ABB IRB 7600 - 500/2.55 Product Manual
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ABB IRB 7600 - 500/2.55 Product Manual

Articulated robot
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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

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Summary of Contents for ABB IRB 7600 - 500/2.55

  • 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 3 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 Except as may be expressly stated anywhere in this manual, 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.

  • Page 5: Table Of Contents

    2.4.5 Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55 ......
  • Page 6 Table of Contents 2.5.9 Fitting equipment on robot............86 2.5.10 Installation of base spacers (option).
  • Page 7 Table of Contents 3.6 Cleaning activities ..............211 3.6.1 Flushing a contaminated gearbox .
  • Page 8 Table of Contents 7 Reference information 7.1 Introduction ..............387 7.2 Applicable Safety Standards .

  • 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 Chapter Contents Reference information Useful information when performing installation, maintenance or repair work. Includes lists of necessary tools, additional documents, safety standards etc. Spare part list Complete spare part list shown in exploded views. Exploded views Detailed illustrations of the robot with reference numbers to the part list.
  • Page 11 New lubricating oil in the gearboxes. Changes made in the chapter Maintenance Part list. • 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...
  • Page 12 Overview Continued Revision Description • New variant of the robot (IRB 7600 - 325/3.1) implemented throughout the manual. • In chapter 3 Maintenance section Oil in gearboxes type of oil and art. no. in gearbox axes 1 has been added. •...

  • Page 13: Product Documentation, M2000/M2000A

    A complete listing of all available software manuals is available from ABB. Controller hardware option manual Each hardware option for the controller is supplied with its own documentation. Each document set contains the types of information specified below: •...

  • Page 14: 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 15 Product documentation, M2004 Continued Operating manuals This group of manuals is aimed at those 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 •...

  • Page 16: 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 17: 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 18: 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 19: 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 20 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 motors and gears may result in burns! With higher environment temperature more surfaces on the robot are getting HOT and may result in burns too! Removed parts may result in collapse of robot!

  • Page 21: 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 22: 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 23: 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 24: 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, need 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 25 1 Safety 1.2.2.5. Risks associated with live electric parts Continued Voltage related risks, IRC5 controller A danger of high voltage is associated with, for example, the following parts: • Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the controller.

  • Page 26: 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 27: 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 system (robot or controller)! 3HAC022033-001 Revision: E...

  • Page 28: 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 29: Brake Testing

    1 Safety 1.2.3.4. Brake testing 1.2.3.4. Brake testing When to test During operation the holding brake 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 the holding brake of each axis motor may be checked as detailed below: 1.

  • Page 30: 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 system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s". 3HAC022033-001 Revision: E...

  • Page 31: Safe Use Of The Flexpendant

    1 Safety 1.2.3.6. Safe use of the FlexPendant 1.2.3.6. Safe use of the FlexPendant NOTE! The enabling device is a push button located on the side of the FlexPendant 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 32: Work Inside The Robot's Working Range

    1 Safety 1.2.3.7. Work inside the robot's working range 1.2.3.7. Work inside the robot'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 33: Signal Lamp (Optional)

    1 Safety 1.2.3.8. Signal lamp (optional) 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: Translate The Information On Safety And Information Labels

    Using a transparent sticker over the standard label with text added in a fourth language. Drawings detailing the design (text, figure, dimensions) of the standard labels can be ordered from ABB. Notice that each label is identified according to the article number located in the lower corner of the label.

  • Page 35: 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 36 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 37: Danger - Moving Robots Are Potentially Lethal

    1 Safety 1.3.2. DANGER - Moving robots are potentially lethal! 1.3.2. DANGER - Moving robots are potentially lethal! Description Any moving robot is a potentially lethal machine. When running the robot, 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 working range of the robot.

  • Page 38: 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 39: Warning - The Brake Release Buttons May Be Jammed After Service Work

    1 Safety 1.3.4. WARNING - The brake release buttons may be jammed after service work 1.3.4. WARNING - The brake release buttons may be jammed after service work Description The brake release unit has push buttons for brake release of each axis motor. When service work is performed inside the SMB recess that includes removal and refitting of the brake release unit, the brake release buttons may be jammed after refitting.

  • Page 40: Warning - The Unit Is Sensitive To Esd

    1 Safety 1.3.5. WARNING - The unit is sensitive to ESD! 1.3.5. WARNING - The unit is sensitive to ESD! Description ESD (electrostatic 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 41 1 Safety 1.3.5. WARNING - The unit is sensitive to ESD! Continued Assemble the wrist strap The picture illustrates how the ESD wrist strap is assembled in the controller. xx0400001055 The strap is fastened to a button on the side of the control module. When not used, the wrist strap is placed on the power supply unit.

  • Page 42: Warning - Safety Risks During Work With Gearbox Oil

    1 Safety 1.3.6. WARNING - Safety risks during work with gearbox oil 1.3.6. 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 43: 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. 3HAC022033-001 Revision: E...

  • Page 44: Robot Transportation Precautions

    Transportation in any other way 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.
  • Page 45 2 Installation and commissioning 2.2. Robot transportation precautions Continued Method 2 Transportation according to method 2 is approved by ABB, if use of method 1 is not possible. Always follow these instructions when transporting an ABB robot according to method 2: •...
  • Page 46 2 Installation and commissioning 2.2. Robot transportation precautions Continued IRB6620 xx0800000036 Transport Support Hexagon socket head cap screw M10x50 Threaded bar M10x280 Nut M10 Continues on next page 3HAC022033-001 Revision: E...
  • Page 47 2 Installation and commissioning 2.2. Robot transportation precautions Continued Transport position with a transport support All transportation of the robot with tool must follow these instructions. IRB 7600/IRB 66XX xx0800000040 Continues on next page 3HAC022033-001 Revision: E...
  • Page 48 2 Installation and commissioning 2.2. Robot transportation precautions Continued IRB 6620 xx0800000041 Continues on next page 3HAC022033-001 Revision: E...
  • Page 49 2 Installation and commissioning 2.2. Robot transportation precautions Continued Recommended transport support Always use the recommended transport support when transporting a robot with tool. IRB 7600/IRB 66XX xx0800000039 Continues on next page 3HAC022033-001 Revision: E...
  • Page 50 2 Installation and commissioning 2.2. Robot transportation precautions Continued IRB 6620 xx0800000038 3HAC022033-001 Revision: E...

  • Page 51: Securing The Robot

    2 Installation and commissioning 2.3. Securing the robot 2.3. Securing the robot General This section describes how to secure the robot using the transport support. DANGER! Releasing 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.
  • Page 52 2 Installation and commissioning 2.3. Securing the robot Continued Action Note 2. Jog the robot into a position as near above as possible to the recommended transport position for the specific robot. specified in section Transport position with a transport CAUTION! support on page Do not try to jog the robot to the exact...

  • Page 53: Unpacking

    Weight, robot The table below shows the weights of the different variants (without DressPack): Robot variant Weight IRB 7600 - 500/2.55 2400 kg IRB 7600 - 500/2.3 2400 kg IRB 7600 - 400/2.55 2400 kg IRB 7600 - 340/2.8...
  • Page 54 Min. levelness 0.5 mm Max. tilt 5° The limit for the maximum payload on the robot is reduced if the robot is tilted from 0°. Contact ABB for further information about acceptable payload. Min. resonance 22 Hz frequency Storage conditions, robot...
  • Page 55 2 Installation and commissioning 2.4.1. Pre-installation procedure Continued Protection classes, robot The table below shows the protection class of the robot: Equipment Protection class Robot, IRB 7600 IP 67 3HAC022033-001 Revision: E...

  • Page 56: Working Range, Irb 7600 - 150/3.5

    2 Installation and commissioning 2.4.2. Working range, IRB 7600 - 150/3.5 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 3HAC022033-001 Revision: E...

  • Page 57: Working Range, Irb 7600 - 325/3.1

    2 Installation and commissioning 2.4.3. Working range, IRB 7600 - 325/3.1 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: 1393 1350 2086 3050 xx0700000720 3HAC022033-001 Revision: E...

  • Page 58: Working Range, Irb 7600 - 340/2.8

    2 Installation and commissioning 2.4.4. Working range, IRB 7600 - 340/2.8 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 3HAC022033-001 Revision: E...

  • Page 59: Working Range, Irb 7600 - 400/2.55, Irb 7600 - 500/2.55

    2 Installation and commissioning 2.4.5. Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55 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:...

  • Page 60: Working Range, Irb 7600 - 500/2.3

    2 Installation and commissioning 2.4.6. Working range, IRB 7600 - 500/2.3 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 3HAC022033-001 Revision: E...

  • Page 61: Risk Of Tipping / Stability

    2 Installation and commissioning 2.4.7. Risk of tipping / stability 2.4.7. Risk of tipping / stability Risk of tipping When the robot is not fastened to the foundation and 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.

  • Page 62: On-Site Installation

    2 Installation and commissioning 2.5.1. Lifting robot with fork lift 2.5 On-site Installation 2.5.1. Lifting robot with fork lift General The robot may be moved using a fork lift, provided that available special aids are used. This section describes how to attach the fork lift equipment to the robot. Different designs There are two different versions of the fork lift that fit one design of the frame respectively.
  • Page 63 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Attachment points The attachment points for the fork lift equipment are shown in the figure below. xx0400000707 Attachment points, spacer and horizontal attachment screws Attachment points, horizontal attachment screws Attachment points, vertical attachment screws Attachment points, horizontal attachment screws Required equipment...
  • Page 64 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Fork lift set, 3HAC0604-2 The fork lift set, 3HAC0604-2, is fitted to the robot as shown in the figure below. xx0100000102 Vertical attachment screws (4 pcs / fork lift pocket) Fork lift pockets (2 pcs) Spacer (2 pcs) Continues on next page...
  • Page 65 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Fork lift set, 3HAC0604-1 The fork lift set, 3HAC0604-1, is fitted to the robot as shown in the figure below. xx0200000379 Fork lift pocket (2 pcs, different from each other) Spacer (2 pcs) Horizontal attachment screws (4 pcs / fork lift pocket) Vertical attachment screws (2 pcs)
  • Page 66 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Action Note 2. Position the robot as shown in the figure to the Release the brakes if required as right! detailed in section Manually releasing the brakes on page NOTE! No load is permitted on the robot if the fork lift set 3HAC0604-2 is used!
  • Page 67 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Action Note 5. Secure the longer fork lift pocket to the spacers Make sure the original screws are with four of the horizontal attachment screws always used (or replacements of and washers.
  • Page 68 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Action Note 7. Secure the fork lift pocket to the robot with the two vertical attachment screws and washers. (only valid for the fork lift set 3HAC 0604-1) NOTE! The vertically and the horizontally attached screws are identical, but tightened with different torques!
  • Page 69 2 Installation and commissioning 2.5.1. Lifting robot with fork lift Continued Action Note CAUTION! The robot weighs 2550 kg! All lifting equipment used must be sized accordingly! 12. Carefully lift the robot and move it to its instal- lation site. WARNING! Personnel must not, under any circumstances, be present under the suspended load!

  • Page 70: Lifting Robot With Lifting Slings

    2 Installation and commissioning 2.5.2. Lifting robot with lifting slings 2.5.2. Lifting robot with lifting slings General This section contains a general overview of how to lift the complete robot using special lifting equipment. More detailed instructions 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...
  • Page 71 2 Installation and commissioning 2.5.2. Lifting robot with lifting slings Continued Required equipment Equipment Art. no. Note Lifting device, robot 3HAC15607-1 Includes • user instructions (3HAC15971-2). Slings attached directly onto robot The section below details how to lift and move the robot using lifting slings when these are attached directly onto the robot frame.

  • Page 72: Lifting Robot With Roundslings

    2 Installation and commissioning 2.5.3. Lifting robot with roundslings 2.5.3. Lifting robot with roundslings General The figure below shows how to lift the complete robot with roundslings. Notice the recommended robot position shown in the figure below! Roundslings attached to the robot xx0200000315 Chain sling with shortener, 4250 kg, 3 pcs (0.5 m, 0.5 m, 0.265 m) Roundsling, 1000 kg, 2 pcs...
  • Page 73 2 Installation and commissioning 2.5.3. Lifting robot with roundslings Continued Slings attached directly on to robot The section below details how to attach roundslings to the robot in order to lift the complete robot. Action Note Recommended robot position is described in section Risk of tipping / stability on page...

  • Page 74: Manually Releasing The Brakes

    2 Installation and commissioning 2.5.4. Manually releasing the brakes 2.5.4. Manually releasing the brakes General This section details how to release the holding brakes of each axis motor. The brakes may be released by: • Internal brake release unit: using push buttons on the robot. This requires either the controller to be connected or that power is supplied to the R1.MP connector, according to section Supplying power to connector R1.MP on page...
  • Page 75 2 Installation and commissioning 2.5.4. Manually releasing the brakes Continued Location of brake release unit at frame The internal brake release unit is located either at the base or at the frame. The figure below shows the unit located at the frame. xx0200000376 Internal brake release unit with push buttons, located on the robot frame Releasing the brakes...
  • Page 76 2 Installation and commissioning 2.5.4. 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 buttons on the robot. Action Note DANGER!

  • Page 77: Manually Releasing The Brakes, External Brake Release Unit

    2 Installation and commissioning 2.5.5. Manually releasing the brakes, external brake release unit 2.5.5. Manually releasing the brakes, external brake release unit General The section below details how to release the holding brakes of each axis motor using push buttons on an external brake release unit. This does not require the controller to be connected. When to use the external brake release 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).
  • Page 78 2 Installation and commissioning 2.5.5. Manually releasing the brakes, external brake release unit Continued Connectors, external brake release unit The illustration below shows the connectors on the robot and on the external brake release unit. xx0200000081 Rear connector plate Connector R1.MP Connector R1.BU External brake release unit Connect to R1.BU...
  • Page 79 2 Installation and commissioning 2.5.5. Manually releasing the brakes, external brake release unit Continued Action Note DANGER! When 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.

  • Page 80: Lifting The Base Plate

    2 Installation and commissioning 2.5.6. Lifting the base plate 2.5.6. Lifting the base plate Required equipment Equipment Art. no. Note Lifting eye, M16 3HAC14457-4 3 pcs Lifting slings 3 pcs Length: approx. 2 m Hole configuration xx0200000096 Attachment holes for lifting eyes (x3) Lifting, base plate Action Note...

  • Page 81: Securing The Base Plate

    2 Installation and commissioning 2.5.7. Securing the base plate 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 3HAC022033-001 Revision: E...
  • Page 82 2 Installation and commissioning 2.5.7. Securing the base plate Continued xx0400000715 Four holes for alternative clamping, 4x Ø18 Continues on next page 3HAC022033-001 Revision: E...
  • Page 83 • 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 These procedures include references be required.
  • Page 84 2 Installation and commissioning 2.5.7. Securing the base plate Continued Recommendations, quality The table specifies any recommendations made by ABB: Variable Recommendation Recommended foundation quality 1 Steel fibre reinforced concrete foundation, 30 kg/m3, class K30, t=250 mm Recommended foundation quality 2 Sturdy concrete foundation, double reinforced by ø10...

  • Page 85: Orienting And Securing The Robot

    2 Installation and commissioning 2.5.8. Orienting and securing the robot 2.5.8. Orienting and securing the robot General This section details how to orient and secure the robot to the base plate in order to run the robot safely. The requirements made on the foundations are shown in the following tables and figures.
  • Page 86 2 Installation and commissioning 2.5.8. Orienting and securing the robot Continued Securing the robot The procedure below details how to secure the robot to the base plate after fitting the plate to the foundation. Action Note 1. Lift the robot. Detailed in section Lifting robot with lifting slings on page...
  • Page 87 2 Installation and commissioning 2.5.8. Orienting and securing the robot Continued 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 3HAC022033-001 Revision: E...

  • Page 88: Fitting Equipment On Robot

    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 IRB 7600 - 500/2.55 2442 mm IRB 7600 - 500/2.3 2192 mm IRB 7600 - 400/2.55 2442 mm IRB 7600 - 340/2.8...
  • Page 89 2 Installation and commissioning 2.5.9. Fitting equipment on robot Continued 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 Continues on next page 3HAC022033-001 Revision: E...
  • Page 90 2 Installation and commissioning 2.5.9. Fitting equipment on robot Continued xx0300000299 Robot variant 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...
  • Page 91 2 Installation and commissioning 2.5.9. Fitting equipment on robot Continued xx0100000118 Continues on next page 3HAC022033-001 Revision: E...
  • Page 92 2 Installation and commissioning 2.5.9. Fitting equipment on robot Continued Illustration, 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.

  • Page 93: Installation Of Base Spacers (Option)

    2 Installation and commissioning 2.5.10. Installation of base spacers (option) 2.5.10. Installation of base spacers (option) Illustration, installation of base spacers xx0500001570 Base spacer (4 pcs) Guide sleeve (4 pcs) Attachment screws and washers (12 pcs) Required equipment Equipment Art. no. Note Base spacers 3HAC 021899-002...
  • Page 94 2 Installation and commissioning 2.5.10. Installation of base spacers (option) Continued Equipment 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. Installation, base spacers The procedure below details how to fit the base spacers between the robot and the base plate.

  • Page 95: Installation Of Cooling Fan For Motors, Axes 1-3 (Option)

    2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) General A cooling fan can be installed on the motors of axes 1, 2 and 3. However, cooling fans for axes 1 and 2 can not be combined! The cabling for the fans is available in different design: •...
  • Page 96 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued Cooling fan The details of the cooling fan are shown in the figure below. xx0500002158 Fanbox Attachment screws, fanbox plates (9 pcs) Groove in the connector Tightening screws, fanbox (3 pcs) Required equipment Equipment...
  • Page 97 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued Equipment Art. no. Note Cable harness inside 3HAC025488-001 controller Locking liquid Loctite 243. Used for the three tightening screws. Standard toolkit The content is defined in section Standard toolkit on page 394.
  • Page 98 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued Installation, fan The procedure below details how to install the cooling fan on any of the motors, axes 1-3 . Action Note 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 99 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued Installation, separate fan cabling axis 1 or 2 The procedure below details how to install the separate cabling for the cooling fan of axis 1 or 2.
  • Page 100 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued Action Note 7. Secure the cable bracket to the bracket of the robot cabling inside the frame. Run the cable underneath the robot cabling and out through the side of the frame, at motor, axis 1 .
  • Page 101 2 Installation and commissioning 2.5.11. Installation of cooling fan for motors, axes 1-3 (option) Continued Adjustments in RobotWare Action Note 1. Modify the settings in RobotWare to RobotWare 4.0: modify the settings in include the cooling fans. RobInstall. RobotWare 4.063 and older must be updated with a newer release.

  • Page 102: Loads

    Specification. The loads must also be defined in the software as detailed in User's Guide(RobotWare 4.0)Operating manual IRC5 with FlexPendant. Stop time and braking distances Robot motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB. 3HAC022033-001 Revision: E...

  • Page 103: Restricting The Working Range

    2 Installation and commissioning 2.6.1. Introduction 2.6 Restricting the working range 2.6.1. 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 104: Mechanically Restricting The Working Range Of Axis 1

    2 Installation and commissioning 2.6.2. Mechanically restricting the working range of axis 1 2.6.2. Mechanically restricting the working range of axis 1 General The working range of axis 1 is limited by fixed mechanical stops and can be reduced by adding additional mechanical stops giving 7.5 or 15 graduation, between 22.5°...
  • Page 105 2 Installation and commissioning 2.6.2. Mechanically restricting the working range of axis 1 Continued Equipment, etc. Art. no. Note User’s guide - S4Cplus (RobotWare Art. no. is specified in section 4.0) References on page Technical reference manual - System parameters (RobotWare 5.0) Installation, mechanical stops axis 1 The procedure below details how to fit the mechanical stops of axis 1 to the robot.

  • Page 106: Mechanically Restricting The Working Range Of Axis 2

    2 Installation and commissioning 2.6.3. Mechanically restricting the working range of axis 2 2.6.3. Mechanically restricting the working range of axis 2 General The working range of axis 2 is limited by fixed mechanical stops and can be reduced by adding up to six additional mechanical stops with 15 graduation in respective direction.
  • Page 107 2 Installation and commissioning 2.6.3. Mechanically restricting the working range of axis 2 Continued Installation, mechanical stops axis 2 The procedure below details how to fit the mechanical stops for axis 2 to the robot. An assembly drawing is also enclosed with the product. Action Note DANGER!

  • Page 108: Mechanically Restricting The Working Range Of Axis 3

    2 Installation and commissioning 2.6.4. Mechanically restricting the working range of axis 3 2.6.4. Mechanically restricting the working range of axis 3 General The working range of axis 3 is limited by fixed mechanical stops and can be reduced by adding additional mechanical stops with 20 graduation in respective direction.
  • Page 109 2 Installation and commissioning 2.6.4. Mechanically restricting the working range of axis 3 Continued Installation, mechanical stops axis 3 The procedure below details how to fit the mechanical stops for axis 3 to the robot. An assembly drawing is also enclosed with the product. Action Note DANGER!

  • Page 110: Installation Of Position Switches (Option)

    The position switch kits may be delivered in one of two ways: • Fitted by ABB Robotics on delivery. In this case, the cams must still be fitted and locked by the user. For axis 1, the cover for the cams must also be fitted.
  • Page 111 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Axis 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.
  • Page 112 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued 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 Position switch, axis 2 Set screw, cam (cam stop)
  • Page 113 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Axis 3 The illustration below 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 Position switch, axis 3 Set screw, cam (cam stop)
  • Page 114 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Connections The position switches are connected to different points on the robot system: • XT8, screw terminal in the controller cabinet when position switch cables are used. • R1.SW1 at the robot base. Customer connection kit is recommended, art. no. is specified in Required equipment on page 108!
  • Page 115 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Illustration, adjust and secure cams The illustration below show how to adjust and secure the position switch cams and profiles. xx0100000113 Cam stop, M5 nut and M5 x 6 set screw Adjustable cam Profile Illustration, cutting the cam...
  • Page 116 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Plate for customer connections, at base xx0500002301 Plate for customer connections Attachment screws, 3 pcs, M6x16 Cable harness for position switches and fans, axes 1-3 xx0500002305 Cable bracket, frame Cable bracket, lower arm Cable bracket, upper arm R1.SW2/3...
  • Page 117 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued R3.FAN3 Connected to the fan of axis 3 R2.SW2 Connected to the position switch of axis 2 R2.SW3 Connected to the position switch of axis 3 Installation of cable harness for position switches and fans The procedure below details how to fit the complete cable harness for position switches and cooling fans to the robot.
  • Page 118 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Action Note 5. Run and secure the cabling inside the frame as detailed below and as shown in the figure to the right: • Secure the cable bracket (A) to the bracket of the robot cabling.
  • Page 119 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Action Note 7. Run the remaining cable harness up through the lower arm and: • secure with the bracket, lower arm, as shown in the figure to the right. •...
  • Page 120 2 Installation and commissioning 2.6.5. Installation of position switches (option) Continued Action Note 10. Connect the connector R1.SW2/3 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.

  • Page 121: Electrical Connections

    2 Installation and commissioning 2.7.1. Robot cabling and connection points 2.7 Electrical connections 2.7.1. 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 controller are divided into the following categories: Cable category...
  • Page 122 2 Installation and commissioning 2.7.1. Robot cabling and connection points Continued Cable Art. no. Robot cable, power, 15 m 3HAC11818-2 Robot cable, power, 22 m 3HAC11818-3 Robot cable, power, 30 m 3HAC11818-4 Robot cable, signals Cable Art. no. Robot cable, signal, shielded, 7 m 3HAC7998-1 Robot cable, signal, shielded, 15 m 3HAC7998-2...
  • Page 123 2 Installation and commissioning 2.7.1. Robot cabling and connection points Continued Cabling between robot base and controller, cooling fans, M2004 The cables specified below are specific for the IRC5 controller and used when the robot is equipped with cooling fans. The cabling for the cooling fans runs all the way from the robot base to the inside of the cabinet.

  • Page 124: Making Robot Ready For Operation (Foundry Prime)

    Humidity 100% Washing detergent with pH <9.0 Washing detergent must contain rust inhibitor and be approved by ABB Cleaning bath temperature <60°C, used in a typical waterjet cleaning application at suitable speed. Air specification for pressurizing of robot The air must be dry and clean, such as instrument air. The table below details the air specifications.
  • Page 125 2 Installation and commissioning 2.8.1. Additional installation procedure Continued WARNING! If the pressurized air contains oil, it could result in a brake failure in the motors and cause the robot arms to fall down, leading to personal injury or physical damage. WARNING! If the air pressure exceeds the specified, it could result in a brake failure in the motors and cause the robot arms to fall down, leading to personal injury or physical damage.
  • Page 126 2 Installation and commissioning 2.8.1. Additional installation procedure Continued Protecting robot from high pressure water WARNING! No part of the robot 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.

  • Page 127: Commissioning (Foundry Prime)

    2 Installation and commissioning 2.8.2. Commissioning (Foundry Prime) 2.8.2. Commissioning (Foundry Prime) General The following should be taken in consideration when running a robot in a water jet application cell: CAUTION! Never switch off the overpressure in motors and serial measurement compartment during cooling down of robot after it has been switched off.
  • Page 128 2 Installation and commissioning 2.8.2. Commissioning (Foundry Prime) 3HAC022033-001 Revision: E...

  • Page 129: 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 130: Maintenance Schedule And Expected Life

    3 Maintenance 3.2.1. Specification of maintenance intervals 3.2 Maintenance schedule and expected life 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 131: 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 132 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Detailed in Equipment Interval activity section Changing Axis 1 gear oil: First change after 6 000 h Do not mix with other oils! Kyodo Yushi TMO Second change after 24 000 h Oil change, gearbox axis 1 on page 181 Changing Axis 2 gear oil:...
  • Page 133 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Detailed in Equipment Interval activity section Replacement Axis 5 gear 96 mths Replacement of gearbox, axis 5 on page 360 Replacement Axis 6 gear As specified by the SIS, or Replacement of typically 96 mths gearbox, axis 6 on page 366 Replacement...
  • Page 134 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Detailed in Equipment Interval Note activity section Inspection Motor fans, axes 12 mths Inspect the fans for 1, 2 and 3 contamination that could hinder the air supply. Clean if necessary. Activities and intervals, Foundry Prime The table below specifies the required maintenance activities and intervals for Foundry Prime.
  • Page 135 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Equipment Interval Detailed in section activity Replacement Axis 2 gearbox As specified Replacement of gearbox, by the SIS or axis 2 on page 342 typically 96 mths Replacement Axis 3 gearbox As specified Replacement of gearbox, by the SIS or axis 3 on page 349...

  • Page 136: Expected Component Life

    3 Maintenance 3.2.3. Expected component life 3.2.3. Expected component life General The life of any component depends on how hard it is run, and it can vary greatly. Expected life Component Expected life Note Cabling for robot, 7th axis, axis 2/3 4,000,000 cycles axis 1 ±180º...

  • Page 137: Inspection Activities

    3 Maintenance 3.3.1. Inspection, oil level gearbox axis 1 3.3 Inspection activities 3.3.1. Inspection, oil level gearbox axis 1 Location of gearbox The axis 1 gearbox is located between the frame and base as shown in the figure below. xx0200000111 Gearbox axis 1 Oil plug, filling Motor, axis 1...
  • Page 138 3 Maintenance 3.3.1. Inspection, oil level gearbox axis 1 Continued Inspection through the oil plug, filling The procedure below details how to inspect the oil level, axis 1 gearbox, when the oil plug for inspection (shown in figure Location of gearbox on page 135) is not available .
  • Page 139 3 Maintenance 3.3.1. Inspection, oil level gearbox axis 1 Continued Inspection through the oil plug, inspection The procedure below details how to inspect the oil level, axis 1 gearbox, when the oil plug for inspection (shown in the figure Location of gearbox on page 135) is available.

  • Page 140: Inspection, Oil Level Gearbox Axis 2

    3 Maintenance 3.3.2. Inspection, oil level gearbox axis 2 3.3.2. Inspection, oil level gearbox axis 2 Different designs The cover of gearbox axis 2 is made in different designs, with different locations of the oil plug hole for filling. The oil plug hole of the later design is located 33 mm below the original placement.
  • Page 141 3 Maintenance 3.3.2. Inspection, oil level gearbox axis 2 Continued Oil plug, later design The axis 2 gearbox is located in the lower arm rotational center. The figure below shows the later design of the gearbox cover, where the oil plug for filling is located 33 mm below the original placement.
  • Page 142 3 Maintenance 3.3.2. Inspection, oil level gearbox axis 2 Continued Inspection, oil level gearbox axis 2 The procedure below details how to inspect the oil level in gearbox axis 2. 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...

  • Page 143: Inspection, Oil Level Gearbox Axis 3

    3 Maintenance 3.3.3. Inspection, oil level gearbox axis 3 3.3.3. Inspection, oil level gearbox axis 3 Location of gearbox The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. xx0200000113 Gearbox, axis 3 Oil plug, filling Oil plug, draining Label, specifies the oil type of axis 3 gearbox...
  • Page 144 3 Maintenance 3.3.3. Inspection, oil level gearbox axis 3 Continued Equipment Art. no. Note Other tools and procedures may These procedures include be required. See references to references to the tools required. these procedures in the step-by- step instructions below. Inspection, oil level gearbox axis 3 The procedure below details how to inspect the oil level in gearbox axis 3.

  • Page 145: Inspection, Oil Level Gearbox Axis 4

    3 Maintenance 3.3.4. Inspection, oil level gearbox axis 4 3.3.4. Inspection, oil level gearbox axis 4 Location of gearbox The axis 4 gearbox is located at the rear of the upper arm as shown in the figure below. xx0200000107 Upper arm housing Cover, axis 4 gearbox Oil plug, filling, secondary gear Oil plug, draining, secondary gear...
  • Page 146 3 Maintenance 3.3.4. Inspection, oil level gearbox axis 4 Continued Equipment, etc. Art. no. Note Other tools and procedures may These procedures include be required. See references to references to the tools required. these procedures in the step-by- step instructions below. Inspection, oil level gearbox axis 4 The procedure below details how to inspect the oil level in gearbox axis 4.
  • Page 147 3 Maintenance 3.3.4. Inspection, oil level gearbox axis 4 Continued Action Note 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 3HAC022033-001 Revision: E...

  • Page 148: Inspection, Oil Level, Gearbox Axis 5

    3 Maintenance 3.3.5. Inspection, oil level, gearbox axis 5 3.3.5. Inspection, oil level, gearbox axis 5 Location of gearbox The axis 5 gearbox is located in the wrist unit as shown in the figure below. xx0200000108 Wrist housing Cover, axis 5 gearbox Oil plug, filling secondary gear Oil plug, draining secondary gear Oil plug, filling, primary gearbox (draining on opposite side of wrist housing, not...
  • Page 149 3 Maintenance 3.3.5. Inspection, oil level, gearbox axis 5 Continued Equipment etc. Art. no. Note Other tools and procedures may These procedures include be required. See references to references to the tools required. these procedures in the step-by- step instructions below. Inspection, oil level gearbox axis 5 The procedure below details how to inspect the oil level in the gearbox axis 5.
  • Page 150 3 Maintenance 3.3.5. Inspection, oil level, gearbox axis 5 Continued Action Note 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 3HAC022033-001 Revision: E...

  • Page 151: Inspection, Oil Level Gearbox Axis 6

    3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 3.3.6. Inspection, oil level 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. The alternative locations of the oil plugs for filling affects the measured oil level. The different oil levels are specified in the procedure.
  • Page 152 3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 Continued Inspection, oil level gearbox axis 6 The procedure below details how to inspect the oil level in the gearbox axis 6. Action Note WARNING! Handling gearbox oil involves several safety risks. Before proceeding, please observe the safety information in section WARNING - Safety risks during...
  • Page 153 3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 Continued Action Note 6. Add oil if required. Art. no. is specified in Required equipment on page 149. Detailed in section Oil change, gearbox axis 6 on page 197. 7. Refit the oil plug, filling. Tightening torque: 24 Nm.
  • Page 154 3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 Continued Then..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 •...

  • Page 155: Inspection, Balancing Device

    3 Maintenance 3.3.7. Inspection, balancing device 3.3.7. Inspection, balancing device General Several points are to be checked on the balancing device during the inspection. This section details how to perform the inspection regarding: • dissonance • damage • leakage • contamination / lack of free space.
  • Page 156 3 Maintenance 3.3.7. Inspection, balancing device Continued Inspection points, balancing device The balancing device is located at the top rear of the frame as shown in the figure below. The figure also shows the inspection points, further detailed in the instructions. xx0300000580 Balancing device Piston rod (inside)
  • Page 157 3 Maintenance 3.3.7. Inspection, balancing device Continued Equipment, etc. Spare part no. Art. no. Note Maintenance kit, 3HAC14962-1 Includes: bearings and seals • kit with bearings, o- rings and seals only • instructions for main- tenance. Upgrade kit 3HAC14965-1 Includes •...
  • Page 158 Check for dissonance from... If dissonance is detected... • cylinder (a tapping sound, ...replace the balancing device or consult caused by the springs inside the ABB Robotics. cylinder). How to replace the device is detailed in section Replacement of balancing device on page 276.
  • Page 159 3 Maintenance 3.3.7. Inspection, balancing device Continued Check for leakage The front ear of the balancing device is lubricated with grease. After filling, excessive grease may normally be forced out between the shaft and the sealing ring in the sealing spacer. This is normal behaviour and must not be confused with incorrect leaks from the ear.
  • Page 160 3 Maintenance 3.3.7. Inspection, balancing device Continued Action Note 1. Clean the area at the front ear from old grease. 2. Run the robot for some minutes, in order to move the balancing device piston. 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 161: Inspection, Cable Harness

    3 Maintenance 3.3.8. Inspection, cable harness 3.3.8. Inspection, cable harness Location of cable harness, axes 1-4 The robot cable harness, axes 1-4, is located as shown in the figure below. xx0200000097 Lower arm Cables attached with velcro straps and mounting plate Connectors at cable harness division point, R2.M5/6 Connectors at base Required equipment...
  • Page 162 3 Maintenance 3.3.8. Inspection, cable harness Continued Inspection, cable harness 1-4 The procedure below details how to inspect the cable harness of axes 1-4. Action Note 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 163 3 Maintenance 3.3.8. Inspection, cable harness Continued Inspection, cable harness, axes 5-6 The procedure below details how to inspect the cable harness of axes 5-6. Action Note 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 164: Inspection, Mechanical Stop, Axis 1

    3 Maintenance 3.3.9. Inspection, mechanical stop, axis 1 3.3.9. Inspection, mechanical stop, axis 1 Location of mechanical stop The mechanical stop axis 1 is located at the base as shown in the figure below. xx0200000151 Mechanical stop pin Required equipment Equipment, etc.
  • Page 165 3 Maintenance 3.3.9. Inspection, mechanical stop, axis 1 Continued Action Note 4. If the stop pin is bent or damaged, it must be Art. no. is specified in Required replaced! equipment on page 162. NOTE! The expected life of gearboxes can be reduced as a result of collissions with the mechanical stop.

  • Page 166: Inspection, Mechanical Stop, Axes 1, 2 And 3

    3 Maintenance 3.3.10. Inspection, mechanical stop, axes 1, 2 and 3 3.3.10. Inspection, mechanical stop, axes 1, 2 and 3 Location of the mechanical stops The figure below shows the location of the additional mechanical stops on axes 1, 2 and 3. xx0200000150 Additional stop Fixed stop...
  • Page 167 3 Maintenance 3.3.10. Inspection, mechanical stop, axes 1, 2 and 3 Continued Inspection, mechanical stops The procedure below details how to inspect the additional mechanical stops on axes 1, 2 and Action Note 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 168: Inspection, Damper Axes 2-5

    3 Maintenance 3.3.11. Inspection, damper axes 2-5 3.3.11. Inspection, damper axes 2-5 Location of dampers The figure below shows the location of all the dampers to be inspected. xx0200000099 Damper, axis 2 (2 pcs) Damper, axis 3 (2 pcs) Damper, axis 4 (2 pcs) Damper, axis 5 (2 pcs) Required equipment Equipment...
  • Page 169 3 Maintenance 3.3.11. Inspection, damper axes 2-5 Continued Inspection, damper axis 2-5 The procedure below details how to inspect the dampers, axis 2-5. Action Note 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 170: Inspection, Position Switch Axes 1, 2 And 3

    3 Maintenance 3.3.12. Inspection, position switch axes 1, 2 and 3 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 Position switch, axis 1 Set screw, cam...
  • Page 171 3 Maintenance 3.3.12. Inspection, position switch axes 1, 2 and 3 Continued The illustration below shows the position switch for axis 2. xx0100000159 Position switch, axis 2 Set screw, cam Rail Rail attachment Continues on next page 3HAC022033-001 Revision: E...
  • Page 172 3 Maintenance 3.3.12. Inspection, position switch axes 1, 2 and 3 Continued The illustration below shows the position switch for axis 3. xx0100000160 Position switch, axis 3 Set screw, cam Rail Rail attachment Required equipment Equipment, etc. Spare part no. Note Position switch, axis 1 3HAC15715-1...
  • Page 173 3 Maintenance 3.3.12. Inspection, position switch axes 1, 2 and 3 Continued Equipment, etc. Spare part no. Note Other tools and procedures may These procedures include be required. See references to references to the tools required. these procedures in the step-by- step instructions below.

  • Page 174: Inspection, Information Labels

    3 Maintenance 3.3.13. Inspection, information labels 3.3.13. Inspection, information labels Location of labels The figures below show the location of the information labels to be inspected. xx0200000100 Warning label "High temperature", 3HAC4431-1 Warning sign, symbol of a lightning flash (located on motor cover), 3HAC1589-1 Instruction label "Safety instructions", 3HAC4591-1 Warning label "Brake release", 3HAC15334-1 Warning label, tools are not allowed around the balancing device during operation,...
  • Page 175 3 Maintenance 3.3.13. Inspection, information labels Continued xx0200000101 Instruction label "Lifting the robot", 3HAC16420-1 Warning label "Robot can tip forward...", 3HAC9191-1 Foundry logotype, 3HAC8256-1 Warning label "Stored energy", 3HAC9526-1 Information label, types of oil in gearboxes of each axis, 3HAC021505-001 Label, type of oil in gearbox, 3HAC021485-001 Required equipment Equipment...

  • Page 176: Inspection, Ul-Lamp

    3 Maintenance 3.3.14. Inspection, UL-lamp 3.3.14. Inspection, UL-lamp Location of UL-lamp The UL-lamp is located as shown in figure below. Notice that the location can vary depending on how the customer harness for axes 4-6 is mounted. xx0200000117 UL signal lamp Warning sign Warning label Position for cable gland...
  • Page 177 3 Maintenance 3.3.14. Inspection, UL-lamp Continued Inspection, UL-lamp The procedure below details how to inspect the function of 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! Part no.

  • Page 178: Inspection Of Air Hoses (Foundry Prime)

    3 Maintenance 3.3.15. Inspection of air hoses (Foundry Prime) 3.3.15. Inspection of air hoses (Foundry Prime) General The air hoses on Foundry Prime robots must be inspected for leakage every six month. Required equipment Equipment, etc. Art. no. Note Leak detection spray Pressure gauge Cut off valve Procedure...

  • Page 179: Changing/Replacement Activities

    3 Maintenance 3.4.1. Type of oil in gearboxes 3.4 Changing/replacement activities 3.4.1. Type of oil in gearboxes Location of gearboxes The gearboxes are located as shown in the figure below. xx0400000798 Gearbox , axis 1 Gearbox , axis 2 Gearbox , axis 3 Gearbox , axis 4 (primary) Gearbox , axis 4 (secondary) Gearbox , axis 5 (primary)
  • Page 180 3 Maintenance 3.4.1. Type of oil in gearboxes Continued NOTE! When there is a change of oil types in the gearbox, it need to be rinsed. See Rinsing gearbox. CAUTION! When filling gearbox oil, do not mix different types of oil as this may cause severe damage to the gearbox! Always use the type of oil specified in the table! If oils are mixed, the gearbox must be thoroughly rinsed! See Rinsing...
  • Page 181 3 Maintenance 3.4.1. Type of oil in gearboxes Continued Labels at robot base Label located at robot base show the types of oil in all gearboxes. Lifting of robot Axis 1 Kyodo Yushi TMO 150 Axis 2 Kyodo Yushi TMO 150 Axis 3 Kyodo Yushi TMO 150 Axis 4 prim.
  • Page 182 • Refill the gearbox with Mobilgear 600 XP320 Equipment, change of oil type Equipment ABB art. no. Note Label set See Spare parts! Includes small labels to each gearbox and the complete label to be fitted at the robot base.

  • Page 183: Oil Change, Gearbox Axis 1

    3 Maintenance 3.4.2. Oil change, gearbox axis 1 3.4.2. Oil change, gearbox axis 1 Location of 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 Gearbox, axis 1 Oil plug, filling...
  • Page 184 3 Maintenance 3.4.2. Oil change, gearbox axis 1 Continued Oil plug in the base In some early versions of the robot, the oil plug for draining may be located in the base, as shown in the figure below. xx0300000065 Oil plug in the base Required equipment Equipment, etc.
  • Page 185 3 Maintenance 3.4.2. Oil change, gearbox axis 1 Continued NOTE! The specified amount of oil is 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 much oil has previously been drained from the gearbox.
  • Page 186 3 Maintenance 3.4.2. Oil change, gearbox axis 1 Continued Filling, oil, gearbox axis 1 The procedure below details how to fill oil in gearbox, axis 1. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no.

  • Page 187: Oil Change, Gearbox Axis 2

    3 Maintenance 3.4.3. Oil change, gearbox axis 2 3.4.3. Oil change, gearbox axis 2 Location of oil plugs The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment. xx0200000112 Gearbox, axis 2 Oil plug, filling (later design) Oil plug, draining Label, specifies the type of oil in the gearbox Required equipment...
  • Page 188 3 Maintenance 3.4.3. Oil change, gearbox axis 2 Continued Equipment, etc. Art. no. Amount Note Standard toolkit The content is defined in section Standard toolkit on page 394. Draining, oil The procedure below details how to drain the oil in gearbox axis 2. When using the oil exchange equipment, follow the instructions enclosed with the kit.
  • Page 189 3 Maintenance 3.4.3. Oil change, gearbox axis 2 Continued Filling, oil The procedure below details how to fill oil into the gearbox, axis 2. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 185.

  • Page 190: Oil Change, Gearbox, Axis 3

    3 Maintenance 3.4.4. Oil change, gearbox, axis 3 3.4.4. Oil change, gearbox, axis 3 Location of gearbox The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. xx0200000113 Gearbox, axis 3 Oil plug, filling Oil plug, draining Label, specifies the type of oil in gearbox Required equipment...
  • Page 191 3 Maintenance 3.4.4. Oil change, gearbox, axis 3 Continued Equipment, etc. Art. no. Amount Note Standard toolkit The content is defined in section Standard toolkit on page 394. Draining, oil The procedure below details how to drain oil from the gearbox, axis 3. When using the oil exchange equipment, follow the instructions enclosed with the kit.
  • Page 192 3 Maintenance 3.4.4. Oil change, gearbox, axis 3 Continued Filling, oil The procedure below details how to fill oil to the gearbox, axis 3. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 188.

  • Page 193: Oil Change, Gearbox, Axis 4

    3 Maintenance 3.4.5. Oil change, gearbox, axis 4 3.4.5. Oil change, gearbox, axis 4 Different types of oil The primary and secondary gear may require different types of oil, that must never be mixed! If they are mixed, the gear must be rinsed according to section Flushing a contaminated gearbox on page 211.
  • Page 194 3 Maintenance 3.4.5. Oil change, gearbox, axis 4 Continued Required equipment Equipment, etc. Art. no. Amount Note Lubricating oil 3HAC032140-001 900 ml Kyodo Yushi TMO 150 Used in the primary gearbox. Lubricating oil 3HAC032140-001 3,850 ml Kyodo Yushi TMO 150 Used in the secondary gearbox.
  • Page 195 3 Maintenance 3.4.5. Oil change, gearbox, axis 4 Continued Filling, oil, gearbox axis 4 The procedure below details how to fill oil in gearbox, axis 4. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no.

  • Page 196: Oil Change, Gearbox, Axis 5

    3 Maintenance 3.4.6. Oil change, gearbox, axis 5 3.4.6. Oil change, gearbox, axis 5 Different types of oil The primary and secondary gear may require different types of oil, that must never be mixed! If they are mixed, the gear must be rinsed according to section Flushing a contaminated gearbox on page 211.
  • Page 197 3 Maintenance 3.4.6. Oil change, gearbox, axis 5 Continued Required equipment Equipment, etc. Art. no. Amount Note Lubricating oil 3HAC032140-001 750 ml Kyodo Yushi TMO 150 Used in the primary gearbox. Lubricating oil 3HAC032140-001 3,800 ml Kyodo Yushi TMO 150 Used in the secondary gearbox.
  • Page 198 3 Maintenance 3.4.6. Oil change, gearbox, axis 5 Continued Filling, oil, gearbox axis 5 The procedure below details how to fill oil in gearbox, axis 5. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no.

  • Page 199: Oil Change, Gearbox Axis 6

    3 Maintenance 3.4.7. Oil change, gearbox axis 6 3.4.7. Oil change, 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. xx0200000114 Gearbox, axis 6 Oil plug, filling (notice the different locations of the plug, shown as B and B Oil plug, draining (can be located on the turning disk instead)
  • Page 200 3 Maintenance 3.4.7. Oil change, gearbox axis 6 Continued NOTE! The specified amount of oil is 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 much oil has previously been drained from the gearbox.
  • Page 201 3 Maintenance 3.4.7. Oil change, gearbox axis 6 Continued Action Note 2. If the oil plug for draining is located on the turning disk, rotate the disk so that the oil plug faces upwards. 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 202: Replacement Of Smb Battery

    Required equipment 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.
  • Page 203 Shown in the figure Location of SMB battery on page 200. Battery includes protection circuits. Replace it only with the specified spare part or with an ABB approved equivalent. Refitting, battery The procedure below details how to refit the SMB battery. Action...
  • Page 204 3 Maintenance 3.4.8. Replacement of SMB battery Continued Action Note 3. Reconnect the battery cable to the SMB battery Art. no. is specified in Required pack and fit it to the frame. equipment on page 200. Shown in the figure Location of SMB battery on page 200.

  • Page 205: Lubrication Activities

    3 Maintenance 3.5.1. Lubrication of spherical roller bearing, balancing device 3.5 Lubrication activities 3.5.1. Lubrication of spherical roller bearing, balancing device Location of bearing The spherical roller bearing is located at the front ear of the balancing device, as shown in the figure below.
  • Page 206 3 Maintenance 3.5.1. Lubrication of spherical roller bearing, balancing device Continued Lubrication, balancing device bearing The procedure below details how to lubricate the spherical roller bearing. Action Note 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 207: Rust Preventive Measures, Bearing Axis 1 (Foundry Prime)

    3 Maintenance 3.5.2. Rust preventive measures, bearing axis 1 (Foundry Prime) 3.5.2. Rust preventive measures, bearing axis 1 (Foundry Prime) Location of bearing axis 1 The bearing axis 1 is located as shown in the illustration. (View from above). xx0600002866 Plastic ring, (bearing cover) Required equipment Equipment...
  • Page 208 3 Maintenance 3.5.2. Rust preventive measures, bearing axis 1 (Foundry Prime) Continued Procedure The following procedure details how to grease the bearing axis 1. Action Note 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 209: Rust Preventive Measures, Bearing Axis 4 (Foundry Prime)

    3 Maintenance 3.5.3. Rust preventive measures, bearing axis 4 (Foundry Prime) 3.5.3. Rust preventive measures, bearing axis 4 (Foundry Prime) Overview The bearing axis 4 is located as shown in the illustration below. xx0500002869 Plastic cover Plastic ring Required equipment Equipment Art.
  • Page 210 3 Maintenance 3.5.3. Rust preventive measures, bearing axis 4 (Foundry Prime) Continued Action Note 3. Remove the plastic cover at the rear end of the upper arm. xx0600002872 Parts: • A: Plastic cover • B: Plastic ring 4. Remove the plastic ring that covers the bearing.

  • Page 211: Rust Preventive Measures, Support Bearing In Wrist (Foundry Prime)

    3 Maintenance 3.5.4. Rust preventive measures, support bearing in wrist (Foundry Prime) 3.5.4. Rust preventive measures, support bearing in wrist (Foundry Prime) Location of bearing The support bearing in the wrist is located as shown in the illustration. xx0500002863 Bearing Cable bracket Cover Required equipment...
  • Page 212 3 Maintenance 3.5.4. Rust preventive measures, support bearing in wrist (Foundry Prime) Continued Greasing bearings The procedure below details how to grease the bearing in the wrist. Action Note 1. Put the robot and the upper arm in a suitable position. DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

  • Page 213: Cleaning Activities

    3 Maintenance 3.6.1. Flushing a contaminated gearbox 3.6 Cleaning activities 3.6.1. Flushing a contaminated gearbox Different types of oil As the Shell Tivela S 150 (Kyodo Yushi TMO 150)is not compatible with mineral oil, contamination with other types of oils used in the gearboxes is not accepted. Equipment used in handling of Tivela S 150 (Kyodo Yushi TMO 150) must be carefully cleaned.
  • Page 214 3 Maintenance 3.6.1. Flushing a contaminated gearbox Continued Flushing The procedure below details how to flush a contaminated gearbox. The procedure is the same for all gearboxes. Action Note 1. Run the Service program until the castings of the Recommended service program gearboxes axis 4, 5 and 6 have reached a detailed in section above: temperature of about 30-35º...

  • Page 215: Cleaning, Robot

    3 Maintenance 3.6.2. Cleaning, robot 3.6.2. Cleaning, robot General The protection class is IP 67, that is the robot is watertight. Activities This instruction specifies 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.
  • Page 216 3 Maintenance 3.6.2. Cleaning, robot Continued Required equipment Equipment, etc. Art. no. Note Steam cleaner • Water pressure at nozzle: max. 2500 kN/m (25 bar) • Type of nozzle: fan jet, min. 45° spread • Flow: max. 100 litres/min. • Water temperature: max.

  • Page 217: 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, for example spare parts numbers, required special tools and materials.

  • Page 218: 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 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 219: 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 3HAB3537-1 Used to grease the bearings, if not specified otherwise.
  • Page 220 4 Repair 4.2.2. Mounting instructions for bearings Continued Greasing of bearings The bearings must be greased after assembly, according to instructions below: • The bearings must not be completely filled with grease. However, if space is available beside the bearing 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.

  • Page 221: 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 3HAB3537-1 Used to lubricate the seals. Rotating seals The procedure below details how to fit rotating seals.
  • Page 222 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 223: Complete Robot

    4 Repair 4.3.1. Replacement of cable harness, axes 1-4 4.3 Complete robot 4.3.1. Replacement of cable harness, axes 1-4 Location of cable harness The cable harness for axes 1-4 is run throughout the base, frame and lower arm as shown in the figure below.
  • Page 224 4 Repair 4.3.1. Replacement of cable harness, axes 1-4 Continued Connectors at motor 5; R3.FB5 and R3.MP5 Connectors at motor 6; R3.FB6 and R3.MP6 Rear cover plate Connector R1.MP Connector R1.SMB Connection of earth cable Required equipment Equipment, etc. Spare part no. Art.
  • Page 225 4 Repair 4.3.1. Replacement of cable harness, axes 1-4 Continued Action Note 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.
  • Page 226 4 Repair 4.3.1. Replacement of cable harness, axes 1-4 Continued Action Note 10. Remove • the cable gland (A), by removing the four attachment screws from inside the SMB recess (B) • the attachment plate (C), by removing the attachment screws and the velcro strap (D).
  • Page 227 4 Repair 4.3.1. Replacement of cable harness, axes 1-4 Continued Action Note 12. Remove the cable gland securing the cables to the arm house. xx0100000143.wmf 13. Remove the velcro strap from the harness Shown in the figure Location of cable at the cable fixing bracket at the arm house.
  • Page 228 4 Repair 4.3.1. Replacement of cable harness, axes 1-4 Continued Action Note 2. In order to facilitate refitting of cable harness, Axes 2 and 3 may be tilted slightly move the robot to the specified position: to improve access. • Axis 1: 0 degrees •...
  • Page 229 4 Repair 4.3.1. Replacement of cable harness, axes 1-4 Continued Action Note 8. Secure the cable gland (A) with four attachment Locking liquid is specified in screws (B) from inside the SMB recess. Required equipment on page 222. Secure the correct attachment plate (C) to the cable gland with its two attachment screws, using locking liquid.
  • Page 230 4 Repair 4.3.1. Replacement of cable harness, axes 1-4 Continued Action Note 9. Reconnect connectors R2.SMB, R1.SMB1-3, R1.SMB4-6 to the SMB unit. Reconnect X8, X9 and X10 if the brake release board is located in frame. Reconnect R1.G if it has been disconnected. xx0200000118 10.
  • Page 231 4 Repair 4.3.1. Replacement of cable harness, axes 1-4 Continued Action Note 15. Reconnect all connectors at motor 3 and motor 4. Specified and shown in the figure Location of cable harness on page 221! 16. Reconnect the connector R2.M5/6 gently at the Shown in the figure Location of cable division point.

  • Page 232: Replacement Of Cable Harness, Axes 5-6

    4 Repair 4.3.2. Replacement of cable harness, axes 5-6 4.3.2. Replacement of cable harness, axes 5-6 Location of cable harness ax 5-6 The location of the cable harness, axes 5-6, is shown in the figure below. xx0100000145 Cable attachment, upper arm Cable attachment, rear Connector at cable harness division;...
  • Page 233 4 Repair 4.3.2. Replacement of cable harness, axes 5-6 Continued Removal, cable harness, axes 5-6 The procedure below details how to remove the upper arm cable harness. Action Note 1. Position the upper arm as follows: • Axis 4: 0 degrees •...
  • Page 234 4 Repair 4.3.2. Replacement of cable harness, axes 5-6 Continued Action Note 5. Secure the small plate to the large plate. Secure the spiral cup with its attachment screw in the bottom of the cup. 6. Secure any excess cable length tightly to the large Excess cable length may be plate in the wrist housing, using cable straps.

  • Page 235: Replacement Of Complete Arm System

    4 Repair 4.3.3. Replacement of complete arm system 4.3.3. Replacement of complete arm system Location of 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.
  • Page 236 4 Repair 4.3.3. Replacement of complete arm system Continued Required equipment Equipment, etc. Art. no. Note Lifting device, robot 3HAC15607-1 Instruction 3HAC15971-2 enclosed! Guide pins, M12 x 130 Used to guide the complete arm system when refitting. Standard toolkit The content is defined in section Standard toolkit on page 394.
  • Page 237 4 Repair 4.3.3. Replacement of complete arm system Continued Action Note CAUTION! The complete arm system weighs 2000 kg! All lifting equipment used must be sized accord- ingly! 7. Fit the lifting device and adjust it as detailed in Art. no. is specified in Required enclosed instruction.
  • Page 238 4 Repair 4.3.3. Replacement of complete arm system Continued Action Note 5. Fit two guide pins, M12 x 130, in the frame attachment holes as shown in the figure to the right. Fit one guide pin next to the guiding hole (for the spring pin in the gearbox) and the other guide pin straight across the frame.
  • Page 239 4 Repair 4.3.3. Replacement of complete arm system 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 3HAC022033-001 Revision: E...

  • Page 240: Replacement Of Air Nipple And Hose (Foundry Prime)

    4 Repair 4.3.4. Replacement of air nipple and hose (Foundry Prime) 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...
  • Page 241 4 Repair 4.3.4. Replacement of air nipple and hose (Foundry Prime) Continued Pos 1D Hose length 1140 mm Pos 1E Hose length 310 mm Pos 1F Hose length 35 mm Pos 1G Hose length 260 mm Pos 1H Hose length 570 mm Pos 1K Hose length 4040 mm Pos 1L...
  • Page 242 4 Repair 4.3.4. Replacement of air nipple and hose (Foundry Prime) Continued Procedure The following procedures details how to replace the Foundry Prime air nipples and hose. The pos. no. in following procedures correspond to the illustration in Hose lengths on page 238and the table in Required equipment on page 239 Action...
  • Page 243 4 Repair 4.3.4. Replacement of air nipple and hose (Foundry Prime) Continued Action Note 5. Balancing device. xx0600003397 Item in illustration is detailed in Hose lengths on page 238. Continues on next page 3HAC022033-001 Revision: E...
  • Page 244 4 Repair 4.3.4. Replacement of air nipple and hose (Foundry Prime) Continued Action Note 6. Axis 1-2. xx0600003418 xx0600003420 xx0600003045 Continues on next page 3HAC022033-001 Revision: E...
  • Page 245 4 Repair 4.3.4. Replacement of air nipple and hose (Foundry Prime) Continued Action Note 7. Upper arm housing. xx0600003046 xx0600003047 8. Tube shaft. xx0600003163 • 1P: Lay the hose in a spiral in the tube shaft. Continues on next page 3HAC022033-001 Revision: E...
  • Page 246 4 Repair 4.3.4. Replacement of air nipple and hose (Foundry Prime) Continued Action Note 9. Wrist. NOTE! Make sure the cable length from 5a to the nipple of axis 6 = S, see Hose lengths on page 238. xx0600003097 3HAC022033-001 Revision: E...

  • Page 247: Upper And Lower Arm

    4 Repair 4.4.1. Replacement of turning disk 4.4 Upper and lower arm 4.4.1. Replacement of turning disk Location of turning disk The turning disk is located in the center of the wrist unit as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
  • Page 248 4 Repair 4.4.1. Replacement of turning disk Continued Equipment, etc. Spare part no. Art. no. Note Other tools and These procedures include procedures may be references to the tools required. See required. references to these procedures in the step- by-step instructions below.
  • Page 249 4 Repair 4.4.1. Replacement of turning disk Continued Action Note 2. Lubricate the o-ring with grease and fit it to the rear Art. no. is specified in Required of the turning disk. equipment on page 245. xx0100000130 A. O-ring, turning disk 3.

  • Page 250: Replacement Of Complete Wrist Unit

    4 Repair 4.4.2. Replacement of complete wrist unit 4.4.2. Replacement of complete wrist unit Location of wrist unit The wrist unit is located in the frontmost part of the upper arm as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
  • Page 251 4 Repair 4.4.2. Replacement of complete wrist unit Continued Equipment, etc. Spare part no. Art. no. Note Standard toolkit The content is defined in section Standard toolkit on page 394. Calibration Pendulum 3HAC15716-1 Complete kit that also toolkit includes operating manual.
  • Page 252 4 Repair 4.4.2. Replacement of complete wrist unit Continued Action Note 11. Remove the wrist unit attachment screws and washers. 12. Pull the cabling forwards through the upper arm tube. Make sure the attachments do not get stuck inside the tube! 13.
  • Page 253 4 Repair 4.4.2. Replacement of complete wrist unit Continued Action Note 11. Reconnect connector R2.M5/6 at the rear cable Shown in the figure Location of division point. wrist unit on page 248. 12. Refit the rear cover with its attachment screws. Shown in the figure Location of wrist unit on page...

  • Page 254: 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 on top of the robot as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
  • Page 255 4 Repair 4.4.3. Replacement of complete upper arm Continued Required equipment Equipment, etc. Art. no. Note Sealing, axis 2/3 3HAC11054-1 Always use a new sealing when reassembling! Washer 3HAC11828-1 Replace if damaged! Standard toolkit The content is defined in section Standard toolkit on page 394.
  • Page 256 4 Repair 4.4.3. Replacement of complete upper arm Continued Action Note 6. Run the lifting chain from the rear lifting point through Art. no. is specified in Required the overhead crane hook, through the hoisting block to equipment on page 253.
  • Page 257 4 Repair 4.4.3. Replacement of complete upper arm Continued Action Note/Illustration 2. Fit the two guide pins, sealing axis 2/3 in two of the Always use a new sealing when attachment screw holes on gearbox 3, see figure to reassembling! the right.
  • Page 258 4 Repair 4.4.3. Replacement of complete upper arm Continued Action Note/Illustration 10. Insert the attachment screws. In some cases, removing the plastic mechanical stops may be Do not remove the guide pins until the attachment required before fitting the upper screws are tightened as detailed below! arm.

  • Page 259: Replacement Of Complete Lower Arm

    4 Repair 4.4.4. Replacement of complete lower arm 4.4.4. 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 chapter Exploded views in the...
  • Page 260 4 Repair 4.4.4. Replacement of complete lower arm Continued xx0200000031 Gearbox Lower arm Balancing device piston rod ear Frame Shaft hole Sealing, axis 2/3 Attachment screw Washer Bearing Thrust washer Bushing Retaining ring Shaft Protection plug Protection washer Required equipment Equipment, etc.
  • Page 261 4.4.4. Replacement of complete lower arm Continued Equipment, etc. Spare part no. Art. no. Note Lifting tool, lower 3HAC14691-1 Tool that may be rent from ABB. Includes • guidings, 3HAC14445- The guidings are used for guiding the sealing, axis 2/3. Rotation tool 3HAC17105-1...
  • Page 262 4 Repair 4.4.4. Replacement of complete lower arm Continued Action Note 2. Remove the upper arm. Detailed in section Replacement of complete upper arm on page 252. 3. Disconnect and remove the cables from inside Detailed in section Replacement of the lower arm.
  • Page 263 4 Repair 4.4.4. Replacement of complete lower arm Continued Action Note 11. Apply the lifting tool to the lower arm. Art. no. is specified in Required equipment on page 258! 12. Drain the oil from gearbox 2. Detailed in section Oil change, gearbox axis 2 on page 185.
  • Page 264 4 Repair 4.4.4. Replacement of complete lower arm Continued Action Note 21. Remove the sealing from the lower arm. Shown in the figure Attachment points, lower arm on page 257. On reassembly a new sealing must be used! Refitting, lower arm The procedure below details how to refit the lower arm to the robot.
  • Page 265 4 Repair 4.4.4. Replacement of complete lower arm Continued Action Note 8. In case the holes of the lower arm and the ones Connect power supply to connector of the gearbox axis 2 doesn´t match, use power R2.MP2: supply to release the motor axis 2 brakes and •...
  • Page 266 4 Repair 4.4.4. Replacement of complete lower arm Continued Action Note 16. Set the indicator on the press tool to zero. 17. Press in the shaft with the hydraulic cylinder by setting the pressure of the hydraulic pump to approximately 35-55 MPa and the pressure of the glycerin pump to 55 MPa.
  • Page 267 4 Repair 4.4.4. Replacement of complete lower arm 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 3HAC022033-001 Revision: E...

  • Page 268: Frame And Base

    4 Repair 4.5.1. Replacement of SMB unit 4.5 Frame and base 4.5.1. Replacement of SMB unit Location of SMB unit The SMB unit (SMB = serial measurement board) is located on the left hand side of the frame as shown in the figure below. xx0200000203 SMB cover SMB unit...
  • Page 269 4 Repair 4.5.1. Replacement of SMB unit Continued Removal, SMB unit The procedure below details how to remove the SMB unit. Action Note 1. Move the robot to the calibration position. 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 270 4 Repair 4.5.1. Replacement of SMB unit Continued Action Note 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. Connect the battery cable to the SMB unit. Shown in the figure Location of SMB unit on page...
  • Page 271 4 Repair 4.5.1. Replacement of SMB unit Continued Action Note 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 3. Remove the SMB unit as detailed in Removal, SMB unit on page 267 4.

  • Page 272: Replacement Of Brake Release Unit

    4 Repair 4.5.2. Replacement of brake release unit 4.5.2. Replacement of brake release unit Different designs Depending on the robot version, the brake release unit may be located either at the base or at the frame. The following two figures show the different locations. The early design includes a brake release unit with or without push buttons, located at the base.
  • Page 273 4 Repair 4.5.2. Replacement of brake release unit Continued Location of brake release unit, frame The later design includes a brake release unit with push buttons, placed together with the SMB unit on the left hand side of the frame as shown in the figure below. xx0200000226 Brake release unit Attachment screws, brake release unit (4 pcs)
  • Page 274 4 Repair 4.5.2. Replacement of brake release unit Continued Equipment, etc. Spare part no. Note Other tools and These procedures include references to the procedures may be tools required. required. See references to these procedures in the step-by-step instructions below. Removal of brake release unit, located at base The procedure below details how to remove the brake release unit, located at the rear of the base.
  • Page 275 4 Repair 4.5.2. Replacement of brake release unit Continued Action Note 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.
  • Page 276 4 Repair 4.5.2. Replacement of brake release unit Continued Refitting of brake release circuit, located at base The procedure below details how to refit the brake release circuit, located at the rear of the base. See the figure Location of brake release unit, base on page 270.
  • Page 277 4 Repair 4.5.2. Replacement of brake release unit Continued Action Note 3. Connect the connectors X8, X9 and X10 to the brake release unit. xx0200000129 A. Connector X8 B. Connector X9 C. Connector X10 D. Push buttons 4. Refit the SMB cover with its attachment screws. Shown in the figure Location of brake release unit, frame on page 271.

  • Page 278: Replacement Of Balancing Device

    4 Repair 4.5.3. Replacement of balancing device 4.5.3. Replacement of balancing device Location of balancing device The balancing device is located on rear top of the frame as shown in the figure below. xx0100000139 Balancing device Rear cover Support shaft inside (included in balancing device 3HAC14675-1) Attachment screws, rear cover Balancing device shaft, including screw and washer Bearing attachment...
  • Page 279 4 Repair 4.5.3. Replacement of balancing device Continued Attachment points, balancing device The attachment points for the lifting tools etc. are located as shown in the figure below. xx0600002653 Attachment hole for lifting eye, M12 Attachment hole for securing screw that secures the bearing attachment to the balancing device (protection plug fitted normally) Hole in frame to access the balancing device front eye shaft with the puller/press tool Attachment hole for locking screw that secures the lower arm to the frame...
  • Page 280 4 Repair 4.5.3. Replacement of balancing device Continued Required equipment Equipment Spare part no. Art. no. Note Balancing device 3HAC14214-1 Includes: • balancing device 3HAC14675-1 or 3HAC023018-001 • o-ring 3HAB3772- 44 (2 pcs) O-ring 3HAB3772-44 2 pcs , to be replaced if damaged! (included with the new balancing device) Locking screw...
  • Page 281 4 Repair 4.5.3. Replacement of balancing device Continued Equipment Spare part no. Art. no. Note Other tools and These procedures include procedures may be references to the tools required. See required. references to these procedures in the step-by-step instruc- tions below. Removal, balancing device The procedure below details how to remove the balancing device.
  • Page 282 4 Repair 4.5.3. Replacement of balancing device Continued Action Note 8. Apply the puller tool, balancing device shaft to Art. no. is specified in Required the shaft through the hole in the frame. equipment on page 278! The shaft has a M20 thread diameter, as shown The hole in the frame is shown in the in the figure to the right.
  • Page 283 4 Repair 4.5.3. Replacement of balancing device Continued Refitting, balancing device The procedure below details how to refit the balancing device. Action Note 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 284 4 Repair 4.5.3. Replacement of balancing device Continued Action Note 11. Secure the rear of the balancing device by Shown in the figure Location of fastening the two bearing attachments to the balancing device on page 276! frame with their four attachment screws. 4 pcs, M16x90, 12.9 quality UNBRAKO, tightening torque: 300 Reused screws may be used,...
  • Page 285 4 Repair 4.5.3. Replacement of balancing device Continued Action Note 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! 21.
  • Page 286 4 Repair 4.5.3. Replacement of balancing device Continued Action Note 2. Pull out the sealing spacers, but let them still remain on the ear. • Apply rust preventive abundantly in the • press the sealing back in place • wipe off surplus material. xx0600003131 •...

  • Page 287: Replacement Of Spherical Roller Bearing, Balancing Device

    4 Repair 4.5.4. Replacement of spherical roller bearing, balancing device 4.5.4. Replacement of spherical roller bearing, balancing device Location of bearing The bearing is located at the front ear of the balancing device, as shown in the figure below. xx0500002249 Spherical roller bearing Sealing ring O-ring...
  • Page 288 4 Repair 4.5.4. Replacement of spherical roller bearing, balancing device Continued Equipment Spare part no. Art. no. Note Toolkit 3HAC15943-1 Includes: • Threaded bar 3HAC15945-1 • Dolly 3HAC15948-1 • Press tool 3HAC15941-1 • Press tool 3HAC15846-1 • Hexagon nut M12 9ADA267-9 •...
  • Page 289 4 Repair 4.5.4. Replacement of spherical roller bearing, balancing device Continued Removal, bearing The procedure below details how to remove the bearing from the balancing device front ear. Action Note 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 290 4 Repair 4.5.4. Replacement of spherical roller bearing, balancing device Continued Action Note 3. Insert the threaded bar through the new Spare part no. is specified in bearing and place it at the front ear. Fit also the Required equipment on page 285.
  • Page 291 4 Repair 4.5.4. Replacement of spherical roller bearing, balancing device 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 3HAC022033-001 Revision: E...

  • Page 292: Unloading The Balancing Device

    4 Repair 4.5.5. Unloading the balancing device 4.5.5. Unloading the balancing device Prerequisite This section details how to unload the balancing device with the press tool. The lower arm must be secured before unloading the balancing device! How to secure the lower arm is detailed in the current repair activity, for example removal of the balancing device.
  • Page 293 4 Repair 4.5.5. Unloading the balancing device Continued Required equipment 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.
  • Page 294 4 Repair 4.5.5. Unloading the balancing device Continued Unloading the balancing device The procedure below details how to use the press tool in order to unload the balancing device. How to remove the press tool, is detailed in section Restoring the balancing device on page 294.
  • Page 295 4 Repair 4.5.5. Unloading the balancing device Continued Action Note 10. Turn the fix plate to position "Closed" in order See the figure Press tool and hydraulic to lock the tool in loaded condition. cylinder on page 290. 11. Unload the hydraulic cylinder. 12.

  • Page 296: Restoring The Balancing Device

    4 Repair 4.5.6. Restoring the balancing device 4.5.6. Restoring the balancing device Overview This section details how to restore the balancing device and how to remove the press tool from the 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.
  • Page 297 4 Repair 4.5.6. Restoring the balancing device Continued Equipment, etc. Art. no. Note Locking liquid Loctite 577 Used to secure the attachment screws of the rear cover at the end of the balancing device. Standard toolkit 3HAC15571-1 The content is defined in section Standard toolkit on page 394.
  • Page 298 4 Repair 4.5.6. Restoring the balancing device Continued Action Note 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! 3HAC022033-001 Revision: E...

  • Page 299: Motors

    4 Repair 4.6.1. Replacement of motor, axis 1 4.6 Motors 4.6.1. Replacement of motor, axis 1 Location of motor The motor axis 1 is located on the left hand side of the robotas shown in the figure below. xx0100000123 Motor, axis 1 Cable gland cover, motor axis Cover for connector access Motor attachment screws...
  • Page 300 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Equipment, etc. Spare part no. Art. no. Note Gasket 3HAC3438-1 Option Foundry Prime Must be replaced if the cabling is dismantled from the motor. Grease 3HAB3537-1 Used to lubricate the o- ring.
  • Page 301 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 3. Remove the cable gland cover at the cable exit by unscrewing its two attachment screws. NOTE! Make sure the gasket is not damaged! xx0200000199 • A: Cable gland cover 4.
  • Page 302 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 2. Make sure the o-ring on the circumference of the Art no. is specified in Required motor is seated properly. Lightly lubricate the o-ring equipment on page 297. with grease. CAUTION! The motor weighs 32 kg! All lifting equipment used must be sized accordingly!
  • Page 303 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Replacement of the motor axis 1 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level. The repair must be done according to the previous repair procedures with the following additions.
  • Page 304 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 5. Fill the four screw recesses on the new motor with Sikaflex. (After hardening, Sikaflex can be formed with a knife) xx0600002875 • A: Motor unit • B: Sikaflex in screw recesses 6.

  • Page 305: Replacement Of Motor Axis 2

    4 Repair 4.6.2. Replacement of motor axis 2 4.6.2. Replacement of motor axis 2 Location of motor The motor, axis 2, is located on the left hand side of the robot as shown in the figure below. xx0100000124 Motor, axis 2 Cable gland cover, motor axis 2 Hole for lock screw Required equipment...
  • Page 306 4 Repair 4.6.2. Replacement of motor axis 2 Continued Equipment, etc. Spare part no. Art. no. Note Locking screw 3HAA1001-266 M16 x 60 For securing the lower arm. Removal tool, motor 3HAC14973-1 Always use the removal M12x tools in pairs! Guide pins M10 x 3HAC15521-1 For guiding the motor.
  • Page 307 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note 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.
  • Page 308 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note CAUTION! The motor weighs 32 kg! All lifting equipment used must be sized accordingly! 15. Lift the motor to get the pinion away from the gear. Make sure the motor pinion does not get damaged! 16.
  • Page 309 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note 9. Use the rotation tool in order to rotate the Art. no. is specified in Required motor pinion when mating it to the gear (see equipment on page 303. the figure to the right).
  • Page 310 4 Repair 4.6.2. Replacement of motor axis 2 Continued Replacement of the motor axis 2 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level. The repair must be done according to the previous repair procedures with the following additions.
  • Page 311 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note DANGER! Secure the weight of the lower arm properly before releasing the brakes of motor, axis 2! When releasing the holding brakes of the motor, the lower arm will be movable and may fall down! 9.

  • Page 312: Replacement Of Motor, Axis 3

    4 Repair 4.6.3. Replacement of motor, axis 3 4.6.3. Replacement of motor, axis 3 Location of motor The motor axis 3 is located on the left hand side of the robot as shown in the figure below. xx0200000186 Motor axis 3 Cable gland cover, motor axis 3 Motor attachment holes (4 pcs) Required equipment...
  • Page 313 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Equipment, etc. Spare part no. Art. no. Note Guide pins M10 x 3HAC15521-1 For guiding the motor. Guide pins M10 x 3HAC15521-2 For guiding the motor. Extension 300mm 3HAC12342-1 for bits 1/2" Rotation tool 3HAC17105-1 Used to rotate the motor...
  • Page 314 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note 2. Unload the upper arm of the robot by either: • Move the robot to a position where the turning disk rests against the foundation (rec- ommended). • Use a fork lift to rest the upper arm onto. •...
  • Page 315 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note CAUTION! The motor weighs 32 kg! All lifting equipment used must be sized accordingly! 15. Lift the motor to get the pinion away from the gear. 16. Remove the motor by gently lifting it straight out and Make sure the motor pinion is not disconnect the brake release voltage.
  • Page 316 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note 9. Use the rotation tool in order to rotate the motor Art no. is specified in Required pinion when mating it to the gear! equipment on page 310. Fit the motor, making sure the motor pinion is Make sure the motor pinion does not properly mated to the gear of gearbox, axis 3.
  • Page 317 4 Repair 4.6.3. Replacement of motor, axis 3 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 Replacement of the motor axis 3 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level.
  • Page 318 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note NOTE! Keep the old top cover with the air nipple mounted. 5. Continue removal of the motor unit, according to step 6 and forwards in section Removal, motor on page 311.

  • Page 319: Replacement Of Motor, Axis 4

    4 Repair 4.6.4. Replacement of motor, axis 4 4.6.4. Replacement of motor, axis 4 Location of motor The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below. xx0200000202 Motor, axis 4 Cable gland cover, motor axis 4 Motor attachment holes (4 pcs) Required equipment...
  • Page 320 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Equipment, etc. Spare part no. Art. no. Note Guide pins M10 x 3HAC15521-1 For guiding the motor. Guide pins M10 x 3HAC15521-2 For guiding the motor. Extension 300mm 3HAC12342-1 for bits 1/2" Rotation tool 3HAC17105-1 Used to rotate the motor...
  • Page 321 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note 3. In horizontal position: unload the upper arm to avoid movement of the axis, with one of the given methods: • move the upper arm to a position where the turning disk rests against the foundation (recommended) •...
  • Page 322 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Refitting, motor axis 4 The procedure below details how to refit motor, axis 4. Action Note 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 323 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note 8. Use the rotation tool in order to rotate the Art. no. is specified in Required motor pinion when mating it to the gear! equipment on page 317. Fit the motor, making sure the motor pinion Make sure the motor pinion does not get is properly mated to the gear, axis 4.
  • Page 324 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Replacement of the motor axis 4 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level. The repair must be done according to the previous repair procedures with the following additions.
  • Page 325 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note 5. Fill the four screw recesses on the new motor with Sikaflex. (After hardening, Sikaflex can be formed with a knife) xx0600002875 • A: Motor unit • B: Sikaflex in screw recesses 6.

  • Page 326: Replacement Of Motor, Axis 5

    4 Repair 4.6.5. Replacement of motor, axis 5 4.6.5. Replacement of motor, axis 5 Location of motor The motor axis 5 is located in the rear of the wrist unit as shown in the figure below. Notice that the left hand side cover already is removed in the figure! xx0100000127 Motor, axis 5 Cable gland cover, motor axis 5...
  • Page 327 4 Repair 4.6.5. Replacement of motor, axis 5 Continued Equipment, etc. Spare part no. Art. no. Note Calibration Pendulum 3HAC15716-1 Complete kit that also toolkit includes operating manual. Other tools and These procedures include procedures may be references to the tools required.
  • Page 328 4 Repair 4.6.5. Replacement of motor, axis 5 Continued Action Note 12. Fit the two guide pins in two of the motor attachment Art. no. is specified in Required screw holes. equipment on page 324. 13. If required, press the motor out of position by fitting Art.
  • Page 329 4 Repair 4.6.5. Replacement of motor, axis 5 Continued Action Note 8. If necessary, use the rotation tool in order to rotate Art. no. is specified in Required the motor pinion when mating it to the gear! equipment on page 324.

  • Page 330: Replacement Of Motor, Axis 6

    4 Repair 4.6.6. Replacement of motor, axis 6 4.6.6. Replacement of motor, axis 6 Location of motor The motor axis 6 is located in the center of the wrist unit as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views on page 429 xx0100000128...
  • Page 331 4 Repair 4.6.6. Replacement of motor, axis 6 Continued Equipment, etc. Spare part no. Art. no. Note Power supply 24 VDC, 1.5 A For releasing the brakes. Grease 3HAB3537-1 For lubricating the o-ring. Standard toolkit The content is defined in section Standard toolkit on page...
  • Page 332 4 Repair 4.6.6. Replacement of motor, axis 6 Continued Action Note 7. Remove the motor by unscrewing its four Art. no. is specified in Required attachment screws and plain washers. equipment on page 328. If required, use the extension 300mm for bits 1/2". 8.
  • Page 333 4 Repair 4.6.6. Replacement of motor, axis 6 Continued Action Note 13. 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. DANGER! Make sure all safety requirements are met when performing the first test run.
  • Page 334 4 Repair 4.6.6. Replacement of motor, axis 6 Continued Action Note 4. Remove the rear motor cover by unscrewing the five attachment screws. xx0600002885 • A: Motor unit • B: Attachment screw (5 pcs) • C: Air nipple • D: Rear motor cover •...
  • Page 335 4 Repair 4.6.6. Replacement of motor, axis 6 Continued Action Note 7. Fill the four screw recesses on the new motor with Sikaflex. (After hardening, Sikaflex can be formed with a knife) xx0600002884 • A: Mercasol 3106 • B: Motor unit •...

  • Page 336: Gearboxes

    4 Repair 4.7.1. Replacement of gearbox, axis 1 4.7 Gearboxes 4.7.1. Replacement of gearbox, axis 1 Location of gearbox The axis 1 gearbox is located between the frame and base as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views on page 429 xx0100000133...
  • Page 337 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Equipment, etc. Spare part no. Art. no. Note O-ring 3HAB3772-55 Replace only when damaged! Sealing ring 3HAC11581-4 Replace only when damaged! Grease 3HAC3537-1 For lubricating the o-rings. Brush Option Foundry Prime Rust preventive 3HAC026621-001 Mercasol 3106 (Option...
  • Page 338 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note 4. Disconnect all cabling in the rear of the robot base and remove the cable support plate inside of the base. 5. Pull the disconnected cabling up through the center of gearbox 1. 6.
  • Page 339 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note 13. Unscrew the 18 attachment screws and remove the 3 washers, shown in the figure to the right. xx0200000227 A view from below: • A: Oil drain hose • B: Attachment screws, gearbox axis 1, 18 pcs •...
  • Page 340 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note 2. Make sure the two o-rings (C, D) on the cir- Art no. is specified in Required cumference of the gearbox are seated equipment on page 334. properly in their grooves respectively. Lubricate them with grease .
  • Page 341 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note 8. Secure the gearbox and the three washers 18 pcs, M16 x 90, 12.9 quality with the 18 attachment screws, gearbox axis UNBRAKO, tightening torque: 300 Nm. Reused screws may be used, providing they are lubricated as detailed in section Screw joints on page 390...
  • Page 342 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note 13. Refit the complete arm system. Detailed in section Refitting of complete system. This is a complex task to be performed with utmost care in order to avoid injury or damage! 14.
  • Page 343 4 Repair 4.7.1. Replacement of gearbox, axis 1 Continued Action Note 2. Apply Mercasol 3106 on unpainted areas. xx0600003132 • A: Surface on the underside of the frame • B: Radial sealing gear axis 1, against base DANGER! Make sure all safety requirements are met when performing the first test run.

  • Page 344: Replacement Of Gearbox, Axis 2

    4 Repair 4.7.2. Replacement of gearbox, axis 2 4.7.2. Replacement of gearbox, axis 2 Location of gearbox The axis 2 gearbox is located in the lower arm rotational center as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
  • Page 345 4 Repair 4.7.2. Replacement of gearbox, axis 2 Continued Equipment, etc. Spare part no. Art. no. Note Grease 3HAB3537-1 For lubricating the o-ring. Standard toolkit The content is defined in section Standard toolkit on page 394. Lifting tool, gearbox axis 2 3HAC12731-1 Fixture lower arm 3HAC13660-1...
  • Page 346 4 Repair 4.7.2. Replacement of gearbox, axis 2 Continued Action Note 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.
  • Page 347 4 Repair 4.7.2. Replacement of gearbox, axis 2 Continued Action Note 10. Remove the 30 rear gearbox attachment screws (A) from inside the lower section of the lower arm. xx0300000064 11. Remove the motor attachment by unscrewing the Shown in the figure Location of front gearbox attachment screws.
  • Page 348 4 Repair 4.7.2. Replacement of gearbox, axis 2 Continued Action Note 18. Remove the sealing from the lower arm. On reassembly a new sealing must be used! Art. no. is specified in the refitting instructions Required equipment on page 342! Refitting, gearbox axis 2 The procedure below details how to refit the gearbox, axis 2.
  • Page 349 4 Repair 4.7.2. Replacement of gearbox, axis 2 Continued Action Note 6. Make sure the o-ring is fitted to the rear of the Art. no. is specified in Required gearbox. Lightly grease the o-ring. equipment on page 342. xx0100000136 A. O-ring, gearbox, axis 2 7.
  • Page 350 4 Repair 4.7.2. Replacement of gearbox, axis 2 Continued Action Note 13. Insert and secure 28 of the 30 attachment screws on the inside of the lower arm. xx0300000064 Tightening torque: 300 Nm. Reused screws may be used, providing they are lubricated as detailed in section Screw joints on page 390...

  • Page 351: Replacement Of Gearbox, Axis 3

    4 Repair 4.7.3. Replacement of gearbox, axis 3 4.7.3. Replacement of gearbox, axis 3 Location of gearbox The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
  • Page 352 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Equipment, etc. Spare part no. Art. no. Note O-ring 3HAB3772-68 1 pc on the gearbox. 3HAB3772-51 Grease 3HAB3537-1 For lubricating the o-rings. Brush Option Foundry Prime Rust preventive 3HAC026621-001 Option Foundry Prime Equivalent: •...
  • Page 353 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Removal, gearbox axis 3 The procedure below details how to remove gearbox, axis 3. Action Note 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 354 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note 9. Fit the lifting eye to the gearbox, in one of the Art. no. is specified in Required attachment screw holes that attaches the gearbox equipment on page 349. to the lower arm .
  • Page 355 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note 6. Make sure the o-ring is fitted to the rear of the Art. no. is specified in Required gearbox. Apply grease to it to make sure it sticks equipment on page 349.
  • Page 356 4 Repair 4.7.3. Replacement of gearbox, axis 3 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 Refitting, gearbox axis 3 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level.

  • Page 357: Replacement Of Gearbox, Axis 4

    4 Repair 4.7.4. Replacement of gearbox, axis 4 4.7.4. Replacement of gearbox, axis 4 Location of gearbox The axis 4 gearbox is located at the rear of the upper arm as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
  • Page 358 4 Repair 4.7.4. Replacement of gearbox, axis 4 Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Gear axis 4 3HAC17810-1 Includes all o-rings! O-ring 3HAB3772-49 Replace if damaged! O-ring 3HAB3772-50 Replace if damaged! Friction washer 3HAC10122-27 2 pcs. Must be replaced at assembly! Gasket, cover axis 4 3HAC11423-3...
  • Page 359 4 Repair 4.7.4. Replacement of gearbox, axis 4 Continued Action Note 6. Loosen the gear attachment screws but do not Shown in the figure Location of remove the gear Z3. gearbox on page 355. 7. Remove the motor, axis 4. Detailed in section Removal, motor axis 4 on page...
  • Page 360 4 Repair 4.7.4. Replacement of gearbox, axis 4 Continued Action Note 5. Fit two new friction washers onto the guide pins. Spare part no. is specified in Required equipment on page 356. NOTE! Make sure the surface beneath the friction washers is clean and dry! 6.
  • Page 361 4 Repair 4.7.4. Replacement of gearbox, axis 4 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 3HAC022033-001 Revision: E...

  • Page 362: Replacement Of Gearbox, Axis 5

    4 Repair 4.7.5. Replacement of gearbox, axis 5 4.7.5. Replacement of gearbox, axis 5 Location of gearbox The axis 5 gearbox is located in the wrist unit as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
  • Page 363 4 Repair 4.7.5. Replacement of gearbox, axis 5 Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Gear axis 5 3HAC17810-1 Includes all o-rings! O-ring 3HAB3772-49 Replace if damaged! O-ring 3HAB3772-50 Replace if damaged! Friction washer 3HAC10122-27 2 pcs. Must be replaced at assembly! VK-cover 3HAA2166-24...
  • Page 364 4 Repair 4.7.5. Replacement of gearbox, axis 5 Continued Action Note 3. Drain the oil from the secondary gearbox. Detailed in section Oil change, gearbox, axis 5 on page 194. 4. Remove the motor, axis 5. Detailed in section Replacement of motor, axis 5 on page 324.
  • Page 365 4 Repair 4.7.5. Replacement of gearbox, axis 5 Continued Action Note 5. Remove the attachment screws, gear Z4. 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 6.
  • Page 366 4 Repair 4.7.5. Replacement of gearbox, axis 5 Continued Action Note 7. Secure the gearbox with 16 of the 18 attachment 18 pcs: M10 x 40: tightening screws and washers. torque: 65 Nm. Shown in the figure Location of gearbox on page 360.
  • Page 367 4 Repair 4.7.5. Replacement of gearbox, axis 5 Continued Refitting, wheel unit The procedure below details how to refit the wheel unit. Action Note 1. Clean the wheel unit and the tube mating surfaces. 2. Lubricate packing box with grease. Art.

  • Page 368: Replacement Of Gearbox, Axis 6

    4 Repair 4.7.6. Replacement of gearbox, axis 6 4.7.6. Replacement 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 Gearbox, axis 6 Attachment screws, gearbox Washers Oil plug, filling...
  • Page 369 4 Repair 4.7.6. Replacement of gearbox, axis 6 Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Gear axis 6 3HAC17811-1 Includes o-ring 3HAB3772- Washers 3HAC10122-13 Not included in the gearbox. Replace if damaged! O-ring 3HAB3772-49 Must be replaced when reas- sembling gearbox! 3HAB3772-64 3HAB3772-61...
  • Page 370 4 Repair 4.7.6. Replacement of gearbox, axis 6 Continued Action Note 5. If required, fit the removal tool, motor M10 to the holes shown in the figure to press it free. xx0200000220 • A: M10 holes for pressing out the gearbox 6.
  • Page 371 4 Repair 4.7.6. Replacement of gearbox, axis 6 Continued Action Note 2. Make sure the o-ring is fitted to the rear of Art. no. is specified in Required equipment the gearbox. Lubricate the o-ring with on page 367. grease. xx0100000132 •...
  • Page 372 4 Repair 4.7.6. Replacement of gearbox, axis 6 Continued Action Note 7. If the robot is going to work in a water jet application cell: • apply Mercasol 3106 on unpainted surfaces between gearbox and turning disk • apply Mercasol 3106 on the screw heads in the front of the turning disk.

  • Page 373: 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 372, and further detailed in separate Calibration manuals.

  • Page 374: 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 375 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 376: Calibration Scales And Correct Axis Position

    5 Calibration information 5.3. Calibration scales and correct axis position 5.3. Calibration scales and correct axis position Introduction This section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration scales/marks, IRB 6600, IRB 6650, IRB 6650S, IRB 7600 The illustration below shows the location of the calibration scales on specific plates and the calibration marks directly in the casting at axes 2 and 3.

  • Page 377: Calibration Movement Directions For All Axes

    5 Calibration information 5.4. Calibration movement directions for all axes 5.4. Calibration movement directions for all axes Overview When calibrating, the axis must consistently be run towards 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.

  • Page 378: Updating Revolution Counters

    5 Calibration information 5.5. Updating revolution counters 5.5. Updating revolution counters General This section details how to perform a rough calibration of each robot axis, that is updating the revolution counter value for each axis, using the pendant. Step 1 - Manually running the robot to the calibration position This procedure details the first step when updating the revolution counter;...
  • Page 379 5 Calibration information 5.5. Updating revolution counters Continued Step 2 - Storing the revolution counter setting with the TPU This section details the second step when updating the revolution counter; storing the revolution counter setting with the TPU (RobotWare 4.0). Action Note 1.
  • Page 380 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 381 5 Calibration information 5.5. Updating revolution counters Continued Action 4. Select the axis to have its revolution counter updated by: • Ticking in the box to the left • Tapping Select all to update all axes. Then tap Update. 5. A dialog box is displayed, warning that the updating operation cannot be undone: •...

  • Page 382: 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 383 This section describes how to jog the robot to all axes zero position. 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.
  • Page 384 5 Calibration information 5.6. Checking the calibration position 3HAC022033-001 Revision: E...

  • Page 385: Decommissioning

    6 Decommissioning 6.1. Environmental information 6 Decommissioning 6.1. Environmental information Hazardous material The table specifies some of the materials in the robot and their respective use throughout the product. Dispose the components properly to prevent health or environmental hazards. Material Example application Batteries, NiCad or Lithium Serial measurement board...

  • Page 386: Decommissioning Of Balancing Device

    6 Decommissioning 6.2. Decommissioning of balancing device 6.2. Decommissioning of balancing device General There is much energy stored in the balancing device. Therefore a special procedure is required to dismantle it. The coil springs inside the balancing device exert a potentially lethal force unless dismantled properly.
  • Page 387 6 Decommissioning 6.2. Decommissioning of balancing device Continued Decommissioning at decommissioning company, balancing device The instruction below details how to decommission the balancing device. Contact ABB Robotics for further consultation. Action Note DANGER! There is stored energy built up by high...
  • Page 388 6 Decommissioning 6.2. Decommissioning of balancing device 3HAC022033-001 Revision: E...

  • Page 389: Reference Information

    7 Reference information 7.1. Introduction 7 Reference information 7.1. Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. 3HAC022033-001 Revision: E...

  • Page 390: Applicable Safety Standards

    7 Reference information 7.2. Applicable Safety Standards 7.2. Applicable Safety Standards Standards, general The robot is designed in accordance with the requirements of: • EN ISO 10218-1: 2006 Robots for industrial environments - Safety requirements - Part 1 Robot. • EN 292-1 - Basic terminology.

  • Page 391: Unit Conversion

    7 Reference information 7.3. Unit conversion 7.3. 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 392: 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 393 7 Reference information 7.4. 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 descriptions.
  • Page 394 7 Reference information 7.4. Screw joints Continued The table below specifies the recommended standard tightening torque for oil-lubricated screws with Allen head screws. Tightening torque Tightening torque Tightening torque (Nm) (Nm) (Nm) Dimension Class 8.8, oil-lubri- Class 10.9, oil-lubri- Class 12.9, oil-lubri- cated cated cated...

  • Page 395: 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 396: Standard Toolkit

    7 Reference information 7.6. Standard toolkit 7.6. 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 397: Special Tools

    7 Reference information 7.7. Special tools 7.7. 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 394, and of special tools, listed directly in the instructions and also gathered in this section.
  • Page 398 3HAC15943-1 Tools that may be rented The table below specifies the tools that may be rented from ABB in order to perform certain service procedures as described in the Product manual. The special tools are also listed directly in the instructions.
  • Page 399 7 Reference information 7.7. Special tools Continued Description Art. no. Note Measuring pin 3HAC13908-5 Sensor fixture 68080011-GM Sensor plate 3HAC0392-1 Sync. adapter 3HAC13908-1 Turn disk fixture 3HAC68080011-GU Calibration equipment, Calibration Pendulum The table below specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method.

  • Page 400: Lifting Equipment And Lifting Instructions

    7 Reference information 7.8. Lifting equipment and lifting instructions 7.8. 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 401: Spare Part / Part List

    8 Spare part / part list 8.1. Introduction 8 Spare part / part list 8.1. Introduction Definitions This chapter specifies all spare parts and replacement articles of the robot. 3HAC022033-001 Revision: E...

  • Page 402: Spare Parts

    8 Spare part / part list 8.2.1. Introduction 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. 3HAC022033-001 Revision: E...

  • Page 403: Spare Part List

    8 Spare part / part list 8.2.2. Spare part list 8.2.2. Spare part list Spare part list The list below specifies all the recommended spare parts for the robot. The item numbers given within parenthesis in the column Note refer to the exploded views in the chapter Exploded views on page 429.
  • Page 404 8 Spare part / part list 8.2.2. Spare part list Continued 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.

  • Page 405: Part List

    8 Spare part / part list 8.3.1. Introduction 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: Rebuilding Parts

    8 Spare part / part list 8.3.2. Rebuilding parts 8.3.2. Rebuilding parts Overview The robot has some rebuilding parts that differ from eachother, depending on the version of the robot. The table below is a general overview of which parts belongs to which versions. Rebuilding parts 500/ 400/...

  • Page 407: Part List, Overview

    8 Spare part / part list 8.3.3. Part list, overview 8.3.3. Part list, overview Overview The table below contains an overview of the parts of the robot. They are further specified in the referred sections and shown in the exploded views according to the item numbers. Item Qty Art.
  • Page 408 8 Spare part / part list 8.3.3. Part list, overview Continued Item Qty Art. number Description Note / Dimension 3HAC16628-4 Wrist See section Wrist, 3HAC16628-4 / (spare part no.) 3HAC16628-3 on page 415. 3HAC16628-3 Wrist Insulated tool flange. (spare part no.) See section Wrist, 3HAC16628-4 /...

  • Page 409: Mechanical Stop Axis 1, 3Hac12812-2

    8 Spare part / part list 8.3.4. Mechanical stop axis 1, 3HAC12812-2 8.3.4. Mechanical stop axis 1, 3HAC12812-2 Part list Item Art. number Description Dimension 3HAC12812-1 Mechanical stop 9ABA142-92 Spring pin, slotted 10 x 30 3HAC022033-001 Revision: E...

  • Page 410: Base Incl Frame Axis 1, 3Hac12304-1

    8 Spare part / part list 8.3.5. Base incl frame axis 1, 3HAC12304-1 8.3.5. Base incl frame axis 1, 3HAC12304-1 Part list Item Qty Art. number Description Note 101.1 3HAC10044-1 Base, machining See section below. 101.2 3HAC12303-1 Frame incl ax 1 gearbox See section below.

  • Page 411: Axis 3-4, 3Hac13063-1 (Irb 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/2.55)

    8 Spare part / part list 8.3.6. Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/2.55) 8.3.6. Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/ 2.55) Part list Item Art. no. Description Note 102.1 3HAC022181-001 Material set ax 4 See table...
  • Page 412 8 Spare part / part list 8.3.6. Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/2.55) Continued Item Art. number Description Note / Dimension 102.1.22 1 3HAC022620-001 Spacer ring 102.1.23 1 3HAC11461-1 Sealing 102.1.24 1 3HAC17219-1 Thrust washer 102.1.25 1 9ABA135-45 Retaining ring, shaft...
  • Page 413 8 Spare part / part list 8.3.6. Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/2.55) Continued Cover axis 4, 3HAC11423-4 Item Art. number Description Note 102.1.9.1.1 3HAC11423-1 Cover axis 4, machined 102.1.9.1.2 3HAC11423-3 Gasket cover axis 4 Tube shaft 2,55, 3HAC10509-1 Item Art.

  • Page 414: Axis 3-4, 3Hac13063-2 (Irb 7600 - 500/2.3)

    8 Spare part / part list 8.3.7. Axis 3-4, 3HAC13063-2 (IRB 7600 - 500/2.3) 8.3.7. Axis 3-4, 3HAC13063-2 (IRB 7600 - 500/2.3) Part list Item Art. number Description Note 102.1 3HAC022181-001 Material set ax 4 See table Material set axis 4, 3HAC022181-001 on page 409.

  • Page 415: Axis 3-4, Foundry, 3Hac13063-4 (Irb 7600 -150/3.5, - 325/3.1, - 340/2.8, - 400/2.55, - 500/2.55)

    8 Spare part / part list 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) 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) Part list Item Art.

  • Page 416: Axis 3-4 Foundry, 3Hac13063-5 (Irb 7600 - 500/2.3)

    8 Spare part / part list 8.3.9. Axis 3-4 Foundry, 3HAC13063-5 (IRB 7600 - 500/2.3) 8.3.9. Axis 3-4 Foundry, 3HAC13063-5 (IRB 7600 - 500/2.3) Part list Item Art. no. Description Note 102.1 3HAC022181-001 Material set ax 4 See table Material set axis 4, 3HAC022181-001 on page 409.

  • Page 417: Wrist, 3Hac16628-4 / 3Hac16628-3

    8 Spare part / part list 8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3 8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3 Part list Item Art. number Description Note / Dimension 103.1 3HAC11409-7 Cover, right See table Cover, right, 3HAC11409-7 on page 417. 103.2 3HAC11409-6 Shoulder Screw M6x8x8 103.5 3HAC16721-1...
  • Page 418 8 Spare part / part list 8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3 Continued Item Art. number Description Note / Dimension 103.28 3HAC024852-002 Axis 6 complete Foundry See table Axis 6 complete Foundry and 3HAC024852-001 Axis 6 complete standard standard, 3HAC024852-002 / 3HAC024852-001 on page 417.
  • Page 419 Only for the insulated wrist! See table Axis 6, insulated, 3HAC024924-001 on page 419. 103.100 2 3HAC021480-001 Label 103.101 2 3HAC17765-1 ABB-logotype Cover, right, 3HAC11409-7 Item Art. number Description Note 103.1.1 3HAC11409-1 Cover, right machining 103.1.2 3HAC11409-5 Gasket RV 125F-97,909 assembly, 3HAC17810-1 Item Art.
  • Page 420 8 Spare part / part list 8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3 Continued Item Art. number Description Note / Dimension 103.28.7 2522122-1 Magnetic plug R1/4" 103.28.8 3HAC11471-1 Sync. Plate 103.28.9 21522012-433 O-ring 104,5x3 103.28.10 2 9ADA618-32 Torx pan head screw M4x8 103.28.11 6 3HAB7116-1 Locking liquid...
  • Page 421 8 Spare part / part list 8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3 Continued Item Art. number Description Note 103.28.10.18 3HAC11471-1 Sync. Plate 103.28.10.19 9ADA618-32 Torx pan head screw Steel 8.8-A2F, M4x8 103.28.10.20 2522122-1 Magnetic plug 103.28.10.21 3HAA2166-27 VK-cover 103.28.10.22 21520441-1 Washer Wheel unit, tightened, 3HAC022184-001 Item Art.

  • Page 422: Material Set Robot, 3Hac13079-1

    8 Spare part / part list 8.3.11. Material set robot, 3HAC13079-1 8.3.11. Material set robot, 3HAC13079-1 Part list Item Art. number Description Note 108.201 3HAC17213-1 Sealing axis 2/3 108.202 3HAB3409-84 Hex socket head cap screw M16x50 108.203 3HAC11828-1 Washer axis 3 108.204 3HAA1001-186 Washer...

  • Page 423: Material Set Axis 1-2, 3Hac13077-1

    Rot ac motor incl pinion See table Rot ac motor incl pinion, 3HAC14723-1 on page 423. 109.307 1 3HAC025752-001 Rot. AC motor incl. IRB 7600 - 500/2.55 pinion See table Rot. AC motor incl. pinion, 3HAC025752-001 on page 423. 109.307 1...
  • Page 424 8 Spare part / part list 8.3.12. Material set axis 1-2, 3HAC13077-1 Continued Item Art. number Description Note / Dimension 109.331 1 3HAC13152-1 Bracket SMB 109.332 1 3HAC14791-3 Cover battery box See table Cover battery box, 3HAC14791-3 on page 423. 109.334 6 9ADA618-53 Torx pan head screw...
  • Page 425 8 Spare part / part list 8.3.12. Material set axis 1-2, 3HAC13077-1 Continued RV 700F-269,21 assembly, 3HAC17272-1 Item Art. number Description Note 109.301.1.1 3HAC10122-21 RV 700F, i=269,21 109.301.1.2 3HAB3772-51 O-ring Rot ac motor incl pinion, 3HAC14723-1 Item Art. number Description Note 109.306.1 3HAC17484-1...

  • Page 426: Material Set Balancing Device, 3Hac13082-1

    8 Spare part / part list 8.3.13. Material set balancing device, 3HAC13082-1 8.3.13. Material set balancing device, 3HAC13082-1 Part list Item Art. number Description Note 110.401 3HAC4310-1 Sealed spherical bearing 110.402 3HAC13124-1 Thrust washer 110.403 3HAC13122-1 Bushing 110.404 9ABA135-32 Retaining ring, shaft 110.405 3HAC13123-1 Shaft...

  • Page 427: Arm Extension Set, 956 Mm, 3Hac12311-1 (Irb 7600 - 150/3.5)

    8 Spare part / part list 8.3.14. Arm extension set, 956 mm, 3HAC12311-1 (IRB 7600 - 150/3.5) 8.3.14. Arm extension set, 956 mm, 3HAC12311-1 (IRB 7600 - 150/3.5) Part list Item Art. number Description Dimension 111.501 3HAC9760-5 Arm extender 956 mm 111.501 3HAC15932-4 Arm extender 956 mm, Foundry...

  • Page 428: Arm Extension Set, 250 Mm, 3Hac12311-2 (Irb 7600 - 340/2,8)

    8 Spare part / part list 8.3.15. Arm extension set, 250 mm, 3HAC12311-2 (IRB 7600 - 340/2,8) 8.3.15. Arm extension set, 250 mm, 3HAC12311-2 (IRB 7600 - 340/2,8) Part list Item Art. number Description Dimension 111.501 3HAC9760-1 Arm extender 250 mm 111.501 3HAC15932-3 Arm extender 250 mm Foundry...

  • Page 429: Arm Extension Set, 500 Mm, 3Hac12311-3 (Irb 7600 - 325/3,1)

    8 Spare part / part list 8.3.16. Arm extension set, 500 mm, 3HAC12311-3 (IRB 7600 - 325/3,1) 8.3.16. Arm extension set, 500 mm, 3HAC12311-3 (IRB 7600 - 325/3,1) Part list Item Qty Art. number Description Dimension 111.501 3HAC9760-1 Arm extender 250 mm 111.501 3HAC15932-3 Arm extender 250 mm, Foundry...
  • 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...

  • Page 431: Exploded Views

    9 Exploded views 9.1. Introduction 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: •...

  • Page 432: Base Incl. Frame

    9 Exploded views 9.2. Base incl. Frame 9.2. Base incl. Frame Exploded view xx0200000329 3HAC022033-001 Revision: E...

  • Page 433: Frame-Lower Arm 1

    9 Exploded views 9.3. Frame-Lower arm 1 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) 3HAC022033-001 Revision: E...

  • Page 434: Frame-Lower Arm 2

    9 Exploded views 9.4. Frame-Lower arm 2 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) 3HAC022033-001 Revision: E...

  • Page 435: Upper Arm

    9 Exploded views 9.5. Upper arm 9.5. Upper arm Exploded view xx0200000333 3HAC022033-001 Revision: E...

  • Page 436: Wrist Complete

    9 Exploded views 9.6. Wrist complete 9.6. Wrist complete Exploded view xx0200000332 3HAC022033-001 Revision: E...

  • Page 437: Circuit Diagram

    10 Circuit Diagram 10.1. Introduction 10 Circuit Diagram 10.1. Introduction Overview This chapter includes the circuit diagram for the robot. 3HAC022033-001 Revision: E...

  • Page 438: Circuit Diagram 3Hac025744-001

    10 Circuit Diagram 10.2.1. Validity of circuit diagram 3HAC025744-001 10.2 Circuit diagram 3HAC025744-001 10.2.1. Validity of circuit diagram 3HAC025744-001 Is this circuit diagram valid 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.

  • Page 439: Circuit Diagram 3Hac13347-1

    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 must not be reproduced or copied without ABB's written permission, and contents therof must not be imparted to a third party nor be used for any unauthorized purpose.
  • Page 440 Table of contents ABB Contents1 Page Page description Comment COPYRIGHT page Table of contents: (1 - 150) Valid For Connection point location IRB 6600 / 6640 / 6650 / 7600 Connection point location IRB 6660 Legend IRB 66XX / 7600...

  • Page 441: Index

    Valid For: This circuit diagram is valid for the following cable harness assemblies: 3HAC 024385-001 Manipulator harness axis 1-6 (IRB 6600 / 6640) 3HAC 024386-001 Manipulator harness axis 1-6 (IRB 6640 / 6650 / 6650S) 3HAC14940-1 rev 3 and later. Manipulator harness axis 1-4 (IRB 6600 ID / 6640 ID / 7600) 3HAC16331-1 rev 1 and later.
  • Page 442 R3.FB5 (IRB 7600, 6600 ID, 6640 ID, 6650 ID) R3.MP5 (IRB 7600, 6600 ID, 6640 ID, 6650 ID) R1.MP R2.M5/6 R3.MP6 R3.MP5 (IRB 6600, 6640, 6650, 6650S) (On IRB7600, 6600 ID, R3.FB6 R3.FB5 (IRB 6600, 6640, 6650, 6650S) 6640 ID, 6650 ID) R4.MP5 (IRB 6600, 6640, 6650, 6650S) R4.FB5 (IRB 6600, 6640, 6650, 6650S) R2.MP4...
  • Page 443 R3.MP6 R3.FB6 R3.MP5 R3.FB5 R2.CP/CS R2.MP4 R2.FB4 R2.MP3 R2.FB3 R2.H1 R2.H2 R2.MP2 R2.FB2 R2.MP1 R2.FB1 R1.SMB1-3 R1.SMB4-6 R2.SMB R1.MP R1.SMB R1.CP/CS Lab/Office: Latest revision: Status: Plant: IRB6660 Location: Manipulator APPROVED Connection point location Sublocation: Document no. Rev. Ind Page 5 Next 3HAC025744-001 IRB 6660...
  • Page 444 Motor Protective Earth Brake Twisted wires Temp sensor (PTC- resistor) Screened wires Resolver Any number i.e. 66XX can be 6600, 6640, 6660 or 6650 Battery Pack Brake Release Unit Feedback unit Serial Measurment Board Position switch Keypin Location pin to avoid mismatch Lab/Office: Latest revision: Status:...

  • Page 445: Brake Release Unit

    BU Brake Release (Simplified) -R1.MP Brake Release -X10 -X10 R1.MP -BU M1 / +Axis 1/30;2 Brake PB Brake Bleed Circuit -BU 0V M1 / +Axis 1/30;2 R1.MP -BU M2 / +Axis 2/40;2 -BU 0V M2 / +Axis 2/40;2 -BU 0V M3 / +Axis 3/50;2 Brake Bleed Circuit -BU 0V M4 / +Axis 4/60;2 R1.MP...

  • Page 446: Serial Measuring Board

    +Axis 3/50;3 / -0V EXT.LAMP R1.SMB R2.SMB R2.SMB SDI-N WHBK SDO-N WHBN WHRD KEYPIN +Axis 3/50;3 / -24V EXT.LAMP R2.G R1.G(X3) R1.G(X3) Lab/Office: Latest revision: Status: 2005-10-17 Plant: 66XX/7600 Location: APPROVED Serial Measuring Board Sublocation: Document no. Rev. Ind Page 20 Next 3HAC025744-001 IRB 66XX / 7600...
  • Page 447 R1.MP -R2.MP1 -R2.MP1 R (U) T (W) S (V) GNYE GNYE GNYE GNYE +BU/10;7 / -BU M1 BU M1 BU + Brake +BU/10;2 / -BU 0V M1 BU 0V M1 BU - -PTC1 PTC M +Axis 2/40;2 / -PTC M2 PTC M2 R1.SMB1-3 R1.SMB1-3...
  • Page 448 R1.MP -R2.MP2 -R2.MP2 R (U) T (W) S (V) GNYE GNYE GNYE GNYE +BU/10;7 / -BU M2 BU M2 BU + Brake +BU/10;2 / -BU 0V M2 BU 0V M2 BU - -PTC2 +Axis 1/30;2 / -PTC M2 PTC M2 +Axis 3/50;2 / -PTC M3 PTC M3 R1.SMB1-3...
  • Page 449 R1.MP -R2.MP3 -R2.MP3 R (U) T (W) S (V) GNYE GNYE GNYE GNYE +BU/10;7 / -BU M3 BU M3 BU + Brake +BU/10;2 / -BU 0V M3 BU 0V M3 BU - -PTC3 +Axis 2/40;2 / -PTC M3 PTC M3 +Axis 4/60;2 / -PTC M4 PTC M4 KEYPIN...
  • Page 450 R1.MP -R2.MP4- -R2.MP4- R (U) T (W) S (V) GNYE GNYE +BU/10;7 / -BU M4 BU M4 BU + Brake +BU/10;2 / -BU 0V M4 BU 0V M4 BU - -PTC4 +Axis 3/50;2 / -PTC M4 PTC M4 =7600+Axis 5/70;2 PTC M5 =66XX+Axis 5/80;2 A Keypin...
  • Page 451 R1.MP R2.M5/6 -R3.MP5 -R3.MP5- R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M5 BU M5 BU M5 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M5 BU 0V M5 BU 0V M5 BU - -PTC5 =66XX/7600+Axis 4/60;2 / -PTC M5 PTC M5 PTC M5 PTC 0V...
  • Page 452 R1.MP R3.MP5 -R4.MP5- -R4.MP5- R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M5 BU M5 BU M5 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M5 BU 0V M5 BU 0V M5 BU - -PTC5 =66XX/7600+Axis 4/60;2 / -PTC M5 PTC M5 PTC M5 +Axis 6/110;2 / -PTC M6.1...
  • Page 453 R1.MP R2.M5/6 -R3.MP5 -R3.MP5- R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M5 BU M5 BU M5 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M5 BU 0V M5 BU 0V M5 BU - -PTC5 =66XX/7600+Axis 4/60;2 / -PTC M5 PTC M5 PTC M5 PTC 0V...
  • Page 454 R1.MP -R2.M5/6- -R3.MP6 -R3.MP6 R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M6 BU M6 BU M6 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M6 BU 0V M6 BU 0V M6 BU - -PTC6 +Axis 5/70;5 / -PTC M6 PTC M6 +Axis 5/70;3 / -PTC 0V PTC 0V...
  • Page 455 R1.MP -R3.MP6- -R3.MP6- R (U) T (W) S (V) GNYE GNYE =66XX/7600+BU/10;7 / -BU M6 BU M6 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M6 BU 0V M6 BU - -PTC6 +Axis 5/80;2 / -PTC M6.1 PTC M6 PTC 0V R1.SMB4-6 R1.SMB4-6 -R3.FB6...
  • Page 456 R1.MP -R2.M5/6- -R3.MP6 -R3.MP6 R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M6 BU M6 BU M6 BU + Brake +Axis 5/90;5 / -BU 0V M6.1 BU 0V M6 BU - -PTC6 +Axis 5/90;5 / -PTC M6.2 PTC M6 +Axis 5/90;3 / -PTC 0V.1 PTC 0V...

  • Page 457: Axis 1

    -SW1.1 Power 1.1.1 Location of position switches Power 1.1.2 Signal 1.1.2 Signal 1.1.1 SW1.6 -SW1.2 SW1.5 Power 1.2.1 Power 1.2.2 SW1.4 Signal 1.2.2 SW1.3 Signal 1.2.1 -SW1.3 SW1.2 Power 1.3.1 SW1.1 Power 1.3.2 Signal 1.3.2 Signal 1.3.1 Position switches -SW1.4 Axis 1 Power 1.4.1 Power 1.4.2...

  • Page 458: Axis

    Location of position switches -SW2.1 R1.SW2/3 R2.SW2 Power 2.1.1 Power 2.1.1 Power 2.1.2 Power 2.1.2 Signal 2.1.2 Signal 2.1.2 Signal 2.1.1 Signal 2.1.1 -SW2.2 Power 2.2.1 Power 2.2.1 Power 2.2.2 Power 2.2.2 Signal 2.2.2 Signal 2.2.2 Signal 2.2.1 Signal 2.2.1 Position switches -SW2.3 Axis 2...

  • Page 459: Axis

    Location of Position switches -SW3.1 R1.SW2/3 R2.SW3 Power 3.1.1 Power 3.1.1 Power 3.1.2 Power 3.1.2 Signal 3.1.2 Signal 3.1.2 Signal 3.1.1 Signal 3.1.1 -SW3.2 Power 3.2.1 Power 3.2.1 Power 3.2.2 Power 3.2.2 Signal 3.2.2 Signal 3.2.2 Signal 3.2.1 Signal 3.2.1 Position switches -SW3.3 Axis 3...
  • Page 460 10 Circuit Diagram 10.3.1. Validity of circuit diagram 3HAC13347-1 10.3 Circuit diagram 3HAC13347-1 10.3.1. Validity of circuit diagram 3HAC13347-1 Is this circuit diagram valid 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.
  • Page 461 s h e e t R e v i s i o n Contents...
  • Page 462 s h e e t R e v i s i o n Connection Point Location...
  • Page 463 s h e e t R e v i s i o n Legend...
  • Page 464 s h e e t R e v i s i o n Brake Release Unit...
  • Page 465 s h e e t R e v i s i o n Serial Measurement Board...
  • Page 466 s h e e t R e v i s i o n Axis 1...
  • Page 467 s h e e t R e v i s i o n Axis 2...
  • Page 468 s h e e t R e v i s i o n Axis 3...
  • Page 469 s h e e t R e v i s i o n Axis 4...
  • Page 470 s h e e t R e v i s i o n Axis 5 (IRB 7600)
  • Page 471 s h e e t R e v i s i o n Axis 6...
  • Page 472 s h e e t R e v i s i o n Switches axis 1...
  • Page 473 s h e e t R e v i s i o n Switches/Fan axis 2...
  • Page 474 s h e e t R e v i s i o n Switches/Fan axis 3...
  • Page 475 s h e e t R e v i s i o n Axis 5 (IRB 6600)
  • Page 476 s h e e t R e v i s i o n Design changes, note 1.1...
  • Page 477 s h e e t R e v i s i o n Design changes, note 2.1-2.7...
  • Page 478 10 Circuit Diagram 10.3.1. Validity of circuit diagram 3HAC13347-1 3HAC022033-001 Revision: E...
  • Page 479 Index requirements 52 resonance frequency 52 Absolute Accuracy, calibration 373 gearbox axis 1, replacement 334 balancing device bearing, replacement 285 gearbox axis 3, replacement 349 balancing device, replacement 276 gearbox axis 6, replacement 366 brakes gearbox oil 177 testing function 27 installation cable harness axes 1-4, replacement 221 mechanical stop axis 1 102...
  • Page 480 IRB 7600 - 340/2.8 56 IRB 7600 - 400/2.55 57 safety equipment IRB 7600 - 500/2.3 58 mechanical stop 102 IRB 7600 - 500/2.55 57 mechanical stop axis 2 104 restricting axis 1 102 mechanical stop axis 3 106 restricting axis 2 104...
  • Page 482 ABB AB Robotics Products S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...

This manual is also suitable for:

Irb 7600 - 500/2.3Irb 7600 - 150/3.5Irb 7600 - 400/2.55Irb 7600 - 340/2.8Irb 7600 - 325/3.1

Table of Contents