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ABB IRB 7600 - 150/3.5, Product Manual

The ABB IRB 7600 - 150/3.5 is a high-performance industrial robot that delivers precise and efficient automation solutions. Here, you can easily access the comprehensive product manual for free, allowing you to maximize its capabilities. Download the manual from our website and unlock the full potential of this exceptional robotic system.

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Table of Contents

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3.6  Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

3.6.1 Flushing a contaminated gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
3.6.2 Cleaning, robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

4  Repair 

215

4.1 Introduction  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

4.2 General procedures  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

4.2.1 Performing a leak-down test  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.2.2 Mounting instructions for bearings  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
4.2.3 Mounting instructions for seals  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

4.3  Complete robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

4.3.1 Replacement of cable harness, axes 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
4.3.2 Replacement of cable harness, axes 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.3.3 Replacement of complete arm system  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
4.3.4 Replacement of air nipple and hose (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

4.4  Upper and lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

4.4.1 Replacement of turning disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
4.4.2 Replacement of complete wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
4.4.3 Replacement of complete upper arm  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 252
4.4.4 Replacement of complete lower arm  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

4.5  Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266

4.5.1 Replacement of SMB unit  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
4.5.2 Replacement of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
4.5.3 Replacement of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
4.5.4 Replacement of spherical roller bearing, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.5.5 Unloading the balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
4.5.6 Restoring the balancing device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 294

4.6  Motors   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297

4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
4.6.2 Replacement of motor axis 2  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
4.6.3 Replacement of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
4.6.4 Replacement of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
4.6.5 Replacement of motor, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
4.6.6 Replacement of motor, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

4.7  Gearboxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

4.7.1 Replacement of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
4.7.2 Replacement of gearbox, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
4.7.3 Replacement of gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
4.7.4 Replacement of gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
4.7.5 Replacement of gearbox, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
4.7.6 Replacement of gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

5 Calibration information

371

5.1 Introduction  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 371
5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372
5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
5.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
5.6 Checking the calibration position   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380

6 Decommissioning

383

6.1 Environmental information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
6.2 Decommissioning of balancing device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384

Summary of Contents for IRB 7600 - 150/3.5

Page 1: ...Product manual Articulated robot IRB 7600 500 2 55 IRB 7600 500 2 3 IRB 7600 400 2 55 IRB 7600 340 2 8 IRB 7600 325 3 1 IRB 7600 150 3 5 M2000 M2000A M2004 ...

Page 2: ......

Page 3: ...t 2004 2008 ABB All rights reserved Product manual IRB 7600 500 2 55 IRB 7600 500 2 3 IRB 7600 400 2 55 IRB 7600 340 2 8 IRB 7600 325 3 1 IRB 7600 150 3 5 M2000 M2000A M2004 Document ID 3HAC022033 001 Revision E ...

Page 4: ...sons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravent...

Page 5: ...rmation on safety and information labels 32 1 3 Safety related instructions 33 1 3 1 Safety signals general 33 1 3 2 DANGER Moving robots are potentially lethal 35 1 3 3 DANGER First test run may cause injury or damage 36 1 3 4 WARNING The brake release buttons may be jammed after service work 37 1 3 5 WARNING The unit is sensitive to ESD 38 1 3 6 WARNING Safety risks during work with gearbox oil ...

Page 6: ...135 3 3 2 Inspection oil level gearbox axis 2 138 3 3 3 Inspection oil level gearbox axis 3 141 3 3 4 Inspection oil level gearbox axis 4 143 3 3 5 Inspection oil level gearbox axis 5 146 3 3 6 Inspection oil level gearbox axis 6 149 3 3 7 Inspection balancing device 153 3 3 8 Inspection cable harness 159 3 3 9 Inspection mechanical stop axis 1 162 3 3 10 Inspection mechanical stop axes 1 2 and 3 ...

Page 7: ...ke release unit 270 4 5 3 Replacement of balancing device 276 4 5 4 Replacement of spherical roller bearing balancing device 285 4 5 5 Unloading the balancing device 290 4 5 6 Restoring the balancing device 294 4 6 Motors 297 4 6 1 Replacement of motor axis 1 297 4 6 2 Replacement of motor axis 2 303 4 6 3 Replacement of motor axis 3 310 4 6 4 Replacement of motor axis 4 317 4 6 5 Replacement of m...

Page 8: ...3HAC13063 2 IRB 7600 500 2 3 412 8 3 8 Axis 3 4 Foundry 3HAC13063 4 IRB 7600 150 3 5 325 3 1 340 2 8 400 2 55 500 2 55 413 8 3 9 Axis 3 4 Foundry 3HAC13063 5 IRB 7600 500 2 3 414 8 3 10 Wrist 3HAC16628 4 3HAC16628 3 415 8 3 11 Material set robot 3HAC13079 1 420 8 3 12 Material set axis 1 2 3HAC13077 1 421 8 3 13 Material set balancing device 3HAC13082 1 424 8 3 14 Arm extension set 956 mm 3HAC1231...

Page 9: ... manual is organized in the following chapters Chapter Contents Safety Safety information that must be read through before performing any installation or service work on the robot Contains general safety aspects as well as more specific information on how to avoid personal injuries and damage to the product Installation and com missioning Required information about installation of the robot includ...

Page 10: ...ame Document ID Note Product specification IRB 7600 3HAC023934 001 Product specification IRB 7600 M2000 M2000A 3HAC13491 1 Product manual IRC5 3HAC021313 001 Product manual S4Cplus M2000 3HAC021333 001 Product manual S4Cplus M2000A 3HAC022419 001 Operating manual IRC5 with FlexPendant 3HAC16590 1 User s guide S4Cplus 3HAC7793 1 Operating manual Calibration Pendulum 3HAC16578 1 Operating manual Ser...

Page 11: ...ricating oil in the gearboxes Changes made in the chapter Maintenance and Part list C New variant of the robot IRB 7600 500 2 55 implemented throughout the manual Wrist unit updated new spare part number is specified in Replacement of complete wrist unit on page 248 and Spare part list on page 401 Insulated wrist unit implemented new spare part number is specified in Replacement of complete wrist ...

Page 12: ...la S 150 has been changed in section Maintenance schedule Section Service Information System has been removed from the manual There is a specific manual for SIS See References Section Chip and dust protection has been removed from the manual This option is no longer available Tightening torque for M24 Allen head screws has been added in section Screw joints Prerequisites in section Overview has be...

Page 13: ...procedures including spare parts Additional procedures if any calibration decommissioning Reference information article numbers for documentation referred to in Product manual procedures lists of tools safety standards Part list Foldouts or exploded views Circuit diagrams Software manuals The software documentation consists of a wide range of manuals ranging from manuals for basic understanding of...

Page 14: ...ures including spare parts Additional procedures if any calibration decommissioning Reference information article numbers for documentation referred to in Product manual procedures lists of tools safety standards Part list Foldouts or exploded views Circuit diagrams Technical reference manuals The following manuals describe the robot software in general and contain relevant reference information R...

Page 15: ... having first hand operational contact with the robot that is production cell operators programmers and trouble shooters The group of manuals includes Emergency safety information General safety information Getting started IRC5 and RobotStudio IRC5 with FlexPendant RobotStudio Introduction to RAPID Trouble shooting IRC5 for the controller and robot Continued ...

Page 16: ...e references to equipment spare parts tools etc required for the different actions in the procedure The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information that is article number dimensions The denomination in the procedure for the component or attachment point corresponds to the denomination in...

Page 17: ... to attend to before performing any service work on the robot These are applicable for all service work and are found in section General safety information on page 16 specific safety information pointed out in the procedure at the moment of the danger How to avoid and eliminate the danger is either detailed directly in the procedure or further detailed in separate instructions found in section Saf...

Page 18: ...robot described in the applicable documents for example User s Guide S4Cplus M2000 Operating Manual IRC5 with FlexPendant M2004 Product Manual Connection of external safety devices Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices Via this interface an external safety function can interact with other machines and per...

Page 19: ...t be crossed before admittance must be set up in front of the robot s working space Light beams or sensitive mats are suitable devices Turntables or the like should be used to keep the operator out of the robot s working space The axes are affected by the force of gravity when the brakes are released In addition to the risk of being hit by moving robot parts you run the risk of being crushed by th...

Page 20: ... does not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 Safety risk Description Cable packs are sensitive to mechanical damage CAUTION The cable packs are sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them Safety risk Description Gears may be damaged if excessive force is used CAUTI...

Page 21: ...safely turn off tools such as milling cutters etc Make sure that guards remain closed until the cutters stop rotating It should be possible to release parts by manual operation valves Safe design Grippers end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller CAUTION Ensure that a gripper is prevented from dropping a workpie...

Page 22: ... to pneumatic and hydraulic systems Residual energy Residual energy may be present in these systems After shutdown particular care must be taken The pressure in pneumatic and hydraulic systems must be released before starting to repair them Safe design Gravity may cause any parts or objects held by these systems to drop Dump valves should be used in case of emergency Shot bolts should be used to p...

Page 23: ...rried out professionally and in accordance with the applicable safety regulations Care must be taken at all times Qualified personnel Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts Extraordinary risks If the working process is interrupted extra care must be taken d...

Page 24: ...side the robot s working space Voltage related risks controller S4Cplus A danger of high voltage is associated with the following parts Be aware of stored electrical energy DC link in the controller Units inside the controller e g I O modules can be supplied with power from an external source The mains supply mains switch The power unit The power supply unit for the computer system 230 VAC The rec...

Page 25: ...VAC The service outlets 115 230 VAC The customer power supply 230 VAC The power supply unit for additional tools or special power supply units for the machining process The external voltage connected to the controller remains live even when the robot is disconnected from the mains Additional connections Voltage related risks robot A danger of high voltage is associated with the robot in The power ...

Page 26: ...mension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell see Product Specification Description Robot Motion Also consider the maximum possible impact caused by ...

Page 27: ...e extinguishing 25 3HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved 1 2 3 2 Fire extinguishing NOTE Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the robot system robot or controller ...

Page 28: ...eased manually by pushing the brake release buttons on the robot How to release the brakes is detailed in section Manually releasing the brakes on page 72 The robot arm may be moved manually on smaller robot models but larger models may require using an overhead crane or similar Increased injury Before releasing the brakes make sure that the weight of the arms does not increase the pressure on the...

Page 29: ...m its function How to test The function of the holding brake of each axis motor may be checked as detailed below 1 Run each robot axis to a position where the combined weight of the robot arm and any load is maximized max static load 2 Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller 3 Check that the axis maintains its position If the robot does not ch...

Page 30: ...01 Revision E 28 Copyright 2004 2008 ABB All rights reserved 1 2 3 5 Risk of disabling function Reduced speed 250 mm s NOTE Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC This will affect the safety function Reduced speed 250 mm s ...

Page 31: ...released or pushed all the way in the robot is taken to the MOTORS OFF state To ensure safe use of the FlexPendant the following must be implemented The enabling device must never be rendered inoperative in any way During programming and testing the enabling device must be released as soon as there is no need for the robot to move The programmer must always bring the FlexPendant with him her when ...

Page 32: ...ntrol panel The robot s speed is limited to max 250 mm s when the operating mode selector is in position manual mode with reduced speed This should be the normal position when entering the working space The position manual mode with full speed 100 may only be used by trained personnel who are aware of the risks that this entails Pay attention to the rotating axes of the robot Keep a distance to th...

Page 33: ...reserved 1 2 3 8 Signal lamp optional Description A signal lamp with an yellow fixed light can be mounted on the robot as a safety device Function The lamp is active in MOTORS ON mode Further information Further information about the MOTORS ON MOTORS OFF mode may be found in the controller documentation ...

Page 34: ... on page 172 Translation possibilities The labels fitted to the product contain space for adding a fourth language underneath the three standard languages English German and French Add a local language to the label by Using a transparent sticker over the standard label with text added in a fourth language Drawings detailing the design text figure dimensions of the standard labels can be ordered fr...

Page 35: ...h for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc warning WARNING Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high volt...

Page 36: ...lectrostatic discharge ESD symbol indicates electrostatic hazards which could result in severe damage to the product Note NOTE Note symbols alert you to important facts and conditions Tip TIP Tip symbols direct you to specific instructions where to find additional information or how to perform a certain operation in an easier way Symbol Designation Signification Continued ...

Page 37: ...tion Action Note 1 Before attempting to run the robot make sure all emergency stop equipment is correctly installed and connected Emergency stop equipment such as gates tread mats light curtains etc 2 If possible use the hold to run function whenever possible The hold to run function is used in manual mode not in automatic mode How to use the hold to run function in RobotWare 5 0 is detailed in se...

Page 38: ... to take into consideration before the first test run Elimination Follow the procedure below when performing the first test run after a service activity repair installation or maintenance Action 1 Remove all service tools and foreign objects from the robot and its working area 2 Install all safety equipment properly 3 Make sure all personnel are standing at a safe distance from the robot that is o...

Page 39: ...se the power is turned on while a brake release button is jammed in depressed position the affected motor brake is released This may cause serious personal injuries and damage to the robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action 1 Make sure the power is turned off 2 Remove the push button guard if necessary 3...

Page 40: ...may potentially transfer high static charges This discharge may destroy sensitive electronics Elimination Location of wrist strap button The wrist strap button is located in the right corner as shown in the illustration below xx0500002171 Action Note 1 Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly 2 Use an ESD protective fl...

Page 41: ...B All rights reserved Assemble the wrist strap The picture illustrates how the ESD wrist strap is assembled in the controller xx0400001055 A The strap is fastened to a button on the side of the control module B When not used the wrist strap is placed on the power supply unit C Power supply unit Continued ...

Page 42: ...the opening Do not overfill the gearbox when filling Do not overfill Overfilling of gearbox oil can lead to internal over pressure inside the gearbox which in turn may damage seals and gaskets completely press out seals and gaskets prevent the robot from moving freely Make sure not to overfill the gearbox when filling with oil After filling check the correct oil level Do not mix types of oil Mixin...

Page 43: ...erved 2 Installation and commissioning 2 1 Introduction General This chapter contains information for installing the robot to the working site More detailed technical data such as load diagram permitted extra loads equipment and location of extra loads equipment may be found in the Product Specification for the robot ...

Page 44: ... than method 1 or 2 can seriously damage the robot If the robot is incorrectly transported and the instructions are not followed the robot is not covered by the warranty and ABB will not accept any compensation claim Method 1 Transportation according to method 1 is strongly recommended by ABB xx0800000030 Always follow these instructions when transporting an ABB robot according to method 1 Always ...

Page 45: ...o method 2 Always read and follow the instructions in section Securing the robot on page 49 Always place the robot in the ABB recommended transport position for robot with tool detailed in sub section Transport position with a transport support on page 45 Always use the recommended transport support detailed in sub section Recommended transport support on page 47 IRB7600 IRB66XX xx0800000037 A Tra...

Page 46: ...transportation precautions 3HAC022033 001 Revision E 44 Copyright 2004 2008 ABB All rights reserved IRB6620 xx0800000036 A Transport Support B Hexagon socket head cap screw M10x50 C Threaded bar M10x280 D Nut M10 Continued Continues on next page ...

Page 47: ...cautions 45 3HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved Transport position with a transport support All transportation of the robot with tool must follow these instructions IRB 7600 IRB 66XX xx0800000040 Continued Continues on next page ...

Page 48: ...2 Installation and commissioning 2 2 Robot transportation precautions 3HAC022033 001 Revision E 46 Copyright 2004 2008 ABB All rights reserved IRB 6620 xx0800000041 Continued Continues on next page ...

Page 49: ...precautions 47 3HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved Recommended transport support Always use the recommended transport support when transporting a robot with tool IRB 7600 IRB 66XX xx0800000039 Continued Continues on next page ...

Page 50: ...2 Installation and commissioning 2 2 Robot transportation precautions 3HAC022033 001 Revision E 48 Copyright 2004 2008 ABB All rights reserved IRB 6620 xx0800000038 Continued ...

Page 51: ...ing the brakes is a hazardous action that may cause injury and damage property It must be done with great care and only when absolutely necessary Securing the robot xx0800000062 Action Note 1 Mount the transport support lower end to the robot using the recommended screw joint A in figure Do not tightening the screw See attachment point for the specific robot in section Transport position with a tr...

Page 52: ...al resting position on the transport support see section Manually releasing the brakes on page 72 See attachment point for the specific robot in section Transport position with a transport support on page 45 4 Tightening all the attachment screws A and B in figure with the brake release for axis 3 still activated starting with the lower end attachment screw CAUTION Do not attempt to tightening any...

Page 53: ...xterior 3 Make sure the lifting device used is dimensioned to handle the weight of the robot Specified in Weight robot on page 51 4 If the robot is not to be installed directly it must be stored Specified in Storage conditions robot on page 52 5 Make sure the appointed operating environment of the robot conforms to the specifications Specified in Operating conditions robot on page 52 6 Before taki...

Page 54: ...for the robot Operating conditions robot The table below shows the allowed operating conditions for the robot Force Endurance load operation Max load emergency stop Force xy 14000 N 31000 N Force z 32000 10000 N 39000 16000 N Torque xy 42000 Nm 72000 Nm Torque z 11000 Nm 19500 Nm Requirement Value Note Min levelness 0 5 mm Max tilt 5 The limit for the maximum payload on the robot is reduced if the...

Page 55: ... Pre installation procedure 53 3HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved Protection classes robot The table below shows the protection class of the robot Equipment Protection class Robot IRB 7600 IP 67 Continued ...

Page 56: ...king range IRB 7600 150 3 5 3HAC022033 001 Revision E 54 Copyright 2004 2008 ABB All rights reserved 2 4 2 Working range IRB 7600 150 3 5 Illustration The illustration below shows the unrestricted working range of IRB 7600 150 3 5 xx0100000101 ...

Page 57: ... 7600 325 3 1 55 3HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved 2 4 3 Working range IRB 7600 325 3 1 Illustration The illustration below shows the unrestricted working range of IRB 7600 325 3 1 xx0700000720 1350 3050 1393 2086 691 3420 ...

Page 58: ...king range IRB 7600 340 2 8 3HAC022033 001 Revision E 56 Copyright 2004 2008 ABB All rights reserved 2 4 4 Working range IRB 7600 340 2 8 Illustration The illustration below shows the unrestricted working range of IRB 7600 340 2 8 xx0300000296 ...

Page 59: ...RB 7600 500 2 55 57 3HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved 2 4 5 Working range IRB 7600 400 2 55 IRB 7600 500 2 55 Illustration The illustration below shows the unrestricted working range of IRB 7600 400 2 55 and IRB 7600 500 2 55 xx0100000100 ...

Page 60: ...king range IRB 7600 500 2 3 3HAC022033 001 Revision E 58 Copyright 2004 2008 ABB All rights reserved 2 4 6 Working range IRB 7600 500 2 3 Illustration The illustration below shows the unrestricted working range of IRB 7600 500 2 3 en0100000099 ...

Page 61: ...d standing still the robot is not stable in the whole working area Moving the arms will displace the center of gravity which may cause the robot to tip over Do not change the robot position before securing it to the foundation Stabililty The figure below shows the robot in its shipping position which also is its most stable position xx0100000103 WARNING The robot is likely to be mechanically unsta...

Page 62: ...ents are shown in the figure below Determine which fork lift set fits the current robot Note The distance between the attachment holes for the fork lift pockets shown in the figure below are different depending on the design of the frame This means that the fork lift sets are unique for one type of frame and not compatible Except for the shorter distance between the attachment holes the later desi...

Page 63: ...ifferent designs on page 60 A Attachment points spacer and horizontal attachment screws B Attachment points horizontal attachment screws C Attachment points vertical attachment screws D Attachment points horizontal attachment screws Equipment etc Art no Note Fork lift set incl all required hardware 3HAC0604 2 See the figure Fork lift set 3HAC0604 2 on page 62 Fork lift set incl all required hardwa...

Page 64: ...E 62 Copyright 2004 2008 ABB All rights reserved Fork lift set 3HAC0604 2 The fork lift set 3HAC0604 2 is fitted to the robot as shown in the figure below xx0100000102 A Vertical attachment screws 4 pcs fork lift pocket B Fork lift pockets 2 pcs C Spacer 2 pcs Continued Continues on next page ...

Page 65: ...h fork lift The section below details how to secure the fork lift set to the robot in order to lift and move the robot using the fork lift ONLY A Fork lift pocket 2 pcs different from each other B Spacer 2 pcs C Horizontal attachment screws 4 pcs fork lift pocket D Vertical attachment screws 2 pcs E Securing screw used for IRB 6650S Action Note 1 If a cooling fan for the axis 1 motor is used it mu...

Page 66: ...e fork lift set 3HAC0604 2 is used Release the brakes if required as detailed in section Manually releasing the brakes on page 72 xx0200000079 When using fork lift set 3HAC0604 2 no load is permitted on the robot xx0200000387 3 Fit the two spacers to the robot and secure Attachment points on the robot are shown in the figure Attachment points on page 61 4 CAUTION The fork lift pocket weighs 60 kg ...

Page 67: ... but tightened with different torques Make sure the original screws are always used or replacements of equivalent quality M16 quality 12 9 Attachment points on the robot are shown in the figure Attachment points on page 61 xx0400001068 A Horizontal attachment screws 4 pcs M16 x 60 Tightening torque 60 Nm B Spacers 2 pcs 6 Make sure the securing screw is removed from the fork lift pocket It is only...

Page 68: ...f equivalent quality M16 quality 12 9 Attachment points on the robot are shown in the figure Attachment points on page 61 8 CAUTION The fork lift pocket weighs 22 kg 9 Secure the shorter fork lift pocket on the other side of the robot with the four remaining horizontal attachment screws 4 pcs M16x60 Tightening torque 60 Nm Make sure the original screws are always used or replacements of equivalent...

Page 69: ... 2550 kg All lifting equipment used must be sized accordingly 12 Carefully lift the robot and move it to its instal lation site 13 WARNING Personnel must not under any circumstances be present under the suspended load 14 Refit the cooling fan to the motor if any Detailed in section Installation of cooling fan for motors axes 1 3 option on page 93 Action Note Continued ...

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

Page 71: ...positioned as shown in the figure on the right If it is not position it that way Release the brakes if required as detailed in section Manually releasing the brakes on page 72 xx0100000103 3 Fit the lifting device robot to the robot as described in the enclosed instruction Art no is specified in Required equipment on page 69 4 CAUTION The robot weighs 2550 kg All lifting equipment used must be siz...

Page 72: ...h roundslings Notice the recommended robot position shown in the figure below Roundslings attached to the robot xx0200000315 Required equipment A Chain sling with shortener 4250 kg 3 pcs 0 5 m 0 5 m 0 265 m B Roundsling 1000 kg 2 pcs C Roundsling 2000 kg 3 pcs 4 m Equipment Note Chain sling with shortener 4250 kg 3 pcs Lengths 0 5 m 2 pcs 0 265 m 1 pc Roundslings 1000 kg 2 pcs Roundslings 2000 kg ...

Page 73: ...erhead crane to a position above the robot 4 Attach the three chain slings with shorteners to the overhead crane hook Shown in the figure Roundslings attached to the robot on page 70 Lengths are specified in Required equipment on page 70 5 Fit the three roundslings 2000 kg to the robot Attach the roundslings to the chain slings hanging from the overhead crane Shown in the figure Roundslings attach...

Page 74: ...ection Supplying power to connector R1 MP on page 74 External brake release unit using push buttons on an external brake release unit This does NOT require the controller to be connected The external unit is used when there are no push buttons on the robot Read about how to use the external brake release unit in section Manually releasing the brakes external brake release unit on page 75 Location ...

Page 75: ...x buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes If the robot is not connected to the controller power must be supplied to the connector R1 MP according to section Supplying power to connector R1 MP on page 74 The buttons are shown in the figure Location of brake release unit at base on page 72 or Location of brake release unit at frame on pag...

Page 76: ...r R1 MP If the robot is not connected to the controller power must be supplied to connector R1 MP in the robot base in order to enable the brake release buttons on the robot Action Note 1 DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 2 Supply 0V on pin 12 and 24V on pin 11 xx0300000565 Continued ...

Page 77: ...lease unit The external brake release unit must only be used when the robot does not have an internal brake release unit when there are no push buttons on the robot Internal brake release unit How to use the internal brake release unit if available is detailed in section Manually releasing the brakes on page 72 Required equipment Connections robot The illustration below shows where to connect the ...

Page 78: ...ase unit A Rear connector plate B Connector R1 MP C Connector R1 BU D External brake release unit E Connect to R1 BU Action Note 1 Remove the rear cover plate from the base of the robot by unscrewing its attachment screws and plain washers Shown in the figure Connec tions robot on page 75 2 Locate the free connector connected to the rear of connector R1 MP behind the rear connector plate Make sure...

Page 79: ...n releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near the robot arm 5 Release the holding brake of each robot axis by pressing the respective button on the external brake release unit 6 Disconnect the external brake release unit 7 Refit the rear cover plate with its attachment screws Action Note Continued ...

Page 80: ...fting base plate Equipment Art no Note Lifting eye M16 3HAC14457 4 3 pcs Lifting slings 3 pcs Length approx 2 m A Attachment holes for lifting eyes x3 Action Note 1 CAUTION The base plate weighs 353 kg All lifting equipment used must be sized accordingly 2 Fit the lifting eyes in the three lifting holes Shown in the figure Hole con figuration on page 78 3 Fit the lifting slings to the eyes and to ...

Page 81: ...ecuring the base plate 79 3HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved 2 5 7 Securing the base plate General This section details how to secure the base plate Base plate dimensions xx0100000105 Continues on next page ...

Page 82: ...on and commissioning 2 5 7 Securing the base plate 3HAC022033 001 Revision E 80 Copyright 2004 2008 ABB All rights reserved xx0400000715 A Four holes for alternative clamping 4x Ø18 Continued Continues on next page ...

Page 83: ...ts attachment holes 4 pcs Equipment Art no Note Base plate 3HAC12937 7 Includes guide sleeves 3HAC2937 3 levelling screws 9ADA120 79 attachment screws and washers for securing the robot to the base plate A drawing of the base plate itself may be ordered from ABB Robotics Standard toolkit The content is defined in section Standard toolkit on page 394 Other tools and procedures may be required See r...

Page 84: ...tion to the robot work location using the three grooves in the base plate Shown in the figure Base plate grooves and holes on page 81 4 Lift the base plate to its mounting position Detailed in section Lifting the base plate on page 78 5 Use the base plate as a template and drill 16 attachment holes as required by the selected bolt dimension If possible observe the recommenda tions specified in sec...

Page 85: ...bot fitted to base plate The illustration below shows the robot base fitted to the base plate xx0100000107 Attachment screws The table below specifies the type of securing screws and washers to be used for securing the robot to the base plate foundation A Robot attachment bolts and washers 12 pcs M24 x 140 B Orienting grooves in the robot base and in the base plate C Levelling screws D Base plate ...

Page 86: ...cinity of its installation location 3 Fit two guide sleeves to the guide sleeve holes in the base plate NOTE One of the guide sleeve holes is elongated 4 Guide the robot gently using two M24 screws while lowering it into its mounting position Make sure the robot base is correctly fitted onto the guide sleeves 5 Fit the bolts and washers in the base attachment holes Specified inAttachment screws on...

Page 87: ...sion E Copyright 2004 2008 ABB All rights reserved Hole configuration base The illustration below shows the hole configuration used when securing the robot xx0300000046 Cross section guide sleeve hole The illustration below shows the cross section of the guide sleeve holes xx0100000109 Continued ...

Page 88: ...re the required mounting holes are accessible when planning the robot cell Illustration fitting of extra equipment on lower arm The illustration below shows the mounting holes available for fitting extra equipment on the lower arm Make sure not to damage the robot cabling on the inside of the lower arm when fitting extra equipment Always use appropriate attachment screws xx0700000722 Robot variant...

Page 89: ...033 001 Revision E Copyright 2004 2008 ABB All rights reserved xx0100000120 Illustration fitting of extra equipment on upper arm The illustration below shows the mounting holes available for fitting extra equipment on the upper arm xx0100000116 Continued Continues on next page ...

Page 90: ...ustration fitting of extra equipment on frame The illustration below shows the mounting holes available for fitting extra equipment on the frame xx0100000117 Robot variant A IRB 7600 500 2 55 1056 mm IRB 7600 500 2 3 806 mm IRB 7600 400 2 55 1056 mm IRB 7600 340 2 8 1306 mm IRB 7600 325 3 1 1556 mm IRB 7600 150 3 5 2012 mm Continued Continues on next page ...

Page 91: ...2 Installation and commissioning 2 5 9 Fitting equipment on robot 89 3HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved xx0100000118 Continued Continues on next page ...

Page 92: ...lustration fitting on turning disk The illustration below shows the mounting holes available for fitting equipment on the turning disk xx0100000119 Fastener quality When fitting tools on the turning disk see the figures above only use screws with quality 12 9 When fitting other equipment standard screws with quality 8 8 may be used Continued ...

Page 93: ...stration installation of base spacers xx0500001570 Required equipment A Base spacer 4 pcs B Guide sleeve 4 pcs C Attachment screws and washers 12 pcs Equipment Art no Note Base spacers 3HAC 021899 002 Includes mounting set with attachment screws and mounting instruction Base plate 3HAC 12937 7 Standard toolkit The content is defined in section Standard toolkit on page 394 Continues on next page ...

Page 94: ...ay with lifting slings Make sure the robot is positioned in the most stable position the transport position Detailed in section Lifting robot with lifting slings on page 68 3 Install the base plate to the foundation if not used previously Detailed in section Securing the base plate on page 79 4 Fit the four base spacers and guiding sleeves to the base plate Shown in the figure Illustration instal ...

Page 95: ...nd 3 Installation of this complete cabling is detailed in section Installation of cable harness for position switches and fans on page 115 separate cabling for axis 1 or 2 including only connections for the cooling fans on axes 1 or 2 Installation of this cabling is detailed in section Installation separate fan cabling axis 1 or 2 on page 97 If both cooling fans and position switches are installed...

Page 96: ...ling if equipping the robot withboth position switches and cooling fansor with cooling fans on axis 3 Cabling cooling fans axes 1 or 2 3HAC023599 001 Choose this cabling if only equipping the robot with cooling fans on axis 1 or 2 not on axis 3and not with position switches Plate for customer connections 3HAC025778 001 An additional connection plate must be fitted to the robot base if not already ...

Page 97: ...Loctite 243 Used for the three tightening screws Standard toolkit The content is defined in section Standard toolkit on page 394 Circuit diagram See chapter Circuit diagram Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Equipment Art no Note A Plate for customer connectio...

Page 98: ...urfaces of the motor when fitting the fanbox turn the connector to the correct position axis 1 groove pointing inwards as shown in the figure Cooling fan on page 94 Positions for axis 2 and 3 are shown in the figureLocation of cooling fans on page 93 Shown in the figure Cooling fan on page 94 3 Temporarily lift the motor cabling out of the way of the current motor to make room for the fanbox 4 Fit...

Page 99: ...c power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Remove the rear cover plate from the robot base Shown in the figure Location of cooling fans on page 93 4 Remove the cable bracket A Shown in the figure Separate cabling for axis 1 or 2 on page 96 5 Fit the plate for customer connections if not already fitted...

Page 100: ...he figure Separate cabling for axis 1 or 2 on page 96 8 Connect the connector R3 FAN2 to the fan of axis 1or 2 NOTE Fans on both axis 1 and 2 can not be used at the same time 9 Connect the connector R1 SW2 3 to the base of the robot Make sure that the cabling run through the frame and base is not twisted and runs freely from the robot cabling 10 Refit the rear cover plate to the robot base 11 Inst...

Page 101: ...e 1 Modify the settings in RobotWare to include the cooling fans RobotWare 4 0 modify the settings in RobInstall RobotWare 4 063 and older must be updated with a newer release RobotWare 5 0 change the settings in the Modifying options dialogue by using the Modify Controller System Wizard in the System Builder of RobotStudio Read more about modifying the system in Operating manual RobotStudio Conti...

Page 102: ...loading motors gears and structure CAUTION Incorrect defined loads may result in operational stops or major damage on the robot References Load diagrams permitted extra loads equipment and their positions are specified in the Product Specification The loads must also be defined in the software as detailed in User s Guide RobotWare 4 0 Operating manual IRC5 with FlexPendant Stop time and braking di...

Page 103: ...ftware signal from adjustable position switch Axis 2 hardware mechanical stop and software signal from adjustable position switch Axis 3 hardware mechanical stop and software signal from adjustable position switch As standard configuration axis 1 is allowed to move 180º The working range may however be increased to 220º with option 561 1 Extended working range axis 1 Notice that this option also r...

Page 104: ... between 22 5 and 135 in both directions Mechanical stops axis 1 The illustration below shows the mounting position of the stop pin and one of the additional mechanical stops available for axis 1 xx0300000049 Required equipment A Additional mechanical stop B Stop pin Equipment etc Art no Note Mechanical stop for axis 1 7 5 3HAC11076 1 Includes attachment screws and an assembly drawing Mechanical s...

Page 105: ...pressure to motors and SMB 2 Fit the additional mechanical stop to the frame according to the figure Mechanical stops axis 1 on page 102 Tightening torque 120 Nm 3 NOTE To utilize the option 561 1 Extended working range axis 1 the software working range limitations must be re defined The motion configuration parameter arm rob1_1 Upper Joint Bound and arm rob1_1 Lower Joint Bound must be changed to...

Page 106: ...2 The illustration below shows the mounting position of the mechanical stops on axis 2 xx0300000047 Required equipment A Additional mechanical stops B Fixed mechanical stop Equipment etc Art no Note Mechanical stop set axis 2 3HAC11077 1 Includes six stops 3HAC11407 1 each one restricting the working range by 15 Includes attachment screws Standard toolkit The content is defined in section Standard...

Page 107: ...tors and SMB 2 Fit and tighten the additional stops in a row starting from the fixed stop Tightening torque 115 Nm Shown in the figure Mechanical stops axis 2 on page 104 3 The software working range limitations must be re defined to correspond to the changes in the mechanical limitations of the working range How to define the range of movement in RobotWare 4 0 is detailed in User s guide S4Cplus ...

Page 108: ... shows the mounting position of the mechanical stops on axis 3 xx0300000048 Required equipment A Additional mechanical stops B Fixed mechanical stop Equipment etc Art no Note Mechanical stop set axis 3 3HAC13128 2 Includes six stops one with 80 restriction 3HAC12708 4 use when limitation angle 80 and five with 20 3HAC 12708 2 Includes attachment screws Standard toolkit The content is defined in se...

Page 109: ...ure to motors and SMB 2 Mount and tighten the additional stops in a row starting from the fixed stop Shown in the figure Mechanical stops axis 3 on page 106 3 NOTE The software working range limitations must be re defined to correspond to the changes in the mechanical limitations of the working range How to define the range of movement in RobotWare 4 0 is detailed in User s guide S4Cplus chapter S...

Page 110: ...equired equipment Description Art no Note Position switch axis 1 3HAC15715 1 Includes position swtich and plate for customer connections Position switch axis 2 3HAC15715 2 Includes only the position switch Position switch axis 3 3HAC15715 3 Includes only the position switch Cabling position switches and cooling fans axes 1 2 and 3 3HAC15390 1 Cabling to be installed on the robot Plate for customer...

Page 111: ...xis 1 The illustration below shows the position switch for axis 1 There is no extra cabling installed on the robot as for axes 2 and 3 Instead the switch is connected directly to the connector in the base R1 SW1 xx0100000158 A Position switch axis 1 B Cam C Set screw cam cam stop D Protection sheet E Rail F Rail attachment Continued Continues on next page ...

Page 112: ...4 2008 ABB All rights reserved Axis 2 The illustration below shows the position switch for axis 2 In addition to the shown components cabling must also be installed from the switch to the robot base xx0100000159 A Position switch axis 2 B Cam C Set screw cam cam stop E Rail F Rail Attachment Continued Continues on next page ...

Page 113: ...ow shows the position switch for axis 3 In addition to the shown components cabling must also be installed from the switch to the robot base xx0100000160 Specifications Maximum voltage current for the position switches A Position switch axis 3 B Cam C Set screw cam cam stop E Rail F Rail attachment Parameter Value Voltage Max 50 VDC Current Max 1 A Continued Continues on next page ...

Page 114: ...19 Fitting and adjusting cams and stops The instruction below details how to fit and adjust the parts of the position switches Action Note 1 Cut the cam to a suitable length Use a sharp knife and rubber hammer or similar 2 Cut the edge of the cam edge to max 30 Shown in Illustration cutting the cam on page 113 If the angle is larger this may damage the position switch 3 Cut the part of the cam run...

Page 115: ...ation adjust and secure cams The illustration below show how to adjust and secure the position switch cams and profiles xx0100000113 Illustration cutting the cam The illustration below show how to cut the position switch cam xx0100000114 A Cam stop M5 nut and M5 x 6 set screw B Adjustable cam C Profile A Remove the gray section Continued Continues on next page ...

Page 116: ...r customer connections at base xx0500002301 Cable harness for position switches and fans axes 1 3 xx0500002305 A Plate for customer connections B Attachment screws 3 pcs M6x16 A Cable bracket frame B Cable bracket lower arm C Cable bracket upper arm R1 SW2 3 Connected to the robot base R3 FAN2 Connected to the fan of axis 1 or 2 Continued Continues on next page ...

Page 117: ...is 2 R2 SW3 Connected to the position switch of axis 3 Action Note 1 Move the robot to its calibration position 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Remove the rear cover A from the robot base and replace the protection B with a plate for customer connections if not ...

Page 118: ... with existing velcro strap B attached around the robot cabling Connect the connector R2 SW2 to the position switch of axis 2 NOTE There is a risk of the balancing device damaging the fan cable if it is not protected by correct routing underneath the robot cabling xx0500002309 A Cable bracket frame Also shown in the figure Cable harness for position switches and fans axes 1 3 on page 114 B Velcro ...

Page 119: ... the fan of axis 3 together with the robot cabling with a velcro strap xx0500002313 A Bracket lower arm Also shown in the figure Cable harness for position switches and fans axes 1 3 on page 114 B Bracket for robot cabling C Connector R2 SW3 D Velcro strap 8 Secure the axis 3 fan cable with the bracket upper arm Shown in the figure Cable harness for position switches and fans axes 1 3 on page 114 ...

Page 120: ...3 to the base of the robot Make sure that the cabling run through the base frame and lower arm is not twisted and is running free from the robot cabling 11 Refit the rear cover to the robot base 12 Install additional cabling to and inside the control cabinet Cabling is specified in section Position switch and fan cables robot base to controller option on page 120 Action Note Continued ...

Page 121: ...d fan cables option Handles supply to and feedback from any position switches and cooling fans on the robot Specified in the table Position switch and fan cables robot base to controller option on page 120 Customer cables option Handles communication with equipment fitted on the robot by the customer including databus communication low voltage signals and high voltage power supply protective groun...

Page 122: ...he cables below are only used for position switches Cabling for the cooling fans is specified in the table Cabling between robot base and controller cooling fans M2004 on page 121 Robot cable power 15 m 3HAC11818 2 Robot cable power 22 m 3HAC11818 3 Robot cable power 30 m 3HAC11818 4 Cable Art no Cable Art no Robot cable signal shielded 7 m 3HAC7998 1 Robot cable signal shielded 15 m 3HAC7998 2 Ro...

Page 123: ...m the robot base to the inside of the cabinet and the additional cabling specified below is therefor not needed Cable Art no Connection point Distributing cable 3HAC022708 001 Robot base R1 SW2 3 Harness cooling 7 m 3HAC022723 001 Distributing cable R1 FAN SW2 3 Inside cabinet A43 X10 and A43 X11 Harness cooling 15 m 3HAC022723 004 Distributing cable R1 FAN SW2 3 Inside cabinet A43 X10 and A43 X11...

Page 124: ...h off the overpressure in motors and serial measurement compartment during cooling down of robot after it has been switched off When turning off a cleaning cell we recommend that the humid air inside a cell is ventilated out to avoid that the humid air is sucked into gearboxes for example due to the raised vacuum when cooled down Environmental conditions The table below details the environmental c...

Page 125: ... balancing device and serial measurement board cavity The robots are prepared with hoses to the motors and the serial measurement board cavity to enable pressurizing of them WARNING The robot must be pressurized also when it is switch off to avoid that the humid environmental air is sucked into the motors when cooling down Action Note 1 Connect a compressed air hose to air connector on robot base ...

Page 126: ...t should be exposed to direct high pressure jet of water The sealings between the moving parts on the wrist should not be exposed to direct or rebounding high pressure jet of water Protection points at the wrist joints The illustration below shows points that are particularly sensitive to water spray xx0600002792 A Axis 5 bearing support side B Axis 5 bearing gear side C Axis 6 mounting flange gea...

Page 127: ...tors and serial measurement compartment during cooling down of robot after it has been switched off NOTE To reduce the risk for corrosion due to condensation in gearboxes it is recommendable that the robot is running with high speed on each axes at least on one occasion each hour This is to lubricate the gearbox cavities NOTE When turning off a cleaning cell we recommend that the humid air is vent...

Page 128: ...2 Installation and commissioning 2 8 2 Commissioning Foundry Prime 3HAC022033 001 Revision E 126 Copyright 2004 2008 ABB All rights reserved ...

Page 129: ...ing intervals and refers to procedures for the activities Each procedure contains all information required to perform the activity that is required tools and materials The procedures are gathered in different sections and divided according to the maintenance activity Safety information Before any service work is commenced it is extremely important that all safety information is observed There are ...

Page 130: ... the working conditions of the robot Calendar time specified in months regardless of whether the robot system is run or not Operating time specified in operating hours More frequent running of the robot means more frequent maintenance activities SIS specified by the robot s SIS Service Information System A typical value is given for a typical work cycle but the value will differ depending on how h...

Page 131: ...Equipment Interval Detailed in section Inspection Axis 1 gear oil level 12 mths 1 Inspection oil level gearbox axis 1 on page 135 Inspection Axis 2 gear oil level 12 mths 1 Inspection oil level gearbox axis 2 on page 138 Inspection Axis 3 gear oil level 12 mths 1 Inspection oil level gearbox axis 3 on page 141 Inspection Axis 4 gear oil level 12 mths Inspection oil level gearbox axis 4 on page 143...

Page 132: ... 24 000 h 5 Do not mix with other oils Oil change gearbox axis 4 on page 191 Changing Axis 5 primary gear oil Kyodo Yushi TMO 150 First change after 6 000 h Second change after 24 000 h 5 Do not mix with other oils Oil change gearbox axis 5 on page 194 Changing Axis 5 secondary gear oil Kyodo Yushi TMO 150 First change after 6 000 h Second change after 24 000 h 5 Do not mix with other oils Oil cha...

Page 133: ...nd intervals optional equipment The table below specifies the required maintenance activities and intervals for common optional equipment Maintenance of other external equipment for the robot is detailed in separate documentation Replacement Axis 5 gear 96 mths Replacement of gearbox axis 5 on page 360 Replacement Axis 6 gear As specified by the SIS or typically 96 mths Replacement of gearbox axis...

Page 134: ... page 166 Inspection Mechanical stop axis 1 12 mths Inspection mechanical stop axes 1 2 and 3 on page 164 Analysis Oil gearbox axis 6 3000h or 6 mths 2 Inspection oil level gearbox axis 6 on page 149 Changing Axis 1 gear oil Kyodo Yushi TMO 150 6000h Oil change gearbox axis 1 Changing Axis 2 gear oil Kyodo Yushi TMO 150 6000h Oil change gearbox axis 2 on page 185 Changing Axis 3 gear oil Kyodo Yus...

Page 135: ...earbox 6 Parts that need to be changed according to the maintenance schedule are not covered by warranty Replacement Axis 2 gearbox As specified by the SIS or typically 96 mths Replacement of gearbox axis 2 on page 342 Replacement Axis 3 gearbox As specified by the SIS or typically 96 mths Replacement of gearbox axis 3 on page 349 Replacement Axis 4 gearbox 4 96 mths 3 Replacement of complete uppe...

Page 136: ...tion position Deviations from this test cycle will result in differences in expected life 3 The robot is dimensioned for a service life of 8 years 350 000 cycles per year in a normal spot welding application Depending on the actual application the life of individual gearboxes may vary greatly from this specification The SIS Service Information System integrated in the robot software keeps track of...

Page 137: ...nspection not available in all designs E Label specifies type of oil in the axis 1 gearbox Equipment etc Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 181 Standard toolkit The content is defined in section Standard toolkit on page ...

Page 138: ...power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Remove the motor axis 1 Detailed in section Removal motor axis 1 on page 298 4 Measure the oil level through the motor hole Required oil level 40 mm 5 mm to the motor hole 5 If necessary fill with lubricating oil or drain Art no is specified in Required equipme...

Page 139: ...work with gearbox oil on page 40 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Open the oil plug inspection Shown in the figure Location of gearbox on page 135 4 Required oil level max 10 mm below the oil plug hole 5 Add oil if required Art no is specified in Required equipme...

Page 140: ...oil plug hole of the later design is located 33 mm below the original placement The measured distance to the oil level varies depending on the design of the cover Oil plug early design The axis 2 gearbox is located in the lower arm rotational center The figure below shows the early design of the gearbox cover xx0300000068 A Gearbox axis 2 behind motor attachment not shown in figure B Oil plug fill...

Page 141: ...wn in figure B Oil plug filling later design C Oil plug draining D Label specifies the type of oil in axis 2 gearbox Equipment etc Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 181 Standard toolkit The content is defined in section...

Page 142: ...n off the air pressure to motors and SMB 3 Open the oil plug filling two different designs Read more about the differences in Oil change gearbox axis 2 on page 185 4 Measure the oil level Required oil level to oil plug early design 35 mm 5 mm Required oil level to oil plug later design max 10 mm below the oil plug hole Shown in the figures Oil plug early design on page 138 or Oil plug later design...

Page 143: ...ure below xx0200000113 Required equipment A Gearbox axis 3 B Oil plug filling C Oil plug draining D Label specifies the oil type of axis 3 gearbox Equipment Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 181 Standard toolkit The con...

Page 144: ...gearbox oil on page 40 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Run the robot to the calibration position Detailed in section Calibration scales and correct axis position on page 374 4 Open the oil plug filling Shown in the figure Location of gearbox on page 141 5 Requir...

Page 145: ...Cover axis 4 gearbox C Oil plug filling secondary gear D Oil plug draining secondary gear E Oil plug filling primary gearbox draining not shown in figure F Label specifies the type of oil in the secondary gear of axis 4 G Label specifies the type of oil in the primary gear of axis 4 Equipment etc Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 To be used in primary and secondary gea...

Page 146: ...the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Run the robot to the calibration position Shown in section Calibration scales and correct axis position on page 374 4 Open the oil plug filling in the primary gearbox Shown in the figure Location of gearbox on page 143 5 Measure the oil level Required oil level 35 mm 5 mm to the oil plug hole 6 Add oil if requi...

Page 147: ...C022033 001 Revision E Copyright 2004 2008 ABB All rights reserved 11 WARNING Do not mix the oil types If wrong oil is refilled the gearbox must be rinsed as detailed in section WARNING Mixed oils may cause severe damage to gearbox on page 41 Action Note Continued ...

Page 148: ... axis 5 gearbox C Oil plug filling secondary gear D Oil plug draining secondary gear E Oil plug filling primary gearbox draining on opposite side of wrist housing not shown in figure F Label specifies the type of oil in primary gear axis 5 G Label specifies the type of oil in secondary gear axis 5 Equipment etc Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 To be used for primary a...

Page 149: ...t For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Run the robot to the calibration position Shown in section Calibration scales and correct axis position on page 374 4 Open the oil plug filling in the primary gearbox Shown in the figure Location of gearbox on page 146 5 Measure the oil level Required oil level 80 mm 5 mm to the oil plug hole 6 Add oil if required Kyod...

Page 150: ...033 001 Revision E 148 Copyright 2004 2008 ABB All rights reserved 11 WARNING Do not mix the oil types If wrong oil is refilled the gearbox must be rinsed as detailed in section WARNING Mixed oils may cause severe damage to gearbox on page 41 Action Note Continued ...

Page 151: ...ecified in the procedure xx0200000114 Required equipment A Gearbox axis 6 B Oil plug filling notice the two possible locations B1 or B2 C Oil plug draining can be located on the turning disk instead D Label specifies the type of oil in gearbox axis 6 Equipment Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 Standard toolkit The content is defined in section Standard toolkit on page ...

Page 152: ...ove the wrist unit and tilthouse so that the oil plug for filling is facing upwards Shown in the figure Location of gearbox on page 149 3 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 4 Open the oil plug filling 5 Measure the oil level measurement a in the figure to the right The...

Page 153: ...x axis 6 on page 197 7 Refit the oil plug filling Tightening torque 24 Nm 8 WARNING Do not mix the oil types If wrong oil is refilled the gearbox must be rinsed as detailed in section WARNING Mixed oils may cause severe damage to gearbox on page 41 Action Note If Then 1 More than 2 water in oil With more than 2 water content there is a risk for corrosion in the gearbox and reduced viscosity in the...

Page 154: ...ght 2004 2008 ABB All rights reserved 2 Less than 2 water in oil normal replacement interval is required for gearbox axis 6 as specified by SIS or typically 96 months as on a standard robot xx0600003156 A Water content in oil from gearbox axis 6 B Months or hours in operation If Then Continued ...

Page 155: ...g the inspection a maintenance may be performed according to specific maintenance kits If the balancing device is an older model it must in some cases be upgraded instead The instruction for the current inspection details if a fault requires a maintenance upgrade and the table below specifies the different models and which of the two actions they require The article number of the balancing device ...

Page 156: ... specifies the equipment used if damage is detected on the balancing device See section Action at detected faults on page 153 to determine whether to perform maintenance or upgrade A Balancing device B Piston rod inside C Shaft including securing screw D Ear bearing and o rings E Label with article number F Inspect the surroundings G Bearing balancing device attachments Equipment etc Spare part no...

Page 157: ...ng the spherical roller bearings Standard toolkit 3HAC15571 1 The content is defined in section Standard toolkit on page 394 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Equipment etc Spare part no Art no Note Check for dissonance from If dissonance is detected 1 bearin...

Page 158: ...iven instructions in Maintenance kit complete Upgrade kit Art no for the kit and the documentation are specified in section Required equipment on page 154 To decide whether to perform maintenance or upgrade see section Action at detected faults on page 153 Check for dissonance from If dissonance is detected Check for damage on If damage is detected 1 the piston rod part of the piston rod that is v...

Page 159: ...This is normal behaviour and must not be confused with incorrect leaks from the ear Leaks at the o rings however are not acceptable and must be attended to immediately in order to avoid any damage to the bearing Check the o rings in the front ear of the balancing device for leaks as shown and detailed below xx0300000284 A Shaft B O ring C Sealing spacer D Sealing ring in sealing spacer E Correct w...

Page 160: ... considered as a leak The o rings are included in the Maintenance kit bearings and seals already assembled with sealing spacers and sealing rings Art no for the kit is specified in Required equipment on page 154 The replacement of the complete bearing is also detailed in section Replacement of spherical roller bearing balancing device on page 285 Incorrect leakage is shown in the previous figure A...

Page 161: ... A Lower arm B Cables attached with velcro straps and mounting plate C Connectors at cable harness division point R2 M5 6 D Connectors at base Equipment etc Art no Note Standard toolkit The content is defined in section Standard toolkit on page 394 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include reference...

Page 162: ...rs at the division point and at the base Shown in the figure Location of cable harness axes 1 4 on page 159 4 NOTE If the robot is used in a Foundry Prime appli cation check the cables for cracks in insulation 5 Check that velcro straps and the mounting plate are properly attached to the frame Also check the cabling leading into the lower arm Make sure it is attached by the straps and not damaged ...

Page 163: ...ction of the cable harness in order to detect wear and damage 3 Check the attachments at the rear of the upper arm and in the upper arm tube Check the connectors at the cable harness division Make sure the attachment plate is not bent or in any other way damaged Shown in the figure Location of cabling axes 5 6 on page 160 4 NOTE If the robot is used in a Foundry Prime appli cation check the cables...

Page 164: ...t the mechanical stop axis 1 A Mechanical stop pin Equipment etc Art no Note Mechanical stop ax 1 3HAC10499 3 To be replaced when damaged Standard toolkit The content is defined in section Standard toolkit on page 394 Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 ...

Page 165: ... E Copyright 2004 2008 ABB All rights reserved 4 If the stop pin is bent or damaged it must be replaced NOTE The expected life of gearboxes can be reduced as a result of collissions with the mechanical stop Art no is specified in Required equipment on page 162 Action Note Continued ...

Page 166: ...on of the additional mechanical stops on axes 1 2 and 3 xx0200000150 Required equipment A Additional stop B Fixed stop Equipment etc Art no Note Mechanical stop ax 1 3HAC11076 1 Limits the robot working range to 7 5 Mechanical stop ax 1 3HAC11076 2 Limits the robot working range to 15 Mechanical stop ax 2 3HAC11077 1 Mechanical stop ax 3 3HAC13128 2 Standard toolkit The content is defined in secti...

Page 167: ... pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Check the additional stops on axes 1 2 and 3 for damage Shown in the figure Location of the mechanical stops on page 164 3 Make sure the stops are properly attached Correct tightening torque 115 Nm 4 If any damage is detected the mechanical stops must be replaced Correct attachme...

Page 168: ...e inspected xx0200000099 Required equipment A Damper axis 2 2 pcs B Damper axis 3 2 pcs C Damper axis 4 2 pcs D Damper axis 5 2 pcs Equipment Art no Note Damper axis 2 3HAC12990 1 Replace if damaged Damper axis 3 3HAC11750 1 Replace if damaged Damper axis 4 3HAC13564 1 Replace if damaged Damper axis 5 3HAC10503 8 Replace if damaged Standard toolkit The content is defined in section Standard toolki...

Page 169: ...plies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Check all dampers for damage such as cracks or existing impressions larger than 1 mm In order to inspect dampers axis 4 the two covers on top of the upper arm must be removed Shown in the figure Location of dampers on page 166 3 Check attachment screws for deformation 4 If any damage is detected the da...

Page 170: ...08 ABB All rights reserved 3 3 12 Inspection position switch axes 1 2 and 3 Location of position switches The position switches axes 1 2 and 3 are located as shown in the figures below xx0100000158 A Position switch axis 1 B Cam C Set screw cam D Protection sheet E Rail F Rail attachment Continues on next page ...

Page 171: ... and 3 169 3HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved The illustration below shows the position switch for axis 2 xx0100000159 A Position switch axis 2 B Cam C Set screw cam E Rail F Rail attachment Continued Continues on next page ...

Page 172: ...n switch axis 3 B Cam C Set screw cam E Rail F Rail attachment Equipment etc Spare part no Note Position switch axis 1 3HAC15715 1 To be replaced in case of detected damage Position switch axis 2 3HAC15715 2 To be replaced in case of detected damage Position switch axis 3 3HAC15715 2 To be replaced in case of detected damage Standard toolkit The content is defined in section Standard toolkit on pa...

Page 173: ...pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Check the position switch Check that the rollers are easy to push in and that they roll freely 3 Check the rail Check that the rail is firmly attached with the attachment screws 4 Check the cams Check that the rollers has not caused any impressions on the cams Check that the cams are clean ...

Page 174: ... lightning flash located on motor cover 3HAC1589 1 C Instruction label Safety instructions 3HAC4591 1 D Warning label Brake release 3HAC15334 1 E Warning label tools are not allowed around the balancing device during operation 3HAC020611 001 F Warning label Shut off power 3HAC17804 1 G Label type of oil in gearbox 3HAC021482 001 H Label type of oil in gearbox 3HAC021480 001 I Label type of grease ...

Page 175: ...ment Art no Note Labels and plate set 3HAC13191 1 Includes all labels specified in the two previous figures The labels are in english Label set oil labels 3HAC021670 003 Includes only the oil labels at the gearboxes and at the robot base Are fitted to the robot if the gearboxes include Kyodo Yushi TMO 150 Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to...

Page 176: ... UL signal lamp B Warning sign C Warning label D Position for cable gland Equipment etc Spare part no Note Signal lamp 3HAC10830 1 To be replaced in case of detected damage Includes UL signal lamp 3HAC 13097 1 Warning label 3HAC 4431 1 Warning sign 3HAC 1589 1 Standard toolkit The content is defined in section Standard toolkit on page 394 Other tools and procedures may be required See references t...

Page 177: ...the UL lamp Action Note 1 Check that the UL lamp is lit when the motors are in operation motors ON 2 If the lamp is not lit trace the fault Check whether the UL lamp is broken If so replace it Check the cable connections Measure the voltage in connectors motor axis 3 24V Check the cabling Replace cabling if a fault is detected Part no is specified in Required equipment on page 174 Continued ...

Page 178: ...ed air to the air connector on robot base and raise the pressure with the knob until the correct value is shown on the pressure gauge Recommended pressure 0 2 0 3 bar xx0600002794 A Air Connection B Cut off valve C Pressure gauge 2 Close the cut off valve It should take at least 5 sec for the pressure to reach 0 bar 3 Test time is 5 seconds If the answer is YES Perform a complete leak test and loc...

Page 179: ...shown in the figure below xx0400000798 Type of oil historically used The gearboxes of the robot have historically been filled with different types of oils Today only the types of oil specified in the table is recommended A Gearbox axis 1 B Gearbox axis 2 C Gearbox axis 3 Dp Gearbox axis 4 primary Ds Gearbox axis 4 secondary Ep Gearbox axis 5 primary Es Gearbox axis 5 secondary F Gearbox axis 6 A B...

Page 180: ...boxes must have the correct label clearly visible xx0800000230 xx0800000234 Gearbox Type of oil Art no Amount Axis 1 Kyodo Yushi TMO 150 3HAC032140 001 7 600 ml Axis 2 Kyodo Yushi TMO 150 3HAC032140 001 4 800 ml Axis 3 Kyodo Yushi TMO 150 3HAC032140 001 4 200 ml Axis 4 primary gear Kyodo Yushi TMO 150 3HAC032140 001 900 ml Axis 4 secondary gear Kyodo Yushi TMO 150 3HAC032140 001 3 850 ml Axis 5 pr...

Page 181: ...hi TMO 150 as well as Shell Tivela S 150 is not compatible with mineral oil contamination with other types of oil in the gearboxes is not accepted Equipment used in handling of Kyodo Yushi TMO 150 as well as Shell Tivela S 150 must be carefully cleaned before use In case of changing the type of oil the gearbox therefor must be thoroughly rinsed See Rinsing gearbox Label at robot base Currently use...

Page 182: ...flushing Refill the gearbox with the correct type of oil Kyodo Yushi TMO 150 mixed with Mobilgear 600 XP320 Use this procedure to rinse the contaminated gearbox if the oil types Kyodo Yushi TMO 150 and Mobilgear 600 XP320 are mixed Flush the gearbox properly three times with Kyodo Yushi TMO 150 Use a service program when flushing Refill the gearbox with Kyodo Yushi TMO 150 Mobilgear 600 XP320 mixe...

Page 183: ...f gearbox The axis 1 gearbox is located between the frame and base as shown in the figure below The oil is drained with a hose that may be reached behind the rear cover of the robot base xx0200000111 A Gearbox axis 1 B Oil plug filling C Motor axis 1 D Oil plug inspection not in all designs E Label specifies the type of oil in the gearbox Continues on next page ...

Page 184: ... Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 181 Oil collecting vessel Capacity 8 000 ml Oil exchange equipment 3HAC17313 1 The content is defined in section Special tools on page 395 Standard toolkit The content is defined in section Standard toolkit on page 394 Other tools an...

Page 185: ... Safety risks during work with gearbox oil on page 40 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Remove the rear cover on the base by unscrewing its attachment screws 4 Pull the oil hose out of the rear of the base Some early versions of the robot has the oil draining plug...

Page 186: ...R Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Open the oil plug filling Shown in the figure Location of gearbox on page 181 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in ...

Page 187: ...xis 2 B Oil plug filling later design C Oil plug draining D Label specifies the type of oil in the gearbox Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 4 800 ml Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 181 Oil collecting vessel Capacity 5 000 ml Oil ...

Page 188: ...supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 40 3 Remove the oil plug draining and drain the gearbox oil using a hose with nipple and an oil collecting vessel Re...

Page 189: ...al safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 40 3 Remove the oil plug filling and the plug from the vent hole Shown in the figure Location of oil plugs on page 185 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously being drained The correct oil le...

Page 190: ...rbox axis 3 B Oil plug filling C Oil plug draining D Label specifies the type of oil in gearbox Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 4 200 ml Kyodo Yushi TMO 150 Do not mix with other oils Check which oil is currently filled in the gearbox as detailed in section Which type of oil does the gearbox contain on page 181 Oil exchange equipment 3HAC021745 001 The content is de...

Page 191: ...e supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 40 3 Remove the oil plug draining and drain the gearbox oil using a hose with nipple and an oil collecting vessel ...

Page 192: ...ase observe the safety information in section WARNING Safety risks during work with gearbox oil on page 40 3 Remove the oil plug filling Shown in the figure Location of gearbox on page 188 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in section Inspection oil level gearbox axis 3 on page ...

Page 193: ...section Flushing a contaminated gearbox on page 211 Location of gearbox The axis 4 gearbox is located at the rear of the upper arm as shown in the figure below xx0200000107 A Upper arm housing B Cover axis 4 gearbox C Oil plug filling secondary gear D Oil plug draining secondary gear E Oil plug filling primary gearbox draining not shown in figure located further down on the motor flange F Label sp...

Page 194: ...ontent is defined in section Standard toolkit on page 394 Action Note 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 40 2 Open the oil plug draining secondary gear Shown in the figure Location of gearbox on page 191 3 Drain the oil from the secondary gearbox by...

Page 195: ... through the oil plug filling secondary gear Kyodo Yushi TMO 150 Art no and amount is specified in Required equipment on page 192 Shown in the figure Location of gearbox on page 191 4 Refill the primary gearbox with oil through the oil plug filling primary gear Make sure the air is ventilated through the oil plug during filling to avoid overpressure in the gearbox The amount of oil to be refilled ...

Page 196: ...d according to section Flushing a contaminated gearbox on page 211 Location of gearbox The axis 5 gearbox is located in the wrist unit as shown in the figure below xx0200000108 A Wrist housing B Cover axis 5 gearbox C Oil plug filling secondary gear D Oil plug draining secondary gear E Oil plug filling primary gearbox draining on opposite side of wrist housing not shown in figure F Label specifies...

Page 197: ...Kyodo Yushi TMO 150 Used in the secondary gearbox Oil collecting vessel Capacity 1 000 ml Oil collecting vessel Capacity 4 000 ml Oil exchange equipment 3HAC17313 1 The content is defined in section Special tools on page 395 Standard toolkit The content is defined in section Standard toolkit on page 394 Action Note 1 WARNING Handling gearbox oil involves several safety risks Before proceeding plea...

Page 198: ... during filling to avoid overpres sure in the gearbox The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in section Inspection oil level gearbox axis 5 on page 146 Kyodo Yushi TMO 150 Art no and total amount is specified in Required equipment on page 195 Shown in the figure Location of gearbox on page 194 4 Refill the secondary gearbox...

Page 199: ...the different locations of the plug shown as B1 and B2 C Oil plug draining can be located on the turning disk instead D Label specifies the type of oil in gearbox axis 6 Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 850 ml 750 ml with insulated turning disk Kyodo Yushi TMO 150 Oil collecting vessel Vessel capacity 1 000 ml Oil exchange equipment 3HAC17313 1 The content is defined...

Page 200: ...s specified in Required equipment on page 197 Action Note 1 WARNING Handling gearbox oil involves several safety risks Before proceeding please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 40 2 Move the wrist so that the oil plug filling of axis 6 gearbox faces upwards If the oil plug draining is located on the turning disk rotate the disk so ...

Page 201: ...ting oil Make sure the air is ventilated through the oil plug during filling to avoid overpressure in the gearbox If the plug hole for draining is located on the turning disk the air is ventilated through the open plug hole The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in section Inspection oil level gearbox axis 6 on page 149 Art...

Page 202: ...rocedure below details how to remove the SMB battery A SMB battery cover B SMB battery pack C Battery cable Equipment etc Spare part no Note Battery pack 3HAC16831 1 Battery includes protection circuits Replace it only with given spare part no or an ABB approved eqvivalent Standard toolkit The content is defined in section Standard toolkit on page 394 Circuit Diagram See chapter Circuit diagram Ac...

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

Page 204: ...re Location of SMB battery on page 200 4 Secure the SMB battery cover with its attachment screws Shown in the figure Location of SMB battery on page 200 5 Update the revolution counter Detailed in chapter Calibration section Updating revolution counters on page 376 6 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER Fir...

Page 205: ... device as shown in the figure below Note The balancing device must be mounted on the robot when lubricating the bearing xx0200000109 Required equipment A Ear spherical roller bearing located inside B Lubrication nipple or securing screw C Sealing spacer D Hole through which the shaft is pressed Equipment etc Art no Note Grease 3HAA1001 294 Optimol PDO 150 ml Lubrication nipple M6 In case a cable ...

Page 206: ...ricate the spherical roller bearing through the lubrication nipple in the ear with grease Fill until excessive grease is forced out between the shaft and the sealing spacer Art no and amount is specified in Required equipment on page 203 Shown in the figure Location of bearing on page 203 The balancing device must be mounted on the robot when lubricating the bearing 3 Clean the area from any exces...

Page 207: ...s shown in the illustration View from above xx0600002866 Required equipment A Plastic ring bearing cover A Equipment Art no Note Brush Rust preventive 3HAC026621 001 Equivalent Mercasol 3106 Standard toolkit The content is defined in section Standard toolkit on page 394 Other tools and procedures may be required See references to these procedures in the step by step instructions below These proced...

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

Page 209: ...ver B Plastic ring Equipment Art no Note Brush Rust preventive 3HAC026621 001 Equivalent Mercasol 3106 Standard toolkit The content is defined in section Standard toolkit on page 394 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Action Note 1 Put the robot in a suitable ...

Page 210: ...per arm xx0600002872 Parts A Plastic cover B Plastic ring 4 Remove the plastic ring that covers the bearing xx0600002871 Parts A Plastic ring 5 Wipe the surface under the plastic ring 6 Apply rust preventive on the radial sealing and the rear part of the tube with a brush xx0600002868 Parts A Radial sealing and rear part of tube B Plastic ring 7 Refit the plastic ring and cover Action Note Continu...

Page 211: ...e wrist is located as shown in the illustration xx0500002863 Required equipment A Bearing B Cable bracket C Cover Equipment Art no Note Brush Rust preventive 3HAC026621 001 Equivalent Mercasol 3106 Standard toolkit The content is defined in section Standard toolkit on page 394 Other tools and procedures may be required See references to these procedures in the step by step instructions below These...

Page 212: ...ctric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Dismantle the air hose from motor axis 6 4 Tighten the hose clamp on motor axis 6 and remove the air hose 5 Remove the cover according to the illus tration xx0600002864 A Cover 6 Apply rust preventive on the bearing and cable bracket with the brush See Lo...

Page 213: ...ed motion axis 3 15 degrees axis 4 6 maximum working range with regard to the installation limitation axis 4 and 5 90 degrees axis 6 180 degrees Draining the gearbox properly The contaminated gearbox must be drained properly before and during the flushing procedure Axis 4 gearbox open both oil plugs filling and draining and run axis 3 in different directions Draw out the last volume approx 40 60 m...

Page 214: ...ut 30 35º C Use the finger tips to measure the temperature Recommendedserviceprogram detailed in section above Service program 2 Drain the gearbox properly Described in section above Draining the gearbox properly on page 211 3 Fill the gearbox with 700 ml of lubricating oil Shell Tivela S 150 001A9646 Art no is specified in Required equipment on page 211 4 Refit the oil plug Tightening torque 24 N...

Page 215: ...cleaning of the robot Periodicity The periodicity of cleaning the robot varies a great deal depending on the actual environment and function of the robot A contaminated robot should be cleaned as required Special points Special points to be observed are shown in the figure below xx0100000265 A Spiral cables to motor 5 B Inside of upper arm tube C Rear of upper arm tube D Inside of lower arm E Insi...

Page 216: ...pressure cleaner onto the sealing cup at the bottom of the motor 6 spiral cable item A in the figure Special points Foundry versions In working environments for example foundries where the robot may be exposed to fluids that dry to make a crusty surface for example release agents clean the cable harnesses so that the crust does not damage the cables Clean the spiral wound cables to motor 5 item A ...

Page 217: ...he component location on the robot Required equipment All equipment required to perform a specific repair activity is listed together with the current procedure The equipment is also gathered in different lists in the Product manual reference information The equipment is also gathered in different lists in the chapter Reference information Safety information Before any service work is commenced it...

Page 218: ...hich are included in the leakdown tester kit Art no is specified in Required equipment on page 216 3 Apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer Recommended value 0 2 0 25 bar 20 25 kPa 4 Disconnect the compressed air supply 5 Wait for approx 8 10 minutes No pressure loss must be detected If the compressed air is signifi cantly colder...

Page 219: ... 1 Used to grease the bearings if not specified otherwise Action Note 1 To avoid contamination let a new bearing remain in its wrapping until it is time for fitting 2 Ensure that all parts included in the bearing fitting are free from burrs grinding waste and other contamination Cast components must be free from foundry sand 3 Bearing rings inner rings and roller elements must under no cir cumstan...

Page 220: ...g fitting the bearing may be totally filled with grease when mounted as excessive grease will be pressed out from the bearing when the robot is started During operation the bearing should be filled to 70 80 of the available volume Ensure that grease is handled and stored properly to avoid contamination Grease the different types of bearings as detailed below Grooved ball bearings must be filled wi...

Page 221: ...to lubricate the seals Action Note 1 Check the seal to ensure that the seal is of the correct type provided with cutting edge there is no damage to the sealing edge feel with a fingernail 2 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced as it may result in future leakage 3 Lubricate the seal with grease just before fitting Not too early as th...

Page 222: ...ver the surface preferably with a brush 4 Tighten the screws evenly when fastening the flange joint Action Action Note 1 Ensure that the correct o ring size is used 2 Check the o ring for surface defects burrs shape accuracy etc Defective o rings may not be used 3 Check the o ring grooves The grooves must be geometrically correct and free from pores and contamination Defective o rings may not be u...

Page 223: ...es are distinguished some from each other Any differences are pointed out in the procedures xx0100000140 1 Alternative with brake release at frame 2 Alternative with brake release at base A Connector at robot base R1 MP and R1 SMB B Connectors at motor 1 R2 FB1 and R2 MP1 C Connectors at motor 2 R2 FB2 and R2 MP2 D Connectors at serial measurement board R1 SMB1 3 R1 SMB4 6 R1 SMB1 7 R2 FB7 and R2 ...

Page 224: ... harness axes 1 4 3HAC14940 1 Brake release located in frame Locking liquid Loctite 638 Used to secure the attachment screws for the attachment plate inside the frame Standard toolkit The content is defined in section Standard toolkit on page 394 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references ...

Page 225: ...n the figure Location of cable harness on page 221 6 Pull the cable and connectors up through the cable guide in the center of the frame 7 Disconnect all connectors at motors 1 and 2 Specified and shown in the figure Location of cable harness on page 221 8 Open the SMB cover carefully The cable between the battery and the SMB unit may stay connected in order to avoid an update of the revolution co...

Page 226: ...e C by removing the attachment screws and the velcro strap D NOTE Different robot versions are fitted with different versions of the attachment plate When replacing the cable harness make sure the correct one is used to avoid cable failure xx0300000560 A Cable gland B Attachment screws cable gland C Attachment plate D Velcro strap 11 Remove the cable gland securing the cables inside the lower arm ...

Page 227: ...t at the arm house Shown in the figure Location of cable harness on page 221 14 Disconnect connector R2 M5 6 at the cable division point Shown in the figure Location of cable harness on page 221 15 Disconnect all connectors at motor 3 and motor 4 Specified and shown in the figure Location of cable harness on page 221 16 Gently pull the cable harness out Action Note Action Note 1 DANGER Turn off al...

Page 228: ...isted with each other or with eventual customer harnesses Make a note of the correct positions of the connectors 4 Reconnect connectors R1 MP and R1 SMB at the rear cover plate Make a note of the correct positions of the connectors Attachment point is shown in the figure Location of cable harness on page 221 5 Reconnect the earth cable Attachment point is shown in the figure Location of cable harn...

Page 229: ...te C to the cable gland with its two attachment screws using locking liquid Refit the velcro strap D NOTE Different robot versions are fitted with different versions of the attachment plate Make sure the correct one is used to avoid cable failure Locking liquid is specified in Required equipment on page 222 xx0300000560 A Cable gland B Attachment screws cable gland C Attachment plate D Velcro stra...

Page 230: ...0000118 10 Secure the SMB cover with its attachment screws 11 WARNING Before continuing any service work please observe the safety information in section WARNING The brake release buttons may be jammed after service work on page 37 12 Pull the cable harness through the lower arm 13 Refit the cable gland securing the cables inside the lower arm xx0100000142 14 Refit the cable gland securing the cab...

Page 231: ...lready mounted with two securing screws A M6x16 Secure the cable harness with two velcro straps B with a distance of approximately 180 mm Fix the strap by wrapping it two turns around the largest cable before wrapping around the complete harness xx0500002320 19 Refit the cable harness to the guide plate axis 2 Shown in the figure Location of cable harness on page 221 20 Refit the velcro strap at t...

Page 232: ... Cable attachment rear C Connector at cable harness division R2 M5 6 D Connectors at motor 5 R3 FB5 and R3 MP5 E Connectors at motor 6 R3 FB6 and R3 MP6 Equipment etc Spare part no Note Cable harness ax 5 6 3HAC11440 1 Standard toolkit The content is defined in section Standard toolkit on page 394 Other tools and procedures may be required See references to these procedures in the step by step ins...

Page 233: ...e correct position 90º to allow the motor 6 cover to open 5 Disconnect all connectors at motor 5 and motor 6 Specified in the figure Location of cable harness ax 5 6 on page 230 6 Remove the plastic cover on the rear of the upper arm by removing the attachment screws 7 Remove the spiral plate by unscrewing the screw at the bottom of the spiral cup 8 Remove eventual cable straps from the harness 9 ...

Page 234: ... is not the maximum 7 Reconnect all connectors at motor 5 and motor 6 Specified in the figure Location of cable harness ax 5 6 on page 230 8 Secure the cable with the cable attachment inside the upper arm 9 Refit the left hand side wrist cover with its attachment screws 10 Reconnect connector R2 M5 6 gently at the cable harness division with two screws M6 Be careful not to bend the attachment plat...

Page 235: ... complete arm system The complete arm system is defined as the complete robot except for the base and gearbox axis 1 that is the upper and lower arms balancing device and frame This is shown in the figure below xx0100000150 A Gearbox axis 1 B Motor axis 1 C Base attachment screws D Upper arm E Lower arm F Frame G Balancing device H Block for calibration Continues on next page ...

Page 236: ...es to these procedures in the step by step instructions below These procedures include references to the tools required Action Note 1 Position the robot in its most stable position as shown in the figure to the right If the brakes need to be released see section Manually releasing the brakes on page 72 xx0100000103 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to t...

Page 237: ...ent screws Shown in the figure Location of complete arm system on page 233 10 Lift the arm system and secure it in a safe area Make sure all hooks and attachments maintain in correct position while lifting the robot Always move the robot at very low speeds making sure it does not tip Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot...

Page 238: ...amage 7 Refit 22 of the 24 attachment screws before the arm system is completely lowered 8 Remove the guide pins and secure the arm system to the base with the 24 base attachment screws and washers Shown in the figure Location of complete arm system on page 233 24 pcs M12 x 110 12 9 quality UNBRAKO tightening torque 110 Nm Reused screws may be used providing they are lubricated as detailed in sect...

Page 239: ... 001 Revision E Copyright 2004 2008 ABB All rights reserved 14 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 36 Action Note Continued ...

Page 240: ...004 2008 ABB All rights reserved 4 3 4 Replacement of air nipple and hose Foundry Prime Location The illustration below shows the routing of the Foundry Prime air hose xx0500002176 Hose lengths xx0600003157 Pos 1A Hose length 40 mm Pos 1B Hose length 40 mm Pos 1C Hose length 1570 mm Continues on next page ...

Page 241: ...nnector C T plug connector a Balancing cylinder rear end b Motor axis 1 c Battery cover d Motor axis 2 e Length 805 mm f Motor axis 6 g Rubber clamp on washer on gear axis 6 h Rubber clamp on tilthouse j Rubber clamp on wrist cover k Motor axis 5 m Motor axis 3 n Motor axis 4 o Bulkhead plug connector Equipment Art no Pos in illustration Velcro strap 3HAC12625 1 9 only in illustrations below Cable...

Page 242: ...lengths on page 238and the table in Required equipment on page 239 Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 2 Locate the damaged hose or air connector and continue to replace the damaged hose Route the hose according to the illustrations in the procedure below 3 Connection at base xx0600003042 Items in illustration are detailed in Requ...

Page 243: ...ple and hose Foundry Prime 241 3HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved 5 Balancing device xx0600003397 Item in illustration is detailed in Hose lengths on page 238 Action Note Continued Continues on next page ...

Page 244: ...Replacement of air nipple and hose Foundry Prime 3HAC022033 001 Revision E 242 Copyright 2004 2008 ABB All rights reserved 6 Axis 1 2 xx0600003418 xx0600003420 xx0600003045 Action Note Continued Continues on next page ...

Page 245: ... Foundry Prime 243 3HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved 7 Upper arm housing xx0600003046 xx0600003047 8 Tube shaft xx0600003163 1P Lay the hose in a spiral in the tube shaft Action Note Continued Continues on next page ...

Page 246: ...ple and hose Foundry Prime 3HAC022033 001 Revision E 244 Copyright 2004 2008 ABB All rights reserved 9 Wrist NOTE Make sure the cable length from 5a to the nipple of axis 6 S see Hose lengths on page 238 xx0600003097 Action Note Continued ...

Page 247: ...iews in the Product manual reference information xx0100000129 Required equipment A Turning disk B Oil plug filling oil plug for draining is located on the opposite side of the tilthouse C Turning disk attachment screws 33 pcs Equipment etc Spare part no Art no Note Turning disk dia 250 3HAC13193 1 Does not include o ring Turning disk insulated 3HAC023124 002 O ring 21522012 433 Must be replaced wh...

Page 248: ...uired Equipment etc Spare part no Art no Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Drain the oil from gearbox 6 Detailed in section Oil change gearbox axis 6 on page 197 3 Remove the turning disk by unscrewing its 33 attachment screws Shown in the figure ...

Page 249: ... disk with 33 attachment screws M10 x 25 12 9 quality UNBRAKO tightening torque 50 Nm Reused screws may be used providing they are lubricated as detailed in section Screw joints on page 390 before fitting 4 Refill the gearbox axis 6 with oil Detailed in section Filling oil gearbox axis 6 on page 198 5 DANGER Make sure all safety requirements are met when performing the first test run These are fur...

Page 250: ...e Product manual reference information xx0100000147 Required equipment A Wrist unit B Wrist unit attachment screws and washers C Attachment cable harness axis 5 6 D Connectors at cable harness division R2 M5 6 E Turning disk F Cover axis 5 G Rear cover H View with cable harness mounted on robot Equipment etc Spare part no Art no Note Wrist type 3 3HAC16628 4 Wrist insulated 3HAC16628 3 Wrist Found...

Page 251: ...pment fitted to the turning disk 3 Turn axis 4 to a position where the cover axis 5 faces upwards Shown in the figure Location of wrist unit on page 248 4 Remove the cover axis 5 by unscrewing its attachment screws 5 CAUTION The complete wrist unit weighs 200 kg All lifting equipment used must be sized accordingly 6 Fit the lifting tool wrist unit to the two holes on the sealing surface against th...

Page 252: ...ingly 3 Remove the cover axis 5 from the wrist unit to be fitted Fit the lifting tool wrist unit to the wrist unit Art no is specified in Required equipment on page 248 4 Lift the wrist unit and move it to its mounting position 5 Fit a new friction washer between the upper arm tube and the wrist unit Art no is specified in Required equipment on page 248 6 Gently pull the wrist unit cable harness t...

Page 253: ...6 Detailed in sections Inspection oil level gearbox axis 5 on page 146 Inspection oil level gearbox axis 6 on page 149 14 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 371 15 Refit any equipment previously removed from the turning disk 16 DANGE...

Page 254: ... detailed view of the component and its position may be found in chapter Exploded views in the Product manual reference information xx0100000148 A Upper arm B Attachment screws upper arm C Connectors at cable harness division R2 M5 6 D Rear cable attachment E Oil plug draining F Oil plug filling G Attachment hole M12 H Sealing between lower arm and gearbox 3 J Attachment holes for lifting device u...

Page 255: ...required See references to these procedures in the step by step instructions below These procedures include references to the tools required Action Note 1 Run the upper arm to a horizontal position 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 CAUTION The complete upper arm w...

Page 256: ...ision point as well as all remaining connections to the upper arm 10 Disconnect all connectors inside motors 3 and 4 11 Remove all brackets securing cabling to the upper arm by unscrewing their attachment screws respectively 12 Raise the lifting equipment to take the weight of the upper arm 13 Carefully remove the upper arm attachment screws Make sure that the upper arm is lifted in a completely l...

Page 257: ...quipment on page 253 5 Fit one of the pieces included in the lifting device upper arm to the attachment holes for lifting device upper arm using the included attachment screws Shown in the figure Location of upper arm on page 252 Art no is specified in Required equipment on page 253 6 Run the lifting chain from the rear lifting point through the overhead crane hook through the hoisting block to th...

Page 258: ...e the guide pins and fit the two remaining attachment screws Tighten them as detailed above 13 Refit any cabling removed during the removal process 14 Reconnect all connectors inside motors 3 and 4 15 Reconnect connector R2 M5 6 gently at the rear cable division point Be careful not to bend the attachment plate when fastening the screws 16 Refill the gearbox with oil Detailed in section Filling oi...

Page 259: ...n the Product manual reference information xx0100000149 Attachment points lower arm The lower arm attachment points are located as shown in the figure below The figure 1 shows gearbox 3 but the location of sealing axis 2 3 in relation to the gearbox is identical for axis 3 The figure 2 shows a cut view through the lower arm pivot point in axis 2 item B in the figure above A Lower arm B Pivot point...

Page 260: ...e piston rod ear D Frame E Shaft hole 201 Sealing axis 2 3 202 Attachment screw 204 Washer 401 Bearing 402 Thrust washer 403 Bushing 404 Retaining ring 405 Shaft 406 Protection plug 409 Protection washer Equipment etc Spare part no Art no Note Bearing 3HAC4310 1 Always use a new bearing Sealing axis 2 3 3HAC11054 1 Always use a new sealing VK cover 3HAA2166 23 Continued Continues on next page ...

Page 261: ...draulic pump 150 MPa Glycerin 3HAC021563 012 To be used together with the press tool axis 2 shaft and the puller tool Press device axis 2 shaft 3HAC021600 001 Press tool axis 2 bearing 3HAC13453 1 Power supply 24 VDC 1 5 A For releasing the brakes Retaining ring pliers Standard toolkit The content is defined in section Standard toolkit on page 394 Calibration Pendulum toolkit 3HAC15716 1 Complete ...

Page 262: ... Unloading the balancing device on page 290 6 Remove the securing screw from the balancing device front shaft Shown in the figure Location of lower arm on page 257 7 Apply the shaft puller tool to the shaft through the hole in the frame The shaft has a M20 thread diameter and a 40 mm depth of thread as shown in the figure to the right Pull the shaft out using the puller tool and the hydraulic pump...

Page 263: ...hown in the figure to the right and mount both the hydraulic pump and the glycerin pump to it Art no is specified in Required equipment on page 258 xx0300000010 17 Increase the pressure of the glycerin pump and at the same time pull out the shaft with the puller tool by increasing the pressure of the hydraulic pump Do not exceed the limit of maximum pressure classified for the pumps 18 Remove the ...

Page 264: ...new VK cover on new lower arm or replace existing if damaged Spare part no is specified in Required equipment on page 258 3 Fit the two guidings in the attachment holes of the lower arm Included in the lifting tool lower arm art no is specified in Required equipment on page 258 xx0200000262 A Attachment holes for the two guidings 4 Fit the new sealing axis 2 3 on the guidings Always use a new seal...

Page 265: ... Secure the lower arm with 28 of the 30 attachment screws and washers in gearbox 2 30 pcs M16 x 50 tightening torque 300 Nm Shown in the figure Attachment points lower arm on page 257 10 Remove the guidings and secure the two remaining attachment screws as detailed above 11 Apply grease to the shaft hole Art no is specified in Required equipment on page 258 12 Push the shaft in by hand xx030000001...

Page 266: ...is to be mounted 22 Press the bearing in with the press tool axis 2 bearing Always use a new bearing when reas sembling Art no is specified in Required equipment on page 258 23 Refit the protection washer and the retaining ring Shown in the figure Attachment points lower arm on page 257 24 Refit the protection plug Shown in the figure Attachment points lower arm on page 257 25 Refit and restore th...

Page 267: ...001 Revision E Copyright 2004 2008 ABB All rights reserved 31 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 36 Action Note Continued ...

Page 268: ...eft hand side of the frame as shown in the figure below xx0200000203 Required equipment A SMB cover B SMB unit C Pins D Battery cable Equipment etc Spare part no Art no Note SMB unit 3HAC16014 1 Brush Option Foundry prime Rust preventive 3HAC026621 001 Option Foundry prime Equivalent Mercasol 3106 Standard toolkit The content is defined in section Standard toolkit on page 394 Circuit Diagram See c...

Page 269: ...WARNING The unit is sensitive to ESD on page 38 4 Remove the SMB cover by unscrewing its attachment screws Shown in the figure Location of SMB unit on page 266 5 Remove the connectors X8 X9 and X10 from the brake release board if need of more space 6 Remove the nuts and washers from the pins securing the board Shown in the figure Location of SMB unit on page 266 7 Gently disconnect the connectors ...

Page 270: ...nit onto the pins Art no is specified in Required equipment on page 266 Shown in the figure Location of SMB unit on page 266 R1 SMB1 3 R1 SMB4 6 and R2 SMB 5 Secure the SMB unit to the pins with the nuts and washers 6 If disconnected reconnect the connectors X8 X9 and X10 to the brake release board 7 Secure the SMB cover with its attachment screws Shown in the figure Location of SMB unit on page 2...

Page 271: ...267 5 NOTE Make sure that the gasket under the SMB cover is not damaged Secure the SMB cover with its attachment screws 6 Apply rust preventive on the surface around the SMB cover and under on top of the screw heads 7 Perform a leakdown test according to Inspection of air hoses Foundry Prime on page 176 8 Update the revolution counter Detailed in chapter Calibration section Updating revolution cou...

Page 272: ... includes a brake release unit with or without push buttons located at the base The later design instead includes a brake release unit with push buttons placed together with the SMB unit on the left hand side of the frame The different designs are not compatible Location of brake release unit base The early design includes a brake release unit with or without push buttons located at the base as sh...

Page 273: ...rt no Note Brake release circuit without buttons at base 3HAC14219 1 Brake release at the base according to figure Location of brake release unit base on page 270 Includes brake release unit 3HAC14228 1 Brake release circuit with buttons at base 3HAC12989 1 Brake release at the base according to figure Location of brake release unit base on page 270 Includes brake release unit 3HAC16036 1 Brake re...

Page 274: ...he tools required Equipment etc Spare part no Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 esd WARNING The unit is sensitive to ESD before handling the unit please observe the safety information in section WARNING The unit is sensitive to ESD on page 38 3 Re...

Page 275: ...nsure a correct refitting of the brake release unit 4 Remove the SMB cover by unscrewing the attachment screws Let the battery stay connected to avoid the need of synchronization of the robot Shown in the figure Location of brake release unit frame on page 271 5 Disconnect the connectors X8 X9 and X10 from the brake release unit xx0200000129 A Connector X8 B Connector X9 C Connector X10 D Push but...

Page 276: ...in the base of the robot Spare part no is specified in Required equipment on page 271 Shown in the figure Location of brake release unit base on page 270 3 Reconnect the cable to the brake release circuit 4 Fasten the attachment screws brake release circuit on the outside of the rear of the base Shown in the figure Location of brake release unit base on page 270 5 Refit the cover of the rear of th...

Page 277: ...g any service work please observe the safety information in section WARNING The brake release buttons may be jammed after service work on page 37 6 Refit the push button guard on the SMB cover Shown in the figure Location of brake release unit frame on page 271 7 If the battery has been disconnected the revolution counters must be updated Detailed in section Updating revolution counters on page 37...

Page 278: ...lancing device is located on rear top of the frame as shown in the figure below xx0100000139 A Balancing device B Rear cover C Support shaft inside included in balancing device 3HAC14675 1 D Attachment screws rear cover E Balancing device shaft including screw and washer F Bearing attachment G Parallel pin inside bearing attachment H Attachment screws bearing attachment Continues on next page ...

Page 279: ...ated as shown in the figure below xx0600002653 A Attachment hole for lifting eye M12 B Attachment hole for securing screw that secures the bearing attachment to the balancing device protection plug fitted normally C Hole in frame to access the balancing device front eye shaft with the puller press tool D Attachment hole for locking screw that secures the lower arm to the frame Continued Continues ...

Page 280: ...aft Grease 3HAA1001 294 150 ml Optimol PDO For lubrication of spherical roller bearing in ear in case of new balancing device Brush Rust preventive 3HAC026621 001 Equivalent Mercasol 3106 Locking liquid Loctite 243 To apply to the securing screw in the shaft Grease pump To lubricate spherical roller bearing Guide pins M16 x 300 3HAC13120 5 Always use guide pins in pairs Lifting eye M12 3HAC14457 3...

Page 281: ...rew into the attachment hole in the frame Attachment hole for the locking screw is shown in the figure Attachment points balancing device on page 277 Art no is specified in Required equipment on page 278 4 CAUTION The balancing device weighs 300 kg All lifting equipment used must be sized accordingly 5 Fit the lifting eye M12 to the balancing device and raise to unload the weight Art no is specifi...

Page 282: ...nts to the balancing device by replacing the protection plug on the outside of each attachment with securing screws The protection plugs must be refitted after refitting the balancing device do not loose them Shown in the figure Attachment points balancing device on page 277 Dimensions for the securing screws are specified in Required equipment on page 278 11 Remove the two bearing attachments fro...

Page 283: ... points balancing device on page 277 Dimension of the securing screws is specified in Required equipment on page 278 4 Refit the two parallel pins in the frame Shown in the figure Location of balancing device on page 276 5 Fit two guide pins to the upper holes in the frame where the bearing attachments are to be attached 6 Fit the lifting eye to the balancing device Art no is specified in Required...

Page 284: ... then pressed in when fitting the shaft 15 Lubricate the shaft with grease Art no is specified in Required equipment on page 278 16 Apply the shaft press tool to the lubricated shaft Fit the shaft to the piston shaft front eye through the hole in the frame using the shaft press tool and the hydraulic pump The hole in the frame is shown in the figure Attachment points balancing device on page 277 A...

Page 285: ...ng device is a safety device for the piston rod during operation Make sure the cover is properly secured before commissioning of the robot 21 Remove the locking screw that secures the lower arm to the frame xx0200000454 1 Attachment hole for the securing screw 22 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First t...

Page 286: ...p press the sealing back in place wipe off surplus material xx0600003131 A Sealing spacers 3 Apply Mercasol 3106 to the shaft and hole in frame xx0600003130 A Mercasol on shaft and in hole B Mercasol between piston rod and ear 4 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage ...

Page 287: ... front ear of the balancing device as shown in the figure below xx0500002249 Required equipment A Spherical roller bearing B Sealing ring C O ring D Sealing spacer E Front ear of balancing device Equipment Spare part no Art no Note Spherical roller bearing 3HAA2167 17 Sealing spacer 3HAC12988 1 2 pcs required O ring 3HAB3772 76 2 pcs required Sealing ring 3HAC11581 6 2 pcs required Grease 3HAB3537...

Page 288: ... tool 3HAC15941 1 Press tool 3HAC15846 1 Hexagon nut M12 9ADA267 9 Plain washer 9ADA312 9 The tools in the set are shown in the figure Tool set on page 286 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Equipment Spare part no Art no Note A Threaded bar B Dolly C Press to...

Page 289: ...ove the balancing device from the robot Detailed in section Removal balancing device on page 279 3 Remove the both sealing spacers with a screwdriver or any equal tool Shown in the figure Location of bearing on page 285 4 Insert the threaded bar through the bearing 5 Fit the press tool and dolly to the threaded bar Secure with the nut and washer at each end xx0500002255 A Threaded bar 3HAC15945 1 ...

Page 290: ...ling spacers Spare part no s are specified in Required equipment on page 285 6 Press in the sealing spacers with the press tools as shown in the figure to the right Secure the press tool and dolly with nuts and washers NOTE Fit the sealing spacers one at a time xx0500002258 A Threaded bar 3HAC15945 1 B Dolly 3HAC15948 1 C Press tool 3HAC15846 1 7 Refit the balancing device to the robot Detailed in...

Page 291: ... 3HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved 10 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 36 Action Note Continued ...

Page 292: ...g device How to secure the lower arm is detailed in the current repair activity for example removal of the balancing device Press tool and hydraulic cylinder The figure below shows the hydraulic cylinder mounted on the press tool The press tool includes two press devices that are used to different models of the balancing device xx0200000174 A Press block B Hydraulic cylinder C Press device D Bolt ...

Page 293: ...evice Equipment etc Art no Note Press tool balancing device 3HAC020902 001 Includes press device 3HAC15767 2 press device 3HAC18100 1 Choose the correct device depending on model of balancing device Hydraulic cylinder 3HAC11731 1 To be used with the press tool Hydraulic pump 80 MPa 3HAC13086 1 To be used with the hydraulic cylinder Standard toolkit The content is defined in section Standard toolki...

Page 294: ...e the rear cover of the balancing device by unscrewing the attachment screws xx0200000175 E Rear cover attachment screws 4 pcs 4 Remove the o ring from the balancing device end 5 Remove the support shaft 6 Fit the press tool to the rear of the balancing device with enclosed bolts Tighten them properly Art no is specified in Required equipment on page 291 See the figure Press tool and hydraulic cyl...

Page 295: ...BB All rights reserved 10 Turn the fix plate to position Closed in order to lock the tool in loaded condition See the figure Press tool and hydraulic cylinder on page 290 11 Unload the hydraulic cylinder 12 The hydraulic cylinder may now be removed from the tool when necessary Action Note Continued ...

Page 296: ...cylinder mounted on the press tool The press tool includes two press devices that are used to different models of the balancing device xx0200000174 Required equipment A Press block B Hydraulic cylinder C Press device D Bolt press device E Moving pin with marking F Bolt 4 pcs G Pin attached to the fix plate Equipment etc Art no Note Hydraulic cylinder 3HAC11731 1 To be used with press tool Hydrauli...

Page 297: ...ess tool and hydraulic cylinder on page 294 Do not apply more pressure than necessary it could damage bearings and sealings at the shaft 3 Unload the cylinder and make sure the moving pin indicates that the tool has returned to its starting position Shown in the figure Press tool and hydraulic cylinder on page 294 4 Remove the hydraulic cylinder 5 Remove the press tool by unscrewing the bolts Show...

Page 298: ...1 Revision E 296 Copyright 2004 2008 ABB All rights reserved 10 DANGER The rear cover of the balancing device is a safety device for the piston rod during operation Make sure the cover is properly secured before commissioning of the robot Action Note Continued ...

Page 299: ...gure below xx0100000123 Required equipment A Motor axis 1 B Cable gland cover motor axis C Cover for connector access D Motor attachment screws Equipment etc Spare part no Art no Note Motor axis 1 3HAC14207 1 Includes motor pinion o ring 21522012 430 O ring 21522012 430 Must be replaced when reassembling motor Sikaflex 521FC 3HAC026759 001 Option Foundry Prime Brush Option Foundry Prime Mercasol 3...

Page 300: ...kes Standard toolkit The content is defined in section Standard toolkit on page 394 Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Other tools and procedures may be required See references to these procedures in the step by step instruc tions below These procedures include references to the tools required Circuit Diagram See chapter Circuit diagram Equipm...

Page 301: ...four attachment screws and plain washers If required use the extension 300mm for bits 1 2 Shown in the figure Location of motor on page 297 Art no is specified in Required equipment on page 297 8 If required press the motor out of position by fitting removal tool motor to the motor attachment screw holes Art no is specified in Required equipment on page 297 Always use the removal tools in pairs 9 ...

Page 302: ... connection of motorcable forwards Make sure the motor pinion does not get damaged 7 Secure the motor with its four attachment screws and plain washers M10 x 40 tightening torque 50 Nm 8 Disconnect the brake release voltage 9 Reconnect all connectors beneath the motor cover 10 Refit the cable gland cover at the cable exit with its two attachment screws Make sure the cover is tightly sealed 11 Refi...

Page 303: ...ures with the following additions Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Remove the cover for connector access on top of the motor by unscrewing its four attachment screws xx0600002874 A Attachment screw B Air hose C Top cover D Motor unit 3 NOTE Keep the o...

Page 304: ...knife xx0600002875 A Motor unit B Sikaflex in screw recesses 6 Continue to refit the new motor according to section Refitting motor axis 1 on page 299 7 After mounting the motor on the robot the surface between the motor and the base frame must be protected with Mercasol 3106 xx0600002877 A Base frame B Motor unit 8 Perform a leak test according to Inspection of air hoses Foundry Prime on page 176...

Page 305: ...w Equipment etc Spare part no Art no Note Motor axis 2 IRB 7600 500 2 3 IRB 7600 400 2 55 IRB 7600 340 2 8 IRB 7600 150 3 5 3HAC14209 2 Includes motor pinion o ring 2152 2012 430 Motor axis 2 IRB7600 500 2 55 IRB7600 325 3 1 3HAC025819 001 Includes motor pinion o ring 2152 2012 430 O ring 21522012 430 Must be replaced when reassembling motor Sikaflex 521FC 3HAC026759 001 Option Foundry Prime Gaske...

Page 306: ...y 24 VDC 1 5 A For releasing the brakes Rotation tool 3HAC17105 1 Used to rotate the motor pinion when mating it to the gear when brakes are released with 24VDC power supply Standard toolkit The content is defined in section Standard toolkit on page 394 Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Other tools and procedures may be required See reference...

Page 307: ...re the weight of the lower arm properly before releasing the brakes of motor axis 2 When releasing the holding brakes of the motor the lower arm will be movable and may fall down Use the lock screw to lock the lower arm as detailed above 9 In order to release the brake connect the 24 VDC power supply Connect to connector R2 MP2 pin 2 pin 5 10 Remove the motor by unscrewing its four attachment scre...

Page 308: ...s seated properly Lightly lubricate the o ring with grease Art no is specified in Required equipment on page 303 3 In order to release the brake remove the cover on top of the motor and connect the 24 VDC power supply Connect to connector R2 MP2 pin 2 pin5 4 Fit the lifting tool motor axis 2 3 4 to the motor Art no is specified in Required equipment on page 303 5 Fit the two guide pins in the two ...

Page 309: ...se voltage 13 Reconnect all connectors beneath the motor cover Connect in accordance with markings on connectors 14 Refit the cable gland cover at the cable exit with its two attachment screws Shown in the figure Location of motor on page 303 15 Refit the cover on top of the motor with its four attachment screws Make sure the cover is tightly sealed 16 Remove the lock screw from the hole for lock ...

Page 310: ...be inserted into the hole for lock screw Shown in the figure Location of motor on page 303 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot 3 Lock the lower arm by inserting the lock screw into the hole Art no and dimension is specified in Required equipment on page 303 4 Drain the oil from gearbox axis 2 Detailed in section Oil change gearbox axis 2 on p...

Page 311: ...down 9 After the weight of the lower arm is properly secured continue removal of the motor unit as detailed in section Removal motor on page 304 10 Fill the four screw recesses on the new motor with Sikaflex After hardening Sikaflex can be formed with a knife xx0600002875 A Motor unit B Sikaflex in screw recesses 11 Continue to refit the new motor according to section Refitting motor on page 306 1...

Page 312: ...3 3HAC14209 1 Includes motor pinion o ring 21522012 430 O ring 21522012 430 Must be replaced when reas sembling motor Sikaflex 521FC 3HAC026759 001 Option Foundry Prime Gasket 3HAC3438 1 Option Foundry Prime Mech stop ax 3 3HAC12708 2 May be used to fix axis 3 Use attachment screws 3HAB 3409 86 M16 x 60 Grease 3HAB3537 1 For lubricating the o ring Removal tool motor M12x 3HAC14973 1 Always use the...

Page 313: ...y 24 VDC max 1 5 A For releasing the brakes Standard toolkit The content is defined in section Standard toolkit on page 394 Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Circuit Dia...

Page 314: ...ews 6 Remove the cable gland cover at the cable exit by unscrewing its two securing screws Shown in the figure Location of motor on page 310 Make sure the gasket is not damaged 7 Disconnect all connectors beneath the motor cover 8 DANGER Secure the weight of the upper arm properly before releasing the brakes of motor axis 3 When releasing the holding brakes of the motor the upper arm will be movab...

Page 315: ... sure the o ring on the circumference of the motor is seated properly Lightly lubricate it with grease Art no is specified in Required equipment on page 310 3 Fit the lifting tool motor axis 2 3 4 to the motor Art no is specified in Required equipment on page 310 4 Fit the two guide pins in the two lower motor attachment holes Art no is specified in Required equipment on page 310 Shown in the figu...

Page 316: ...ening torque 50 Nm Art no is specified in Required equipment on page 310 12 Disconnect the brake release voltage 13 Reconnect all connectors beneath the motor cover Connect in accordance with markings on connectors 14 Refit the cable gland cover at the cable exit with its two attachment screws Make sure the cover is tightly sealed Shown in the figure Location of motor on page 310 15 Refit the cove...

Page 317: ...all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 36 Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Remove the motor according to step 2 4 in...

Page 318: ...g to step 6 and forwards in section Removal motor on page 311 6 Fill the four screw recesses on the new motor with Sikaflex After hardening Sikaflex can be formed with a knife xx0600002875 A Motor unit B Sikaflex in screw recesses 7 Continue to refitt the new motor according to section Refitting motor on page 313 8 Perform a leak test according to Inspection of air hoses Foundry Prime on page 176 ...

Page 319: ...ncludes motor pinion o ring 21522012 430 O ring 21522012 430 Must be replaced when reas sembling motor Sikaflex 521FC 3HAC026759 001 Option Foundry Prime Gasket 3HAC3438 1 Option Foundry Prime Lifting tool motor ax 1 4 5 3HAC14459 1 Lifting tool motor ax 2 3 4 3HAC14459 1 Lifting tool motor ax 2 3 4 3HAC14459 1 Grease 3HAC3537 1 Used to lubricate the o ring Lifting tool motor ax 1 4 5 3HAC14459 1 ...

Page 320: ...1 Complete kit that also includes operating manual Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Circuit Diagram See chapter Circuit diagram Equipment etc Spare part no Art no Note Action Note 1 Move the upper arm to one of the basic positions upper arm is pointed straig...

Page 321: ...e brake connect the 24 VDC power supply Connect to connector R2 MP4 pin 2 pin 5 9 CAUTION The motor weighs 22 kg All lifting equipment used must be sized accordingly 10 Unscrew the motors four attachment screws and plain washers Shown in the figure Location of motor on page 317 11 Fit the two guide pins in two of the motor attachment screw holes 12 If required press the motor out of position by fi...

Page 322: ...ting equipment used must be sized accordingly 4 Fit the lifting tool to the motor Choose the correct lifting tool lifting tool motor axis 1 4 and 5 if the upper arm is positioned vertically lifting tool motor axis 2 3 and 4 if the upper arm is positioned hori zontally Art no is specified in Required equipment on page 317 5 In order to release the brakes connect the 24 VDC power supply Connect to c...

Page 323: ...ed equipment on page 317 11 Disconnect the brake release voltage 12 Reconnect all connectors beneath the motor cover 13 Refit the cover on top of the motor with its four attachment screws Make sure the cover is tightly sealed 14 Refit the cable gland cover at the cable exit with its two attachment screws Shown in the figure Location of motor on page 317 15 Perform a leak down test if gearbox has b...

Page 324: ...ocedures with the following additions Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Remove the cover for connector access on top of the motor by unscrewing its four attachment screws xx0600002874 A Attachment screw B Air hose C Top cover D Motor unit 3 NOTE Keep t...

Page 325: ...ecesses on the new motor with Sikaflex After hardening Sikaflex can be formed with a knife xx0600002875 A Motor unit B Sikaflex in screw recesses 6 Continue to refit the new motor according to section Refitting motor axis 4 on page 320 7 Perform a leak test according to Inspection of air hoses Foundry Prime on page 176 Action Note Continued ...

Page 326: ...art no Art no Note Motor axis 5 3HAC14725 1 Includes motor pinion o ring 21522012 430 O ring 21522012 430 Must be replaced when replacing motor Grease 3HAB3537 1 For lubricating the o ring Standard toolkit The content is defined in section Standard toolkit on page 394 Guide pins M10 x 100 3HAC15521 1 For guiding the motor Guide pins M10 x 150 3HAC15521 2 For guiding the motor Lifting tool motor ax...

Page 327: ...ressure to motors and SMB 3 Remove the left hand side cover of the wrist unit by unscrewing its six attachment screws The motor is accessible behind the rear part of the cover 4 Remove the heat protection plate by unscrewing its two attachment screws Shown in the figure Location of motor on page 324 5 Remove the cover on top of the motor by unscrewing its four attachment screws 6 Remove the cable ...

Page 328: ...ll electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Make sure the o ring on the circumference of the motor is seated properly Lightly lubricate the o ring with grease Art no is specified in Required equipment on page 324 3 CAUTION The motor weighs 22 kg All lifting equipment used must be sized accord...

Page 329: ...le gland cover at the cable exit with its two attachment screws Shown in the figure Location of motor on page 324 13 Refit the cover on top of the motor with its four attachment screws Make sure the cover is tightly sealed 14 Refit the heat protection plate with its two attachment screws Shown in the figure Location of motor on page 324 15 If cables are loose place them correctly and tie them up w...

Page 330: ...9 xx0100000128 Required equipment A Motor axis 6 Equipment etc Spare part no Art no Note Motor axis 6 3HAC14211 1 Includes motor pinion o ring 21522012 430 O ring 21522012 430 Must be replaced when reas sembling motor Brush Option Foundry Prime Mercasol 3106 3HAC026621 001 Option Foundry Prime Sikaflex 521FC 3HAC026759 001 Option Foundry Prime Loctite 574 Loctite 480 Gasket 3HAC12877 1 Must be rep...

Page 331: ... the robot to one of the recommended positions to a position where the motor in axis 6 is pointed straight up This position enables the motor to be replaced without draining the gear oil which in turn saves time to a position where the motor in axis 6 is close to horizontal This position may be selected when the gearbox is to be replaced i e when the gearbox oil has to be drained anyway 2 DANGER T...

Page 332: ...n order to release the brake connect the 24 VDC power supply Connect to connector R3 MP6 pin 2 pin 5 3 Fit the two guide pins in two of the motor attachment holes Art no is specified in Required equipment on page 328 4 Fit the motor with guidance from the pins making sure the motor pinion is properly mated to the gear of gearbox axis 6 Make sure the pinion on the motor shaft is not damaged 5 Remov...

Page 333: ...are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 36 Action Note Action Note 1 Move the robot to one of the recommended positions to a position where the motor in axis 6 is pointed straight up This position enables the motor to be replaced without draining the gear oil which in turn saves time to a position whe...

Page 334: ...r by unscrewing the five attachment screws xx0600002885 A Motor unit B Attachment screw 5 pcs C Air nipple D Rear motor cover E Gasket G Air nipple 5 Continue to remove the motor unit according to step 6 and forwards in Removal motor on page 329 6 NOTE Keep the old rear motor cover with the air nipple Action Note Continued Continues on next page ...

Page 335: ...0600002884 A Mercasol 3106 B Motor unit C Attachment screw 4pcs D Sikaflex in screw recesses E Loctite 570 F Tilt house 8 Apply Mercasol 3106 on the surface between tilt house and motor pinion side and Loctite 570 between gasket and tilt house 9 Continue to refit the new motor according to section Refitting motor on page 330 10 Perform a leak test according to Inspection of air hoses Foundry Prime...

Page 336: ...gure below A more detailed view of the component and its position may be found in chapter Exploded views on page 429 xx0100000133 Required equipment A Gearbox axis 1 B Oil plug filling C Attachment screws gearbox to frame D Frame E Base Attachment screws base to gearbox not shown in figure Equipment etc Spare part no Art no Note Gearbox 3HAC10828 1 Includes gearbox all o rings and sealing rings O ...

Page 337: ...chain 3HAC15556 1 Standard toolkit The content is defined in section Standard toolkit on page 394 Other tools and procedures may be required See references to these procedures in the step by step instruc tions below These procedures include references to the tools required Equipment etc Spare part no Art no Note Action Note 1 Move the robot to its most stable position shown in the figure to the ri...

Page 338: ...ool chain to the gearbox Art no is specified in Required equipment on page 334 9 CAUTION The base and gearbox weighs 510 kg together All lifting equipment must be used accordingly 10 Lift the robot base to allow fitting the support base and gear 1 on each sides of the base Art no is specified in Required equipment on page 334 11 Fit the support base Make sure the base remains in a stable position ...

Page 339: ...ashers 3 pcs 14 Remove the cable guide in the center of gearbox 1 by unscrewing its attachment screws xx0200000256 A Location for attachment screws cable guide cable guide removed in the figure 15 CAUTION The gearbox weighs 200 kg All lifting equipment used must be sized accordingly 16 Lift the gearbox away with the already mounted lifting tools Action Note Action Note 1 If the base is not support...

Page 340: ...E Sealing ring 3HAC 11581 4 3 Refit the cable guide in the center of gearbox 1 with its attachment screws xx0200000256 A Location for attachment screws cable guide cable guide removed in figure 4 Fit the lifting device base and the lifting tool chain to the gearbox Art no is specified in Required equipment on page 334 5 CAUTION The gearbox weighs 200 kg All lifting equipment used must be sized acc...

Page 341: ...xis 1 18 pcs C Washers 3 pcs 9 Refit the bottom plate underneath the robot base by pushing it into the groove and fitting the attachment screw If removed also refit the rear connector plate NOTE Direct the bends on the bottom plate downwards 1 screw M6 x 8 xx0300000612 A Bottom plate B Rear connector plate C Attachment screw D Groove 10 CAUTION The base and gearbox weighs 510 kg together All lifti...

Page 342: ...nd reconnect the cabling in the rear of the robot base 15 Perform a leak down test Detailed in section Performing a leak down test on page 216 16 Refill the gearbox with oil Detailed in section Filling oil gearbox axis 1 on page 184 17 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in se...

Page 343: ...asol 3106 on unpainted areas xx0600003132 A Surface on the underside of the frame B Radial sealing gear axis 1 against base 3 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 36 Action Note A B Continued ...

Page 344: ...manual reference information xx0100000135 Required equipment A Gearbox axis 2 behind motor attachment not shown in figure B Motor axis 2 C Oil plug filling D Oil plug draining E Front gearbox attachment screws F Attachment holes fixture lower arm G Motor attachment H Sealing between gearbox and lower arm not shown in figure I Hole for locking screw lower arm M16 x 60 Equipment etc Spare part no Ar...

Page 345: ... pairs Guide pins sealing ax 2 3 80mm 3HAC14627 2 For guiding the sealing axis 2 3 Guides are to be used in pairs Guide pins sealing ax 2 3 100mm 3HAC14627 3 For guiding the sealing axis 2 3 Guides are to be used in pairs Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Other tools and procedures may be required See references to these procedures in the ste...

Page 346: ...ture are screwed back Align the fixture with the frame and lower arm Tighten the four M16 bolts C on the inside of the frame in attachment holes with tightening torque 220 Nm Screw in the two adjusters B until they rest against the flats on the lower arm Tighten by hand Lock using the two ring nuts D Tighten the two M12 bolts E in the attachment holes fixture lower arm with tightening torque 91 Nm...

Page 347: ...rt no is specified in Required equipment on page 342 13 CAUTION The gearbox weighs 125 kg All lifting equipment used must be sized accordingly 14 Fit the lifting tool gearbox axis 2 to the gearbox Art no is specified in Required equipment on page 342 15 Fit two guide pins in 180 relation to each other instead of the removed front attachment screws Art no is specified in Required equipment on page ...

Page 348: ...ot turn off the air pressure to motors and SMB 2 Fit the guide pins sealing axis 2 3 on gearbox axis 2 Only the holes showed in figure beside are allowed to be used to the guide pins xx0200000125 A Holes for guide pins sealing axis 2 3 on gearbox 2 Always use a new sealing when reassembling Art no is specified in Required equipment on page 342 3 Fit the new sealing axis 2 3 on gearbox axis 2 with ...

Page 349: ...he gearbox is seated properly 9 Remove the lifting tool 10 In a similar way fit the lifting tool to the motor flange Lock the tool with the hook Lift it and slide it onto the guide pins Remove the lifting tool 11 Insert and secure 18 of the 20 attachment screws on the front of the motor attachment Remove the guide pins and tighten the remaining two screws Tightening torque 300 Nm Reused screws may...

Page 350: ...x with oil Detailed in section Filling oil on page 187 18 Restore the balancing device by removing the balancing device tools Detailed in section Restoring the balancing device on page 295 19 Remove the fixture lower arm 20 Remove the locking screw lower arm 21 Refit any mechanical stops if such were removed during disassembly 22 Refit any equipment to the turning disc if such was removed during a...

Page 351: ...omponent and its position may be found in chapter Exploded views in the Product manual reference information xx0100000137 Required equipment A Gearbox axis 3 B Attachment screws gearbox C Oil plug filling D Oil plug draining E Motor axis 3 F Attachment screws upper arm G Attachment screws motor H Sealing axis 2 3 between lower arm and gearbox 3 Equipment etc Spare part no Art no Note Gearbox 3HAC1...

Page 352: ...57 4 Guide pins M16 x 250 3HAC13120 4 For guiding the gearbox Use guides in pairs Guide pins M16 x 300 3HAC13120 5 For guiding the gearbox Use guides in pairs Guide pins sealing ax 2 3 80mm 3HAC14627 2 For guiding the sealing axis 2 3 Use guides in pairs Guide pins sealing ax 2 3 100mm 3HAC14627 3 For guiding the sealing axis 2 3 Use guides in pairs Standard toolkit The content is defined in secti...

Page 353: ...uipment on page 349 xx0300000051 A Third and final attachment hole B Fixed mechanical stop 3 Remove the motor axis 3 Detailed in section Removal motor on page 311 NOTE When removing the motor axis 3 the brake on axis 3 is released Make sure the upper arm is secured and disabled to move 4 Remove the upper arm Detailed in section Removal upper arm on page 253 5 Remove the sealing axis 2 3 between th...

Page 354: ...used must be sized accordingly 11 Remove the gearbox with guidance from the guide pins using an overhead crane or similar Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Turn the upper arm in such a position that the gear mating surface faces upwards 3 F...

Page 355: ...ng tool 11 Secure the gearbox with 18 of the 20 gearbox attachment screws Remove the guide pins and tighten the remaining two screws 20 pcs M16 x 90 12 9 quality UNBRAKO tightening torque 300 Nm Reused screws may be used providing they are lubricated as detailed in section Screw joints on page 390 before fitting 12 Refit the upper arm with a new sealing axis 2 3 Art no is specified in Required equ...

Page 356: ...the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 36 Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Apply Mercasol on surfaces on lower arm and gear before assembly Area where Mercasol shal...

Page 357: ...ore detailed view of the component and its position may be found in chapter Exploded views in the Product manual reference information xx0100000144 A Upper arm housing B Gearbox axis 4 C Cover axis 4 gearbox D Attachment screws cover axis 4 E Oil plug filling secondary gearbox F Oil plug draining secondary gearbox G Gear Z3 H Gear attachment screws I Motor axis 4 J Motor flange K Oil plug filling ...

Page 358: ...on Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off...

Page 359: ...55 10 Pull the motor flange and gearbox axis 4 out along with the friction washers If required insert screws into two holes in the gearbox to press it out M10 Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Make sure the two o rings on the circumference ...

Page 360: ...9 Refit the motor axis 4 Detailed in section Refitting motor axis 4 on page 320 10 Refit gear Z3 to the gearbox with its gear attachment screws Shown in the figure Location of gearbox on page 355 9 pcs M12 x 50 tightening torque 115 Nm 6 pcs M16 x 60 tightening torque 300 Nm 11 Replace the gasket cover axis 4 Art no is specified in Required equipment on page 356 12 Refit the cover axis 4 gearbox w...

Page 361: ...1 Revision E Copyright 2004 2008 ABB All rights reserved 17 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in section DANGER First test run may cause injury or damage on page 36 Action Note Continued ...

Page 362: ...and its position may be found in chapter Exploded views in the Product manual reference information xx0100000146 A Wrist housing B Cover axis 5 gearbox C Attachment screws cover axis 5 D Oil plug secondary filling E Oil plug secondary draining F Gear Z3 G Wheel unit H Attachment screws gear Z3 K Gearbox axis 5 L Oil plug primary filling draining plug on the opposite side of the wrist housing not s...

Page 363: ...s defined in section Standard toolkit on page 394 Lifting eye M12 3HAC14457 3 2 pcs required For lifting the gearbox Removal tool wheel unit 3HAC15814 1 For removing and lifting the wheel unit Guide pins M10 x 100 3HAC15521 1 Always use guide pins in pairs Guide pins M10 x 150 3HAC15521 2 Always use guide pins in pairs Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operat...

Page 364: ...s attachment screws and removing the washers Shown in the figure Location of gearbox on page 360 18 pcs M10 x 40 9 Apply two lifting eyes to the gearbox axis 5 in opposite positions Art no is specified in Required equipment on page 361 10 Remove the gearbox by gently lifting it straight out 11 Remove the friction washers located beneath the gearbox from the wrist housing Action Note Action Note 1 ...

Page 365: ...ies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Make sure the two o rings on the circumference of the gearbox are seated properly in their grooves respectively Lightly lubricate the o rings with grease Art no is specified in Required equipment on page 361 3 Fit two guide pins in the housing Art no is specified in Required equipment on page 361 4 Refit...

Page 366: ...o is specified in Required equipment on page 361 12 Refit the cover axis 5 gearbox with its attachment screws and secure with locking liquid 14 pcs tightening torque 10 Nm Shown in the figure Location of gearbox on page 360 13 Refit the motor axis 5 Detailed in section Refitting motor axis 5 on page 326 14 Perform a leak down test Detailed in section Performing a leak down test on page 216 15 Refi...

Page 367: ...tinuing the mounting 6 Fasten the bearing washer with its attachment screws and secure with locking liquid Turn the gear Z4 in order to reach all the screws xx0200000068 A Gear Z4 B Surface beneath VK cover C VK cover D Attachment screws gear Z4 21 pcs M16 E Attachment screws bearing washer 7 pcs M6 7 Clean the surface beneath the VK cover with iso propanol 8 Secure the wheel unit with attachment ...

Page 368: ...nt of gearbox axis 6 Location of gearbox The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below xx0100000131 A Gearbox axis 6 B Attachment screws gearbox C Washers D Oil plug filling E Oil plug draining can be located on the turning disk instead O ring not shown in the figure Continues on next page ...

Page 369: ... pairs Standard toolkit The content is defined in section Standard toolkit on page 394 Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Action Note 1 DANGER Turn off all electric power...

Page 370: ...or M10 to the holes shown in the figure to press it free xx0200000220 A M10 holes for pressing out the gearbox 6 Remove the gearbox axis 6 by lifting it out carefully Be careful not to damage the motor pinion Action Note Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB...

Page 371: ...axis 6 into the wrist unit Art no is specified in Required equipment on page 367 Shown in the figure Location of gearbox on page 366 Make sure the gears of the gearbox mate with the gears of the motor 5 Fit the both washers and secure the gearbox with the attachment screws Shown in the figure Location of gearbox on page 366 18 pcs M10 x 50 12 9 quality UNBRAKO Tightening torque 65 Nm Reused screws...

Page 372: ...rew heads 8 Perform a leak down test Detailed in section Performing a leak down test on page 216 9 Refill the gearbox with oil Detailed in section Filling oil gearbox axis 6 on page 198 10 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in section Calibration information on page 371 11 DA...

Page 373: ...obot has Absolute Accuracy calibration it is also recommended but not always needed to be calibrated for new Absolute Accuracy The resolver values will change when parts affecting the calibration position are replaced on the robot for example motors or parts of transmission Contents of the revolution counter memory are lost If the contents of the revolution counter memory are lost the counters mus...

Page 374: ...ion Pendulum standard method or Levelmeter calibration alternative method Absolute Accuracy calibration optional Based on standard calibration and besides positioning the robot at home position the Absolute Accuracy calibration also compensates for mechanical tolerances in the robot structure deflection due to load Absolute Accuracy calibration focuses on positioning accuracy in the Cartesian coor...

Page 375: ...ical tolerances to the toolkit parts as the standard method with Calibration Pendulum This method may after calibration require modifications in the robot program and is therefore not recommended The calibration equipment for Levelmeter Calibration is ordered as separate parts for each robot and the operating manual for Levelmeter Calibration is enclosed with the Levelmeter 2000 CalibWare Absolute...

Page 376: ...00 but the scales and their positions are the same for IRB 6650S and IRB 7600 xx0200000176 Calibration marks at axes 2 and 3 The calibration marks at axes 2 3 and 6 shown in the figure above consist of two single marks that should be positioned opposite to one another when the robot is standing in its calibration position One of the marks is more narrow than the other and should be positioned with...

Page 377: ...ards the calibration position in the same direction in order to avoid position errors caused by backlash in gears etc Positive directions are shown in the figure below This is normally handled by the robot calibration software Calibration movement directions 6 axes Note The figure shows an IRB 7600 but the positive direction is the same for all 6 axis robots except the positive direction of axis 3...

Page 378: ...her on the lower arm or underneath the flange plate on the base At delivery the robot is in the correct position do NOT rotate axis 4 or 6 at power up before the revolution counters are updated If one of the below mentioned axes are rotated one or more turns from its calibration position before updating the revolution counter the correct calibration position will be lost due to uneven gear ratio T...

Page 379: ...If there is more than one unit connected to the robot they will be listed in the window xx0100000201 3 Select the desired unit and choose Rev Counter Update from the Calib menu The Revolution Counter Update window appears xx0100000202 4 Select the desired axis and press Incl to include it it will be marked with an x or press All to select all axes 5 Press OK when all axes that are to be updated ar...

Page 380: ...he calibration position very carefully after each update How to perform the check is detailed in section Checking the calibration position on page 380 Action Note Action 1 On the ABB menu tap Calibration All mechanical units connected to the system are shown along with their calibration status 2 Tap the mechanical unit in question A screen is displayed tap Rev Counters en0400000771 3 Tap Update Re...

Page 381: ...updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the ticked revolution counters and removes the tick from the list of axes 6 CAUTION If a revolution counter is incorrectly updated it will cause incorrect robot positioning which in turn may cause damage or injury Check the cal...

Page 382: ...J 0 0 0 0 0 0 9E9 9E9 9E9 9E9 9E9 9E9 NoEOffs v1000 z50 Tool0 4 Run the program in manual mode 5 Check that the calibration marks for the axes align correctly If they do not update the revolution counters The calibration marks are shown in section Calibration scales and correct axis position on page 374 How to update the revolution counters is detailed in section Updating revolution counters on pa...

Page 383: ...libration marks for the axes align correctly If they do not update the revolution counters The calibration marks are shown in section Calibration scales and correct axis position on page 374 Detailed in section Updating revolution counters on page 376 Action Note 1 Tap Jogging in the ABB menu 2 Tap Motion mode to choose group of axes to jog 3 Tap axis 1 3 to jog axis 1 2 or 3 4 Manually run the ro...

Page 384: ...5 Calibration information 5 6 Checking the calibration position 3HAC022033 001 Revision E 382 Copyright 2004 2008 ABB All rights reserved ...

Page 385: ...with local regulations Do no dispose of oil and grease near lakes ponds ditches down drains or on to soil Incineration must be carried out under controlled conditions in accordance with local regulations Also note that Spills may form a film on water surfaces causing damage to organisms Oxygen transfer could also be impaired Spillage may penetrate the soil causing ground water contamination Materi...

Page 386: ...tion on field decommissioning The procedure below details the actions to perform on field when the balancing device is to be decommissioned Equipment Art no Note Standard toolkit The content is defined in section Standard toolkit on page 394 Cutting torch For opening housing and cutting coils Other tools and procedures may be required See references to these procedures in the step by step instruct...

Page 387: ...alancing device The device also contains some grease 2 Place the device on a workbench or similar Make sure it is clamped in position with a vice or similar 3 Open a hole in the side of the housing as shown in the figure Use a cutting torch The measurements shown below are maximum values xx0200000082 4 Cut the coils of the three springs inside the housing as specified below Outer spring cut at lea...

Page 388: ...6 Decommissioning 6 2 Decommissioning of balancing device 3HAC022033 001 Revision E 386 Copyright 2004 2008 ABB All rights reserved ...

Page 389: ...3HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved 7 Reference information 7 1 Introduction General This chapter includes general information complementing the more specific information in the different procedures in the manual ...

Page 390: ...t of machines Part 1 General requirements EN 1050 Principles for risk assessment ANSI RIA 15 06 1999 Industrial robots safety requirements DIN 19258 Interbus S International Standard Standards robot cell The following standards are applicable when the robot is part of a robot cell EN 953 Fixed and moveable guards EN 811 Safety distances to prevent danger zones being reached by the lower limbs EN 3...

Page 391: ...04 2008 ABB All rights reserved 7 3 Unit conversion Converter table Use the table below to convert units used in this manual Quantity Units Length 1 m 3 28 ft 39 37 in Weight 1 kg 2 21 lb Pressure 1 bar 100 kPa 14 5 psi Force 1 N 0 738 lbf Moment 1 Nm 0 738 lbf tn Volume 1 L 0 264 US gal ...

Page 392: ...mo is a special surface treatment to reduce the friction when tightening the screw joint Screws treated with Gleitmo may be reused 3 4 times before the coating disappears After this the screw must be discarded and replaced with a new one When handling screws treated with Gleitmo protective gloves of nitrile rubber type should be used Screws lubricated in other ways Screws lubricated with Molycote ...

Page 393: ... specified overrides the standard torque Use the correct tightening torque for each type of screw joint Only use correctly calibrated torque keys Always tighten the joint by hand and never use pneumatical tools Use the correct tightening technique that is do not jerk Tighten the screw in a slow flowing motion Maximum allowed total deviation from the specified value is 10 The table below specifies ...

Page 394: ...r and air connectors when one or both connectors are made of brass Dimension Tightening torque Nm Class 8 8 oil lubri cated Tightening torque Nm Class 10 9 oil lubri cated Tightening torque Nm Class 12 9 oil lubri cated M5 6 M6 10 M8 24 34 40 M10 47 67 80 M12 82 115 140 M16 200 290 340 M24 725 960 1150 Dimension Tightening torque Nm Class 10 9 Molycote lubricated Tightening torque Nm Class 12 9 Mo...

Page 395: ...cified All components exceeding 22 kg 50 lbs are high lighted in this way To avoid injury ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg A wide range of lifting tools and devices are available for each manipulator model Example Below is an example of how a weight specification is presented inside a procedure table Action Note CAUTION The motor we...

Page 396: ...olkit and defined in the table below This way the tools required are the sum of the Standard Toolkit and any tools listed in the instruction Contents standard toolkit Qty Tool Rem 1 Ring open end spanner 8 19 mm 1 Socket head cap 5 17 mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 10 100 Nm 1 Torque wrench 75 400 Nm 1 Ratchet head for torque wrench 1 2 2 Hexagon headed screw M10x100 1...

Page 397: ...directly in concerned instructions in the Product manual procedures Description Qty Art no Bolts M16 x 80 for Mech stop ax 3 2 3HAB3409 89 Extension 300mm for bits 1 2 1 3HAC12342 1 Guide pins M8 x 100 2 3HAC15520 1 Guide pins M8 x 150 2 3HAC15520 2 Guide pins M10 x 100 2 3HAC15521 1 Guide pins M10 x 150 2 3HAC15521 2 Lifting tool wrist unit 1 3HAC12734 1 Lifting tool motor ax 1 4 5 1 3HAC14459 1 ...

Page 398: ...e upper arm 1 3HAC15536 1 Lifting eye VLBG M12 1 3HAC16131 1 Lifting eye M12 2 3HAC14457 3 Lifting eye M16 2 3HAC14457 4 Lifting tool chain 1 3HAC15556 1 Lifting tool gearbox axis 2 1 3HAC12731 1 Measuring tool 1 6896134 GN Motor press pinion 1 3HAC021883 001 Oil injector max 500 MPa 1 3HAC021590 001 Press tool axis 2 bearing 1 3HAC13453 1 Puller device axis 2 shaft 1 3HAC021563 001 Press device a...

Page 399: ...mended equipment for oil exhange Measuring pin 3HAC13908 5 Sensor fixture 68080011 GM Sensor plate 3HAC0392 1 Sync adapter 3HAC13908 1 Turn disk fixture 3HAC68080011 GU Description Art no Note Description Art no Note Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Description Art no Note Oil exchange equipment 3HAC021745 001 Includes vacuum pump with regul...

Page 400: ...General Many repair and maintenance activities require different pieces of lifting equipment which are specified in each procedure The use of each piece of lifting equipment is not detailed in the activity procedure but in the instruction delivered with each piece of lifting equipment This implies that the instructions delivered with the lifting equipment should be stored for later reference ...

Page 401: ...st 8 1 Introduction 399 3HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved 8 Spare part part list 8 1 Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot ...

Page 402: ...pyright 2004 2008 ABB All rights reserved 8 2 Spare parts 8 2 1 Introduction Overview This section specifies all articles considered spare parts of the robot The spare parts are also specified as required equipment directly in the repair instruction of the current spare part ...

Page 403: ...1 G Motor axis 4 3HAC14210 2 3HAC027318 001 With pinion 102 1 2 Foundry Prime H Gear axis 4 3HAC17810 1 102 1 8 1 I Friction washer 3HAC10122 27 102 1 33 J SMB Unit 3HAC022286 001 109 326 K Battery pack 3HAC16831 1 109 328 Harness manipulator 1 4 3HAC12782 1 Brake release at base 106 Harness manipulator 1 4 3HAC14940 1 Brake release in frame 106 Cable harness ax 5 6 3HAC11440 1 103 40 L Wrist type...

Page 404: ...E 402 Copyright 2004 2008 ABB All rights reserved Location spare parts The items are specified in the previous table xx0600002679 Repair instructions Each spare part is replaced as described in corresponding repair instruction in the chapter Repair on page 215 Continued ...

Page 405: ...08 ABB All rights reserved 8 3 Part list 8 3 1 Introduction Overview This section specifies all the replacement articles of the robot The parts are shown in exploded views or in foldouts either in this or in a separate chapter Specific spare parts are listed separately in a Spare part list ...

Page 406: ... X X 102 2 Standard 3HAC15932 1 Tube shaft 2 55 X X X X X 102 2 Foundry 3HAC10509 5 Tube shaft 2 3 X 102 2 Standard 3HAC15932 2 Tube shaft 2 3 X 102 2 Foundry 3HAC9760 1 Arm extender 250mm X 2X 111 501 Standard 3HAC15932 3 Arm extender 250mm X 2X 111 501 Foundry 3HAC9760 5 Arm extender 956mm X 111 501 Standard 3HAC15932 4 Arm extender 956mm X 111 501 Foundry 3HAC11755 1 Friction washer X 2X X 111 ...

Page 407: ...Torx pan head screw Steel 8 8 A2F M6 x 20 10 2 3HAC10509 11 Cover 101 1 3HAC12304 1 Base incl frame ax 1 See section Base incl frame axis 1 3HAC12304 1 on page 408 102 1 3HAC13063 1 Axis 3 4 Standard protection IRB 7600 150 3 5 325 3 1 340 2 8 400 2 55 500 2 55 See section Axis 3 4 3HAC13063 1 IRB 7600 150 3 5 325 3 1 340 2 8 400 2 55 500 2 55 on page 409 3HAC13063 2 Axis 3 4 Standard protection I...

Page 408: ...79 1 on page 420 109 1 3HAC13077 1 Material set ax 1 2 See section Material set axis 1 2 3HAC13077 1 on page 421 110 1 3HAC13082 1 Mtrl set balancing device See section Material set balancing device 3HAC13082 1 on page 424 111 1 3HAC12311 1 Arm extension set 956mm IRB 7600 150 3 5 See section Arm extension set 956 mm 3HAC12311 1 IRB 7600 150 3 5 on page 425 1 3HAC12311 2 Arm extension set 250mm IR...

Page 409: ...HAC12812 2 407 3HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved 8 3 4 Mechanical stop axis 1 3HAC12812 2 Part list Item Qty Art number Description Dimension 5 1 1 3HAC12812 1 Mechanical stop 5 2 1 9ABA142 92 Spring pin slotted 10 x 30 ...

Page 410: ...ad cap screw UNBRAKO 12 9 Gleitmo 610 M16x90 101 5 1 3HAC11529 1 Rubber lined clip D 28 101 6 1 3HAC14453 1 Hose with flange 101 7 1 3HAC14453 2 Plug 101 8 1 3HAC4428 2 Hose Clip 101 9 1 9ADA618 56 Torx pan head screw Steel 8 8 A2F M6x16 Item Qty Art number Description Note 101 1 1 1 3HAC10044 2 Base casting 101 1 2 5 3HAC4836 7 Protection plug 101 1 3 1 3HAC1383 2 Protection Cover compl 101 1 4 1...

Page 411: ...ocket head cap screw Steel 12 9 Gleitmo 610 M10x40 102 1 4 4 3HAB4233 1 Washer 102 1 5 1 3HAC11499 1 Motor flange machining 102 1 6 18 3HAB3409 60 Hex socket head cap screw Steel 12 9 Gleitmo 610 M10x80 102 1 7 2 3HAC10122 12 Washer RV 125 F axis4 5 T 3 102 1 8 1 3HAC17810 1 RV 125F 97 909 assembly See table RV 125F 97 909 assembly 3HAC17810 1 on page 410 102 1 9 1 3HAC12640 1 Cover ax 4 incl seal...

Page 412: ...BA107 56 Parallel pin 10x20 102 1 33 2 3HAC10122 27 Friction washer 102 1 34 1 3HAB7116 1 Locking liquid 102 1 35 30 3HAB3537 1 Bearing grease 102 1 36 1 3HAC020486 001 Pinion Z3 4 5 102 1 37 1 3HAC020619 001 Set of shims Z3 4 5 102 1 38 9 3HAB7700 69 Hex socket head cap screw UNBRAKO 12 9 Gleitmo 610 M12x50 102 1 39 6 3HAB3409 86 Hex socket head cap screw Steel 12 9 Gleitmo 610 M16x60 102 1 40 2 ...

Page 413: ...1 1 3HAC10502 3 Axis 4 housing mach 102 3 2 1 3HAC12641 1 RV 700F incl gear See following table 102 3 3 20 3HAB7700 89 Hex socket head cap screw UNBRAKO 12 9 Gleitmo 610 M16x90 102 3 4 20 3HAC10264 1 Washer 17x30x3 102 3 5 1 3HAC14724 1 Rot ac motor incl pinion See following table 102 3 6 4 3HAB3409 50 Hex socket head cap screw Steel 12 9 Gleitmo 610 M10x40 102 3 7 4 3HAB4233 1 Washer 102 3 8 1 3H...

Page 414: ... shaft 2 3 3HAC10509 5 Item Qty Art number Description Note 102 1 1 3HAC022181 001 Material set ax 4 See table Material set axis 4 3HAC022181 001 on page 409 102 2 1 3HAC10509 5 Tube shaft 2 3 See table below 102 3 1 3HAC13062 1 Axis 3 See table Axis 3 3HAC13062 1 on page 411 Item Qty Art number Description Note 102 2 1 1 3HAC10509 6 Tube shaft 2 55 cast 102 2 2 1 3HAC1383 2 Protection Cover compl...

Page 415: ... 8 400 2 55 500 2 55 Part list Tube shaft 2 55 Foundry 3HAC15932 1 Item Qty Art no Description Note 102 1 1 3HAC022181 001 Material set ax 4 See table Material set axis 4 3HAC022181 001 on page 409 102 2 1 3HAC15932 1 Tube shaft 2 55 Foundry See table below 102 3 1 3HAC13062 1 Axis 3 See table Axis 3 3HAC13062 1 on page 411 Item Qty Art number Description Note 102 2 1 1 3HAC10509 2 Tube shaft 2 55...

Page 416: ... Tube shaft 2 55 Foundry 3HAC15932 2 Item Qty Art no Description Note 102 1 1 3HAC022181 001 Material set ax 4 See table Material set axis 4 3HAC022181 001 on page 409 102 2 1 3HAC15932 2 Tube shaft 2 55 See table below 102 3 1 3HAC13062 1 Axis 3 See table Axis 3 3HAC13062 1 on page 411 Item Qty Art number Description Note 102 2 1 1 3HAC10509 6 Tube shaft 2 55 cast 102 2 2 1 3HAC1383 2 Protection ...

Page 417: ...3 9 1 3HAC10503 3 Wrist housing machining 103 10 2 2522122 1 Magnetic plug R1 4 103 11 4 9ADA183 35 Hex socket head cap screw 103 12 2 3HAC10503 8 Damper ax 5 103 13 2 3HAC10122 27 Friction washer 103 14 4 3HAB3409 50 Hex socket head cap screw M10x40 103 15 4 3HAB4233 1 Washer 103 16 1 3HAC14725 2 Rot ac motor incl pinion See table Rot ac motor incl pinion 3HAC14725 2onpage 417 103 17 2 21520441 1...

Page 418: ...16 103 37 1 3HAB7116 1 Locking liquid 103 38 1 3HAC11440 5 Heat protection plate 103 39 3 21662055 3 Cable straps outdoors 103 40 1 3HAC11440 1 Cable harness manip ax5 6 103 41 3 800 ml 3HAC032140 001 Lubricating oil Kyodo Yushi TMO 150 Do not mix the oils The different types of oils are further specified in section Oil in gearboxes on page 179 103 42 750 ml 3HAC032140 001 Lubricating oil Kyodo Yu...

Page 419: ...t number Description Note 103 6 1 1 3HAC11384 1 RV 125F i 97 909 103 6 2 1 3HAB3772 50 O ring 103 6 3 1 3HAB3772 49 O ring Item Qty Art number Description Note 103 16 1 1 3HAC17484 2 Rotational ac motor M2 103 16 2 1 3HAC10122 17 Pinion RV 125F 97 909 Item Qty Art number Description Dimension 103 24 1 1 3HAC11470 1 Shaft 103 24 2 1 3HAA2325 12 Ball bearing incl two seal 130x200x33 103 24 3 3 9ADA6...

Page 420: ... Item Qty Art number Description Note Dimension Item Qty Art number Description Dimension 103 28 2 1 1 3HAC10122 1 RV 125F i 178 41 103 28 2 2 1 3HAB3772 49 O ring 189 3x3 1 Item Qty Art number Description Note 103 28 3 1 3HAC023124 002 Turning disk insulated 103 28 5 33 3HAC022910 002 Sleeve plastic 103 28 6 33 3HAC022843 001 Washer insulating 103 28 7 33 3HAC022910 003 Cover plastic 103 28 8 33 ...

Page 421: ...e Item Qty Art number Description Dimension 103 33 1 1 3HAC020487 001 Gear Z4 5 103 33 2 1 3HAC10503 12 Bearing Washer 103 33 3 1 3HAB3710 19 Groove ball bearing 160x220x28 103 33 4 1 3HAC10503 15 Support Ring 103 33 5 1 3HAB7116 2 Locking liquid Item Qty Art number Description Note 103 51 4 750 ml 3HAC032140 001 Lubricating oil Kyodo Yushi TMO 150 103 51 10 1 3HAC14263 1 Protection Cover 103 51 1...

Page 422: ...08 212 1 3HAC11771 1 Cable guide end part 108 213 1 3HAC13960 1 Connection plate ax3 108 214 2 3HAC11750 1 Damper axis 3 108 215 2 3HAC12990 1 Damper axis 2 108 216 2 9ADA624 65 Torx counters head screw M6x60 108 217 2 9ADA334 7 Spring washer conical 8 4x18x2 108 218 2 9ADA618 57 Torx pan head screw M6x20 108 220 2 3HAC9953 1 Syncplate with nonie 108 222 1 3HAC14658 1 Syncplate with nonie ax 3 108...

Page 423: ...752 001 on page 423 109 307 1 3HAC14724 1 Rot ac motor incl pinion IRB 7600 500 2 3 400 2 55 340 2 8 325 3 1 150 3 5 See table Rot ac motor incl pinion 3HAC14724 1 on page 423 109 308 8 3HAB3409 50 Hex socket head cap screw M10x40 109 309 8 3HAB4233 1 Washer 109 310 1 3HAC12252 1 Bottom plate 109 311 1 3HAC14131 1 Connection plate base 109 312 1 3HAC11774 3 Adapter complete 109 313 1 3HAC11769 1 C...

Page 424: ...e 179 109 342 4 800 ml 3HAC032140 001 Lubricating oil Kyodo Yushi TMO 150 109 344 1 ml 3HAB7116 1 Locking liquid 109 345 2 9ADA267 6 Hexagon nut M6 109 346 1 3HAC16036 1 BU w buttons DSQC 561 3HAC14219 1 BU at the base Read more about the difference in section Replacement of brake release unit on page 270 3HAC12989 1 BU at the base 109 347 1 3HAC2744 1 Push button guard 109 348 4 9ADA629 56 Torx p...

Page 425: ...nal ac motor M1 109 306 2 1 3HAC11350 1 Pinion RV 500C RV 320C 109 306 3 1 21522012 430 O ring D 89 5x3 Item Qty Art number Description Note 109 307 1 1 3HAC025724 001 Rotational AC motor M13 109 307 2 1 3HAC11632 1 Pinion Z1 2 3 109 307 3 1 21502012 430 O ring D 89 5x3 Item Qty Art number Description Note 109 307 1 1 3HAC17484 1 Rotational ac motor M1 109 307 2 1 3HAC11632 1 Pinion Z1 2 3 109 307...

Page 426: ... washer 110 403 1 3HAC13122 1 Bushing 110 404 1 9ABA135 32 Retaining ring shaft 110 405 1 3HAC13123 1 Shaft 110 406 1 3HAC4836 7 Protection plug 16x12 3x9x7 110 407 4 3HAB7700 89 Hex socket head cap screw M16x90 110 408 2 9ABA107 56 Parallel pin 10x20 110 409 1 3HAC12548 2 Protection washer 110 410 1 3HAC11427 1 Shaft Balancing device 110 411 4 3HAA1001 186 Washer 17x25x3 110 412 120 ml 3HAA1001 2...

Page 427: ...m extension set 956 mm 3HAC12311 1 IRB 7600 150 3 5 Part list Item Qty Art number Description Dimension 111 501 1 3HAC9760 5 Arm extender 956 mm 111 501 1 3HAC15932 4 Arm extender 956 mm Foundry 111 502 1 3HAC11755 1 Friction washer 111 503 20 3HAB7700 69 Hex socket head cap screw M12x50 111 504 20 3HAA1001 134 Washer 13x19x1 5 111 505 1 9ABA107 56 Parallel pin 10x20 ...

Page 428: ...m extension set 250 mm 3HAC12311 2 IRB 7600 340 2 8 Part list Item Qty Art number Description Dimension 111 501 1 3HAC9760 1 Arm extender 250 mm 111 501 1 3HAC15932 3 Arm extender 250 mm Foundry 111 502 1 3HAC11755 1 Friction washer 111 503 20 3HAB7700 69 Hex socket head cap screw M12x50 111 504 20 3HAA1001 134 Washer 13x19x1 5 111 505 1 9ABA107 56 Parallel pin 10x20 ...

Page 429: ...m extension set 500 mm 3HAC12311 3 IRB 7600 325 3 1 Part list Item Qty Art number Description Dimension 111 501 2 3HAC9760 1 Arm extender 250 mm 111 501 2 3HAC15932 3 Arm extender 250 mm Foundry 111 502 2 3HAC11755 1 Friction washer 111 503 40 3HAB7700 69 Hex socket head cap screw M12x50 111 504 40 3HAA1001 134 Washer 13x19x1 5 111 505 2 9ABA107 56 Parallel pin 10x20 ...

Page 430: ...8 Spare part part list 8 3 16 Arm extension set 500 mm 3HAC12311 3 IRB 7600 325 3 1 3HAC022033 001 Revision E 428 Copyright 2004 2008 ABB All rights reserved ...

Page 431: ...ved 9 Exploded views 9 1 Introduction Definitions This chapter contains detailed views of the components on the manipulator The numbered details are specified with item numbers in the Part List The exploded views are divided into Base incl frame Frame Lower arm 1 Frame Lower arm 2 Upper arm Wrist complete ...

Page 432: ...9 Exploded views 9 2 Base incl Frame 3HAC022033 001 Revision E 430 Copyright 2004 2008 ABB All rights reserved 9 2 Base incl Frame Exploded view xx0200000329 ...

Page 433: ...HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved 9 3 Frame Lower arm 1 Exploded view xx0200000330 Correction Pos 109 332 1 109 305 3HAA1001 186 Washer 17x25x3 Pos 109 332 1 109 304 3HAB3409 92 Hex socket head cap screw M16x110 ...

Page 434: ... E 432 Copyright 2004 2008 ABB All rights reserved 9 4 Frame Lower arm 2 Exploded view xx0200000331 Correction Pos 109 303 108 201 3HAC17213 1 Sealing axis 2 3 Pos 109 304 108 202 3HAB3409 84 Hex socket head cap screw M16x50 Pos 109 305 108 204 3HAA1001 186 Washer ...

Page 435: ...9 Exploded views 9 5 Upper arm 433 3HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved 9 5 Upper arm Exploded view xx0200000333 ...

Page 436: ...9 Exploded views 9 6 Wrist complete 3HAC022033 001 Revision E 434 Copyright 2004 2008 ABB All rights reserved 9 6 Wrist complete Exploded view xx0200000332 ...

Page 437: ...rcuit Diagram 10 1 Introduction 435 3HAC022033 001 Revision E Copyright 2004 2008 ABB All rights reserved 10 Circuit Diagram 10 1 Introduction Overview This chapter includes the circuit diagram for the robot ...

Page 438: ...alid for your robot The validity of the circuit diagram depends on which cable harness is fitted to the robot Check the article number of the cable harness fitted to the robot and see page 3 of the circuit diagram in order to determine if the diagram is valid for the harness or not Where to find the article number Action Label on the cable harness The label is located at the connectors in the base...

Page 439: ...rs that may appear in this document Except as may be expressly stated anywhere in this document nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses damages to persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this document This document and parts thereof mus...

Page 440: ...ge Page description ABB Contents1 1 COPYRIGHT page 2 Table of contents 1 150 3 Valid For 4 Connection point location IRB 6600 6640 6650 7600 5 Connection point location IRB 6660 9 Legend IRB 66XX 7600 10 Brake Release Unit IRB 66XX 7600 20 Serial Measuring Board IRB 66XX 7600 30 Axis 1 IRB 66XX 7600 40 Axis 2 IRB 66XX 7600 50 Axis 3 Incl optional signal lamp IRB 66XX 76 60 Axis 4 IRB 66XX 7600 70 ...

Page 441: ...1 Manipulator harness axis 5 IRB 6600 6640 6650 6650S 3HAC11440 1 Manipulator harness axis 5 6 IRB 7600 3HAC023717 001 Manipulator harness axis 5 6 IRB 6600 ID 6640 ID 6650 ID 3HAC15930 1 UL signal lamp IRB 6600 6640 6650 6600 ID 6640 ID 6650 ID 6650S 7600 3HAC12498 1 Pos SW 3 functions IRB 6600 6640 6650 6600 ID 6640 ID 6650 ID 6650S 7600 3HAC12587 1 Pos SW 2 functions IRB 6600 6650 6600 ID 6650 ...

Page 442: ...7 8 R1 G R1 SMB1 7 R3 FAN2 R2 FB7 R2 G R2 SMB R1 SMB1 3 R1 SMB4 6 R2 SW2 X8 X9 X10 R2 MP2 R2 FB2 R2 MP4 R2 FB4 R3 FAN3 R2 FB3 R2 MP3 R2 H1 R2 H2 R2 M5 6 IRB7600 6600 ID 6640 ID 6650 ID R2 MP1 R2 FB1 R3 MP5 IRB 7600 6600 ID 6640 ID 6650 ID R3 FB5 IRB 7600 6600 ID 6640 ID 6650 ID R3 MP6 R3 FB6 R3 MP5 IRB 6600 6640 6650 6650S R3 FB5 IRB 6600 6640 6650 6650S R4 MP5 IRB 6600 6640 6650 6650S R4 FB5 IRB ...

Page 443: ...opyright 2003 ABB Page 5 21 Total IRB 6660 3HAC025744 001 Latest revision Approved by date Connection point location Location Plant Sublocation IRB6660 Manipulator Document no Next Rev Ind 02 Lab Office Status APPROVED 1 2 3 4 5 6 7 8 R3 MP6 R3 FB6 R3 MP5 R3 FB5 R2 MP3 R2 FB3 R2 H1 R2 H2 R2 MP1 R2 FB1 R1 MP R1 SMB R1 CP CS R2 MP4 R2 FB4 R2 MP2 R2 FB2 R1 SMB1 3 R1 SMB4 6 R2 SMB X8 X9 X10 R2 CP CS ...

Page 444: ...revision Approved by date Legend Location Plant Sublocation IRB66XX 7600 Manipulator Document no Next Rev Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 M B PTC R G BU FB SMB FAN SW Keypin Motor Brake Temp sensor PTC resistor Resolver Battery Pack Brake Release Unit Feedback unit Serial Measurment Board Fan Position switch Location pin to avoid mismatch Protective Earth Twisted wires...

Page 445: ... Circuit Brake Bleed Circuit Brake Bleed Circuit Brake Bleed Circuit Brake Bleed Circuit Brake Bleed Circuit 9 1 Key Pin Key Pin BU Brake Release Simplified R1 MP 13 4 3 5 2 X8 1 X8 1 5 3 11 12 X10 1 3 5 X9 4 8 10 X10 1 3 5 X9 4 8 10 Brake Release Brake PB 2 1 R1 MP R1 MP R1 MP R1 MP R1 MP R1 MP 5 6 7 8 9 10 0V 4 BU M1 Axis 1 30 2 BU M2 Axis 2 40 2 BU M3 Axis 3 50 2 BU M4 Axis 4 60 2 BU M5 7600 Ax...

Page 446: ...otal IRB 66XX 7600 3HAC025744 001 Latest revision Approved by date Serial Measuring Board Location Plant Sublocation 66XX 7600 SMB Document no Next Rev Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 A B C D E F L KEYPIN M R1 SMB 9 5 8 4 3 7 R2 SMB SDI SDI N SDO SDO N 0V 24V BK WHBK BN WHBN RD WHRD OG SMB 9 5 8 4 3 7 2 1 R2 SMB 2 1 R1 G X3 R1 G X3 G 0V Axis 3 50 3 0V EXT LAMP Axis 3 5...

Page 447: ...xt Rev Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 M 3 S V T W R U PE R2 MP1 1 6 7 9 2 5 Brake MU1 RD WH BK GNYE BU BU R2 MP1 1 6 7 9 12 2 17 18 19 R1 MP M1R M1S M1T BU M1 BU 0V M1 1 3 5 GNYE 9 10 R2 FB1 6 1 7 2 8 3 Resolver FB1 RD BK BU YE WHBK WHYE WHRD R2 FB1 6 1 7 2 8 3 2 14 3 15 6 18 R1 SMB1 3 BK WHBK BN WHBN RD WHRD X1 0V X1 Y1 0V Y1 0V EXC1 EXC1 2 14 3 15 6 18 R1 SMB1 3 SMB...

Page 448: ...02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 SMB R1 SMB1 3 4 16 5 17 7 19 R1 MP 32 31 30 4 16 5 17 7 19 R1 SMB1 3 BK WHBK BN WHBN RD WHRD M2R M2S M2T BU M2 BU 0V M2 1 2 4 GNYE 9 10 X2 0V X2 Y2 0V Y2 0V EXC1 EXC1 R2 MP2 1 6 7 9 2 5 R2 FB2 6 1 7 2 8 3 FB2 MU2 R2 MP2 1 6 7 9 2 5 R2 FB2 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver 4 3 10 12 R...

Page 449: ...4 5 6 7 8 SMB R1 SMB1 3 9 21 10 22 8 20 R1 MP 3 5 7 9 21 10 22 8 20 R1 SMB1 3 BK WHBK BN WHBN RD WHRD M3R M3S M3T PE PE BU M3 1 2 3 GNYE GNYE 9 X3 0V X3 Y3 0V Y3 0V EXC1 EXC1 R2 MP3 1 6 7 9 12 2 R2 FB3 6 1 7 2 8 3 FB3 MU3 R2 MP3 1 6 7 9 2 5 R2 FB3 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver KEYPIN B KEYPIN A A K 1 2 R2 H1 R2 H2 R2 H1 R2 H2 OG R3 H S...

Page 450: ...v Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 SMB R1 SMB4 6 2 14 3 15 6 18 R1 MP 1 2 10 2 14 3 15 6 18 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M4R M4S M4T PE BU M4 BU 0V M4 1 2 3 GNYE 6 7 X4 0V X4 Y4 0V Y4 0V EXC2 EXC2 R2 MP4 1 3 7 9 2 5 R2 FB4 6 1 7 2 8 3 FB4 MU4 R2 MP4 1 3 7 9 2 5 R2 FB4 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver PTC4 ...

Page 451: ...5 17 7 19 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M5R M5S M5T PE BU M5 BU 0V M5 1 2 3 GNYE 6 7 X5 0V X5 Y5 0V Y5 0V EXC2 EXC2 R3 MP5 1 3 7 9 2 5 R3 FB5 6 1 7 2 8 3 FB5 MU5 R3 MP5 1 3 7 9 2 5 R3 FB5 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver C1 C2 C3 GND B9 B1 B7 B8 8 11 C1 C2 C3 GND B9 B1 B7 8 11 PTC5 1 2 BU BK M5R M5S M5T PE BU M5 BU 0V M5 1 2 3 GNYE 6 ...

Page 452: ... 16 5 17 7 19 20 28 29 R1 SMB4 6 R1 MP BK WHBK BN WHBN RD WHRD M5R M5S M5T PE BU M5 BU 0V M5 PTC M5 5 1 2 3 GNYE 6 7 4 X5 0V X5 Y5 0V Y5 0V EXC2 EXC2 A B C D E F A B C D E F R3 FB5 R3 MP5 1 2 3 GND C D A B BK WHBK BN WHBN RD WHRD 1 2 3 GND C D A B M5R M5S M5T PE BU M5 BU 0V M5 PTC M5 PTC M6 X5 0V X5 Y5 0V Y5 0V EXC2 EXC2 1 2 3 GNYE 6 7 4 5 R4 FB5 6 1 7 2 8 3 R4 MP5 1 3 7 9 2 5 8 11 FB5 R4 FB5 6 1 ...

Page 453: ...6XX 7600 BU 10 2 BU 0V M5 66XX 7600 Axis 4 60 2 PTC M5 20 28 29 15 4 16 5 17 7 19 PTC 0V R1 SMB4 6 5 BK WHBK BN WHBN RD WHRD M5R M5S M5T PE BU M5 BU 0V M5 PTC M5 X5 0V X5 Y5 0V Y5 0V EXC2 EXC2 1 2 3 GNYE 6 7 4 R2 M5 6 C1 C2 C3 GND B9 B1 B7 A1 A7 A2 A8 A3 A9 C1 C2 C3 GND B9 B1 B7 A1 A7 A2 A8 A3 A9 R2 M5 6 BN WHBN RD WHRD OG WHOG M5R M5S M5T PE BU M5 BU 0V M5 PTC M5 PTC M6 1 2 3 GNYE 9 11 7 X5 0V X5...

Page 454: ... 20 R1 MP 9 8 16 9 21 10 22 8 20 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M6R M6S M6T PE BU M6 BU 0V M6 1 2 3 GNYE 6 7 X6 0V X6 Y6 0V Y6 0V EXC2 EXC2 R3 MP6 1 3 7 9 2 5 R3 FB6 6 1 7 2 8 3 FB6 MU6 R3 MP6 1 3 7 9 2 5 R3 FB6 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U PE Brake Resolver 8 11 BU BK PTC6 1 2 8 11 R2 M5 6 C4 C5 C6 GND B11 B12 B10 C4 C5 C6 GND B11 B12 B10 M6R M6S M...

Page 455: ... 6 Document no Next Rev Ind 02 Lab Office Status APPROVED 2005 10 17 1 2 3 4 5 6 7 8 SMB R1 SMB4 6 9 21 10 22 8 20 R1 MP 9 8 16 9 21 10 22 8 20 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M6R M6S M6T PE BU M6 BU 0V M6 1 2 3 GNYE 6 7 X6 0V X6 Y6 0V Y6 0V EXC2 EXC2 R3 MP6 1 3 7 9 2 5 R3 FB6 6 1 7 2 8 3 FB6 MU6 R3 MP6 1 3 7 9 2 5 R3 FB6 6 1 7 2 8 3 RD BK BU YE WHBK WHYE WHRD RD WH BK GNYE BU BU M 3 S V T W R U...

Page 456: ...9 21 10 22 8 20 9 21 10 22 8 20 R1 MP 66XX 7600 BU 10 7 BU M6 9 8 16 R1 SMB4 6 BK WHBK BN WHBN RD WHRD M6R M6S M6T PE BU M6 X6 0V X6 Y6 0V Y6 0V EXC2 EXC2 1 2 3 GNYE 6 R2 M5 6 C4 C5 C6 GND B11 B10 R2 M5 6 A4 A10 A5 A11 A6 A12 C4 C5 C6 GND B11 B10 A4 A10 A5 A11 A6 A12 M6R M6S M6T PE BU M6 BU 0V M6 PTC 0V BK WHBK BN WHBN RD WHRD 1 2 3 GNYE 6 7 5 X6 0V X6 Y6 0V Y6 0V EXC2 EXC2 PTC M6 4 R3 FB6 6 1 7 2...

Page 457: ...0 17 1 2 3 4 5 6 7 8 SW1 1 22 21 14 13 SW1 2 22 21 14 13 SW1 3 22 21 14 13 SW1 4 22 21 14 13 SW1 5 22 21 14 13 SW1 6 22 21 14 13 A B D C E F H G J K M L N P S R T U W V X Y a Z Position switches Axis 1 Power 1 1 1 Power 1 1 2 Signal 1 1 1 Signal 1 1 2 Power 1 2 1 Power 1 2 2 Signal 1 2 2 Signal 1 2 1 Power 1 3 1 Power 1 3 2 Signal 1 3 2 Signal 1 3 1 Power 1 4 1 Power 1 4 2 Signal 1 4 2 Signal 1 4 ...

Page 458: ... A B D C E F H G J K M L Power 2 1 1 Power 2 1 2 Signal 2 1 2 Signal 2 1 1 Power 2 2 1 Power 2 2 2 Signal 2 2 2 Signal 2 2 1 Power 2 3 1 Power 2 3 2 Signal 2 3 2 Signal 2 3 1 1 2 4 3 5 6 8 7 9 10 12 11 SW2 1 22 21 14 13 SW2 2 22 21 14 13 SW2 3 22 21 14 13 Position switches Axis 2 R1 SW2 3 A B D C E F H G J K M L A B D C E F H G J K M L R2 SW2 Power 2 1 1 Power 2 1 2 Signal 2 1 2 Signal 2 1 1 Power...

Page 459: ...8 T U W V X Y a Z b c e d f h g R1 SW2 3 Power 3 1 1 Power 3 1 2 Signal 3 1 2 Signal 3 1 1 Power 3 2 1 Power 3 2 2 Signal 3 2 2 Signal 3 2 1 Power 3 3 1 Power 3 3 2 Signal 3 3 2 Signal 3 3 1 1 2 4 3 5 6 8 7 9 10 12 11 13 15 14 A B D C E F H G J K M L A B D C E F H G J K M L R2 SW3 Power 3 1 1 Power 3 1 2 Signal 3 1 2 Signal 3 1 1 Power 3 2 1 Power 3 2 2 Signal 3 2 2 Signal 3 2 1 Power 3 3 1 Power ...

Page 460: ...to the robot Check the article number of the cable harness fitted to the robot This circuit diagram is valid for the following cable harness assemblies For remaining cable harness assemblies see section Circuit diagram 3HAC025744 001 on page 436 Where to find the article number Action Label on the cable harness The label is located at the connectors in the base Remove the rear cover plate to see t...

Page 461: ... Copyright 2004 2006 ABB All rights reserved Revision 02 sheet Circuit Diagram 3HAC 13347 1 Contents 101 ...

Page 462: ... Copyright 2004 2006 ABB All rights reserved Revision 02 sheet Circuit Diagram 3HAC 13347 1 Connection Point Location 102 ...

Page 463: ... Copyright 2004 2006 ABB All rights reserved Revision 02 sheet Circuit Diagram 3HAC 13347 1 Legend 103 ...

Page 464: ... Copyright 2004 2006 ABB All rights reserved Revision 02 sheet Circuit Diagram 3HAC 13347 1 Brake Release Unit 104 ...

Page 465: ... Copyright 2004 2006 ABB All rights reserved Revision 02 sheet Circuit Diagram 3HAC 13347 1 Serial Measurement Board 105 ...

Page 466: ... Copyright 2004 2006 ABB All rights reserved Revision 02 sheet Circuit Diagram 3HAC 13347 1 Axis 1 106 ...

Page 467: ... Copyright 2004 2006 ABB All rights reserved Revision 02 sheet Circuit Diagram 3HAC 13347 1 Axis 2 107 ...

Page 468: ... Copyright 2004 2006 ABB All rights reserved Revision 02 sheet Circuit Diagram 3HAC 13347 1 Axis 3 108 ...

Page 469: ... Copyright 2004 2006 ABB All rights reserved Revision 02 sheet Circuit Diagram 3HAC 13347 1 Axis 4 109 ...

Page 470: ... Copyright 2004 2006 ABB All rights reserved Revision 02 sheet Circuit Diagram 3HAC 13347 1 Axis 5 IRB 7600 110 ...

Page 471: ... Copyright 2004 2006 ABB All rights reserved Revision 02 sheet Circuit Diagram 3HAC 13347 1 Axis 6 111 ...

Page 472: ... Copyright 2004 2006 ABB All rights reserved Revision 02 sheet Circuit Diagram 3HAC 13347 1 Switches axis 1 113 ...

Page 473: ... Copyright 2004 2006 ABB All rights reserved Revision 02 sheet Circuit Diagram 3HAC 13347 1 Switches Fan axis 2 114 ...

Page 474: ... Copyright 2004 2006 ABB All rights reserved Revision 02 sheet Circuit Diagram 3HAC 13347 1 Switches Fan axis 3 115 ...

Page 475: ... Copyright 2004 2006 ABB All rights reserved Revision 02 sheet Circuit Diagram 3HAC 13347 1 Axis 5 IRB 6600 901 ...

Page 476: ... Copyright 2004 2006 ABB All rights reserved Revision 02 sheet Circuit Diagram 3HAC 13347 1 Design changes note 1 1 905 ...

Page 477: ... Copyright 2004 2006 ABB All rights reserved Revision 02 sheet Circuit Diagram 3HAC 13347 1 Design changes note 2 1 2 7 906 ...

Page 478: ...10 Circuit Diagram 10 3 1 Validity of circuit diagram 3HAC13347 1 3HAC022033 001 Revision E 438 Copyright 2004 2008 ABB All rights reserved ...

Page 479: ...symbols 33 F FlexPendant jogging to calibration position 381 MoveAbsJ instruction 380 updating revolution counters 378 forces and torques robot 52 fork lift 60 foundation 52 levelness 52 loads 52 requirements 52 resonance frequency 52 G gearbox axis 1 replacement 334 gearbox axis 3 replacement 349 gearbox axis 6 replacement 366 gearbox oil 177 I installation mechanical stop axis 1 102 mechanical s...

Page 480: ...uring robot 83 securing upper arm 312 serial measurement board unit replacement 266 special tools 395 stability 59 storage conditions robot 52 symbols safety 33 sync marks 374 T temperatures allowed operating robot 52 stored robot 52 testing brakes 27 tightening torque mechanical stop axis 1 103 mechanical stop axis 2 105 tilt max value on foundation 52 tool set balancing device bearing replacemen...

Page 481: ......

Page 482: ...ABB AB Robotics Products S 721 68 VÄSTERÅS SWEDEN Telephone 46 0 21 344000 Telefax 46 0 21 132592 3HAC022033 001 Revision E en ...

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