Strap Strap the battery cable to the holder Shown in figure Location of SMB battery on page 135 Secure the SMB battery cover with its attachment screws 4 Detailed in chapter Calibration section Updating revolution coun ters on page 356 Update the revolution counters 5 DANGER Make sure all safety requirements are m...

Page 139: ...shows the location of bearings and piston rod Note Balancing device must be fitted on robot when lubricating bearings xx0500002489 Ear bearing located inside A Support washer B Lock nut C Piston rod D Guide ring not visible in this view E Continues on next page Product manual IRB 760 139 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 5 1 Lubricating balancing...

Page 140: ...e axis 2 to calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Be careful not to loose the sup port washer in the process Remove the locknut 3 Fit the lubricating tool It should be tightened to the bottom by hand only 4 Grease through nipple on the lubricating tool 5 Continue filling g...

Page 141: ...n rod is extended to the greatest extent possible 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Clean piston rod with isopropanol before applying new grease 3 Type of grease is specified in Required equipment on page140 Apply new grease 4 Product manual IRB 760 141 3HAC039838 001 Revision M Copyright ...

Page 142: ...activities on page 102 2 Write down the oil level 3 Inspect the oil level again after for example 6 months 4 If the oil level is decreased then replace the gearbox Special cleaning considerations This section specifies some special considerations when cleaning the robot Always use cleaning equipment as specified Any other cleaning equipment may shorten the life of the robot Always check that all p...

Page 143: ...rime can be cleaned by rinsing with water water cleaner 1 The following list defines the prerequisites Maximum water pressure at the nozzle 700 kN m2 7 bar I Fan jet nozzle should be used min 45 spread Minimum distance from nozzle to encapsulation 0 4 meters Maximum flow 20 liters minI I Typical tap water pressure and flow Cables Movable cables need to be able to move freely Remove waste material ...

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Page 145: ... perform a specific repair activity are listed in the respective procedures The details of equipment are also available in different lists in the chapter Reference information on page 381 Safety information There are general safety information and specific safety information The specific safety information describes the danger and safety risks while performing specific steps in a procedure Make su...

Page 146: ...The pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that n...

Page 147: ...o any stresses during the assembly work 3 Assembly of tapered bearings Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing gradually until the...

Page 148: ...tarted During operation the bearing should be filled to 70 80 of the available volume Ensure that grease is handled and stored properly to avoid contamination Grease the different types of bearings as following description Grooved ball bearings must be filled with grease from both sides Tapered roller bearings and axial needle bearings must be greased in the split condition 148 Product manual IRB ...

Page 149: ...e correct type provided with cutting edge There is no damage to the sealing edge feel with a fingernail 1 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced since it may result in future leakage 2 Article number is specified in Equipment on page149 Lubricate the seal with grease just before fitting Not too early there is a risk of dirt and foreig...

Page 150: ...enly when fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damaged or deformed o rings may not be used Check the o ring for surface defects burrs shape accuracy or deformation 2 Defective o rings may not be used Check the o ring grooves 3 The grooves must be geometrically ...

Page 151: ...052 001 Touch up paint Standard Foundry Plus ABB Orange Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 Product manual IRB 760 151 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights re...

Page 152: ...ge to the robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action Make sure the power is turned off 1 Remove the push button guard if necessary 2 Verify that the push buttons of the brake release unit are working by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a button gets ja...

Page 153: ...3 and upper end axis 6 This procedure describes how to replace the lower end of the cable harness How to replace the upper end can be found in section Replacing the cable harness upper end incl axis 6 on page 163 Continues on next page Product manual IRB 760 153 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 1 Replacing cable harness lower end axes 1 3 ...

Page 154: ... 1 3 is located throughout the base frame and lower arm as shown in the figure xx1000001177 Continues on next page 154 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 1 Replacing cable harness lower end axes 1 3 Continued ...

Page 155: ...h lug H Required equipment Note Art no Equipment etc For spare part no see Spare parts on page 393 Cable harness 1 6 Motor axes 1 3 Gasket Replace if damaged The content is defined in the sec tion Standard tools on page 389 Standard toolkit Continues on next page Product manual IRB 760 155 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 1 Replacing cable harness ...

Page 156: ... to the calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 xx1000001313 Remove the rear cover plate from the robot by removing its attachment screws 3 Shown in Location of cable harness lower end axes 1 3 on page 154 Disconnect the earth cable 4 See the figure Location of cable har nes...

Page 157: ...he screws of the motor covers for axes 1 2 and 3 and lift away the covers This is done in order to reach the motor connectors 8 See sections Replacing motor axis 1 on page 291 Replacing motors axes 2 and 3 on page 298 Disconnect all connectors at motors for axes 1 2 and 3 9 Continues on next page Product manual IRB 760 157 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Rep...

Page 158: ...nnect X8 X9 and X10 from the brake re lease unit 13 Remove the SMB cover and put somewhere safe 14 xx1000001330 Unscrew the screws for the cable gland SMB from inside the SMB recess and lift the cable gland out Perform this removal with care in order not to damage any of the components inside the SMB recess 15 Continues on next page 158 Product manual IRB 760 3HAC039838 001 Revision M Copyright 20...

Page 159: ... axes 1 3 Use this procedure to refit the cable harness lower end axes 1 3 Note Action xx1000001331 Push the cable harness and connectors down through the cable guide axis 1 in the center of the frame CAUTION Make sure the cables are not twisted with each other or with customer harness if any 1 Continues on next page Product manual IRB 760 159 3HAC039838 001 Revision M Copyright 2011 2018 ABB All ...

Page 160: ...ents inside the SMB recess 2 Tightening torque for R1 SMB 10 Nm Reconnect connectors R1 MP and R1 SMB at the robot base 3 Attachment points are shown in the figure Location of cable harness lower end axes 1 3 on page 154 xx1000001314 Reconnect the earth cable 4 Continues on next page 160 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 1 Rep...

Page 161: ...ith its attachment screws 8 If cabling is used for 7th axis option refit the connector R2 FB7 to the SMB cover and tighten with 6 Nm WARNING Before continuing any service work please observe the safety information in section The brake release buttons may be jammed after service work on page 152 9 Push the cable harness up through the lower arm 10 Fasten the metal clamp that hold the cable harness ...

Page 162: ...revolution counters on page 356 Update the revolution counter 14 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 15 162 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 1 Replacing cable harness lower end axes 1 ...

Page 163: ... axis 6 The procedure for replacing the lower end axis 1 3 is detailed in section Replacing cable harness lower end axes 1 3 on page 153 Location of cable harness upper end The upper end of the cable harness is located as shown in the figure xx1000001176 Continues on next page Product manual IRB 760 163 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 2 Replacing ...

Page 164: ...quired equipment Note Art no Equipment etc For spare part no see Spare parts on page 393 Cable harness 1 6 Motor axis 6 Gasket Content is defined in section Standard tools on page 389 Standard toolkit Continues on next page 164 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 2 Replacing the cable harness upper end incl axis 6 Continued ...

Page 165: ... robot to the calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Detailed in section Replacing cable har ness lower end axes 1 3 on page 153 If the complete cable harness is being re placed start removal by removing the cable harness lower end 3 xx1000001106 Remove the axis 6 motor cov...

Page 166: ...gland Disconnect connectors at axis 6 motor 5 xx1000001336 Remove the metal clamp that holds the cable at the tilt house by removing its nuts 6 Carefully pull the cable harness out of motor axis 6 7 Continues on next page 166 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 2 Replacing the cable harness upper end incl axis 6 Continued ...

Page 167: ...wer arm 10 Refitting cable harness upper end Use this procedure to refit the cable harness upper end Note Action Detailed in section Replacing cable har ness lower end axes 1 3 on page 153 Start by fitting the cable harness lower end if it has been removed 1 Continues on next page Product manual IRB 760 167 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 2 Replac...

Page 168: ...mps with the nuts 2 2 pcs from the outside of the upper arm Twist the cable one turn between the cable clamps 3 xx1000001340 Refit the axis 3 cable guide 4 Continues on next page 168 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 2 Replacing the cable harness upper end incl axis 6 Continued ...

Page 169: ... motor axis 6 7 Check the gasket If damaged replace it 8 A xx0600002694 Refit the cable gland with its attachment screw 9 A Screw holding the cable gland Make sure the gasket is not damaged Replace if damaged Continues on next page Product manual IRB 760 169 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 2 Replacing the cable harness upper end incl axis 6 Contin...

Page 170: ...d in section Updating revolution counters on page 356 Update the revolution counter 11 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page26 12 170 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 2 Replacing the cable ...

Page 171: ...ntact has longer lifetime for the battery It is important that the SMB unit uses the correct battery Make sure to order the correct spare parts Do not replace the battery contact Note Article number Equipment etc For spare part number see Spare parts on page 393 SMB unit For spare part number see Spare parts on page 393 Battery pack Content is defined in section Standard tools on page 389 Standard...

Page 172: ...CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 4 Use caution and remove the connectors X8 X9 and X10 from the brake release board if need of more space 5 Shown in the figure Location of SMB unit on page 171 Remove the nuts and washers from the guide pins that secure the board 6 Connectors R1 SMB1 3 R1 SM...

Page 173: ...171 Fit the SMB unit onto the guide pins 5 Secure the SMB unit to the pins with the nuts and washers 6 X9 X8 X10 xx1700000978 If disconnected reconnect the connectors X8 X9 and X10 to the brake release board Be careful not to damage the sockets or pins Make sure the connector and its locking arms are snapped down properly 7 Shown in the figure Location of SMB unit on page 171 Secure the SMB cover ...

Page 174: ...Required equipment Note Article number Equipment etc DSQC1050 3HAC065020 001 Brake release board Content is defined in section Standard tools on page 389 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page 174 Product manual IRB 760 3HAC...

Page 175: ...SMB cover by unscrewing the attach ment screws Let the battery stay connected to avoid the need of synchronization of the robot CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 4 Take a picture or make notes of how the robot cabling is positioned in regard to the brake release board 5 Remove the complete b...

Page 176: ...brake release board on page 174 Art no is specified in Required equip ment on page 174 Refit the complete brake release board includ ing brake release board and bracket to the SMB recess with the two attachment screws 4 Verify that the robot cabling is positioned cor rectly according to previously taken pic ture notes WARNING Screened cables must not get in contact with the brake release board aft...

Page 177: ...e 356 If the battery has been disconnected the revolu tion counter must be updated 10 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 11 Product manual IRB 760 177 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 4 Replacing the brake ...

Page 178: ...omplete arm system as defined above xx1000001416 Required equipment Note Art no Equipment etc Used to guide the complete arm system when refitting 3HAC022637 001 Guide pins M12 x 130 Always use the guide pins in pairs Guide pins that are longer than 140 mm will not be pos sible to remove because the lack of space Continues on next page 178 Product manual IRB 760 3HAC039838 001 Revision M Copyright...

Page 179: ...n All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is complet...

Page 180: ...ve the robot to the transport position 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 3 Run an overhead crane to a position above the robot 4 Continues on next page 180 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 5 Replacing the base includin...

Page 181: ...placing motor axis 1 on page291 Remove the axis 1 motor 8 CAUTION The robot arm system weighs 1800 kg All lifting accessories used must be sized accordingly 9 Make sure the lift is done completely level Fit the lifting accessories and adjust it as described in the enclosed user instructions 10 This is detailed in section Lifting robot with lifting slings on page 64 Continues on next page Product m...

Page 182: ... out to be unbalanced despite earlier adjust ments The risk of damaging the interface is bigger if the load is lowered unbalanced 13 CAUTION Always move the robot at very low speed making sure it does not tip See Replacing the axis 1 gearbox on page 316 If needed continue to remove the axis 1 gearbox from the base 14 Refitting the complete arm system Use this procedure to refit the complete arm sy...

Page 183: ...m and move it at very low speed to the mounting site making sure it does not tip Note The refitting must be made completely level Make sure the roundslings are adjusted prior to refitting the arm system 5 xx1100000258 Fit two guide pins in opposite holes in the frame Tip In order to make refitting easier it is recom mended to use two guide pins of different lengths Notice that longer guide pins th...

Page 184: ...lock washer 24 pcs B Axis 1 gearbox C Attachment screws M12x110 qual ity 12 9 gleitmo 24 pcs Fit 22 of the 24 attachment screws before the arm system is completely lowered 10 This is done in order to be able to attach all screws into the threads correctly Replace the guide pins with the remaining attachment screws and secure the complete arm system to the base with its attachment screws and washer...

Page 185: ... with the calibration tools Recalibrate the robot 19 Axis Calibration is described in Calibrat ing with Axis Calibration method on page 360 General calibration information is included in section Calibration on page 349 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 20...

Page 186: ...d For spare part no see Spare parts on page 393 Turning disk Must be replaced when replacing the turning disk 21522012 433 O ring Used to lubricate the o rings 3HAB3537 1 Grease Loctite 574 3HAC034903 001 Flange sealant Content is defined in section Standard tools on page 389 Standard toolkit Continues on next page 186 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All ri...

Page 187: ...e 353 Note This is done in order to fascilitate fitting of the turning disk in the correct position Rotate axis 6 to its calibration position 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 Remove any equipment fitted to the turning disk 4 See section Changing oil gearbox axis 6 on page 133 Drain the ax...

Page 188: ... this procedure to refit the turning disk Note Action Art no is specified in Required equip ment on page 186 xx1000001285 Lubricate the o ring of the turning disk with grease and fit it to the turning disk 1 Continues on next page 188 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 1 Replacing the turning disk Continued ...

Page 189: ...vided that the axis 6 was set in calibration position before the turning disk was removed 2 xx1400000995 Foundry Plus Apply Loctite 574 flange sealant on the contact surface 3 xx1000001290 Attachment screws M10x25 quality 12 9 33 pcs Tightening torque 50 Nm Reused screws may be used providing they are lubricated as detailed in sec tion Screw joints on page385 before fit ting Secure the turning dis...

Page 190: ...h oil 6 Refit any equipment removed during disas sembly to the turning disk 7 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 8 190 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 1 Replacing the turning disk Co...

Page 191: ...bly axis 6 on page 197 Removing the tilthouse unit on page 198 Premounting the outer races of the bearings and other parts axis 2 side on page 204 Premounting the outer races of the bearings and other parts axis 3 side on page 206 Refitting shafts on page 206 Refitting lock nuts and the remaining parts on page 209 Location of tilthouse unit The tilthouse unit is located as shown in the figure xx10...

Page 192: ... arm axis 2 and the parallel arm axis 3 These two sides of the robot will be referred to in the replacing procedures xx1000001427 Axis 2 side See marking on lower arm Continues on next page 192 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the tilthouse unit Continued ...

Page 193: ... Axis 3 side See marking on parallel arm Continues on next page Product manual IRB 760 193 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the tilthouse unit Continued ...

Page 194: ...001424 Axis 2 side A Axis 3 side B VK cover VK 90x8 2 pcs C VK cover VK 19x6 2 pcs D Screw M6x10 quality 8 8 A2F 4 pcs Washers 4 pcs E Retaining ring bore Steel 80 2 pcs F Continues on next page 194 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the tilthouse unit Continued ...

Page 195: ...ng axis 6 T 2 mm 3HAC039277 006 Shims Tribol GR 100 2 PD 3HAB9408 1 Grease Mercasol 3106 Rust preventive Loctite 243 3HAB7116 1 Locking liquid Content is defined in section Standard tools on page 389 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below For art...

Page 196: ...rdered separatly All parts except the hydraulic cylinder are inluded when ordering the complete tool Threaded bar A Stop nut B Hydraulic cylinder must be ordered separately C Distance and screws M6x14 2 pcs D Press housing 3HAC039277 004 E Press washer 3HAC039277 005 F Continues on next page 196 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4...

Page 197: ...ic cylinder is included when ordering the tool NOTE The shims is not part of the tool It can be ordered separately Stop nut 2 pcs A Hydraulic cylinder 201 kN 80 MPa Nike CHF 184 B Adapter C Press housing D Support housing 3HAC039277 003 E Torsion bar M20 L 650 mm fitting F Torsion bar M20 L 900 mm removal F Shims T 2 mm G Continues on next page Product manual IRB 760 197 3HAC039838 001 Revision M ...

Page 198: ...for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 361 If no previous reference values exist and no new reference values can be created then reference calibration is not possible Read more about reference calibration for Pendulum Calibration in Operating manu al...

Page 199: ...sure supply air pressure supply to the robot before entering the robot working area 4 Secure the tilthouse with a roundsling in an overhead crane or similar 5 See Replacing motor axis 6 on page 309 Disconnect motor cables from motor axis 6 Place the motor cables in a way that it will not be damaged 6 Continues on next page Product manual IRB 760 199 3HAC039838 001 Revision M Copyright 2011 2018 AB...

Page 200: ...o be able to loosen the link end at the tilthouse Note It is not needed to remove the upper link com pletely from the linkage only to loosen the end that is fastened to the tilthouse unit 7 Part A Upper link xx1000001420 Remove the M6 screws and washer for filling grease on both sides 8 Continues on next page 200 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights r...

Page 201: ... M6 hole for filling grease in order to remove the VK cover Do this on both sides Put a hand with some paper over the VK cover in order to catch it CAUTION Only a very low air pressure is needed 11 Parts A Screw M6x10 quality steel 8 8 A2F B Washer Continues on next page Product manual IRB 760 201 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the ti...

Page 202: ...nut on the right side of the right shaft Put the distance ring on the bar on the left side of the shaft Apply the hydraulic pump on the bar Secure the hydraulic pump with a nut Remove the shaft with the press tool mounting axis 6 by following the steps below Note A longer threaded bar M16 is needed when re moving the shaft than the one specified when fitting 14 Continues on next page 202 Product m...

Page 203: ...similar before proceeding with the next shaft 17 Follow steps above Remove the shaft on the axis 3 side in the same way 18 CAUTION The robot tilt house weighs 85 kg All lifting accessories used must be sized ac cordingly 19 Continues on next page Product manual IRB 760 203 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 2 Replacing the tilthouse unit Continued ...

Page 204: ... 2 side Use this procedure to fit the outer races of the bearings and other parts in the tilthouse on the axis 2 side before fitting the tilthouse to the upper arm This work is best done on a workbench or similar Note Action CAUTION The tilthouse unit weighs 85 kg All lifting equipment must be sized accordingly 1 Lift the tilthouse unit to a workbench or similar with a roundsling in an overhead cr...

Page 205: ...bore Shown in the figure Cut away view of the assembly of the tilthouse unit on page 194 Thread the sealing ring with dustlip and the in ner bearing complete on the presswasher of the pressing tool premounting bearings 6 Shown in the figure Press tool pre mounting bearing on page 196 Art no is specified in Required equip ment on page 195 Apply the pressing tool and press the parts to gether 7 Show...

Page 206: ... distance ring B Outer race close to VK cover C Surface for VK cover D Distance ring Shown in the figure Cut away view of the assembly of the tilthouse unit on page 194 Thread the sealing ring with dustlip and the in ner bearing complete on the press washer of the pressing tool premounting bearings 4 Shown in the figure Press tool pre mounting bearing on page 196 Art no specified in Required equip...

Page 207: ...a work bench some pallets or similar as when remov ing it 2 xx1000001437 Apply rust preventive Mercasol 3106 on the surfaces where the tilthouse faces the upper arm 3 Parts A Tilthouse B Upper arm Art no is specified in Required equipment on page 195 Apply some grease in the holes for the shafts in the upper arm 4 Shown in the figure Location of axes 2 and 3 sides of the robot on page192 Note Fit ...

Page 208: ...ilthouse unit on page 194 Thread the race of the remaining bearing com plete facing the outside of the tilthouse on the press housing of the press tool mounting axis 6 and fit it on the shaft 10 Shown in the figure Press tool as sembly disassembly axis 6 on page 197 Art no is specified in Required equipment on page 195 Art no is specified in Required equipment on page 195 Fit the hydraulic cylinde...

Page 209: ...ert it on the axis 2 side Fit the axis 2 side in the same way by following the steps above 14 Refitting lock nuts and the remaining parts Before starting this procedure perform the procedure Refitting shafts on page 206 Use this procedure to refit the lock nuts and the other remaining parts of the tilthouse unit Note Action Note Start the assembly on the axis 2 side 1 Apply locking liquid Loctite ...

Page 210: ...on page 309 Refit the motor cable axis 6 9 Pendulum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibration tools Recalibrate the robot 10 Axis Calibration is described in Calib rating with Axis Calibration method on page 360 General calibration information is in cluded in section Calibration on page 349 DANGER Make sure all safety requirements are met when...

Page 211: ...n of the upper arm The upper arm is located as shown in the figure xx1100000016 Continues on next page Product manual IRB 760 211 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 3 Replacing the upper arm ...

Page 212: ...ock nut axis 3 B Shaft axis 2 C Lock nut axis 2 D Radial sealing 1 1 pc E Rust preventive Mercasol 3106 F Taper roller bearing D 80 125 T 29 1 1 pc G Bearing grease Tribol GR 100 2 PD H O ring D119x3 1 1 pc J Sealing 1 1 K Sealing ring 1 1 pc L Oil plug 1 1 pcs M Bushing N Continues on next page 212 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repa...

Page 213: ... 1 Locking liquid Content is defined in section Standard tools on page 389 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which r...

Page 214: ...robot Removing the upper arm Preparations with the robot powered up Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 Remove all equipment fitted to upper arm and tilthouse unit 2 Shown in the figure Synchronization marks and syn chronization position for axes on page 353 Jog the robot to calibration position 3 See section Re...

Page 215: ... See section Replacing the tilthouse unit on page 191 Remove the tilthouse unit 4 Run an overhead crane to a position above the robot 5 xx1100000088 Secure the upper arm in the crane with roundslings 6 Raise the lifting accessories to take the weight of the upper arm 7 See section Replacing the parallel rod on page 253 Remove the parallel rod 8 Removing the shafts Note Action Before continuing mak...

Page 216: ... 5 Continue the removal on this side until the shaft is removed completely Leave the other lock nut and shaft as they are for now 6 Shown in the figure Cut away view of the assembly of the upper arm components on page 212 Remove the magnetic plug and wipe hole and shaft end meticulously clean 7 Attach the glycerine adapter Note Tighten the glycerine adapter very hard in order to avoid leakage 8 Re...

Page 217: ...ed to remove the shaft D Guide sleeve E Shaft F Bushing G 3HAC038174 004 Glycerine adapter H Anvil support shaft J 11 Secure the shaft and the removal tool to the upper arm using lifting eyes and a short roundsling This is done as a safety precau tion 12 CAUTION DO NOT stand close to the robot on any side when the shaft is being removed 13 Continues on next page Product manual IRB 760 217 3HAC0398...

Page 218: ...nd remove the shaft 16 Put the shaft in a clean and safe place 17 Remove the other shaft in the same way by following the steps above 18 Removing the upper arm Note Action CAUTION The upper arm excluding the tilthouse unit weighs 150 kg All lifting equipment used must be sized accordingly 1 Shown in the figure Cut away view of the assembly of the upper arm components on page 212 Remove the radial ...

Page 219: ...ands or anything else that may contaminate them 4 Inspect the sealing ring Replace if damaged 5 Fit the radial sealings in the upper arm Note Do not put grease on the sealing rings 6 Shown in the figure Cut away view of the assembly of the upper arm components on page 212 For article number see Required equipment on page 213 Fill the bearings with bearing grease using the grease filling tool 7 CAU...

Page 220: ... Action Note Refit the shaft on the axis 3 side first 1 Apply a thin layer of glycerine on the tapered part of the shaft and in the corresponding cone in the upper arm 2 Specified in Required equipment on page 213 Lubricate the outer race of the bearing with bearing grease 3 Align upper and lower arm holes 4 Fit the shaft into the upper arm 5 For art no see Required equipment on page 213 Fit the g...

Page 221: ...038174 004 Glycerine adapter F Anvil support shaft G Horseshoe shim 2 5 mm H 7 Fit the anvil with measurement range 3HAC038174 003 8 Connect the hydraulic pump and the glycer ine pump 9 Push the shaft in by screwing the nut by hand Note Feel that the shaft guides into the arm joint 10 Tighten with torque 20 Nm 11 Set the dial gauge to zero 12 Continues on next page Product manual IRB 760 221 3HAC0...

Page 222: ... Securing the shafts Use this procedure to secure the upper arm shafts Continue the refitting procedure starting on the axis 2 side Note Action Shown in the figure Cut away view of the assembly of the upper arm components on page 212 Check that there is no grease on the radial sealings in the upper arm Note There must not be any grease at all on the radial sealing Otherwise grease will appear on t...

Page 223: ...axis 2 side See the exploded view of the parts in the continued procedure of fitting the axis 2 side 3 Shown in the figure Cut away view of the assembly of the upper arm components on page 212 Place the outer race of the tapered roller bearing on the shaft 4 Shown in the figure Cut away view of the assembly of the upper arm components on page 212 Place the tapered roller bearing already filled wit...

Page 224: ...ith the o ring fitted in the lower arm using a plastic mallet or simil ar 11 Wipe the lock nut clean from grease 12 Shown in the figure Cut away view of the assembly of the upper arm components on page 212 Fit the sealing on the lock nut 13 For art no see Required equipment on page 213 Shown in the figure Cut away view of the assembly of the upper arm components on page 212 Apply locking liquid Lo...

Page 225: ...icable to the axis 2 side 18 Tighten the lock nut while at the same time checking the measure between the slide cal iper and the lower arm until the lower arm is pushed together to a gap of 0 3 mm Remove the 2 5 mm shims 19 xx1100000040 Only applicable to the axis 2 side Measure the distance between the slide cal iper and the lower arm on the side shown in the figure using a feeler gage 0 3 mm The...

Page 226: ... tilthouse unit 2 See sections Replacing linkage upper link arm on page 228 Replacing the linkage lower link arm on page 235 Replacement of linkage link on page 242 Refit the linkage system 3 See section Replacing the cable harness upper end incl axis 6 on page 163 Refit the cable harness 4 Move the robot to synchronization position 5 See section Replacing the balancing device on page 278 Refit th...

Page 227: ...od on page 360 General calibration information is included in section Calibration on page 349 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 8 Product manual IRB 760 227 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 3 Replacing the...

Page 228: ...wer link arm and link see Replacing the linkage lower link arm on page 235 Replacement of linkage link on page 242 Location of upper link arm The upper link arm is located as shown in the figure xx1000001083 Upper link arm A Link B Lower link arm C Continues on next page 228 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 4 Replacing linkag...

Page 229: ...ay be required See refer ences to these procedures in the step by step instruc tions below Removing the upper link arm Use this procedure to remove the upper link arm of the linkage system Note Action Check especially that it is possible to re move the lock nut at the link Put the robot in a position where it is possible to reach all parts that shall be removed 1 xx1000001132 Let the tilthouse uni...

Page 230: ... supply hydraulic pressure supply air pressure supply to the robot before entering the robot work ing area 4 xx1000001080 Remove the lock nuts complete 1 1 pc and support washers 1 1 pc that secure the upper link arm Use a KM10 socket 5 CAUTION The link weighs 23 kg All lifting accessories used must be sized accordingly 6 Continues on next page 230 Product manual IRB 760 3HAC039838 001 Revision M ...

Page 231: ...00001082 Remove the inner support washers and spacer rings complete 2 2 pcs 8 Remove residual grease and sealing com pound 9 Refitting the upper link arm Use this procedure to refit the upper link arm of the linkage system Note Action If needed replace the bearings in the upper link arm Note The bearings are sensitive for pushes Make sure they are not damaged 1 Continues on next page Product manua...

Page 232: ...aling compound Permatex No 3 on the surface of both shaft ends where the spacer rings complete will be fitted 3 xx1000001263 Refit the spacer rings complete on the shaft ends of the link and tilthouse 4 Continues on next page 232 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 4 Replacing linkage upper link arm Continued ...

Page 233: ...dge of the link arm on both sides 6 CAUTION The link weighs 23 kg All lifting accessories used must be sized accordingly 7 xx1000001088 Place the upper link arm on the shafts as shown in the figure Note The link arm must be pushed in completely 8 Continues on next page Product manual IRB 760 233 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 4 Replacing linkage ...

Page 234: ... Nm xx1000001080 Refit the support washer and lock nuts complete securing the upper link arm at both ends of the link arm Use a KM10 socket 11 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page26 12 234 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB...

Page 235: ... upper link arm and link see Replacing linkage upper link arm on page 228 Replacement of linkage link on page 242 Location of lower link arm The lower link arm is located as shown in the figure below xx1000001083 Upper link arm A Link B Lower link arm C Continues on next page Product manual IRB 760 235 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 5 Replacing t...

Page 236: ...n section Standard tools on page 389 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below Removal lower link arm Use this procedure to remove the lower link arm of the linkage Note Action DANGER Turn off all electric power supply hydraulic pressure supply ai...

Page 237: ...1 Remove the lock nuts and support washers that hold the lower link arm at each end Note The support washers can stick to the grease and can easily be forgotten and lost when removing the lock nuts 3 CAUTION The link weighs 23 kg All lifting accessories used must be sized accordingly 4 Continues on next page Product manual IRB 760 237 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights re...

Page 238: ...nd the sealing spacer rings 6 Remove residual grease and sealing com pound 7 Refitting lower link arm Use this procedure to refit the lower link arm of the linkage Note Action Spare part no is specified in Required equipment on page 236 If needed replace the bearings Note The bearings are sensitive for pushes Make sure they are not damaged 1 Continues on next page 238 Product manual IRB 760 3HAC03...

Page 239: ...86 Apply sealing compound on the surface of both shaft ends wher the spacer rings will be fitted 3 xx1000001258 Refit the sealing spacer rings to the shaft ends on the link and frame 4 Continues on next page Product manual IRB 760 239 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 5 Replacing the linkage lower link arm Continued ...

Page 240: ...link arm are fitted correctly that is in the center of the hole The same distance from bear ing to the edge of the lower link arm on both sides 6 CAUTION The link weighs 23 kg All lifting accessories used must be sized accordingly 7 Continues on next page 240 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 5 Replacing the linkage lower link...

Page 241: ...he support washers on the lock nuts 10 xx1000001262 Refit the lock nuts on the shaft ends Use a KM10 socket 11 Tightening torque 120 Nm DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page26 12 Product manual IRB 760 241 3HAC039838 001 Revision M Copyright 2011 2018 ABB All ri...

Page 242: ... How to replace the upper link arm and lower link arm see Replacing linkage upper link arm on page 228 Replacing the linkage lower link arm on page 235 Location of link The link is located as shown in the figure xx1000001083 Continues on next page 242 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 6 Replacement of linkage link ...

Page 243: ... D 120 mm T 12 mm A Small VK cover B Lock nut C Locking liquid Loctite 243 D Bearing outer races 2 pcs E Bearing inner races 2 pcs F Bearing grease G Link H Support ring J Continues on next page Product manual IRB 760 243 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 6 Replacement of linkage link Continued ...

Page 244: ...include references to the tools required Other tools and proced ures may be required See references to these proced ures in the step by step instructions below Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action might be required prior to beginning the repair work of the robot see the table Note ...

Page 245: ... Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removal link Use this procedure to remove the link of the linkage Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 DANGER Turn off all el...

Page 246: ...ir to remove the VK cov er Blow with a very low air pressure into the hole for filling grease CAUTION Only a very low air pressure is needed 6 Put one hand with some paper on top of the VK cover in order to catch it when re leased Shown in Cut away view of the assembly of the link on page 243 Remove the small VK cover 7 Continues on next page 246 Product manual IRB 760 3HAC039838 001 Revision M Co...

Page 247: ...ing puller to remove the link 10 Remove the link 11 Remove the support ring with the radial seal 12 Wipe off residual grease 13 If needed replace the bearings and radial seal 14 Continues on next page Product manual IRB 760 247 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 6 Replacement of linkage link Continued ...

Page 248: ... xx1100000023 Radial sealing with dust lip D 120 mm 140 mm T 13 mm A Bearing outer race 2 pcs B Mandrel bearing and seal C Guide 2 pcs D Link E Pressring bearing F Distance G Hydraulic cylinder H Connecting rod J Stop nut M16 D 80 mm T 20 mm K Note Action Put the link on a workbench 1 Continues on next page 248 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights res...

Page 249: ...l and fit the outer rings and sealing 3 Press tool link The figure shows how to use the press tool link A B C D F G E H J K L xx1100000038 Shaft A Support ring B Link C Radial sealing with dust lip D 120 140 mm T 13 mm D Tapered roller bearing 2 pcs E Auxiliary shaft F Press housing G Distance fitted on hydraulic cylinder with M6x15 screws 2 pcs H Connection rod J Hydraulic cylinder K Stop nut L C...

Page 250: ...it ted on the shaft 4 xx1100000043 Fill the gap between the radial sealing ring and the support ring with rust preventive Mercasol 3106 See figure 5 See Cut away view of the assembly of the link on page 243 Lubricate and place the bearings and link on the shaft in the following order bearing link bearing 6 Art no is specified in Required equipment on page 244 Apply the pressing tool and secure the...

Page 251: ...er in the hole for filling grease 12 Detailed in section Replacing linkage upper link arm on page 228 Refit the upper link arm to the link 13 Detailed in section Replacing the linkage lower link arm on page 235 Refit the upper link arm to the link 14 Pendulum Calibration is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 15 Axis Calibra...

Page 252: ...orming the first test run These are further detailed in the section First test run may cause injury or damage on page26 16 252 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 6 Replacement of linkage link Continued ...

Page 253: ...ipment etc For spare part no see Spare parts on page 393 Parallel rod 3HAC5021 1 Mounting Demounting tool Loctite 243 3HAB7116 1 Locking liquid Mercasol 3110 Waxcoat 3HAC034903 001 Rust preventive Continues on next page Product manual IRB 760 253 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 7 Replacing the parallel rod ...

Page 254: ...ove the parallel rod The procedure is the same in both ends of the parallel rod Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 xx1100000088 CAUTION Secure the upper arm with a roundsling in an overhead crane or similar in order to avoid accidents 2 Foundry Plus 3 Remove the protection plugs C...

Page 255: ...t B Cover washer C Parallel rod D Sealed spherical bearing E Bearing grease F Thrust washer Remove the upper shaft A and cover washer B using the fitting removing tool 5 See figure above Remove the thrust washer F 6 Continues on next page Product manual IRB 760 255 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 7 Replacing the parallel rod Continued ...

Page 256: ...r lock screw and washer 2 Remove the lower shaft A and cover washer B 3 Remove the thrust washer F 10 Remove the parallel rod from the robot 11 See figure above Replace the bearings D if necessary 12 Refitting parallel rod Use this procedure to refit the parallel rod The procedure is the same in both ends of the parallel rod Note Action Start by refitting the lower end 1 Verify that the bearings a...

Page 257: ... lower end and let it rest on the the balancing weight 4 xx1400001126 Foundry Plus Apply rust preventive on the highlighted areas Note Rust preventive should be applied in both ends of the parallel rod 5 Continues on next page Product manual IRB 760 257 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 7 Replacing the parallel rod Continued ...

Page 258: ...n the axis 3 side of the parallel rod 7 Art no is specified in Required equip ment on page 253 Refit the shaft A by pressing it through the parallel bar with the fitting removing tool 8 See figure above Loctite 243 Apply locking liquid in the hole of the lock screw 9 Continues on next page 258 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4...

Page 259: ...rod up into position for fitting the upper end 11 Refit the upper end of the parallel rod in the same way as the lower end 12 Foundry Plus 13 Refit the protection plugs Continues on next page Product manual IRB 760 259 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 7 Replacing the parallel rod Continued ...

Page 260: ...orming the first test run These are further detailed in the section First test run may cause injury or damage on page26 14 260 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 7 Replacing the parallel rod Continued ...

Page 261: ...Spare parts on page 393 Lower arm Always change the sealing 3HAC022379 001 Sealing axes 2 3 Used to keep the axes 2 3 sealing in place during refitting of lower arm 3HAC14446 1 Guide sleeves 3HAC023132 001 Crank M16x55 Lock screw Lifting capacity 500 kg Roundsling Continues on next page Product manual IRB 760 261 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 8 ...

Page 262: ...erence values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine...

Page 263: ...ing weight 5 See Replacing the balancing device on page 278 Remove the balancing device 6 See Replacing the parallel rod on page 253 Remove the parallel rod 7 See Remove the cable harness in the upper and lower arm 8 Secure the cable harness in a way that it is pro tected from oil spill and damage See Replacing the upper arm on page 211 Remove the complete upper arm 9 See Replacing motors axes 2 a...

Page 264: ...1 Secure the complete lower arm system includ ing the parallel arm with a roundsling in an overhead crane or similar 13 xx1000001101 Remove the lock screw that secures the lower arm system 14 Continues on next page 264 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 8 Replacing the complete lower arm Continued ...

Page 265: ... before lifting the lower arm system If not secured the parallel arm can fall down and cause a serious accident 16 CAUTION The parallel arm system weighs 125 kg All lifting accessories used must be sized accord ingly 17 Continues on next page Product manual IRB 760 265 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 8 Replacing the complete lower arm Continued ...

Page 266: ...ogether with help of an iron bar or similar before remov ing them 19 CAUTION The robot lower arm weighs 270 kg All lifting accessories used must be sized accord ingly 20 xx1000001358 Remove the complete lower arm including the parallel arm 21 How to replace the parallel arm is detailed in section Replacement of parallel arm on page271 22 Continues on next page 266 Product manual IRB 760 3HAC039838...

Page 267: ...ure the parallel arm to the lower arm before lifting the lower arm system If not secured the parallel arm can fall down and cause a serious accident 3 Specified in Required equipment on page 261 Art no is specified in Required equipment on page 261 xx1000001368 Fit two guide sleeves for the axes 2 3 sealings to the lower arm and put the sealings on them See figure 4 Continues on next page Product ...

Page 268: ...e on the axis 2 side 8 Tightening torque M12 120 Nm Push the parallel arm against the axis 3 side with the help of an iron bar or similar 9 Tightening torque M12 120 Nm Refit all screws and washers that are possible to fit on the axis 3 side Note The axis 3 side has no M16 screws 10 Remove the guide sleeves and secure two screws more 11 Change the position of the lower arm in order to reach the re...

Page 269: ...vice 19 See Replacing linkage upper link arm on page 228 Refit the linkage 20 See Replacing the linkage lower link arm on page 235 See Replacement of linkage link on page 242 See Replacing the balancing weight on page 287 Refit the balancing weight 21 Remove the lock screw 22 Pendulum Calibration is described in Operating manual Calibration Pen dulum enclosed with the calibration tools Recalibrate...

Page 270: ...ing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 24 270 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 8 Replacing the complete lower arm Continued ...

Page 271: ... For spare part no see Spare parts on page 393 Parallel arm D 120 mm T 12 mm 3HAA2166 23 VK cover D 35 mm T 8 mm 3HAA2166 18 VK cover 3HAB9408 1 Bearing grease Mercasol 3110 Waxcoat 3HAC034903 001 Rust preventive Continues on next page Product manual IRB 760 271 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 9 Replacement of parallel arm ...

Page 272: ...exPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Refere...

Page 273: ...age 261 Remove the complete lower arm 3 xx1000001024 Put the complete lower arm on a workbench as shown in the figure Tip Removal of the parallel arm is best performed on a workbench 4 xx1000001371 Remove the two VK covers 5 Continues on next page Product manual IRB 760 273 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 9 Replacement of parallel arm Continued ...

Page 274: ...page 271 Disassemble the parallel arm from the lower arm by using the pressing tool lower arm 7 CAUTION The parallel arm system weighs 125 kg All lifting accessories used must be sized accord ingly 8 xx1000001018 Remove the parallel arm 9 If needed change the bearings 10 Continues on next page 274 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair...

Page 275: ... spacing sleeves on the surfaces that face the parallel arm 2 xx1000001376 Refit a spacing sleeve on each shaft 3 Art no is specified in Required equipment on page 271 xx1000001377 Refit a bearing on each shaft with pressing tool lower arm 4 Continues on next page Product manual IRB 760 275 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 9 Replacement of parallel...

Page 276: ... in Required equipment on page 271 Lift the parallel arm onto the workbench where the lower arm is placed 8 Adjust the lower arm in a way that both holes are parallel 9 Use a level xx1000001380 Apply some grease in the holes in the lower arm thick blue arrows Note Do not put grease on the surfaces for the VK covers thin red arrow 10 Continues on next page 276 Product manual IRB 760 3HAC039838 001 ...

Page 277: ...described in Operating manual Calibration Pendulum enclosed with the cal ibration tools Recalibrate the robot 15 Axis Calibration is described in Calibrating with Axis Calibration method on page 360 General calibration information is included in section Calibration on page 349 DANGER Make sure all safety requirements are met when performing the first test run These are further de tailed in the sec...

Page 278: ...red equipment Note Art no Equipment etc For spare part num ber see Spare parts on page 393 Balancing device Replace if damaged 3HAC037262 001 Spacer ring complete M16 x 55 Lock screw For securing the lower arm Continues on next page 278 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the balancing device ...

Page 279: ...om the floor in order the be lifted in the most secure way Move the robot to a position close enough to its calibration position to allow the lock screw to be inserted into the hole for the lock screw 1 See the figure in Location balancing device on page 278 xx1000001101 Lock the lower arm by inserting the lock screw into the hole CAUTION Tighten by hand 2 DANGER Turn off all electric power supply...

Page 280: ...der inside 5 The length of the cylinder is now locked and the balancing device is unloaded It should now be possible to easily rotate the balancing device xx1000001112 Attach a lifting accessories to the balancing device Use the hole in the lifting ear 6 Continues on next page 280 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing ...

Page 281: ...f the balancing device Note The ball bearing puller must be applied around the spacer ring See figure 9 CAUTION The balancing device weighs 100 kg All lifting accessories used must be sized ac cordingly 10 Continues on next page Product manual IRB 760 281 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the balancing device Continued ...

Page 282: ...Remove upper and lower spacer rings and support washers 2 2 pcs 13 Remove residual grease and sealing compound 14 Refitting balancing device use this procedure to refit the balancing device Note Action Check the bearings Replace if needed 1 Continues on next page 282 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the balancing ...

Page 283: ...in the balancing device are fitted correctly that is in the center of the hole The distance from the bearing to the edge of the rod must be the same on both sides 4 CAUTION The balancing device weighs 100 kg All lifting accessories used must be sized ac cordingly 5 Continues on next page Product manual IRB 760 283 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 1...

Page 284: ...of the M12 screws used to neutralize the spring force This length should preferably be 0 5 mm too short than 0 1 mm too long If the distance is too long the bearings may be damaged when erecting the balancing device 7 Continues on next page 284 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the balancing device Continued ...

Page 285: ...ricating tool and wipe off pro truding grease 11 Specified in section Required equip ment on page 278 Apply locking liquid on the threads of the lock nuts 12 Tightening torque 120 Nm xx1000001113 Refit the lock nuts and support washers 13 Check play min 0 1 mm between support washers and bearing seat at both bearings 14 Remove the M12x50 screws from the balancing device to restore the springforce ...

Page 286: ...ANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 18 286 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the balancing device Continued ...

Page 287: ...01286 Required equipment Note Art no Equipment etc For art no see Spare parts on page 393 Balancing weight M16 Lifting lugs 2 pcs Loctite 243 3HAB7116 1 Locking liquid Continues on next page Product manual IRB 760 287 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the balancing weight ...

Page 288: ... on page 353 Move the robot to its calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 xx1000001298 Fit two lifting lugs in the balancing weight 3 CAUTION The balancing weight weighs 350 kg All lifting accessories used must be sized accordingly 4 Secure the balancing weight with round s...

Page 289: ...s procedure to refit the balancing weight Note Action xx1000001298 Fit two lifting lugs M16 in the balancing weight 1 CAUTION The balancing weight weighs 350 kg All lifting accessories used must be sized accordingly 2 Continues on next page Product manual IRB 760 289 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the balancing weight Continued ...

Page 290: ...quid Loctite 243 on the attach ment screws 5 Tightening torque 165 Nm xx1000001296 Secure the balancing weight with its attach ment screws and washers 6 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page26 7 290 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011...

Page 291: ...001175 Required equipment Note Art no Equipment etc Includes motor pinion o ring The old o ring must be replaced when replacing the motor For spare part number see Spare parts on page 393 Motor axis 1 Continues on next page Product manual IRB 760 291 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing motor axis 1 ...

Page 292: ...1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move...

Page 293: ...the cable exit of the motor Note Make sure the gasket is undamaged Replace if damaged 4 Disconnect all connectors beneath the motor cover 5 Connect to connector R2 MP1 pin 2 pin 5 In order to release the brake connect the 24 VDC power supply 6 xx1000001090 Remove the attachment screws of the motor Use the bits extension 7 Continues on next page Product manual IRB 760 293 3HAC039838 001 Revision M ...

Page 294: ...sized ac cordingly 9 xx1000001021 Remove the motor by carefully lifting it straight up to get the pinion away from gear CAUTION Be careful not to damage the pinion in the pro cess 10 Disconnect the brake release voltage 11 Check the pinion If there is any damage the pinion must be replaced 12 Continues on next page 294 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All ri...

Page 295: ...accessories used must be sized ac cordingly 2 Connect to connector R2 MP1 pin 2 pin 5 In order to release the brake connect the 24 VDC power supply 3 xx1000001269 Gently lower the motor into the gear making sure the pinion is properly mated to the gearbox of axis 1 Note Make sure the motor is turned the right way See figure Note Make sure the motor pinion does not get dam aged 4 Continues on next ...

Page 296: ... Replace gasket if damaged 8 xx1000001092 Refit the motor cover with its attachment screws Note Make sure the cover is tightly sealed 9 Pendulum Calibration is described in Operating manual Calibration Pendu lum enclosed with the calibration tools Recalibrate the robot 10 Axis Calibration is described in Calib rating with Axis Calibration method on page 360 General calibration information is in cl...

Page 297: ...rforming the first test run These are further detailed in the section First test run may cause injury or damage on page 26 11 Product manual IRB 760 297 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 6 1 Replacing motor axis 1 Continued ...

Page 298: ...oth motors xx1000001100 Required equipment Note Art no Equipment etc Includes motor pinion o ring the o ring must be re placed when the motor is re placed For spare part no see Spare parts on page 393 chapter Motor axes 2 3 Continues on next page 298 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing motors axes 2 and 3 ...

Page 299: ...ork of the robot see the table Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create r...

Page 300: ...r arm by inserting the lock screw into the hole of the frame 3 This is done in order to secure axis 2 from col lapsing when the axis 2 motor is being removed CAUTION Tighten by hand Run axis 3 to the end position so that it rests against the mechanical stop Release the brake of axis 3 in order to set the weight of axis 3 against the mechanical stop 4 This is done in order to secure axis 3 from col...

Page 301: ...it Note Make sure the gasket is not damaged Replace if damaged 8 Disconnect all connectors beneath the motor cover 9 Connect to connector R2 MP2 pin 2 pin 5 In order to release the brake connect the 24 VDC power supply 10 Continues on next page Product manual IRB 760 301 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing motors axes 2 and 3 Continued ...

Page 302: ... Art no is specified in Required equipment on page 298 xx1000001131 Fit two guide pins in two of the motors attach ment holes 12 Continues on next page 302 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing motors axes 2 and 3 Continued ...

Page 303: ...es 2 3 to the motor 14 CAUTION The motor weighs 32 kg All lifting accessories used must be sized ac cordingly 15 xx1000001105 Pull out the motor on the guide pins to get the pinion away from the gear Make sure the pinion does not get damaged 16 Remove the motor by gently lifting it straight out and place it on a secure surface 17 Disconnect the brake release voltage 18 Continues on next page Produ...

Page 304: ...ing on the circumference of the motor is seated properly Lightly lubricate the o ring with grease 1 Connect to connector R2 MP1 pin 2 pin 5 In order to release the brake connect the 24 VDC power supply 2 Art no is specified in Required equipment on page 298 Fit the lifting tool motor axes 2 3 to the motor 3 Continues on next page 304 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 ...

Page 305: ...de it on to the guide pins as close to the correct position as possible without pushing the motor pinion into the gear Note Make sure the motor is turned the right way that is connections for the cables facing down wards 6 Remove the lifting tool and allow the motor to rest on the guide pins 7 Continues on next page Product manual IRB 760 305 3HAC039838 001 Revision M Copyright 2011 2018 ABB All r...

Page 306: ...01104 Secure the motor with its four attachment screws and plain washers Use the bits exten sion Reused screws can be used providing they are lubricated as detailed in section Screw joints on page 385 before fitting 10 Attachment screws M10 x 40 quality 12 9 Gleitmo Tightening torque 50 Nm Disconnect the brake release voltage 11 Connect in accordance with markings on connectors Reconnect all conne...

Page 307: ...ed 14 xx1000001101 Remove the lock screw from the hole for lock screw 15 See section Performing a leak down test on page 146 Perform a leak down test of the axis 2 or 3 gearbox 16 See section Changing oil gearbox axes 2 and 3 on page 129 Refill the gearbox with oil 17 Continues on next page Product manual IRB 760 307 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 ...

Page 308: ...on page 360 General calibration information is in cluded in section Calibration on page 349 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 26 19 308 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 6 2 Replacing moto...

Page 309: ...pment etc Includes motor pinion o ring the o ring must be replaced when the motor is replaced For spare part no see Spare parts on page 393 Motor axis 6 Used to reach attachment screws for motor 3HAC023760 001 Bits extension Continues on next page Product manual IRB 760 309 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 6 3 Replacing motor axis 6 ...

Page 310: ...ven in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about r...

Page 311: ...lic pressure supply air pressure supply to the robot before entering the robot working area 3 xx1000001106 Remove motor cover 4 A xx0600002694 Remove the cable gland cover at the cable exit by unscrewing its attachment screw A on the inside Note Make sure the gasket is not damaged 5 Continues on next page Product manual IRB 760 311 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reser...

Page 312: ...24 VDC power supply 7 xx1000001012 Remove attachment screws and washers Use the bits extension 8 Always use the screws for removal in pairs If required press the motor out of position by fitting two screws in the motor attach ment holes diagonal to each other 9 xx1000001108 Lift the motor carefully to get the pinion away from the gear Note Make sure the pinion does not get dam aged 10 Continues on...

Page 313: ...aced 1 Parts A Pinion B O ring C Circumference Connect to connector R2 MP6 pin 2 pin 5 In order to release the brake connect the 24 VDC power supply 2 Art no is specified in Required equipment on page 309 Fit the two guide pins in two of the motor attach ment holes 3 xx1000001108 Lift the motor carefully in place Make sure the motor pinion is properly mated to the gearbox axis 6 Note Make sure the...

Page 314: ...lity 8 8 A2F Tightening torque 50 Nm Disconnect the brake release voltage 8 See section Performing a leak down test on page 146 Perform a leak down test of the axis 6 gearbox 9 Connect in accordance with markings on connectors Reconnect all connectors in motor axis 6 10 Refit the connections to the UL lamp if the ro bot is equipped with one 11 xx1000001224 Check the gasket If damaged replace it 12...

Page 315: ... Pendu lum enclosed with the calibration tools Recalibrate the robot 15 Axis Calibration is described in Calib rating with Axis Calibration method on page 360 General calibration information is in cluded in section Calibration on page 349 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or ...

Page 316: ...0001309 Required equipment Note Art no Equipment etc Includes gearbox all o rings and seal ing rings For spare part no see Spare parts on page393 Gearbox Replace if damaged 3HAB3772 54 O ring Continues on next page 316 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox ...

Page 317: ... tools on page 389 Standard toolkit These procedures include references to the tools re quired Other tools and pro cedures may be re quired See refer ences to these pro cedures in the step by step instructions below Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action might be required prior to be...

Page 318: ...ce calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removal gearbox axis 1 Use this procedure to remove gearbox axis 1 Note Action Decide which calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 xx1...

Page 319: ...ll lifting accessories used must be sized accordingly 8 Art no is specified in Required equip ment on page 316 Lift the robot base including the axis 1 gearbox to allow the base and gear 1 sup port be fitted on each sides of the base 9 xx1000000364 A Support base 4 pcs Secure the support to the base and to the foundation Make sure the base remains in a stable position before performing any work un...

Page 320: ...rews It may be necessary to also remove the rear connector plate 11 xx0300000612 A Bottom plate B Rear connector plate C Attachment screw D Groove Continues on next page 320 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continued ...

Page 321: ...earbox 1 by unscrewing its attachment screws 13 CAUTION The gearbox weighs 200 kg All lifting accessories used must be sized accordingly 14 Lift the gearbox away with the already mounted lifting tools 15 Continues on next page Product manual IRB 760 321 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continued ...

Page 322: ...s procedure to refit gearbox axis 1 Note Action Mounting of the support base and gear 1 is detailed in section Removal gear box axis 1 on page 318 xx1000000364 A Support base 4 pcs Fit the support base and gear 1 to the base 1 Continues on next page 322 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continued...

Page 323: ...earbox are seated properly in their respective groove Lubricate them with grease 2 xx1000001392 Make sure the small o ring around the oil hole is fitted properly 3 Continues on next page Product manual IRB 760 323 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continued ...

Page 324: ...ipment on page 316 Fit two guide pins in two of the attachment holes in the gearbox parallel to each other 5 CAUTION The gearbox weighs 200 kg All lifting accessories used must be sized ac cordingly 6 Continues on next page 324 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continued ...

Page 325: ...ith the base 7 xx1000001391 Always use guide pins in pairs Lift gearbox axis 1 onto the guide pins and lower it carefully to its mounting position 8 Continues on next page Product manual IRB 760 325 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continued ...

Page 326: ...ding they are lubricated as detailed in sec tion Screw joints on page385 before fit ting xx1000001394 xx1000001393 Refit the cable guide in the center of gearbox 1 with its attachment screws 10 Continues on next page 326 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continued ...

Page 327: ...g the base including axis 1 gearbox on page 178 Refit the complete arm system CAUTION This is a complex task to be performed with utmost care in order to avoid injury or dam age 15 See section Performing a leak down test on page 146 Perform a leak down test 16 See Changing oil axis 1 gearbox on page 126 Refill the gearbox with oil 17 Pendulum Calibration is described in Operating manual Calibratio...

Page 328: ...rming the first test run These are further detailed in the section First test run may cause injury or damage on page 26 19 328 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 gearbox Continued ...

Page 329: ...2 3 Always replace 3HAC022379 001 Sealing axes 2 3 Replace if damaged 3HAB3772 127 O ring Use to lock the lower arm Lock screw M16x55 2 pcs Use to unload the balancing device Screw M12x50 2 pcs must have full thread Use to press the gearbox free from the frame Screw M12x100 Use guide pins in pairs Guide pins M12 Continues on next page Product manual IRB 760 329 3HAC039838 001 Revision M Copyright ...

Page 330: ...s DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values T...

Page 331: ...is 2 to 40 axis 3 to 15 and all other axes to 0 Axis 2 xx1100000623 When removing axis 2 gearbox Remove all screws in the lower screw area on the inside of the lower arm 7 pcs M12 2 pcs M16 See figure When removing axis 3 gearbox Remove all screws in the upper front screw area and three screws in the upper back area 3 Axis 3 xx1100000624 Put two loading pallets on the foot of the robot and run axi...

Page 332: ...ice Note Keep the plastic screws They will be refit ted later 9 See the previous figure Insert two screws M12x50 in the holes to neutralize the spring force Screw in the screws until they have proper contact with the cylinder inside 10 The length of the cylinder is now locked and the balancing device is unloaded It should now be possible to easily rotate the balancing device Continues on next page...

Page 333: ...ved Protect the cables from getting damaged and from oil spill 13 Remove one gearbox at a time 14 Detailed in section Replacing motors axes 2 and 3 on page 298 Remove the axis 2 or axis 3 motor depend ing on which gearbox is being removed 15 xx1000001405 Remove all remaining attachment screws that secure the gearbox to the lower arm system Axis 2 M16 and M12 Axis 3 M12 16 Continues on next page Pr...

Page 334: ...he gearbox weighs 69 kg All lifting accessories used must be sized accordingly 21 If required apply two screws M12x100 to the holes in the gearbox in order to press it free The screws need to have a full thread 22 CAUTION When the gearbox comes free from the frame and comes off the guide pins it will tilt and there is a risk of damage to the gearbox surfaces Be aware of this and re move the gearbo...

Page 335: ...guide pins 24 xx1000001403 Remove the sealing from the lower arm and clean it Note The sealing can hang onto the gearbox sticking to the oil 25 Continues on next page Product manual IRB 760 335 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 2 Replacing the gearbox axes 2 3 Continued ...

Page 336: ... the frame 2 Use two of the attachment holes for the screws that hold the gearbox CAUTION The gearbox weighs 69 kg All lifting equipment used must be sized accordingly 3 Specified in Required equipment on page 329 Fit the lifting accessory to the gearbox and lift it with an overhead crane 4 Continues on next page 336 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All righ...

Page 337: ...t one guide sleeve in the middle screw hole in the upper back area and one guide sleeve in the middle screw hole in the the lower area Axis 3 xx1100000622 xx1400000993 Foundry Plus Apply bearing grease on the highlighted areas on both sides of the sealing Note Do not apply grease closer than 20 mm from the edge of the holes in the sealing 6 Continues on next page Product manual IRB 760 337 3HAC039...

Page 338: ...er arm with the attachment screws and washers in two of the screw areas the third is not reach able at this point Do not remove the guide sleeves yet 10 M12x60 quality 12 9 Gleitmo 6 6 pcs Tightening torque 120 Nm M16x90 quality 12 9 Gleitmo 2 2 pcs Tightening torque 300 Nm Axis 3 M12x60 quality 12 9 Gleitmo Tightening torque 120 Nm M12x60 quality 12 9 Gleitmo 1 1 pc Tightening torque 120 Nm Remov...

Page 339: ...screws and washers Note Fit the cover so that the arrow on the cover points upwards 16 Tightening torque 24 Nm xx1000001408 See Replacing motors axes 2 and 3 on page 298 Refit the motors axes 2 3 17 See Performing a leak down test on page 146 Perform a leakdown test 18 Continues on next page Product manual IRB 760 339 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4...

Page 340: ...y 12 9 Gleitmo Tightening torque 120 Nm Pendulum Calibration is described in Op erating manual Calibration Pendulum enclosed with the calibration tools Recalibrate the robot 23 Axis Calibration is described in Calibrating with Axis Calibration method on page360 General calibration information is included in section Calibration on page 349 DANGER Make sure all safety requirements are met when perfo...

Page 341: ...see Spare parts on page 393 Turning disk Not included in gearbox 3HAC039489 001 Washers Replace only if damaged 3HAB3772 83 O ring Must be replaced when reas sembling gearbox 3HAB3772 57 164 7x3 53 Must be replaced when reas sembling gearbox 3HAB3772 64 150 0x2 0 Must be replaced when reas sembling gearbox 3HAB3772 61 13 1x1 6 Continues on next page Product manual IRB 760 341 3HAC039838 001 Revisi...

Page 342: ... to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 361 If no previous r...

Page 343: ...oil from the gearbox 4 See section Replacing the turning disk on page 186 Remove the turning disk 5 xx1000001410 Remove the calibration plate axis 6 6 xx1000001411 Remove the gearbox by unscrewing the at tachment screws and washers that secure it 7 Continues on next page Product manual IRB 760 343 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 3 Replacing gearbo...

Page 344: ...t the gearbox 8 A M8 holes for pressing out the gearbox xx1000001412 Remove gearbox axis 6 carefully without damaging pinion or gear 9 Continues on next page 344 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 3 Replacing gearbox axis 6 Continued ...

Page 345: ...ir pressure supply to the robot before entering the robot working area 1 For art no see Required equipment on page 341 xx1000001414 Make sure the o ring is undamaged and fit ted to the gearbox If the o ring is damaged replace Lubricate the o ring with grease 2 Continues on next page Product manual IRB 760 345 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 3 Repl...

Page 346: ...xx1000001412 Carefully insert the axis 6 gearbox into the tilthouse using guide pins Make sure the gears of the gearbox mate with the pinion of the axis 6 motor CAUTION Do not damage pinion or gears in the pro cess 5 Continues on next page 346 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 3 Replacing gearbox axis 6 Continued ...

Page 347: ... See section Replacing the turning disk on page 186 Refit the turning disk 7 See section See section Performing a leak down test on page 146 Perform a leak down test 8 See section Changing oil gearbox axis 6 on page 133 Refill the gearbox with oil 9 xx1000001410 Refit the calibration plate 10 Continues on next page Product manual IRB 760 347 3HAC039838 001 Revision M Copyright 2011 2018 ABB All ri...

Page 348: ...hod on page360 General calibration information is included in section Calibration on page 349 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page26 12 348 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 3 Replacing gea...

Page 349: ...at is used for calibration of the robot Calibration position A generic term for all calibration methods that aim to move the robot to calibration position Standard calibration A calibration routine that generates a new zero posi tion of the robot Fine calibration A calibration routine that in the first step generates a reference to current zero position of the robot The same calibration routine ca...

Page 350: ...rdinate system for the robot Absolute accuracy calibration option al Absolute accuracy calibration data is found on the SMB serial measurement board in the robot For robots with RobotWare 5 05 or older the absolute accuracy calibration data is delivered in a file absacc cfg supplied with the robot at delivery The file replaces the calib cfg file and identifies motor positions as well as absolute a...

Page 351: ...of how to perform the calibration procedure and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step CalibWare Absolute Accuracy calibration To achieve a good positioning in the Cartesian coordinate system Absolute Accuracy calibration is used as a TCP calibration The CalibWare tool guides through the calibration process and calculat...

Page 352: ...unter memory is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 356 This will occur when The battery is discharged A resolver error occurs The signal between a resolver and measurement board is interrupted A robot axis is moved with the control system disconnected The revolution counters must also be updated after the robot and co...

Page 353: ...ition for each axis Synchronization marks IRB 760 xx1000001146 Synchronization plate axis 1 A Synchronization tab on robot B Synchronization mark axis 2 C Synchronization mark axis 3 D Synchronization plate and mark axis 6 E Continues on next page Product manual IRB 760 353 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchroni...

Page 354: ...te to one another when the robot is standing in its synchronization position One of the marks is more narrow than the other and should be positioned within the limits of the wider mark 354 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes Continued ...

Page 355: ...n the graphic below Calibration service routines will handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions 4 axes Note The graphic shows an IRB 260 The positive direction is the same for all 4 axis robots xx0500001927 Product manual IRB 760 355 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights res...

Page 356: ... resulting in an incorrect manipulator calibration Make sure the axes are positioned according to the correct calibration values not only according to the synchronization marks The correct values are found on a label located either on the lower arm underneath the flange plate on the base or on the frame At delivery the manipulator is in the correct position do NOT rotate axis 4 or 6 at power up be...

Page 357: ... ABB menu tap Calibration xx1500000942 1 All mechanical units connected to the system are shown with their calibration status 2 Tap the mechanical unit in question xx1500000943 Continues on next page Product manual IRB 760 357 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 358: ...s calibration method used during last field calibration Tap Manual Method Advanced xx1500000944 A screen is displayed tap Rev Counters en0400000771 4 Continues on next page 358 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 359: ...he 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 selected revolution counters and removes the tick from the list of axes 7 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn may cause damage or injury C...

Page 360: ...vable calibration tool is inserted by the operator into a calibration bushing on the axis chosen for calibration according to instructions on the FlexPendant WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB Using other pins in the calibration bushings may cause severe damage to the robot and or personnel WARNING The calibration tool must be fully inse...

Page 361: ... the FlexPendant to create reference values When reference calibration is performed the robot is restored to the status given by the reference values Note When calibrating the robot with the reference calibration routine the robot must be dressed with the same tools process cabling and any other equipment as when the reference values were created Update revolution counters Choose this routine to m...

Page 362: ...ngs may cause severe damage to the robot and or personnel Note Article number Equipment etc Delivered as a set of calibration tools Required if Axis Calibration is the valid calib ration method for the robot 3HAC055412 001 Calibration tool box Axis Calibration Examining the calibration tool Check prior to usage Before using the calibration tool make sure that the tube insert the plastic protection...

Page 363: ...solution Note Action It is possible to use any RFID solution with the correct dimensions ABB has verifed function on some suppliers fulfilling the requirements of NFC compatible devices 13 56 Mhz according to ISO 14443 or ISO 15693 Note The maximum dimensions on the RFID chip must not exceed Ø7 9 mm x 8 0 mm Ø5 9 mm x 8 0 mm or Ø3 9 mm x 8 0 mm depending on calibra tion tool size 1 There is a cavi...

Page 364: ...on pin the axis is equipped with two bushings instead for installation of two calibration tools when calibration is carried out This is shown in the figure xx1600000700 The fixed calibration pin for axis 1 is installed on a removable tower The tower will need to be removed if electronic position switches are fitted to the robot Keep the tower in a safe location for future recalibration needs and m...

Page 365: ... in the bushing Replace damaged parts with new if needed Note Article number Spare part Contains replacement calibration pin covers and protective plugs for the bushing 3HAC056806 001 Protection cover and plug set Product manual IRB 760 365 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 5 Calibration 5 4 3 Installation locations for the calibration tools Continued ...

Page 366: ...ure on the FlexPendant The actual instructions of how to perform the calibration procedure and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step Use the following list to learn about the calibration procedure before running the RobotWare program on the FlexPendant It gives you a brief overview of the calibration procedure sequence...

Page 367: ...ant while conducting it Note Action DANGER While conducting the calibration the robot needs to be connected to power Make sure that the robots working area is empty as the robot can make unpredictable movements 1 Use a clean cloth Wipe the calibration tool clean Note The calibration method is exact Dust dirt or color flakes will affect the calibration value 2 Starting the calibration procedure Use...

Page 368: ...n the FlexPendant is given in Overview of the calibra tion procedure on the FlexPendant on page 366 Follow the instructions given on the FlexPendant 4 Restarting an interrupted calibration procedure If the Axis Calibration procedure is interrupted before the calibration is finished the RobotWare program needs to be started again Use this procedure to take required action Action Situation Press and...

Page 369: ...alibration SafeMove needs to be unsynchronized The Axis Calibration routine recognizes if the robot is equipped with SafeMove and will force SafeMove to unsynchronize automatically However SafeMove may generate other warning messages anytime during the Axis Calibration routine Safety controller not synchronized SafeMove message Note Action SafeMove generates the message Safety control ler not sync...

Page 370: ... Unsynchronized time limit expired SafeMove message anytime during Axis Calibration routine Note Action SafeMove generates the message Unsynchron ized time limit expired anytime xx1500002482 1 Press OK to continue Axis Calibration procedure 2 Restart Axis Calibration procedure by pressing Play 3 Continues on next page 370 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All...

Page 371: ...ection cover and plug set 3HAC056806 001 xx1500000952 Reinstall the protective plug and sealing in the bushing on each axis directly after the axis has been calibrated Ensure that the sealing is not damaged Replace the plug and the sealing with new spare part if missing or damaged 3 Protection cover and plug set 3HAC056806 001 Product manual IRB 760 371 3HAC039838 001 Revision M Copyright 2011 201...

Page 372: ...ndulum Detailed instructions of how to perform Pendulum Calibration are given in the documentation enclosed with the calibration tools 372 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 5 Calibration 5 5 Calibrating with Calibration Pendulum method ...

Page 373: ...change the position of the robot axes after running the program 1 This is detailed in section Synchronization marks and synchronization position for axes on page 353 Adjust the synchronization marks when the calibration is done if necessary 2 Write down the values on a new label and stick it on top of the calibration label 3 The label is located on the lower arm Remove any calibration equipment fr...

Page 374: ... page 353 and Updating revolution counters on page 356 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis...

Page 375: ...Cables motors Copper Base lower arm upper arm Cast iron nodular iron Gears screws base frame and so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Foam Gearboxes Oil grease Covers synchronization brackets Aluminium Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with local ...

Page 376: ...to organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 376 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 6 Decommissioning 6 1 Environmental information Continued ...

Page 377: ...attery is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire When motors are removed from the robot the robot will collapse if it is not properly supported before the motor is removed Product manual IRB 760 377 3HAC039838 001 Revision M Copyright 2011 2018 ABB All ri...

Page 378: ...ures in the step by step in structions below DANGER Do not under any circumstances deal with the balancing device in any other way than that detailed in the product documentation For example attempting to open the balancing device is potentially lethal Action on field decommissioning The procedure below details the actions to perform on field when the balancing device is to be decommissioned Note ...

Page 379: ...t from a safe distance and somewhat from above 2 WARNING There is some grease and a plastic layer inside the balancing device When opening a hole in the device the cutting torch will cause the plastic and the grease to start to burn Wear protective clothing Make sure that the working area is well ventilated 3 DANGER The hole must be cut as specified in the figure Pieces of the spring can be thrown...

Page 380: ...our coils Inner spring cut at least eight coils 6 Double check the number of coils cut and make sure all the tension in the springs is removed 7 Double check the number of coils cut and make sure all the tension in the springs is removed Cut more coils if there is still tension in the springs 380 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 6 Decommi...

Page 381: ...apter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 760 381 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 1 Introduction ...

Page 382: ...015i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 IEC 61000 6 2 2005 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1 2012ii Arc welding equipment Part 10 EMC requirements EN IEC 60974 10 2014ii Safety of machinery Electrical equipment o...

Page 383: ... R15 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 Product manual IRB 760 383 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 2 Applicable standards Continued ...

Page 384: ...39 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 384 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 3 Unit conversion ...

Page 385: ...ld be used Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair maintenance or installation procedure descriptions In such cases proceed as follows 1 Apply lubricant to the screw thread 2 Apply lubricant between the plain washer and screw head 3 Screw dimensions of M8 or larger must be tightened with a torque wrench Screw dimensions ...

Page 386: ...pair maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The...

Page 387: ...ening torque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual IRB 760 387 3HAC039838 001 Rev...

Page 388: ...sory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The robot weighs 2300 kg All lifting accessories used must be sized accord ingly 388 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB ...

Page 389: ...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 1 Hexagon headed screw M10x100 2 Hex bit socket head cap no 14 socket 40 mm L 100 mm 1 To be shortened to 12 mm Hex bit socket head cap no 14 socket 40 mm L 20 mm 1 Hex bit socket head cap no 6 socket 40 mm L 145 m...

Page 390: ...s the calibration equipment needed when calibrating the robot with the Axis Calibration method The robot is calibrated by either Calibration Pendulum or Axis Calibration at factory Always use the same calibration method as used at the factory Information about valid calibration method is found on the calibration label or in the calibration menu on the FlexPendant If no data is found related to sta...

Page 391: ...AC039304 002 Press tool link bearing and shaft 3HAC039305 001 Assembly tool linkage Standard KM10 socket 3HAC039302 002 Press tool link bearing and sealing 3HAC023092 001 Press tool lower arm 3HAC5021 1 Fitting Removing tool Parallel rod 3HAC039277 006 Shims T 2 mm 3HAC038147 031 Shims T 2 5 mm 3HAC5281 1 Auxiliary shaft 3HAC039296 001 Lubrication tool spherical roller bearing 3HAC039571 002 Lubri...

Page 392: ...ting accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference 392 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 8 Lifting accessories and lifting i...

Page 393: ...iews are not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRB 760 393 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 8 Spare parts 8 1 Spare part lists and illustrations ...

Page 394: ...This page is intentionally left blank ...

Page 395: ...B 140 type C 3HAC025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB ...

Page 396: ...B 6650S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram Product ProductName 3HAC056159 002 Circuit diagram IRB 910SC 396 Product manual IRB 760 3HAC039838 001 Revision M Copyright 2011 2018 ABB All rights reserved 9 Circuit diagrams 9 1 Circuit diagrams C...

Page 397: ...h 356 standard type 350 verification 373 when to calibrate 352 calibration Absolute Accuracy 351 calibration manuals 351 calibration marks 353 calibration position jogging to 374 scales 353 calibration scales 353 CalibWare 350 carbon dioxide extinguisher 20 cast iron disposal 375 changing oil axis 1 126 axis 2 129 axis 3 129 axis 6 133 cleaning 142 climbing on robot 23 Cold environments 93 connect...

Page 398: ...d 228 Lithium disposal 375 loads on foundation 49 lubricating balancing device bearing 139 balancing device piston rod 139 lubrication amount in gearboxes 124 type of lubrication 124 M maintenance schedule 99 manually releasing brakes 67 mechanical stop axis 1 90 mechanical stop location 116 MoveAbsJ instruction 374 N nation specific regulations 17 negative directions axes 355 neodymium disposal 3...

Page 399: ... SMB battery extension of lifetime 135 171 replacing 135 171 special tools 390 speed adjusting 93 stability 55 standards 382 ANSI 383 CAN 383 EN 382 EN IEC 382 EN ISO 382 start of robot in cold environments 93 steel disposal 375 storage conditions 50 symbols safety 38 synchronization position 356 sync marks 353 system integrator requirements 17 T temperatures operation 51 storage 50 testing brakes...

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Page 402: ...Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC039838 001 Rev M en Copyright 2011 2018 ABB All rights reserved Specifications subject to change without notice ...

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