ABB IRB 260 Product Manual
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ABB IRB 260 Product Manual

Articulated robot
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Articulated robot
IRB 260
M2004

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Summary of Contents for ABB IRB 260

  • Page 1 Product manual Articulated robot IRB 260 M2004...
  • Page 3 Product manual IRB 260 M2004 Document ID: 3HAC026048-001 Revision: A...
  • Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of gurantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    Table of Contents Overview ................7 Product documentation, M2004 .
  • Page 6 Table of Contents 3 Maintenance 3.1 Introduction ............... 75 3.2 Maintenace schedule .
  • Page 7 7.4 Spare parts - robot IRB 260 ........
  • Page 8 Table of Contents 3HAC026048-001 Revision: A...

  • Page 9: Overview

    Prerequisites A maintenance/repair/ installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters:...
  • Page 10 Overview Continued References Procedures in this product manual contain references to the following manuals: Product specification Document name Document ID Product specification - IRB 260 3HAC025046-001 Product manual Document name Document ID Product manual IRC5 3HAC021313-001 Operating manual Document name...

  • Page 11: Product Documentation, M2004

    This means that any given delivery of robot products will not contain all documents listed, only the ones pertaining to the equipment delivered. However, all documents listed may be ordered from ABB. The documents listed are valid for M2004 robot systems.
  • Page 12 Product documentation, M2004 Continued Application manuals Specific applications (e.g. software or hardware options) are described in Application manuals. An application manual can describe one or several applications. An application manual generally contains information about: • The purpose of the application (what it does and when it is useful) •...

  • Page 13: How To Read The Product Manual

    How to read the product manual How to read the product manual Reading the procedures The procedures contain references to figures, tools, material etc. The references are read as described below. References to figures The procedures often include references to components or attachment points located on the robot/controller.
  • Page 14 How to read the product manual 3HAC026048-001 Revision: A...

  • Page 15: Safety

    1 Safety 1.1. Introduction 1 Safety 1.1. Introduction Overview The safety information in this manual is divided in two categories: • general safety aspects, important to attend to before performing any service work on the robot. These are applicable for all service work and are found in section General safety information on page •...

  • Page 16: General Safety Information

    Limitation of liability Any information given in this manual regarding safety, must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. Related information...

  • Page 17: Safety Risks

    Nation/region specific regulations To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Non-voltage related risks •...
  • Page 18 1 Safety 1.2.2.1. Safety risks during installation and service work on robot Continued Complete robot Safety risk Description Hot components! Caution! Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! Removed parts may result in collapse of robot! Warning! Take any necessary measures to ensure that the robot...

  • Page 19: Safety Risks Related To Tools/Workpieces

    1 Safety 1.2.2.2. Safety risks related to tools/workpieces 1.2.2.2. Safety risks related to tools/workpieces Safe handling It must be possible to 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).

  • Page 20: Safety Risks Related To Pneumatic/Hydraulic Systems

    1 Safety 1.2.2.3. Safety risks related to pneumatic/hydraulic systems 1.2.2.3. Safety risks related to pneumatic/hydraulic systems General Special safety regulations apply to pneumatic and hydraulic systems. Residual energy • Residual energy may be present in these systems. After shutdown, particular care must be taken.

  • Page 21: Safety Risks During Operational Disturbances

    1 Safety 1.2.2.4. Safety risks during operational disturbances 1.2.2.4. Safety risks during operational disturbances General • The industrial robot is a flexible tool which can be used in many different industrial applications. • All work must be carried out professionally and in accordance with the applicable safety regulations.

  • Page 22: Risks Associated With Live Electric Parts

    1 Safety 1.2.2.5. Risks associated with live electric parts 1.2.2.5. Risks associated with live electric parts Voltage related risks, general • Although troubleshooting may, on occasion, have to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.

  • Page 23: Safety Actions

    1 Safety 1.2.3.1. Safety fence dimensions 1.2.3. Safety actions 1.2.3.1. Safety fence dimensions General Install a safety cell around the robot to ensure safe robot installation and operation. Dimensioning Dimension 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.

  • Page 24: Fire Extinguishing

    1 Safety 1.2.3.2. Fire extinguishing 1.2.3.2. Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot (manipulator or controller)! 3HAC026048-001 Revision: A...

  • Page 25: Emergency Release Of The Robot's Arm

    1 Safety 1.2.3.3. Emergency release of the robot’s arm 1.2.3.3. Emergency release of the robot’s arm Description In an emergency situation, any of the robot's axes may be released manually by pushing the brake release buttons on the robot. How to release the brakes is detailed in section: •...

  • Page 26: Brake Testing

    1 Safety 1.2.3.4. Brake testing 1.2.3.4. Brake testing When to test During operation the holding brakes of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function. How to test The function of each axis' motor holding brakes may be checked as detailed below: 1.

  • Page 27: Risk Of Disabling Function "Reduced Speed 250 Mm/S

    1 Safety 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" NOTE! Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant Unit or a PC. This will affect the safety function Reduced speed 250 mm/s. 3HAC026048-001 Revision: A...

  • Page 28: Safe Use Of The Teach Pendant Unit

    1 Safety 1.2.3.6. Safe use of the Teach Pendant Unit 1.2.3.6. Safe use of the Teach Pendant Unit NOTE! The enabling device is a push button located on the side of the Teach Pendant Unit (TPU) which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.

  • Page 29: Work Inside The Manipulator's Working Range

    1 Safety 1.2.3.7. Work inside the manipulator's working range 1.2.3.7. Work inside the manipulator's working range WARNING! If work must be carried out within the robot’s work envelope, the following points must be observed: • The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel.

  • Page 30: Translate The Information On Safety And Information Labels

    Drawings detailing the design (text, figure, dimensions) of the standard labels can be ordered from ABB. Notice that each label is identified according to the article number located in the lower corner of the label.

  • Page 31: Safety Related Instructions

    1 Safety 1.3.1. Safety signals, general 1.3 Safety related instructions 1.3.1. Safety signals, general General This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of: •...
  • Page 32 1 Safety 1.3.1. Safety signals, general Continued Symbol Designation Signification ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates DISCHARGE (ESD) electrostatic hazards which could result in severe damage to the product. Electrostatic discharge (ESD) NOTE Note symbols alert you to important facts and conditions.

  • Page 33: Danger - Moving Manipulators Are Potentially Lethal

    1 Safety 1.3.2. DANGER - Moving manipulators are potentially lethal! 1.3.2. DANGER - Moving manipulators are potentially lethal! Description Any moving manipulator is a potentially lethal machine. When running the manipulator, it may perform unexpected and sometimes irrational movements. However, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the manipulator working range.

  • Page 34: Danger - First Test Run May Cause Injury Or Damage

    1 Safety 1.3.3. DANGER - First test run may cause injury or damage! 1.3.3. DANGER - First test run may cause injury or damage! Description Since performing a service activity often requires disassembly of the robot there are several safety risks 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):...

  • Page 35: Warning - The Unit Is Sensitive To Esd

    1 Safety 1.3.4. WARNING - The unit is sensitive to ESD! 1.3.4. WARNING - The unit is sensitive to ESD! Description ESD (electro static discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges.

  • Page 36: Warning - Safety Risks During Work With Gearbox Oil

    1 Safety 1.3.5. WARNING - Safety risks during work with gearbox oil 1.3.5. WARNING - Safety risks during work with gearbox oil Description When handling the gearbox oil, there are several dangers to both personal injuries and product damages! Following safety information must be regarded before performing any work with the oil in the gearboxes! Warnings and elimination Warning...
  • Page 37 1 Safety 1.3.5. WARNING - Safety risks during work with gearbox oil Continued Warning Description Elimination / Action The specified amount of oil is After refilling, check the oil level. based on the total volume of the gearbox. When changing the oil, the amount of refilled oil may differ from the specified amount, depending on how...
  • Page 38 1 Safety 1.3.5. WARNING - Safety risks during work with gearbox oil 3HAC026048-001 Revision: A...

  • Page 39: Installation And Commissioning

    2 Installation and commissioning 2.1. Introduction 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. 3HAC026048-001 Revision: A...

  • Page 40: Unpacking

    Lifting of robot on page Weight, robot Robot model Weight IRB 260 340 kg Loads on foundation The table below shows the different forces and torques working on the robot during various kinds of operation. Note! These forces and torques are extreme values that are rarely encountered during operation.
  • Page 41 Max. ambient temperature +45° C Max. ambient humidity Max. 95% at constant temperature Protection classes The table below shows the protection class of the main parts of the robot system: Equipment Protection class Robot IRB 260 IP 67 3HAC026048-001 Revision: A...

  • Page 42: Working Range

    2.2.2. Working range 2.2.2. Working range Working range This section specifies the working areas of the robot models. IRB 260 The extreme positions of the robot are specified at the tool flange center (dimensions in mm). xx0500001926 Position at mechanical stop...
  • Page 43 2 Installation and commissioning 2.2.2. Working range Continued Position in figure Position (mm) Angles (º) Axis 2 Axis 3 1506 1313 1148 Type of motion Axis Type of motion Range of movement Rotation motion +180º to -180º Arm motion +85º to -28º Arm motion +119º...

  • Page 44: On-Site Installation

    2 Installation and commissioning 2.3.1. Lifting of robot 2.3 On-site installation 2.3.1. Lifting of robot Methods for lifting The robot can be lifted with: • lifting slings, or • lifting chains. Required equipment Equipment Specification Overhead crane Lifting capacity: 500 kg. Lifting slings Lifting chains, 3 pcs Lengths:...
  • Page 45 2 Installation and commissioning 2.3.1. Lifting of robot Continued Lifting chains - attachment and axis position The lifting chains are attached to the robot as shown in the figure below. The axis positions are specified below the figure. xx0500002141 Axis 2 position: -28º...
  • Page 46 2 Installation and commissioning 2.3.1. Lifting of robot Continued Lifting of robot The procedure below details how to lift the complete robot. Action Note 1. Move the robot to the correct lifting Depending on the method of lifting, the position. correct axis positions are shown in: If necessary, release the brakes of •...

  • Page 47: Manually Releasing The Brakes

    2 Installation and commissioning 2.3.2. Manually releasing the brakes 2.3.2. Manually releasing the brakes General The holding brakes of each axis’ motor are of an electromechanical type and are released when voltage is applied. This section details how to release the brakes, using the internal brake release unit, in order to enable the axes to move manually.
  • Page 48 2 Installation and commissioning 2.3.2. Manually releasing the brakes Continued Supplying power to connector 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 unit on the robot. Action Note/Illustration Caution!

  • Page 49: Orienting And Securing The Robot

    2 Installation and commissioning 2.3.3. Orienting and securing the robot 2.3.3. Orienting and securing the robot General This section details how to orient and secure the robot to the foundation in order to safely run the robot. The requirements for the foundations are shown in the tables and figures below. Bolting requirements When bolting a base plate or the base to a concrete floor, follow the general instructions for expansion-shell bolts.
  • Page 50 2 Installation and commissioning 2.3.3. Orienting and securing the robot Continued Cross section, guide sleeve hole The figure below shows the cross section of the guide sleeve holes (from previous figure): xx0200000182 Guide sleeves Two guide sleeves can be fitted to the two rear bolt holes to allow the same robot to be remounted without re-adjusting the program.

  • Page 51: Fitting Equipment On The Robot And Robot Dimensions

    2 Installation and commissioning 2.3.4. Fitting equipment on the robot and robot dimensions 2.3.4. Fitting equipment on the robot and robot dimensions General This section shows the dimensions and available mounting holes on the robot. Main dimensions xx0500001928 At maximum working range axis 3 Mounting hole for safety lamp Mounting hole for external air hose Continues on next page...
  • Page 52 2 Installation and commissioning 2.3.4. Fitting equipment on the robot and robot dimensions Continued Fitting equipment on the robot xx0500002102 M8 (3x) Depth 16 mm, R=77 M8 (3x) Depth 16 mm, R=92 Max. 35 kg total The rear side of the robot Continues on next page 3HAC026048-001 Revision: A...
  • Page 53 2 Installation and commissioning 2.3.4. Fitting equipment on the robot and robot dimensions Continued Turning radius, axis 2 xx0500001929 Continues on next page 3HAC026048-001 Revision: A...
  • Page 54 2 Installation and commissioning 2.3.4. Fitting equipment on the robot and robot dimensions Continued Turning disk, dimensions The figure below shows the mounting holes available for fitting equipment on the turning disk. xx0500001932 3HAC026048-001 Revision: A...

  • Page 55: Loads

    Specification. The loads must also be defined in the software as detailed in User's Guide (RobotWare 4.0), or Operating manual (RobotWare 5.0). Stop time and braking distances Robot motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB. 3HAC026048-001 Revision: A...

  • Page 56: Load Diagram

    2 Installation and commissioning 2.3.6. Load diagram 2.3.6. Load diagram Load diagram, IRB 260-30/1.5 The figure below shows the maximum permitted load mounted on the robot tool flange at different positions (center of gravity). xx0500002100 3HAC026048-001 Revision: A...

  • Page 57: Installation Of Signal Lamp (Option)

    2 Installation and commissioning 2.3.7. Installation of signal lamp (option) 2.3.7. Installation of signal lamp (option) General As an option, a signal lamp can be installed on the robot. The lamp is activated when the controller is in the MOTORS ON state. Signal lamp on robot The signal lamp is installed on the upper arm, as shown in the figure below.
  • Page 58 2 Installation and commissioning 2.3.7. Installation of signal lamp (option) Continued Required equipment Equipment Spare part no. Note Signal lamp 3HAC025254-001 Includes all components shown in the previous figure. Standard toolkit The contents are defined in section Standard toolkit on page 190, in part 2 of the Product manual.

  • Page 59: Restricting The Working Range

    2 Installation and commissioning 2.4.1. Introduction 2.4 Restricting the working range 2.4.1. Introduction General When installing the robot, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited. The working range of the following axes may be restricted: •...

  • Page 60: Mechanically Restricting The Working Range Of Axis 1

    2 Installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 2.4.2. Mechanically restricting the working range of axis 1 Restrictions in the working range The working range of axis 1 can be restricted within the area from 50º to 140º as shown in the figure below.
  • Page 61 2 Installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 Continued Required equipment Equipment Art. no. Note Stop, axis 1 3HAB 7298-1 Includes: • removable stop (2 pcs) • plain washers (4 pcs) • hex socket head cap screw (4 pcs, M12x30) •...
  • Page 62 2 Installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 Continued Location of where to drill holes for extra stops The figure below shows the drill pattern used when drilling for mechanical stops on axis 1. xx0200000206 Maximum working range, axis 1 Minimum working range, axis 1 Drilling pattern enclosed with the mechanical stop.
  • Page 63 2 Installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 Continued Hidden stiffening ribs and forbidden drilling sector xx0600002647 Drilling not allowed inside this sector! Center lines for the hidden stiffening ribs Continues on next page 3HAC026048-001 Revision: A...
  • Page 64 2 Installation and commissioning 2.4.2. Mechanically restricting the working range of axis 1 Continued Drill template xx0200000207 3HAC026048-001 Revision: A...

  • Page 65: Installation Of Position Switch, Axis 1

    2 Installation and commissioning 2.4.3. Installation of position switch, axis 1 2.4.3. Installation of position switch, axis 1 General This section details how to install the position switch to axis 1. Location of position switch, axis 1 The position switch is installed between the frame and the base, as shown in the figure below. xx0600002676 Position switch Attachment screws, position switch (2 pcs for each switch) M4 x 16...
  • Page 66 2 Installation and commissioning 2.4.3. Installation of position switch, axis 1 Continued Attachment screws, attachment plate (2 pcs) M6 x 16 Shims Bracket Attachment screws, bracket (2 pcs) M6 x 30 Mechanical stop Cable straps Attachment screw, clamp Clamp Required equipment All parts are included in the delivery of the kits specified below.
  • Page 67 2 Installation and commissioning 2.4.3. Installation of position switch, axis 1 Continued Action Note 7. Secure the cabling with straps and Shown in the figure Location of position clamps. switch, axis 1 on page 8. Connect the position switch cabling. The cabling and connection points are specified in section Position switch cables,...
  • Page 68 2 Installation and commissioning 2.4.4. Mechanically restricting the working range of axis 2 2.4.4. Mechanically restricting the working range of axis 2 General The stops are installed as standard, not movable and must always be installed during operation of the robot! Restrictions in working range The mechanical stops are not movable or optional! They function as solid stops and must be installed during robot operation.
  • Page 69 2 Installation and commissioning 2.4.4. Mechanically restricting the working range of axis 2 Continued Installation, mechanical stops axis 2 The procedure below details how to fit the mechanical stops to the axis 2. Action Note 1. Move the robot to its calibration position. Shown in section Calibration scales and correct axis position on page 178.
  • Page 70 2 Installation and commissioning 2.4.4. Mechanically restricting the working range of axis 2 Continued Action Note 6. The software working range limitations How to define the range of movement in must be re-defined to correspond to the RobotWare 5.0 is detailed in the Technical changes in the mechanical limitations of reference manual - System parameters-...

  • Page 71: Mechanically Restricting The Working Range Of Axis 3

    2 Installation and commissioning 2.4.5. Mechanically restricting the working range of axis 3 2.4.5. Mechanically restricting the working range of axis 3 General The stop of axis 3 is installed as standard, not movable and must always be installed during operation of robot! Restrictions in working range The mechanical stop is not movable or optional! It functions as a solid stop and must be...
  • Page 72 2 Installation and commissioning 2.4.5. Mechanically restricting the working range of axis 3 Continued Installation, mechanical stop The procedure below details how to fit the mechanical stop to the robot. Action Note Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.

  • Page 73: Electrical Connections

    2 Installation and commissioning 2.5.1. Connectors on robot 2.5 Electrical connections 2.5.1. Connectors on robot Connectors on the robot The figure below shows all connections of the robot cabling, including the customer connections. xx0500002434 3HAC026048-001 Revision: A...

  • Page 74: Robot Cabling And Connection Points

    2 Installation and commissioning 2.5.2. Robot cabling and connection points 2.5.2. Robot cabling and connection points General Connect the robot and controller to each other after securing them to the foundation. The lists below specify which cables to use for each respective application. Main cable categories All cables between the robot and control cabinet are divided into the following categories: Cable category...
  • Page 75 2 Installation and commissioning 2.5.2. Robot cabling and connection points Continued Robot cable, signals Cable Art. no. Robot cable, signal, shielded, 7 m 3HAC 7998-1 Robot cable, signal, shielded, 15 m 3HAC 7998-2 Robot cable, signal, shielded, 22 m 3HAC 7998-3 Robot cable, signal, shielded, 30 m 3HAC 7998-4 Position switch cables, robot base to control cabinet (option)
  • Page 76 2 Installation and commissioning 2.5.2. Robot cabling and connection points 3HAC026048-001 Revision: A...

  • Page 77: Maintenance

    3 Maintenance 3.1. Introduction 3 Maintenance 3.1. Introduction Structure of this chapter This chapter details all maintenance activities recommended for the robot and any external units of the robot. It is based on the maintenance schedule, located in the beginning of the chapter. The schedule contains information about required maintenance activities including intervals and refers to procedures for the activities.

  • Page 78: Maintenace Schedule

    3 Maintenance 3.2.1. Specification of maintenance intervals 3.2 Maintenace schedule 3.2.1. Specification of maintenance intervals Description The intervals may be specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the robot: •...

  • Page 79: Maintenance Schedule

    3 Maintenance 3.2.2. Maintenance schedule 3.2.2. Maintenance schedule General The robot must be maintained regularly to ensure proper function. The maintenance activities and intervals are specified in the table below. Non-predictable situations also give rise to inspections of the robot. Any damages must be attended to immediately! The inspection intervals do not specify the life of each component.

  • Page 80: Inspection Activities

    3 Maintenance 3.3.1. Inspection of information labels 3.3 Inspection activities 3.3.1. Inspection of information labels Location of labels The labels are located on the robot as shown in the figure below. xx0600002622 A, B Instruction plate. Specified further in the following table. Rating label (silver coloured) Calibration label.
  • Page 81 3 Maintenance 3.3.1. Inspection of information labels Continued Inspection, labels Action Note Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Inspect that all labels are fitted to the robot. Replace Shown in the figure Location of them if damaged or missing.

  • Page 82: Changing Activites

    3 Maintenance 3.4.1. Oil in gearboxes 3.4 Changing activites 3.4.1. Oil in gearboxes Location of gearboxes The figure below shows the location of all the gearboxes. xx0500001950 Gearbox, axis 1 Gearbox, axis 2 Gearbox, axis 3 Gearbox, axis 6 Type and amount of oil in the gearboxes Gearbox Type of oil Art.

  • Page 83: Oil Change, Gearbox Axis 6 (Wrist Unit)

    3 Maintenance 3.4.2. Oil change, gearbox axis 6 (wrist unit) 3.4.2. Oil change, gearbox axis 6 (wrist unit) Location of oil plugs, gearbox The gearbox is located in the frontmost part of the upper arm. Oil plugs are located as shown in the figure below.
  • Page 84 3 Maintenance 3.4.2. Oil change, gearbox axis 6 (wrist unit) Continued Action Note 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 3.

  • Page 85: Replacement Of Smb Battery

    3 Maintenance 3.4.3. Replacement of SMB battery 3.4.3. Replacement of SMB battery Location of SMB battery The SMB battery is located inside the robot base, as shown in the figure below. xx0300000067 SMB battery SMB battery cable Required equipment Equipment Spare part no.
  • Page 86 3 Maintenance 3.4.3. Replacement of SMB battery Continued Replacement, SMB battery The procedure below details how to replace the SMB battery. Action Note Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Warning! WARNING! The unit is sensitive to ESD, before handling the unit please observe the safety information in section WARNING - The unit is sensitive to...

  • Page 87: Repair

    4 Repair 4.1. Introduction 4 Repair 4.1. Introduction Structure of this chapter This chapter details all repair activities recommended for the robot and any external units of the robot. It is made up of separate procedures, each detailing a specific repair activity. Each procedure contains all information required to perform the activity, e.g.

  • Page 88: General Procedures

    4 Repair 4.2.1. Performing a leak-down test 4.2 General procedures 4.2.1. Performing a leak-down test General After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equipment Equipment, etc.

  • Page 89: Mounting Instructions For Bearings

    4 Repair 4.2.2. Mounting instructions for bearings 4.2.2. Mounting instructions for bearings General This section details how to mount and grease different types of bearings on the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB 3537-1 Used to grease the bearings, if not specified otherwise.

  • Page 90: Mounting Instructions For Seals

    4 Repair 4.2.3. Mounting instructions for seals 4.2.3. Mounting instructions for seals General This sections details how to mount different types of seals to the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB 3537-1 Used to lubricate the seals. Rotating seals The procedure below details how to fit rotating seals.
  • Page 91 4.2.3. Mounting instructions for seals Continued Action 2. Clean the surfaces properly and in accordance with ABB recommendations. 3. Distribute the sealing compound evenly over the surface, preferably with a brush. 4. Tighten the screws evenly when fastening the flange joint.

  • Page 92: Complete Robot

    4 Repair 4.3.1. Replacement of cable unit, axes 1-3 4.3 Complete robot 4.3.1. Replacement of cable unit, axes 1-3 Location of cabling The cable unit of axes 1-3 is run from the base of the robot to the motors, axes 1, 2 and 3, as shown in the figure below.
  • Page 93 4 Repair 4.3.1. Replacement of cable unit, axes 1-3 Continued Equipment, etc. Spare part no. Art. no. Note Gasket, cover 3HAC3200-1 Cable straps, outdoor 2166 2055-3 Flange sealing 1234 0011-116 Loctite 574 Circuit diagram See chapter Circuit diagram in the Product manual, reference information.
  • Page 94 4 Repair 4.3.1. Replacement of cable unit, axes 1-3 Continued Action Note/Illustration 6. Loosen the nuts (D) and remove the SMB unit carefully from the bracket. The cable (A) between the battery (B) and the SMB unit (C) may stay connected, in order to avoid recalibration of the robot.
  • Page 95 4 Repair 4.3.1. Replacement of cable unit, axes 1-3 Continued Action Note/Illustration 12. Disconnect all the connectors at the motors of axes 1, 2 and 3. xx0200000401 A. R3.MP1-3 B. R3.FB1-3 C. Connection box 13. Remove the three screws of the connection box for the motors of axes 1, 2 and 3.
  • Page 96 4 Repair 4.3.1. Replacement of cable unit, axes 1-3 Continued Action Note/Illustration 6. Refit the upper bracket securing the cables to the arm house, using the two attachment screws. 7. Fit the cable guide to the harness and secure the holder to the frame with its two attachment screws (A).
  • Page 97 4 Repair 4.3.1. Replacement of cable unit, axes 1-3 Continued Action Note/Illustration 10. Refit the SMB unit to the bracket with the nuts (D). Be careful not to let the weight of the SMB-unit strain the cable! (A). xx0200000398 Note! The cable (A) between the battery (B) and the SMB-unit (C) may stay connected, in order to avoid recalibration of the robot.

  • Page 98: Replacement Of Cable Unit, Axis 6

    4 Repair 4.3.2. Replacement of cable unit, axis 6 4.3.2. Replacement of cable unit, axis 6 Location of cable unit, axis 6 The cabling of axis 6 is run throughout the robot, from the base to the wrist unit. Besides the power and signal cable, the cable unit also includes a customer cable, an UL lamp cable and an air hose.
  • Page 99 4 Repair 4.3.2. Replacement of cable unit, axis 6 Continued Required equipment Equipment Spare part no. Note Cable unit axis 6 3HAC024115-001 Standard toolkit The contents are defined in section Standard toolkit on page 190, in part 2 of the Product manual.
  • Page 100 4 Repair 4.3.2. Replacement of cable unit, axis 6 Continued Action Note/Illustration 6. Loosen the nuts (D) and remove the SMB- unit from the bracket carefully. Leaving the cable (A) between the battery (B) and the SMB-unit (C) connected avoids recalibration of the robot. But be careful not to let the weight of the SMB-unit strain the cable! In order to remove the SMB-unit...
  • Page 101 4 Repair 4.3.2. Replacement of cable unit, axis 6 Continued Action Note/Illustration 12. Gently pull down the cable harness through the lower arm and remove it from the robot. Refitting, cable unit axis 6 The procedure below details how to refit the cable unit of axis 6 to the robot. Action Note/Illustration Danger!
  • Page 102 4 Repair 4.3.2. Replacement of cable unit, axis 6 Continued Action Note/Illustration 6. Refit the SMB unit to the bracket by tightening the nuts (D). Reconnect the battery cable (A), if discon- nected. xx0200000398 7. Secure the cable bracket inside the base. Shown in the figure Location of cable unit, axis 6 on page...
  • Page 103 4 Repair 4.3.2. Replacement of cable unit, axis 6 Continued Action Note/Illustration 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 3HAC026048-001 Revision: A...

  • Page 104: Upper Arm

    4 Repair 4.4.1. Replacement of shaft and bearings, tilthouse 4.4 Upper arm 4.4.1. Replacement of shaft and bearings, tilthouse Location of shaft and bearings The tilthouse is located in the front part of the upper arm, linked to the upper arm with a shaft, as shown in the figure below.
  • Page 105 4 Repair 4.4.1. Replacement of shaft and bearings, tilthouse Continued Required equipment Equipment Spare part no. Art. no. Note Shaft 3HAC024867-001 Taper roller bearing 3HAA2103-14 2 pcs. Sealing ring with dust lip 3HAB3701-25 Always replace with a new one! Sealing ring 3HAC7877-2 Always replace with a new one!
  • Page 106 4 Repair 4.4.1. Replacement of shaft and bearings, tilthouse Continued Dismounting tool, tilthouse shaft The tool for removing the tilthouse shaft from the tilthouse is assembled with the parts shown in the figure below (included in the toolkit for service). Note! The parts cannot be ordered separately, but are included in the complete toolkit! The article numbers are only given for identification.
  • Page 107 4 Repair 4.4.1. Replacement of shaft and bearings, tilthouse Continued Dismounting tool, bearing race, upper arm The tool for removing the bearing race from the upper arm is assembled with the parts shown in the figure below (included in the toolkit for service). Note! The parts cannot be ordered separately, but are included in the complete toolkit! The article numbers are given only for identification.
  • Page 108 4 Repair 4.4.1. Replacement of shaft and bearings, tilthouse Continued Press washer, 3HAC023963-007 Hex socket head cap screw, 9ADA183-25, 2 pcs, M6 x 25 Connection rod, M16, length= 400 mm Nut, 3HAC5507-1 Nut, 3HAC023963-028 Sleeve, 3HAC023963-037 Mounting tool, tilthouse shaft The tool for fitting the tilthouse shaft to the tilthouse is assembled with the parts shown in the figure below (included in the toolkit for service).
  • Page 109 4 Repair 4.4.1. Replacement of shaft and bearings, tilthouse Continued Mounting tool, bearing race and sealing, upper arm The tool for fitting the bearing race and sealing to the upper arm is assembled with the parts shown in the figure below (included in the toolkit for service). Note! The parts cannot be ordered separately, but are included in the complete toolkit! The article numbers are given only for identification.
  • Page 110 4 Repair 4.4.1. Replacement of shaft and bearings, tilthouse Continued Press washer, 3HAC023963-007 Hex socket head cap screw, 9ADA183-25, 2 pcs, M6 x 25 Connection rod, M16, length= 400 mm Nut, 3HAC5507-1 Nut, 3HAC023963-028 Sleeve, 3HAC023963-037 Removal, shaft and bearings The procedure below details how to remove the shaft and bearings.
  • Page 111 4 Repair 4.4.1. Replacement of shaft and bearings, tilthouse Continued Action Note/Illustration 10. If removing the remaining bearing race from the The assembly is shown in the figure shaft, rebuild the tool to a dismounting tool, Dismounting tool, bearing race, bearing race, tilthouse shaft.
  • Page 112 4 Repair 4.4.1. Replacement of shaft and bearings, tilthouse Continued Action Note/Illustration 4. Fit a new sealing ring to the press washer (A) and place it on the inner side of the seating, as shown in the figure to the right. Fasten the bar (B) to the press washer.
  • Page 113 4 Repair 4.4.1. Replacement of shaft and bearings, tilthouse Continued Action Note/Illustration 14. Insert the bar (A) through the shaft and secure with press washer (B). xx0500002584 15. If not already fitted, fit the press washer to the Shown in the figure Mounting tool, hydraulic cylinder with the two M6 bolts.
  • Page 114 4 Repair 4.4.1. Replacement of shaft and bearings, tilthouse Continued Action Note/Illustration 24. 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 175.

  • Page 115: Replacement Of Turning Disk

    4 Repair 4.4.2. Replacement of turning disk 4.4.2. Replacement of turning disk Location of turning disk The turning disk is located at the frontmost part of the robot, as shown in the figure below. A more detailed view of the component and its position may be found in section Tilthouse, exploded view on page 219 in part 2 of the Product manual.
  • Page 116 4 Repair 4.4.2. Replacement of turning disk Continued Removal, turning disk The procedure below details how to remove the turning disk from the robot. Action Note Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 117 4 Repair 4.4.2. Replacement of turning disk Continued Action Note 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 3HAC026048-001 Revision: A...

  • Page 118: Replacement Of Complete Upper Arm

    4 Repair 4.4.3. Replacement of complete upper arm 4.4.3. Replacement of complete upper arm Location of upper arm The upper arm is located as shown in the figure below. A more detailed view of the component and its position may be found in section Robot IRB 260, exploded view 1 of 2 on page 206 in part 2 of the Product manual.
  • Page 119 4 Repair 4.4.3. Replacement of complete upper arm Continued Equipment Spare part no. Art. no. Note Lifting straps For lifting the upper arm. Guide pins 3HAC024097- 3 pcs required. Length: 62 mm. Diameter: 6 mm. Thread: M6x12. Used for guiding the shaft end of the upper arm into place.
  • Page 120 4 Repair 4.4.3. Replacement of complete upper arm Continued Action Note/Illustration 3. Remove the linkage. Detailed in sections: • Removal, upper rod on page • Removal, lower rod on page • Removal, link on page 131 4. Remove the parallel bar. Detailed in section Removal, parallel bar on page...
  • Page 121 4 Repair 4.4.3. Replacement of complete upper arm Continued Action Note/Illustration 11. Remove the VK cover from the opposite side by making a hole in the middle. Be careful not to damage the parts underneath! 12. Untighten and remove the lock nut and the bearing also from this side of the upper arm.
  • Page 122 4 Repair 4.4.3. Replacement of complete upper arm Continued Action Note/Illustration 4. Fit the lifting equipment to the upper arm according to the figure to the right. Note! The tilthouse is movable, be careful not to damage it! xx0500002549 5. Lubricate the mounting holes of the upper arm Art.
  • Page 123 4 Repair 4.4.3. Replacement of complete upper arm Continued Action Note/Illustration 9. Secure the other side of the upper arm to the lower arm by fitting the shaft end with guidance from the guide pins. xx0600002605 A. Shaft end B. Guide pins, 3 pcs C.
  • Page 124 4 Repair 4.4.3. Replacement of complete upper arm Continued Action Note/Illustration 16. Fit the other tapered roller bearing and Art. no. is specified in Required lubricated lock nut to the opposite side of the equipment on page 116. upper arm. Use the extended KM nut and tighten the lock nut with 55 Nm, then untighten and retighten with 35 Nm.

  • Page 125: Replacement Of Linkage - Upper Rod

    4 Repair 4.4.4. Replacement of linkage - upper rod 4.4.4. Replacement of linkage - upper rod Overview The link system consists of three basic parts - upper rod, lower rod and link. The procedures below details how to remove and refit the upper rod. Location of upper rod The upper rod is located as shown in the figure below.
  • Page 126 4 Repair 4.4.4. Replacement of linkage - upper rod Continued Equipment Spare part no. Art no. Note Support washer 3HAB6279-1 Replace if damaged. Bearing grease 3HAB3537-1 Used to lubricate the bearings. Locking liquid 3HAB7116-1 Loctite 243 Press sleeve 3HAC023963-013 Used for pressing new bearings into the rod, if replaced.
  • Page 127 4 Repair 4.4.4. Replacement of linkage - upper rod Continued Refitting, upper rod The procedure below details how to refit the upper rod of the linkage. Action Note 1. If needed, replace the bearings in the rod. Spare part no. is specified in Required equipment on page 123.

  • Page 128: Replacement Of Linkage - Lower Rod

    4 Repair 4.4.5. Replacement of linkage - lower rod 4.4.5. Replacement of linkage - lower rod Overview The linkage consists of three basic parts - upper rod, lower rod and link. The procedures below details how to remove and refit the lower rod. Location of lower rod The lower rod is located as shown in the figure below.
  • Page 129 4 Repair 4.4.5. Replacement of linkage - lower rod Continued Equipment Spare part no. Art no. Note Standard toolkit The contents are defined in section Standard toolkit on page 190, in part 2 of the Product manual. Other tools and These procedures procedures may be include references to the...
  • Page 130 4 Repair 4.4.5. Replacement of linkage - lower rod Continued Action Note 2. Lubricate the bearings properly with bearing Specified in Required equipment on grease. page 126. 3. Refit the sealing rings to the shaft ends on the Shown in the figure Location of lower link and frame.

  • Page 131: Replacement Of Linkage - Link

    4 Repair 4.4.6. Replacement of linkage - link 4.4.6. Replacement of linkage - link Overview The link system consists of three basic parts - upper rod, lower rod and link. The procedures below details how to remove and refit the link. Location of link The link is located at the upper arm as shown in the figure below.
  • Page 132 4 Repair 4.4.6. Replacement of linkage - link Continued Required equipment Equipment Spare part no. Art. no. Note Protection hood 2522 2101-17 Replace if damaged! VK-cover 3HAC12165-2 Replace if damaged! Toolkit for service 3HAC023963- A tool for pressing the bearing and the link to the upper arm shaft is assembled from the loose parts in the kit.
  • Page 133 4 Repair 4.4.6. Replacement of linkage - link Continued Auxiliary shaft, 3HAC024097-005 Screw, M6x12, 9ADA183-24 (2 pcs) Distance, 3HAC023062-001 Removal, link The procedure below details how to remove the link from the robot. Action Note/Illustration Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 134 4 Repair 4.4.6. Replacement of linkage - link Continued Refitting, link The procedure below details how to refit the link to the robot. Action Note/Illustration Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Check that the bearings and the radial sealing inside the link seating are undamaged.
  • Page 135 4 Repair 4.4.6. Replacement of linkage - link Continued Action Note/Illustration 10. Fit a protection hood to the lock nut. It must be Spare part no. is specified in replaced if damaged! Required equipment on page 130. Shown in the figure Location of link on page 129.

  • Page 136: Lower Arm

    4 Repair 4.5.1. Replacement of complete lower arm 4.5 Lower arm 4.5.1. Replacement of complete lower arm Location of lower arm The lower arm is located as shown in the figure below. A more detailed view of the component and its position may be found in section Axes 1-3, spare part view 2 on page 211 in part 2 of the Product manual.
  • Page 137 4 Repair 4.5.1. Replacement of complete lower arm Continued Equipment, etc. Spare part no. Art. no. Note Bearing grease 3HAB 3537-1 Used to lubricate the sealing ring. Hoisting equipment Standard toolkit The contents are defined in section Standard toolkit on page 190, in part 2 of the Product manual.
  • Page 138 4 Repair 4.5.1. Replacement of complete lower arm Continued Action Note/Illustration 4. Fit the lifting equipment to the lower arm to secure its weight. xx0200000439 5. Remove the parallel bar. Detailed in section Removal, parallel bar on page 139. 6. Remove the parallel arm. Detailed in section Removal, parallel arm on page...
  • Page 139 4 Repair 4.5.1. Replacement of complete lower arm Continued Action Note Caution! The lower arm weighs 27 kg! Use a suitable lifting device to avoid injury to personnel! 5. Lift the lower arm into position. 6. Fit the spring tension plate to the lower arm 12 pcs;...

  • Page 140: Replacement Of Parallel Bar

    4 Repair 4.5.2. Replacement of parallel bar 4.5.2. Replacement of parallel bar Location of parallel bar The parallel bar is located as shown in the figure below. A more detailed view of the component and its position may be found in section Axes 1-3, spare part view 1 on page 210 in part 2 of the Product manual.
  • Page 141 4 Repair 4.5.2. Replacement of parallel bar Continued Equipment, etc. Spare part no. Art. no. Note Bearing sealing 3HAC10088-4 One at each end of the bar. (Item D in the figure Location of parallel bar on page 138.) Bearing sealing 3HAC10089-2 One at each end of the bar.
  • Page 142 4 Repair 4.5.2. Replacement of parallel bar Continued Action Note 3. Use a crane to secure the weight of the upper If the upper arm is also to be arm. removed, secure the weight as shown in the figure below. xx0500002549 4.
  • Page 143 4 Repair 4.5.2. Replacement of parallel bar Continued Action Note 7. Refit the locking washer. Shown in the figure Location of parallel bar on page 138. 8. Refit the attachment screw at both ends of M8 x 16. the bar, using locking liquid. Loctite 243 Shown in the figure Location of parallel...

  • Page 144: Frame And Base

    4 Repair 4.6.1. Replacement of SMB unit 4.6 Frame and base 4.6.1. Replacement of SMB unit Location of SMB unit The SMB unit (SMB = serial measurement board) is located on the left hand side of the base, as shown in the figure below. A more detailed view of the component and its position may be found in section Axes 1-3, spare part view 5 on page 215...
  • Page 145 4 Repair 4.6.1. Replacement of SMB unit Continued Equipment Spare part no. Art. no. Note Standard toolkit The contents are defined in section Standard toolkit on page 190, in part 2 of the Product manual. Circuit Diagram See chapter Circuit diagram in the Product manual, reference...
  • Page 146 4 Repair 4.6.1. Replacement of SMB unit Continued Replacement, SMB unit The procedure below details how to replace the SMB unit. Action Note Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the rear cover plate (A) from the base by unscrewing the attachment screws (B).

  • Page 147: Replacement Of Brake Release Unit

    4 Repair 4.6.2. Replacement of brake release unit 4.6.2. Replacement of brake release unit Location of brake release unit The brake release unit is located behind the flange plate at the robot base, as shown below. xx0200000459 Brake release unit with buttons Required equipment Equipment, etc.
  • Page 148 4 Repair 4.6.2. Replacement of brake release unit Continued Action 7. Refit the cover to the rear of the base. 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 3HAC026048-001 Revision: A...

  • Page 149: Replacement Of Parallel Arm

    4 Repair 4.6.3. Replacement of parallel arm 4.6.3. Replacement of parallel arm Location of parallel arm The parallel arm is located at the frame, as shown in the figure below. xx0600002591 Parallel arm Parallel bar Required equipment Equipment Spare part no. Art.
  • Page 150 4 Repair 4.6.3. Replacement of parallel arm Continued Equipment Spare part no. Art. no. Note Other tools and procedures These procedures include may be required. See references to the tools references to these required. procedures in the step-by- step instructions below. Removal, parallel arm The procedure below details how to remove the parallel arm.
  • Page 151 4 Repair 4.6.3. Replacement of parallel arm Continued Assembly, parallel arm The figure below shows the assembly of the parallel arm. xx0200000450 Parallel arm Sealing V- ring (2 pcs) Groove ball bearing Attachment screws and washers (8 pcs) Refitting, parallel arm The procedure below details how to refit the complete parallel arm to the robot.
  • Page 152 4 Repair 4.6.3. Replacement of parallel arm Continued Action Note 4. 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 175. Danger! Make sure all safety requirements are met when performing the first test run.

  • Page 153: Motors

    4 Repair 4.7.1. Replacement of motor, axis 1 4.7 Motors 4.7.1. Replacement of motor, axis 1 Location of motor, axis 1 The motor, axis 1, is located on the left hand side of the robot as shown in the figure below: A more detailed view of the component and its position may be found in section Axes 1-3, spare part view 1 on page...
  • Page 154 4 Repair 4.7.1. Replacement of motor, axis 1 Continued Required equipment Equipment Spare part no. Art. no. Note Motor unit, axes 1 and 3 3HAC025712-001 O-ring 3HAB 3772-1 Always fit a new one! Gasket 3HAB 3676-1 Measuring tool, motor 3HAB7887-1 Power supply 24 VDC, max.
  • Page 155 4 Repair 4.7.1. Replacement of motor, axis 1 Continued Action Note/Illustration 4. Remove the connection box by unscrewing its Shown in the figure Location of three attachment screws and plain washers. motor, axis 1 on page 151. 5. Use a marker pen to mark the position of the motor (A).
  • Page 156 4 Repair 4.7.1. Replacement of motor, axis 1 Continued Action Note/Illustration 7. Fit the measuring tool to the rear of the motor. Art. no. is specified in Required equipment on page 152. Shown in the figure below. 8. Rotate the motor shaft several turns, using the measuring tool.
  • Page 157 4 Repair 4.7.1. Replacement of motor, axis 1 Continued Action Note/Illustration 16. Refit the cover of the connection box. Shown in the figure Location of motor, axis 1 on page 151. 17. Recalibrate the robot. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools.

  • Page 158: Replacement Of Motor, Axis 2

    4 Repair 4.7.2. Replacement of motor, axis 2 4.7.2. Replacement of motor, axis 2 Location of motor, axis 2 The motor, axis 2, is located on the left hand side of the robot as shown in the figure below: xx0200000470 Attachment screws, cover (5 pcs) Cover Connection box...
  • Page 159 4 Repair 4.7.2. Replacement of motor, axis 2 Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Motor unit, axis 2 3HAC025713-001 O-ring 3HAB 3772-1 Always fit a new one! Gasket 3HAB 3676-1 Measuring tool, motor 3HAB7887-1 Power supply 24 VDC, max.
  • Page 160 4 Repair 4.7.2. Replacement of motor, axis 2 Continued Action Note/Illustration 4. Remove the connection box by unscrewing its three attachment screws and plain washers. 5. Use a marker pen to mark out the position of the motor. Secure the robot arms before unscrewing any of the attachment screws of the axis 2 motor.
  • Page 161 4 Repair 4.7.2. Replacement of motor, axis 2 Continued Action Note/Illustration 2. Check that the assembly surfaces are clean and the motor is unscratched. 3. Fit the o-ring. Always fit a new one, see art. no. in Required equipment on page 157.
  • Page 162 4 Repair 4.7.2. Replacement of motor, axis 2 Continued Action Note/Illustration 13. Tighten the four attachment screws. 4 pcs. Tightening torque: 23 Nm. 14. Perform a leak-down test. Detailed in section Performing a leak-down test on page 15. Fill the gearbox with oil. Type and amount of oil is specified in section Oil in gearboxes on page...

  • Page 163: Replacement Of Motor, Axis 3

    4 Repair 4.7.3. Replacement of motor, axis 3 4.7.3. Replacement of motor, axis 3 Location of motor, axis 3 The motor, axis 3, is located on the right hand side of the robot, as shown in the figure below: A more detailed view of the component and its position may be found in section Axes 1-3, spare part view 2 on page 211 in part 2 of the Product manual.
  • Page 164 4 Repair 4.7.3. Replacement of motor, axis 3 Continued Required equipment Equipment Spare part no. Art. no. Note Motor unit, axes 1 and 3 3HAC025712-001 Gasket 3HAB 3676-1 O-ring 3HAB 3772-1 Always fit a new one. Measuring tool, motor 3HAB7887-1 Power supply 24 VDC, max.
  • Page 165 4 Repair 4.7.3. Replacement of motor, axis 3 Continued Action Note/Illustration 4. Remove the connection box by unscrewing its Shown in the figure Location of three attachment screws and plain washers. motor, axis 3 on page 161. 5. Use a marker pen to mark out the position of the motor.
  • Page 166 4 Repair 4.7.3. Replacement of motor, axis 3 Continued Action Note/Illustration 3. Fit a new o-ring to the motor. Always mount a new one, see art. no. in section Required equipment on page 162. 4. Fit the motor, by gently lifting it straight on. Note the position of the motor! Use the mark on the motor base, made before removal.
  • Page 167 4 Repair 4.7.3. Replacement of motor, axis 3 Continued Action Note/Illustration 14. Perform a leak-down test. Detailed in section Performing a leak- down test on page 15. Refill the gearbox with oil. Type and amount of oil is specified in section Oil in gearboxes on page 16.

  • Page 168: Replacement Of Motor, Axis 6

    4 Repair 4.7.4. Replacement of motor, axis 6 4.7.4. Replacement of motor, axis 6 Location of motor, axis 6 The motor, axis 6 is located in the tilthouse, as shown in the figure below. A more detailed view of the component and its position may be found in section Tilthouse, exploded view on page 219 in part 2 of the Product manual.
  • Page 169 4 Repair 4.7.4. Replacement of motor, axis 6 Continued Removal, motor, axis 6 The procedure below details how to remove the motor, axis 6 from the robot. Action Note Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 170 4 Repair 4.7.4. Replacement of motor, axis 6 Continued Action Note 8. 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 175. Danger! Make sure all safety requirements are met when performing the first test run.

  • Page 171: Gearboxes

    4 Repair 4.8.1. Replacement of gearbox, axis 1-3 4.8 Gearboxes 4.8.1. Replacement of gearbox, axis 1-3 Location of gearbox, axis 1-3 The axis 1 gearbox is located between the frame and base as shown in the figure below. Axis 1 gearbox is of the conventional type, manufactured with high precision. Together with the gearboxes for axes 2 and 3, it forms a complete unit.
  • Page 172 4 Repair 4.8.1. Replacement of gearbox, axis 1-3 Continued Equipment Spare part no. Art. no. Note Other tools and procedures These procedures include may be required. See references to the tools references to these required. procedures in the step-by- step instructions below. Removal, gearbox axis 1-3 The procedure below details how to remove the gearbox, axis 1-3.
  • Page 173 4 Repair 4.8.1. Replacement of gearbox, axis 1-3 Continued Refitting, gearbox axis 1-3 The procedure below details how to refit the gearbox, axis 1-3. Action Note Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Caution! The complete gearbox unit weighs 200 kg (without the base)! All lifting equipment used...

  • Page 174: Replacement Of Gearbox, Axis 6

    4 Repair 4.8.2. Replacement of gearbox, axis 6 4.8.2. Replacement of gearbox, axis 6 Location of gearbox, axis 6 The gearbox, axis 6, is located at the frontmost part of the robot, as shown in the figure below. xx0500001939 Gearbox, axis 6 Attachment screws, gearbox (8 pcs) Required equipment Equipment...
  • Page 175 4 Repair 4.8.2. Replacement of gearbox, axis 6 Continued Removal, gearbox, axis 6 The procedure below details how to remove the gearbox, axis 6 from the robot. Action Note Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
  • Page 176 4 Repair 4.8.2. Replacement of gearbox, axis 6 Continued Action Note 8. 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 175. Danger! Make sure all safety requirements are met when performing the first test run.

  • Page 177: Calibration Information

    The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied from ABB. Calibrate the robot carefully with standard calibration. The different methods are briefly described in section Calibration methods on page 176, and further detailed in separate Calibration manuals.

  • Page 178: Calibration Methods

    5 Calibration information 5.2. Calibration methods 5.2. Calibration methods Overview This section specifies the different types of calibration and the calibration methods that are supplied from ABB. Types of calibration Type of calibra- Description Calibration method tion Standard The calibrated robot is positioned at home...
  • Page 179 Calibration Pendulum - standard method Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the standard type of calibration. It is the recommended method in order to achieve proper performance.

  • Page 180: Calibration Scales And Correct Axis Position

    This section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration scales, IRB 260 When axis 3 is put in calibration position, the mark on the calibration plate is visible above the mechanical stop, as shown in the figure below.

  • Page 181: Calibration Movement Directions For All Axes

    This is normally handled by the robot calibration software. Calibration movement directions, 4 axes Note! The figure shows an IRB 260, but the positive direction is the same for all 4-axis robots xx0500001927 3HAC026048-001 Revision: A...

  • Page 182: Updating Revolution Counters

    This procedure details the second step when updating the revolution counter; storing the revolution counter setting with the FlexPendant (RobotWare 5.0). Action 1. On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status.
  • Page 183 5 Calibration information 5.5. Updating revolution counters Continued Action 2. Tap the mechanical unit in question. A screen is displayed: tap Rev. Counters. en0400000771 3. Tap Update Revolution Counters..A dialog box is displayed, warning that updating the revolution counters may change programmed robot positions: •...

  • Page 184: Checking The Calibration Position

    This section describes how to create a program, which runs all the robot axes to their zero position. Action Note 1. On ABB menu tap Program Editor. 2. Create a new program. 3. Use MoveAbsJ in the Motion&Proc menu. 4. Create the following program: MoveAbsJ...

  • Page 185: Reference Information

    6 Reference information 6.1. Introduction 6 Reference information 6.1. Introduction General This chapter includes general information, complementing the more specific information in Product manual (part 1 of 2), procedures. 3HAC 026048-001 Revision: -...

  • Page 186: Applicable Safety Standards

    6 Reference information 6.2. Applicable safety standards 6.2. Applicable safety standards Overview The robot conforms to the standards specified below. Standards, EN Standard Description EN ISO 12100-1 Safety of machinery, terminology EN ISO 12100-2 Safety of machinery, technical specifications EN 954-1 Safety of machinery, safety related parts of control systems EN 60204 Electrical equipment of industrial machines...

  • Page 187: Unit Conversion

    6 Reference information 6.3. Unit conversion 6.3. Unit conversion Converter table Use the table below to convert units used in this manual. Quantity Units Length 3.28 ft 39.37 in Weight 1 kg 2.21 lb Pressure 1 bar 100 kPa 14.5 psi Force 0.738 lbf Moment...

  • Page 188: Screw Joints

    UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below), and is extremely resistant to fatigue.
  • Page 189 6 Reference information 6.4. Screw joints Continued Tightening torque Before tightening any screw, note the following: • Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure description.
  • Page 190 6 Reference information 6.4. Screw joints Continued The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass. Tightening torque Tightening torque Tightening torque Dimension Nm - Nominal Nm - Min.

  • Page 191: Weight Specifications

    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.

  • Page 192: Standard Toolkit

    6 Reference information 6.6. Standard toolkit 6.6. Standard toolkit General All service (repairs, maintenance and installation) procedures contain lists of tools required to perform the specified activity. All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the Standard toolkit and defined in the table below.

  • Page 193: Special Tools

    6 Reference information 6.7. Special tools 6.7. Special tools General All service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in section Standard toolkit on page 190, and of special tools, listed directly in the instructions and also gathered in this section.
  • Page 194 6 Reference information 6.7. Special tools Continued Item Description Art. no. Note Press sleeve 3HAC023963-038 D= 48.8 mm Connection rod 3HAC025192-006 M16, length= 280 mm 3HAC023963-029 Press washer 3HAC023963-014 D= 70 mm Press head 3HAC023963-039 D= 55 mm Sleeve 3HAC023963-037 D= 55 mm Press sleeve 3HAC023963-015...
  • Page 195 6 Reference information 6.7. Special tools Continued Mounting tool, tilthouse shaft. Assembly is shown in the figure Mounting tool, tilthouse shaft on page 194. Mounting tool, bearing race and sealing, upper arm. Assembly is shown in the figure Mounting tool, bearing race and sealing, upper arm on page 195.
  • Page 196 6 Reference information 6.7. Special tools Continued Mounting tool, tilthouse shaft The tool for fitting the tilthouse shaft to the tilthouse is assembled with the parts shown in the figure below (included in the toolkit for service). Note! The parts cannot be ordered separately, but are included in the complete toolkit! The article numbers are given only for identification.
  • Page 197 6 Reference information 6.7. Special tools Continued Mounting tool, bearing race and sealing, upper arm The tool for fitting the bearing race and sealing to the upper arm is assembled with the parts shown in the figure below (included in the toolkit for service). Note! The parts cannot be ordered separately, but are included in the complete toolkit! The article numbers are given only for identification.
  • Page 198 6 Reference information 6.7. Special tools Continued Hex socket head cap screw, 9ADA183-25, 2 pcs, M6 x 25 Nut, 3HAC5507-1 Sleeve, 3HAC023963-027 Nut, 3HAC023963-028 Press sleeve, 3HAC023963-038 Connection rod, 3HAC025192-006 Dismounting tool, bearing race, tilthouse shaft The tool for removing the bearing race from the tilthouse shaft is assembled with the parts shown in the figure below (included in the toolkit for service).
  • Page 199 6 Reference information 6.7. Special tools Continued Mounting tool, bearing race, tilthouse shaft The tool for fitting a bearing race to the tilthouse shaft is assembled with the parts shown in the figure below (included in the toolkit for service). Note! The parts cannot be ordered separately, but are included in the complete toolkit! The article numbers are given only for identification.
  • Page 200 6 Reference information 6.7. Special tools Continued Press tool, link The tool for fitting the bearing and the link to the upper arm shaft includes the parts shown in the figure below (included in the toolkit for service). Note! The parts cannot be ordered separately, but are included in the complete toolkit! The article numbers are only given for identification! xx0600002618 Hydraulic cylinder, 3HAC11731-1...

  • Page 201: Lifting Equipment And Lifting Instructions

    6 Reference information 6.8. Lifting equipment and lifting instructions 6.8. Lifting equipment and lifting instructions 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.
  • Page 202 6 Reference information 6.8. Lifting equipment and lifting instructions 3HAC 026048-001 Revision: -...

  • Page 203: Spare Part Lists And Exploded Views

    7 Spare part lists and exploded views 7.1. Introduction 7 Spare part lists and exploded views 7.1. Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot. 3HAC 026048-001 Revision: -...

  • Page 204: Spare Parts - Overview

    Spare part no. section: Cover Foundry Spare parts - cover on page 203 Instruction plate 3HAC2814-2 Warning of brake release. Robot IRB 260 Spare parts - robot IRB 260 on page 205 Instruction plate 2945 4489-16 Rating label 3HAB9549-1 Warning sign 3HAC1589-1 Lightning flash.

  • Page 205: Spare Parts - Cover

    7 Spare part lists and exploded views 7.3. Spare parts - cover 7.3. Spare parts - cover Cover, spare part list The items specified below are shown in the figure Cover, spare part view on page 204. Item Qty Description Spare part no.
  • Page 206 7 Spare part lists and exploded views 7.3. Spare parts - cover Continued Cover, spare part view xx0500002436 3HAC 026048-001 Revision: -...

  • Page 207: Spare Parts - Robot Irb 260

    Robot IRB 260, spare part list The items specified below are shown in the figures Robot IRB 260, exploded view 1 of 2 on page 206 Robot IRB 260, exploded view 2 of 2 on page 206. Item Qty Description Spare part no.
  • Page 208 Spare part no. Note Protection hood 2522 2101-17 Lifting eye 2179 090-25 Plain washer 9ADA312-9 13x24x2,5 Bearing sealing 3HAC10089-2 Robot IRB 260, exploded view 1 of 2 xx0500001936 Robot IRB 260, exploded view 2 of 2 xx0500001937 3HAC 026048-001 Revision: -...
  • Page 209 7 Spare part lists and exploded views 7.4. Spare parts - robot IRB 260 3HAC 026048-001 Revision: -...

  • Page 210: Spare Parts - Axes 1-3

    7 Spare part lists and exploded views 7.5. Spare parts - axes 1-3 7.5. Spare parts - axes 1-3 Axes 1-3, spare part list The items specified below are shown in the figures Axes 1-3, spare part view 1 on page 210 Axes 1-3, spare part view 2 on page 211.
  • Page 211 7 Spare part lists and exploded views 7.5. Spare parts - axes 1-3 Continued Item Qty Description Spare part no. Dimension Washer 21512082-150 6.1x20x2 Friction washer 3HAC0447-1 Calibration mark, axis 2 3HAB5522-1 Parallel bar complete 3HAC025714-001 Spherical roller bearing 3HAA2167-12 Included in the complete parallel bar.
  • Page 212 7 Spare part lists and exploded views 7.5. Spare parts - axes 1-3 Continued Axes 1-3, spare part view 1 xx0500002047 Continues on next page 3HAC 026048-001 Revision: -...
  • Page 213 7 Spare part lists and exploded views 7.5. Spare parts - axes 1-3 Continued Axes 1-3, spare part view 2 xx0500002065 Continues on next page 3HAC 026048-001 Revision: -...
  • Page 214 7 Spare part lists and exploded views 7.5. Spare parts - axes 1-3 Continued Axes 1-3, spare part list The items specified below are shown in the figures Axes 1-3, spare part view 3 on page 213, Axes 1-3, spare part view 4 on page 214 Axes 1-3, spare part view 5 on page 215.
  • Page 215 7 Spare part lists and exploded views 7.5. Spare parts - axes 1-3 Continued Axes 1-3, spare part view 3 xx0500002084 Continues on next page 3HAC 026048-001 Revision: -...
  • Page 216 7 Spare part lists and exploded views 7.5. Spare parts - axes 1-3 Continued Axes 1-3, spare part view 4 xx0500002085 The housing must be removed from the cabling for foundry option Conductors from R2.BU, R2.BU1-3, R2.BU4-6 and PE conductors under strap Option: internal connectors Option: external connectors Continues on next page...
  • Page 217 7 Spare part lists and exploded views 7.5. Spare parts - axes 1-3 Continued Axes 1-3, spare part view 5 xx0500002086 3HAC 026048-001 Revision: -...

  • Page 218: Spare Parts - Upper Arm

    7 Spare part lists and exploded views 7.6. Spare parts - upper arm 7.6. Spare parts - upper arm Upper arm, spare part list The items specified below are shown in the figure Upper arm, exploded view on page 217. Item Description Spare part no.
  • Page 219 7 Spare part lists and exploded views 7.6. Spare parts - upper arm Continued Upper arm, exploded view xx0500001934 3HAC 026048-001 Revision: -...

  • Page 220: Spare Parts - Tilthouse

    7 Spare part lists and exploded views 7.7. Spare parts - tilthouse 7.7. Spare parts - tilthouse Tilthouse, spare part list The items specified below are shown in the figure Tilthouse, exploded view on page 219. Item Qty Description Spare part no. Dimension Tilthouse, machining 3HAC025733-001...
  • Page 221 7 Spare part lists and exploded views 7.7. Spare parts - tilthouse Continued Tilthouse, exploded view xx0500001935 3HAC 026048-001 Revision: -...

  • Page 222: Spare Parts - Linkage

    7 Spare part lists and exploded views 7.8. Spare parts - linkage 7.8. Spare parts - linkage Linkage, spare part list Item Description Spare part no. Dimension Parallel rod, lower 3HAC024576-001 Parallel rod upper 3HAC024575-001 Radial Seal 35x62x7 Link machining Taper roller bearing Needle bearing 3HAB6432-1...

  • Page 223: Spare Parts - Material Set Cabling Axis 6

    7 Spare part lists and exploded views 7.9. Spare parts - material set cabling axis 6 7.9. Spare parts - material set cabling axis 6 Material set cabling axis 6, spare part list The items specified below are shown in the figure Material set cabling axis 6, spare part view on page 222.
  • Page 224 7 Spare part lists and exploded views 7.9. Spare parts - material set cabling axis 6 Continued Material set cabling axis 6, spare part view xx0500002438 3HAC 026048-001 Revision: -...

  • Page 225: Circuit Diagram

    8 Circuit diagram 8.1. Introduction 8 Circuit diagram 8.1. Introduction Overview This chapter includes the circuit diagram for the robot. 3HAC 026048-001 Revision: -...
  • Page 226 8 Circuit diagram 8.1. Introduction 3HAC 026048-001 Revision: -...

  • Page 227: Index

    !"" !"" !"" !"" !""< !"" 7 !"" !## !"" ! !" -92> 1 0? @A &' ) " 0 /2 7217 '%( )*+, /0112 &...
  • Page 228 /21 2 > /2 E2 /21 2 > &' ) " 0 /2 7217 ,),#9 %!*9 /0112 &...
  • Page 229 > F"0 F" 1 5%12 F"1 1 5%720 1 +1 F" -5" "G "G12 "G720 F"12 F"720 1 #- 1 5% 1 -5" 1 %& - &' ) " 0 /0112...
  • Page 230 > 2"G " : 2 1 5% 2 1 5%720 "G " !H9 9# "G " !H9 9# "G " !H9 9# "G " !H9 9# "G "G12 2" !H9 9# 1 & 4!I)- 1& "? " !H9 %" "G "...
  • Page 231 > -5" 1 -5" -5" -5" " -.)26 "G -.'26 4 7@ > > 4"!,-G% @ "!,#. H9(%)6 *CI D *CI D &' /2 /2 / ) " 0 -5" " /0112...
  • Page 232 > 25G1 2 1 5% 2 1 5%12 "H 1> , C D "H - C@D "H "H *6(9 *6(9 *6(9 " @ %, "G "G 4!I)- & 7 & 2%, 1 %, 1 "H 4"G& > & 4"G2" !H9 9# 1 "...
  • Page 233 > 2 1 5% 2 1 5%12 "H > > , C D "H - C@D > "H "H *6(9 *6(9 *6(9 4!I)- 1& 7 & 4!I)- 12%, 1 %, 1 "G 4!I)- & 7 7 & 2%, "H 4"G& >...
  • Page 234 > 2 1 5% 2 1 5%12 "H 1> , C D "H 1> 1> - C@D "1 "H "H *6(9 *6(9 *6(9 4!I)- & 7 & 4!I)- 2%, "G 4"G& > & 2%, "H 4"G& > & 4"G2" !H9 9# "...
  • Page 235 > 25G0 2 1 5% 2 1 5%720 "H , C D .> "H - C@D "H "H "1 *6(9 *6(9 4"G& > & 4"G2" !H9 9# 0 " !H9 9# 0 "G 4 " : 4"G& > & 4"G2 @ " !H9 0 @ "...
  • Page 236 > 4#-2 1 %& - 4#-2 1 % %! & "H "1 %" %" & "6 " % & . %. & '* %9 & (9 " %F & *6 %J & "G %H & @, %# & *( " >...
  • Page 237 > 1 #- "H %'-),)'6 )6.) !,' '55'6 "H 1 & 17& 7 "H "H " 1&11 &1 1 & 17& 7 1&11 &1 "6 5!6)%G#!,' !, -,!,)'6 1 "G "G 5!6)%G#!,' !, -,!,)'6 "6 H9( %)6 & -,)F, #-121 *6(9 "H "...
  • Page 238 Index Symbols ¶restricting endurance load 38 working range axis 1 63 damage elimination 33 sensitive equipment 33 Absolute Accuracy, calibration 177 explanation, safety symbols 29 application manual article number 8 attachment screws figures securing robot 47 connectors on robot 71 where to use special tools 192 fitting equipment on robot 49 brake release unit, replacing 145...
  • Page 239 Index load diagram 54 replacing loads 38 brake release unit 145 loads on foundation 38 cable unit axes 1-3 90 location of connectors 71 cabling axis 6 96 lower arm gearbox axes 1-3 169 replacing 134 gearbox axis 6 172 securing 136 link, linkage 129 lower arm 134...
  • Page 240 Index robot 205 tilthouse 218 upper arm 216 special tools 191 storage conditions 39 symbols, safety 29 sync marks. See calibration - marks. technical reference manual article number 8 testing, brakes 24 tie rod, replacing 138 tightening torque gearbox axes 1-3 171 gearbox axis 6 173 lower arm 137 motor, axis 1 154...
  • Page 241 Index 3HAC026048-001 Revision: A...
  • Page 243 ABB AB Robotics Products S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...

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