IRC5-IRB1600 Prod Man 3HAC023637-001 Procedures Rev - en

Product manual (part 1 of 2), procedures
Articulated robot
IRB 1600 - 5/1.2 IRB 1600 - 5/1.45 IRB 1600 - 7/1.2 IRB 1600 - 7/1.45 M2004
Product manual (part 1 of 2), procedures IRB 1600 - 5/1.2 IRB 1600 - 5/1.45 IRB 1600 - 7/1.2 IRB 1600 - 7/1.45
M2004 Document ID: 3HAC 023637-001 Revision: -
The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. 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. In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein. This manual and parts thereof must not be reproduced or copied without ABBs written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this manual may be obtained from ABB at its then current charge.
Copyright 2005 ABB All right reserved. ABB Automation Technologies AB Robotics SE-721 68 Vsters Sweden
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 1 Safety 11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.2.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.1.1 Safety, service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 1.2.1.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 1.2.1.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.2.2 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.1 Safety risks during service work on robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 1.2.2.2 Safety risks related to gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1.2.2.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 1.2.2.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 1.2.2.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 1.2.2.6 Safety risks during installation and service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 1.2.2.7 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.3 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 1.2.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 1.2.3.3 Emergency release of the robots arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 1.2.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1.2.3.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 1.2.3.7 Work inside the manipulators working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 1.3.3 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 1.3.4 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 2 Installation and commissioning 37
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2.2.2 Working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.3.1 Lifting robot with roundsling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 2.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 2.3.3 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 2.3.4 Load diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 2.3.5 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 2.3.6 Fitting equipment on the robot (robot dimensions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 2.3.7 Installation of signal lamp (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 2.4.2 Installation of additional mechanical stops on axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 2.4.3 Installation of additional mechanical stop on axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 2.4.4 Installation of additional mechanical stops on axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 2.4.5 Installation of position switch, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3HAC 023637-001 Revision: -
Table of Contents
2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
2.5.1 Connectors on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 2.5.2 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 2.5.3 Customer connections on the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 3 Maintenance 85
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
3.2 Maintenance schedule and expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.3.1 Inspection, damper axes 2, 3 and 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

3.4 Replacement activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
3.4.1 Oil in gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 3.4.2 Oil change, gearbox axes 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 3.4.3 Replacement of measurement system battery pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.5 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
3.5.1 Cleaning, complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 4 Repair 99
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.3 Complete manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
4.3.1 Replacement of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

4.4 Upper and lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.4.1 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.2 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.3 Replacement of wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.4 Replacement of damper, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.5 Replacement of damper, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4.6 Replacement of damper, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
112 117 121 124 126 128
4.5 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
4.5.1 Replacement of base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130 4.5.2 Replacement of serial measurement unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134 4.5.3 Replacement of push button unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
4.6.1 Replacement of motor, axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.2 Replacement of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.3 Replacement of motor, axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.4 Replacement of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.5 Replacement of motor and timing belt, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6.6 Replacement of motor and timing belt, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
140 144 148 152 156 161
4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.7.1 Replacement of gearbox, axes 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 4.7.2 Service work on gearboxes, axes 3, 4, 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
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5 Calibration information
171
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 5.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Overview
Overview
About this manual This manual contains instructions for Usage This manual should be used during installation, from lifting the robot to its work site and securing it to the foundation, to making it ready for operation maintenance work repair work and calibration. mechanical and electrical installation of the robot maintenance of the robot mechanical and electrical repair of the robot.
Who should read this manual? This manual is intended for: Prerequisites The reader should... be a trained maintenance/repair craftsman have the required knowledge of mechanical and electrical installation/repair/ maintenance work. installation personnel maintenance personnel repair personnel.
Overview
Organization of chapters The manual is organized in the following chapters: Chapter

Safety, service
Contents
Safety information that must be read through before performing any installation or service work on robot. Contains general safety aspects as well as more specific information on how to avoid personal injuries and damage to the product. Required information about lifting and installation of the robot. Step-by-step procedures that describe how to perform maintenance of the robot. Based on a maintenance schedule that may be used to plan periodical maintenance. Step-by-step procedures that describe how to perform repair activities of the robot. Based on available spare parts. Procedures that do not require specific calibration equipment. General information about calibration. Environmental information about the robot and its components.
Installation and commissioning Maintenance
Repair Calibration information Decommissioning
Revisions Revision
-
Description
First edition.
Product documentation, M2004

General The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. 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. Hardware manuals All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts: Product manual, procedures Safety information Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software) Maintenance (descriptions of all required preventive maintenance procedures including intervals) Repair (descriptions of all recommended repair procedures including spare parts) Additional procedures, if any (calibration, decommissioning)
Product manual, reference information RobotWare manuals The following manuals describe the robot software in general and contain relevant reference information: RAPID Overview: An overview of the RAPID programming language. RAPID reference manual part 1: Description of all RAPID instructions. RAPID reference manual part 2: Description of all RAPID functions and data types. Technical reference manual - System parameters: Description of system parameters and configuration workflows. Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards) Part list Foldouts or exploded views Circuit diagrams
Application manuals Specific applications (e.g. software or hardware options) are described in Application manuals. An application manual can describe one or several applications. An application manual generally contains information about: Operators manuals This group of manuals is aimed at those having first hand operational contact with the robot, i.e. production cell operators, programmers and trouble shooters. The group of manuals include: Operators manual - IRC5 with FlexPendant Operators manual - RobotStudio Online Trouble shooting manual for the controller and robot The purpose of the application (what it does and when it is useful) What is included (e.g. cables, I/O boards, RAPID instructions, system parameters) How to use the application Examples of how to use the application
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. The components or attachment points are marked with italic text in the procedures and completed with a reference to the figure where the current component or attachment point is shown. The denomination in the procedure for the component or attachment point corresponds to the denomination in the referenced figure. The table below shows an example of a reference to a figure from a step in a procedure.
Step
8.
Action
Remove the rear attachment screws, gearbox.
Note/Illustration
Shown in the figure Location of gearbox on page xx.
References to required equipment The procedures often include references to equipment (spare parts, tools etc.) required for the different actions in the procedure. The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information, i.e. article number, dimension. The denomination in the procedure for the component or attachment point corresponds to the denomination in the referenced list. The table below shows an example of a reference to a list of required equipment, from a step in a procedure.
Step
3.
Action
Fit a new sealing, axis 2 to the gearbox.
Note/Illustration
Art. no. is specified in Required equipment on page xx.
Safety information The manual includes a separate safety chapter that must be read through before proceeding with any service or installation procedures. All procedures also include specific safety information when dangerous steps are to be performed. Read more in chapter Safety on page 11.
10
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 12. specific safety information, pointed out in the procedure at the moment of the danger. How to avoid and eliminate the danger is either detailed directly in the procedure, or further detailed in separate instructions, found in section Safety related instructions on page 30.
11
1 Safety
1.2.1.1. Safety, service
1.2 General safety information 1.2.1. General information 1.2.1.1. Safety, service
Validity and responsibility The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment, which can influence the safety of the total system. To protect personnel, the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed. The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that the safety devices necessary to protect people working with the robot system are designed and installed correctly. Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, e.g. Users Guide and Product Manual. Connection of external safety devices Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot. In the Product Manual - Installation and Commissioning, instructions are provided for connecting safety devices between the robot and the peripheral equipment.
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1 Safety
1.2.1.2. Limitation of Liability
1.2.1.2. Limitation of Liability

General 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.
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1 Safety
1.2.1.3. Related information
1.2.1.3. Related information

General The list below specifies documents which contain useful information: Documents Type of information
Installation of safety devices Changing robot modes
Detailed in document
Product manual for the robot Operators manual (RobotWare 5.0)
Section
Installation and commissioning Operating modes Installation and commissioning
Restricting the working space Product manual for the robot
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1 Safety
1.2.2.1. Safety risks during service work on robot
1.2.2. Safety risks 1.2.2.1. Safety risks during service work on robot
Overview This section includes information of general safety risks to be considered when performing service work on the robot. Complete robot Safety risk
Hot components!
Description
Caution!
Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! Removed parts may result in collapse of robot!
Warning!
Take any necessary measures to ensure that the robot does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Cabling Safety risk

Cable packs are sensitive to mechanical damage!
Description
Caution!
The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them!
15
1 Safety
1.2.2.1. Safety risks during service work on robot
Gearboxes and motors Safety risk

Gears may be damaged if excessive force is used!
Description
Caution!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used!
Balancing device Safety risk

Dangerous balancing device!
Description
Warning!
Do not under any circumstances, deal with the balancing device in any other way than that detailed in the product documentation! For example, attempting to open the balancing device is potentially lethal!
16
1 Safety
1.2.2.2. Safety risks related to gripper
1.2.2.2. Safety risks related to gripper

CAUTION! Ensure that a gripper is prevented from dropping a workpiece, if such is used.
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1 Safety
1.2.2.3. Safety risks related to tools/workpieces
1.2.2.3. 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). Safe design Grippers/end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller.
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1 Safety
1.2.2.4. Safety risks related to pneumatic/hydraulic systems
1.2.2.4. 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 so, after shutdown, particular care must be taken. The pressure in pneumatic and hydraulic systems must be released before starting to repair them.
Safe design Gravity may cause any parts or objects held by these systems to drop. Dump valves should be used in case of emergency. Shot bolts should be used to prevent tools, etc., from falling due to gravity.
19
1 Safety
1.2.2.5. Safety risks during operational disturbances
1.2.2.5. Safety risks during operational disturbances

General Qualified personnel Remedial action must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts. 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. Care must be taken at all times.
Extraordinary risks If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually.
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1 Safety
1.2.2.6. Safety risks during installation and service
1.2.2.6. Safety risks during installation and service

General risks during installation and service The instructions in the Product Manual - Installation and Commissioning must always be followed. Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly. Those in charge of operations must make sure that safety instructions are available for the installation in question. Those who install the robot must have the appropriate training for the robot system in question and in any safety matters associated with it.
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 Safety zones, which have to be crossed before admittance, must be set up in front of the robot's working space. Light beams or sensitive mats are suitable devices. Turntables or the like should be used to keep the operator out of the robot's working space. The axes are affected by the force of gravity when the brakes are released. In addition to the risk of being hit by moving robot parts, you run the risk of being crushed by the parallel arm. Energy, stored in the robot for the purpose of counterbalancing certain axes, may be released if the robot, or parts thereof, are dismantled. When dismantling/assembling mechanical units, watch out for falling objects. Be aware of stored heat energy in the controller. Never use the robot as a ladder, i.e. do not climb on the robot motors or other part during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot.
To be observed by the supplier of the complete system The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function. The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.
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1 Safety
1.2.2.7. Risks associated with live electric parts
1.2.2.7. Risks associated with live electric parts

Voltage related risks, general Although troubleshooting may, on occasion, have to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units. The mains supply to the robot must be connected in such a way that it can be turned off outside the robot's working space.
Voltage related risks, controller A danger of high voltage is associated with the following parts: Be aware of stored electrical energy (DC link) in the controller. Units inside the controller, e.g. I/O modules, can be supplied with power from an external source. The mains supply/mains switch The power unit The power supply unit for the computer system (230 VAC) The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!) The drive unit (700 VDC) The service outlets (115/230 VAC) The power supply unit for tools, or special power supply units for the machining process The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains. Additional connections
Voltage related risks, robot A danger of high voltage is associated with the robot in: The power supply for the motors (up to 800 VDC) The user connections for tools or other parts of the installation (max. 230 VAC, see Installation and Commissioning Manual)
Voltage related risks, tools, material handling devices, etc Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged.
22
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. Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell (see Product Specification - Description, Robot Motion). Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the manipulator.
23
1 Safety
1.2.3.2. Fire extinguishing
1.2.3.2. Fire extinguishing

NOTE! Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulator or controller)!
24
1 Safety
1.2.3.3. Emergency release of the robots arm
1.2.3.3. Emergency release of the robots arm

Description In an emergency situation, any of the robots axes may be released manually by pushing the brake release buttons on the robot. How to release the brakes is detailed in section: Manually releasing the brakes on page 47.
The robot arm may be moved manually on smaller robot models, but larger models may require using an overhead crane or similar. Increased injury Before releasing the brakes, make sure that the weight of the arms does not increase the pressure on the trapped person, further increasing any injury!
25
1 Safety
1.2.3.4. Brake testing
1.2.3.4. Brake testing

When to test During operation the holding brakes of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function. How to test The function of each axis motor holding brakes may be checked as detailed below: 1. Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized (max. static load). 2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller. 3. Check that the axis maintains its position. If the manipulator does not change position as the motors are switched off, then the brake function is adequate.
26
1 Safety
1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"
1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"

NOTE! Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant Unit or a PC. This will affect the safety function Reduced speed 250 mm/s.
27
1 Safety
1.2.3.6. Safe use of the Teach Pendant Unit
1.2.3.6. Safe use of the Teach Pendant Unit

NOTE! The enabling device is a push button located on the side of the Teach Pendant Unit (TPU) which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state. To ensure safe use of the Teach Pendant Unit, the following must be implemented: The enabling device must never be rendered inoperative in any way. During programming and testing, the enabling device must be released as soon as there is no need for the robot to move. The programmer must always bring the Teach Pendant Unit with him/her, when entering the robot's working space. This is to prevent anyone else taking control of the robot without the programmer knowing.
28
1 Safety
1.2.3.7. Work inside the manipulators working range
1.2.3.7. Work inside the manipulators working range

WARNING! If work must be carried out within the robots 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. The robot's speed is limited to max. 250 mm/s when the operating mode selector is in position < 250 mm/s. This should be the normal position when entering the working space. The position 100% "full speed" may only be used by trained personnel who are aware of the risks that this entails. Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in order not to get entangled with hair or clothing. Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell. Test the motor brake on each axis, according to section Brake testing on page 26.
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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: A caption specifying the danger level (DANGER, WARNING or CAUTION) and the type of danger. A brief description of what will happen if the operator/service personnel does not eliminate the danger. An instruction of how to eliminate the danger to facilitate performing the activity at hand.
Danger levels The table below defines the captions specifying the danger levels used throughout this manual.
Symbol
Designation
DANGER
Signification
Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc. Warns that an accident may occur if the instructions are not followed, that can lead to serious injury, possibly fatal, and/or great damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc. The electrocution or electrical shock symbol indicates electrical hazards which could result in severe personal injury or death.
danger
WARNING
warning
ELECTRICAL SHOCK
Electrical shock
CAUTION
caution
Warns that an accident may occur if the instructions are not followed, that can result in injury and/or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment, where there is a risk of damaging the product or causing a breakdown.
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1 Safety
1.3.1. Safety signals, general
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.
Note
TIP
Tip symbols direct you to specific instructions, where to find additional information or how to perform a certain operation in an easier way.
Tip
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1 Safety
1.3.2. DANGER - Moving manipulators are potentially lethal!
1.3.2. DANGER - Moving manipulators are potentially lethal!

Description Any moving manipulator is a potentially lethal machine. When running the manipulator, it may perform unexpected and sometimes irrational movements. However, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the manipulator working range. Elimination Step
1.
Action
Info/Illustration
Before attempting to run the manipulator, Emergency stop equipment such as make sure all emergency stop equipment is gates, tread mats, light curtains, etc. correctly installed and connected. If possible, use the hold-to-run button whenever possible. The hold-to-run button is used in manual mode, not in automatic mode. Make sure no personnel are present within the manipulator working range before pressing the start button. How to use the hold-to-run control in RobotWare 5.0 is detailed in section How to use the hold-to-run switch in the Operators Manual, IRC5.
2.
3.
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1 Safety
1.3.3. WARNING - The unit is sensitive to ESD!
1.3.3. WARNING - The unit is sensitive to ESD!

Description ESD (electro static discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges. This discharge may destroy sensitive electronics. Elimination Step
1.
Action
Use a wrist strap
Note/Illustration
Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly. The mat must be grounded through a currentlimiting resistor. The mat should provide a controlled discharge of static voltages and must be grounded.
2. 3.
Use an ESD protective floor mat. Use a dissipative table mat.
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1 Safety
1.3.4. 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 Description
Changing and draining gearbox oil may require handling hot oil of up to 90C!
Elimination / Action
Make sure that protective gear like goggles and gloves are always worn during this activity.
Hot oil! When opening the oil plug, Open oil plug carefully and keep there may be pressure present away from the opening. Do not in the gearbox, causing oil to overfill the gearbox when filling. spray from the opening!
-
Possible pressure build up in gearbox! Overfilling of gearbox oil can lead to internal over-pressure inside the gearbox which in turn may: damage seals and gaskets completely press out seals and gaskets prevent the manipulator from moving freely. Mixing types of oil may cause severe damage to the gearbox! Make sure not to overfill the gearbox when filling with oil! After filling, check the correct oil level.
Do not overfill!
When filling gearbox oil, do not mix different types of oil unless specified in the instruction. Always use the type of oil specified by the manufacturer!
Do not mix types of oil! Warm oil drains quicker than cold oil. When changing gearbox oil, first run the robot for a time to heat up the oil.
Heat up the oil!
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1 Safety
Warning
Description
Elimination / Action
Specified amount depends on drained volume!
The specified amount of oil is After refilling, check the oil level. based on the total volume of the gearbox. When changing the oil, the amount of refilled oil may differ from the specified amount, depending on how much oil has previously been drained from the gearbox.
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1 Safety
36
2 Installation and commissioning

2.1. Introduction

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.
37

2.2.1. Pre-installation procedure
2.2 Unpacking 2.2.1. Pre-installation procedure

General This instruction is primarily intended for use when unpacking and installing the robot for the first time. It also contains information useful during later re-installation of the robot. Checking the pre-requisites for installation The check-list below details what must be observed before proceeding with the actual installation of the robot: Step
1.
Action
Make sure only qualified installation personnel conforming to all national and local codes are allowed to perform the installation. Make sure the robot has not been damaged, by visually inspecting its exterior. Make sure the lifting device to be used is dimensioned to handle the weight of the robot. If the robot is not to be installed directly, it must be stored. Make sure the appointed operating environment of the robot conforms to the specifications. Before taking the robot to its installation site, make sure the site conforms to applicable requirements. Before moving the robot, make sure it does not tip over! When these prerequisites have been met, the robot may be taken to its installation site.
Detailed in section:
2. 3. 4. 5.
Weight on page 39. Storage conditions on page 39. Operating conditions on page 39 and Protection classes on page 40. Loads on foundation on page 39 and Requirements on foundation on page 39.
6.
7. 8.
Lifting robot with roundsling on page 45.
38

Weight The table below shows the weight of the robot model. Robot model
IRB 1600 - x/1.2 IRB 1600 - x/1.45
Weight
247 kg 250 kg
Loads on foundation The table below shows the various forces and torques working on the robot during different kinds of operation. Note! These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum simultaneously! Max. load (emergency stop)
5000 N 5000 N 6000 N - 2500 3000 N + 2500 3000 N + 2100 3000 N 5500 Nm 2000 Nm
Force
Force XY
Mounting
Floor mounted Inverted Tilted 30 Floor mounted Inverted Tilted 30 All All
Endurance load
1600 N 1600 N 2500 N - 2500 1600 N + 2500 1600 N + 2100 1600 N 2000 Nm 350 Nm
Force Z
Torque XY Torque Z
Requirements on foundation The table below shows the requirements for the foundation where the robot is installed. Requirement
Levelness
Value
max. 0.5 mm
Note
The value for levelness aims at the circumstance of the three anchoring points in the robot base.
Storage conditions The table below shows the allowed storage conditions for the robot. Parameter
Min. ambient temperature Max. ambient temperature Max. ambient temperature (less than 24 hrs) Max. ambient humidity
Value
-25 C +55 C +70 C Max. 95% at constant temperature
Operating conditions The table below shows the allowed operating conditions for the robot. Parameter
Min. ambient temperature Max. ambient temperature Max. ambient humidity
Value
+5 C +45 C Max. 95% at constant temperature
39

Protection classes The table below shows the protection class of the robot. Equipment
Robot, standard Robot, Foundry Robot, Wash
Protection class
IP 54 IP 67 IP 67
40

2.2.2. Working range

General This section specifies the working ranges for the different robot models. The turning radius is also shown separately in the last figure. Illustration, working range IRB 1600 - 5/1.2 and IRB 1600 - 7/1.2
xx0400001260
Pos
0 1 2 3 4 5 6 7
Positions at wrist center (mm)

X 750 150 494 1225 897 386 321 -808 Z 961.5 1561.5 470 486.5 -287 737 786 975
Angle (degrees)
axis 2 0 0 0 +90 +136 +136 -63 -63 axis 3 0 -90 +55 -90 -90 -235 +55 -90
41

Angles, working range IRB 1600 - 5/1.2 and IRB 1600 - 7/1.2 Axis
Axis 1 Axis 2 Axis 3 Axis 4
Angle from
+180 +136 +55 +200 +190 revolutions
Angle to
-180 -63 -235 -200 -190 revolutions
Note
Default value Maximum value. The default working range for axis 4 can be extended by changing parameter values in the software. Default Maximum value. The default working range for axis 6 can be extended by changing parameter values in the software.
Axis 5 Axis 6
+115 +400 +288 revolutions
-115 -400 -288 revolutions
Illustration, working range IRB 1600 - 5/1.45 and IRB 1600 - 7/1.45
xx0400001261
42

Pos
0 1 2 3 4 5 6 7
Positions at wrist center (mm)

X 750 150 404 1450 800 448 -6 -1150 Z 1186.5 1786.5 643 486.5 -639 478 740 486.5
Angle (degrees)
axis 2 0 0 0 +90 +150 +150 -90 -90 axis 3 0 -90 +65 -90 -90 -245 +65 -90
Angles, working range IRB 1600 - 5/1.45 and IRB 1600 - 7/1.45 Axis
Axis 1 Axis 2 Axis 3 Axis 4
Angle from
+180 +150 +65 +200 +190 revolutions
Angle to
-180 -90 -245 -200 -190 revolutions
Note
Default value Maximum value. The default working range for axis 4 can be extended by changing parameter values in the software. Default Maximum value. The default working range for axis 6 can be extended by changing parameter values in the software.
Axis 5 Axis 6
+115 +400 +288 revolutions
-115 -400 -288 revolutions
43

Turning radius IRB 1600 - all models The turning radius for the robot is shown in the figure below. Notice the differences depending on the length of the lower arm.
xx0400001259
(A)
Minimum turning radius axis 1 (all models)
44

2.3.1. Lifting robot with roundsling
2.3 On-site installation 2.3.1. Lifting robot with roundsling

Recommended lifting position The figure below shows the recommended lifting positions. It is important that the roundsling has free space and does not wear against any part of the robot.
xx0400001296
Required equipment Equipment

Overhead crane Roundsling
Art. no.
-
Note
Lifting capacity: 500 kg. Length: 2 m. Lifting capacity: 500 kg.
45

2.3.1. Lifting robot with roundsling
Lifting the robot with roundsling Step

1.
Action
Note
Move the robot to an appropriate lifting position. Shown in the figure Recommended lifting position on page 45. Secure the roundsling safely at the lifting eye and at the overhead crane. Make sure the roundsling has free space and does not wear against any part of the robot. Capacity for the roundsling is specified in Required equipment on page 45. Attachment is shown in the figure Recommended lifting position on page 45.
2.
3.
Caution! The robot weighs 250 kg! All lifting equipment must be sized accordingly! 4.
Warning!
WARNING! Personnel must not, under any circumstances, be present under the suspended load! 5. Raise the overhead crane to lift the robot.
46

2.3.2. Manually releasing the brakes

General The section below details how to release the holding brakes of each axis motor. This may be done in one of three ways: using the brake release unit when the robot is connected to the controller. using the brake release unit when the robot is disconnected from the controller, but connected to an external power supply at the connector R1.MP. using an external voltage supply directly on the motor connector.
Using the brake release unit when the robot is connected to the controller This section details how to release the holding brakes using the internal brake release unit. Step
1.
Action
The internal brake release unit is located at the base of the robot and equipped with six buttons for controlling the axes brakes. The buttons are numbered according to the numbers of the axes.
Info/Illustration
xx0400001255
2.
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! 3. Release the holding brake on a particular robot axis by pressing the corresponding button on the internal brake release panel and keeping it depressed. The brake will function again as soon as the button is released.
47

Using the brake release unit with an external power supply This section details how to release the holding brakes with the internal brake release unit using an external voltage supply. This is done if the robot is not connected to the controller. Step
1.
Action
Info/Illustration
Also, be careful not to interchange the 24V and 0V pins. If they are mixed up, damage can be caused to a resistor diode and to the system board.
Danger! Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously! 2. Connect an external power supply to connector R1.MP. Supply: 0V on pin C10 24V on pin B8.
xx0400001302
3.
Push the brake release button to release the holding brakes, according to the previous procedure.
48

2.3.3. Orienting and securing the robot

General This section details how to orient and secure the robot at a horizontal level at the installation site. Hole configuration, base The figure below shows the hole pattern and dimensions of the robot base.
xx0400001300
Center of axis 1
49

Dimension, mounting surface and guiding sleeve The figure below shows the dimension of the mounting surface and guiding sleeves, if used.
xx0400001306
50

Attachment bolts, specification

Attachment bolts, 3 pcs M16 x 60 (installation directly on foundation of steel) M16 x 70/80 (installation on foundation or base plate, using guiding sleeves) 17 x 30 x 3 Quality 8.8 (wall or angle mounted robot: Quality 12.9) 200 Nm (needed if wall or angle mounted, or if the robot is calibrated with AbsAcc)
Washers, 3 pcs Quality Tightening torque Guiding sleeves, 2 pcs
Orienting and securing the robot to installation site Step

1.
Action
Make sure the installation site for the robot conforms to the specifications in section Pre-installation procedure on page 38. Prepare the installation site with attachment holes. If the robot is calibrated with AbsAcc, it must be installed using guiding sleeves.
Note
2.
Hole configuration of the base is shown in the figure Hole configuration, base on page 49. Dimension of mounting surface and the guiding sleeves are shown in the figure Dimension, mounting surface and guiding sleeve on page 50. Detailed in section Lifting robot with roundsling on page 45.
3. 4.
Lift the robot to the installation site. Guide the robot gently using two of the M16 attachment bolts while lowering it into its mounting position.
5.
Fit and tighten the bolts and washers in the Specified in section Attachment bolts, base attachment holes. specification on page 51.
51

2.3.4. Load diagrams

General The load diagrams include a nominal pay load inertia, J0 of 0.012 kgm2, and an extra load of 15 kg for the IRB 1600-5/x variants and 5 kg for the IRB 1600-7/x variants, at the upper arm housing. At different arm load and moment of inertia the load diagram will be changed. Accurate load diagram For an accurate load diagram, please use the calculation program ABB RobotLoad IRB 1600, Stand alone application on: Inside.abb.com/atma, click on Products ---> Robots ---> IRB 1600 or http://www.abb.com/roboticspartner, click on Product Range ---> Robots ---> IRB 1600
The application requires Microsoft.NET Framework and Microsoft Excel 9.0 software.
52

Load diagram - IRB 1600-5/1.2, IRB 1600-5/1.45
xx0500001449
Maximum permitted load mounted on the robot tool flange at different positions (center of gravity)
53

Load diagram - IRB 1600-5/1.2, IRB 1600-5/1.45, "Vertical Wrist" (10)
xx0500001450
Maximum permitted load mounted on the robot tool flange at different positions (center of gravity) at "Vertical Wrist" (10)
Description
For wrist down (0 deviation from the vertical line)
Value
Max load = 6 kg ZMax = 0.11 m LMax = 0.04 m
54

Load diagram - IRB 1600-7/1.2, IRB 1600-7/1.45
xx0500001451
Maximum permitted load mounted on the robot tool flange at different positions (center of gravity)
55

Load diagram - IRB 1600-7/1.2, IRB 1600-7/1.45, "Vertical Wrist" (10)
10 10 L - Distance (m) Z
xx0500001452
Maximum permitted load mounted on the robot tool flange at different positions (center of gravity) at "Vertical Wrist" (10)
Description
For wrist down (0 deviation from the vertical line)
Value
Max load = 9 kg ZMax = 0.075 m LMax = 0.045 m
56

2.3.5. Loads
2.3.5. Loads
General Any loads mounted on the robot must be defined correctly and carefully (with regard to the position of center of gravity and inertia factor) in order to avoid jolting movements and overloading the motors. If this is not done correctly operational stops may result. Permitted extra loads and their positions The shaded areas indicate the permitted positions (center of gravity) for extra loads mounted on the wrist, upper arm housing and on the frame.
xx0500001448
The center of gravity of the extra load must be within the marked load areas.
Robot
IRB 1600 - 5/X IRB 1600 - 7/X
Max load
Load area A Load area B Load area A+B 15 kg 5 kg 5 kg 5 kg 15 kg 5 kg Load area C Load area D 0.5 kg 0.5 kg 15 kg 15 kg
57

2.3.6. Fitting equipment on the robot (robot dimensions)

General This section shows the robot dimensions and available mounting holes on the robot. Main dimensions The two figures below show the main dimensions of the robot. The remaining dimensions and mounting holes on the upper arm, frame and turning disk are shown in the following figures.
xx0400001253
(A) (B)
Centerline of axis 1 Smallest circumscribed radius, axis 1
58

Mounting holes on the frame The three available mounting holes for equipment on the frame must be threaded according to the figure below.
xx0400001252
59

Dimensions of the upper arm and mounting holes The figure below shows the dimensions of the upper arm and available mounting holes for equipment on the arm.
xx0400001251
(A) (B) (C) (D) (E)
Centerline of axis 3 Centerline of axis 4 Turning radius for axis 3 Smallest circumscribed radius for axis 4 Mounting holes for equipment
60

Dimensions of the turning disk The figure below shows the dimensions of the turning disk.
xx0200000063
Fastener quality When fitting tools on the turning disk, use only screws with quality 12.9. When fitting equipment on other places, standard screws with quality 8.8 can be used.
61

2.3.7. Installation of signal lamp (option)

General A signal lamp with an yellow fixed light can be mounted on the robot, as a safety device. The signal lamp is required on an UL/UR approved robot. The lamp is active in MOTORS ON mode. Location of signal lamp The signal lamp is fitted to the upper arm housing of the robot, as shown in the figure below.
xx0400001265
A C D E F
Signal lamp Cable gland Cable bracket Attachment holes for the signal lamp Cover, upper arm housing
62


Signal lamp Gasket, customer connections Gasket upper arm cover
Art. no.
3HAC 022235-001 3HAC 022050-001 3HAC 022049-001
Note
Replace if damaged. Replace if damaged.
Installation, signal lamp The procedure below details how to install the signal lamp to the robot. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the cover from the upper arm housing to get access to the connectors inside the housing. Remove the protection plug (A) from the insertion hole in the contact panel. Run the cables of the lamp through the hole in the contact panel. Secure the cable gland in the hole. Shown in the figure Location of signal lamp on page 62.
3.
xx0400001264
4. Connect the lamp connectors, R3.H1 and R3.H2 and place the cables safely inside the housing. Take out the lamp unit through the hole in the upper arm housing cover and refit the cover. Make sure the gaskets are not damaged.
A: Plug with o-ring, M10
5.
Shown in the figure Location of signal lamp on page 62.
63

Step
6.
Action
Fit the cable bracket of the signal lamp to the two mounting holes in the upper arm housing (B).
Note
Shown in the figure Location of signal lamp on page 62.
xx0400001263
7. The signal lamp is now ready for use and is lit in MOTORS ON mode.
B: Mounting holes, M8 x 12
64

2.4.1. Introduction
2.4 Restricting the working range 2.4.1. Introduction

General When installing the robot, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited. The working range of following axes may be restricted: Axis 1, hardware (mechanical stop and position switch) Axis 2, hardware (mechanical stop) Axis 3, hardware (mechanical stop)
This section describes how to install hardware that restricts the working range. Notice that adjustments must also be made in the software. References to software manuals are given in following installation procedures.
65

2.4.2. Installation of additional mechanical stops on axis 1

General This section details how to install additional mechanical stops on axis 1 in order to restrict the working range of the axis. Restrictions in working range The working range of axis 1 can be restricted by fitting one or two additional mechanical stops on the casted groove at the base. The figure below shows both the minimum and maximum working range of the robot, when restricted by the additional mechanical stops. The working range can be restricted freely within the shown scope, depending on where the mechanical stop is installed along the casted groove.
xx0400001286
A B
Mounting position of two additional stops for maximum working area (168) Mounting position of two additional stops for minimum working area (64)
66

Illustration, mechanical stop, axis 1 The additional mechanical stop of axis 1 is fitted to the base of the robot, as shown in the figure below.
xx0400001287
A B C E F G
Mechanical stop, axis 1 (additional) Attachment bolts and washers, mechanical stop Stop pin (standard) Casted groove Guiding pin Hidden stiffening ribs

Working range limit axis 1
Art. no.
3HAC 023110-001
Note
Includes mechanical stops (2 pcs), attachment bolts and washers.
67

Installation of mechanical stop, axis 1 The procedure below details how to install the mechanical stop to axis 1. Step
1.
Action
Note/Illustration
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Place the stop at the base, with the guiding pin in the casted groove. Turn the stop until the holes align with the groove. The stop can be mounted in either direction, resulting in differences in the working range.
xx0400001288
Also see the figure Illustration, mechanical stop, axis 1 on page 67. 3. Drill two holes in the casted groove, with guidance from the circular and the elliptical hole. Drill the holes through 10.2 mm. If drilling in a stiffening rib, drill depth must be min. 30 mm. Cut the threads M12. If cutting in a stiffening rib, thread depth must be min. 23 mm. Fit the stop to the base without tightening the bolts. Turn axis 1 manually and check the working area between the stops. How to release the holding brake of the axis motor is detailed in section Manually releasing the brakes on page 47. 2 pcs/stop: M12 x 40, tightening torque: 85 Nm.
4.
5. 6.
7. 8.
Tighten the bolts.
Warning! If the mechanical stop is deformed after a hard collision, it must be replaced!
68

2.4.3. Installation of additional mechanical stop on axis 2

General This section details how to install an additional mechanical stop on axis 2 in order to restrict the working range of the axis. Restrictions in working range The working range of axis 2 can be restricted by fitting an additional mechanical stop at the frame. The working range can only be restricted backwards, as shown in the figures below. Notice the different working ranges for the different models!
xx0400001289
xx0400001290
69

Illustration, mechanical stop, axis 2 The additional mechanical stop for axis 2 is fitted together with a damper to the frame, as shown in the figure below.
xx0400001291
A B C D E F
Mechanical stop, axis 2 Attachment bolts, mechanical stop (2 pcs) Attachment holes, mechanical stop Damper, axis 2 Washer Attachment screw, damper

Art. no.
3HAC 023108-001
Note
Includes mechanical stop, damper and attachment bolts.
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
70

Step
2.
Action
Fit the mechanical stop to the frame, without tightening the bolts. Make sure that the stop is in contact with the lower boss on the gearbox, as the arrow shows in the figure to the right.
Note
Attachment holes are shown in the figure Illustration, mechanical stop, axis 2 on page 70.
3.
xx0400001292
Note! It is important that the mechanical stop is fitted in contact with the lower boss on the gearbox! 4. 5. Tighten the attachment bolts. 2 pcs; M8 x 35, tightening torque: 25 Nm.
Fit the damper to the mechanical stop, with its Shown in the figure Illustration, attachment screw and washer. Tighten the mechanical stop, axis 2 on page screw. 70.
6.
Warning! If the mechanical stop is deformed after a hard collision, it must be replaced!
71


General This section details how to install an additional mechanical stop on axis 3 in order to restrict the working range of the axis. Restrictions in working range The working range of axis 3 can be restricted into two different working areas, as shown in the two figures below. Notice the differences between the different models.
xx0400001283
A B
Robot models IRB 1600 - x/1.2 Working range A Working range B
72

xx0400001284
A B
Robot models IRB 1600 - x/1.45 Working range A Working range B
73

Illustration, mechanical stop, axis 3 The mechanical stop is installed at the upper arm housing, as shown in the figure below.
xx0400001285
A B
Mechanical stop, axis 3 Attachment screws and washers (2 pcs)

Art. no.
3HAC 023109-001
Note
Includes mechanical stop, attachment screws and washers.
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Fit the mechanical stop to the two mounting holes at the upper arm housing, with the two attachment screws and washers. Tighten the screws. Shown in the figure Illustration, mechanical stop, axis 3 on page 74. 2 pcs: M8 x 25, tightening torque: 25 Nm.
3.
Warning! If the mechanical stop is deformed after a hard collision, it must be replaced! 74 3HAC 023637-001 Revision: -

2.4.5. Installation of position switch, axis 1

General This section details how to install the position switch to axis 1. Location of position switch, axis 1 The position switch is installed between the frame and the base, as shown in the figure below.
xx0400001356
A B C D E F G H I
Position switch Attachment screws, position switch, 2 pcs: M6 x 30 Holder ring (2 parts) Attachment screws, holder ring, 6 pcs: M8 x 12 Cam Bracket Attachment screws, housing, 2 pcs: M6 x 8 Cable straps Attachment screws, attachment plate, 2 pcs: M6 x 16

Position switch, axis 1
Art. no.
3HAC 023973-001
Note
Includes 3 switches. All parts are included in the delivery. Instruction of how to cut the cams is enclosed in the kit.
75

Installation, position switch axis 1 The procedure below details how to install the position switch to the robot. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Fit the two holder rings underneath the Shown in the figure Location of position frame with the six attachment screws. switch, axis 1 on page 75. 6 pcs, M8 x 12. Cut the cams according to instructions, enclosed with the position switch kit. Fit the cams to the holder ring with the Shown in the figure Location of position attachment screws. switch, axis 1 on page 75. M6 x 12. Attach the position switch to the bracket with two attachment screws. 2 pcs, M6 x 30.
3. 4.
5. 6.
Fit the complete bracket to the base of Shown in the figure Location of position the robot with the two attachment switch, axis 1 on page 75. screws. 2 pcs, M6 x 8. Fit the attachment plate (A) to the base 2 pcs, M6 x 16. of the robot with the two attachment Shown in the figure Location of position screws. switch, axis 1 on page 75. Fit the switches to the attachment plate. Adjust the height of the switches with shims (B) until each roller (C) aligns with corresponding cam (D).
7.
xx0400001358
8. 9.
Secure the cabling inside the housing with cable straps. Connect the position switch cabling.
Shown in the figure Location of position switch, axis 1 on page 75. The cabling and connection points are specified in section Position switch cables (option) on page 79. 3HAC 023637-001 Revision: -
76

2.5.1. Connectors on robot
2.5 Electrical connections 2.5.1. Connectors on robot

Connectors on the robot The figure below shows all connections of the robot cabling, including the customer connections.
xx0400001262
A B
Connection for air Connection for signal lamp
77

2.5.2. Robot cabling and connection points

General Connect the robot and controller to each other after securing them to the foundation. The lists below specify which cables to use for each respective application. Main cable categories All cables between the robot and control cabinet are divided into the following categories:
Cable category
Robot cables
Description
Handles power supply to and control of the robots motors as well as feedback from the serial measurement board. Specified in table Robot cables on page 78.
Position switch cables (option) Handles supply to and feedback from any position switches and cooling fans on the robot. See the product manual for the controller. Specified in table Position switch cables (option) on page 79. Customer cables (option) Handles communication with equipment fitted on the robot by the customer, low voltage signals and high voltage power supply + protective ground. See the product manual for the controller. Art. no. is specified in section Document references in the Product manual, reference information. Also specified in tableCustomer cables (option) on page 79. Handles power supply to and control of the external axes motors as well as feedback from the servo system. See the product manual for external axes. Art. no. is specified in section Document references in the Product manual, reference information.
External axes cables (option)
These categories are divided into sub-categories which are specified below: Robot cables These cables are included in the standard delivery. They are completely pre-manufactured and ready to plug in.
Cable sub-category Description

Robot cable, power
Connection Connection point, cabinet point, robot

R1.MP
Transfers drive power from the XS1 drive units in the control cabinet to the robot motors. Transfers resolver data from the XS2 serial measurement board and power supply to the SMB.
Robot cable, signals
R1.SMB
78

Robot cable, power, for robots with standard protection Cable (standard)
Robot cable, power, 7 m Robot cable, power, 15 m Robot cable, power, 22 m Robot cable, power, 30 m
Art. no.
3HAC 2492-1 3HAC 2529-1 3HAC 2539-1 3HAC 2564-1
Robot cable, power, for robots with foundry and wash protection Cable (foundry)
Robot cable, power, 7 m Robot cable, power, 15 m Robot cable, power, 22 m Robot cable, power, 30 m
Art. no.
3HAC 9038-1 3HAC 9038-2 3HAC 9038-3 3HAC 9038-4
Robot cable, signals Cable

Robot cable, signal, shielded, 7 m Robot cable, signal, shielded, 15 m Robot cable, signal, shielded, 22 m Robot cable, signal, shielded, 30 m
Art. no.
3HAC 2493-1 3HAC 2530-1 3HAC 2540-1 3HAC 2566-1
Position switch cables (option) The cable is delivered in one length only and should be winded to suitable length.
Cable
Position switch cable, axis 1, 30 m
Art. no.
3HAC 7997-4
Connection Connection point, point, robot cabinet

XS8 R1.LS
Customer cables (option) The customer cables are ordered according to current protection class of the robot. Customer cables for robots with standard protection Connection point, robot
R1.CP/CS R1.CP/CS R1.CP/CS R1.CP/CS
Cable (standard)
Customer cable, power-signal, 7 m Customer cable, power-signal, 15 m Customer cable, power-signal, 22 m Customer cable, power-signal, 30 m
Art. no.
3HAC 3353-1 3HAC 3354-1 3HAC 3355-1 3HAC 3356-1
79

Customer cables for robots with foundry and wash protection Connection point, robot
R1.CP/CS R1.CP/CS R1.CP/CS R1.CP/CS
Cable (foundry and wash)

Customer cable, power-signal, 7 m Customer cable, power-signal, 15 m Customer cable, power-signal, 22 m Customer cable, power-signal, 30 m
Art. no.
3HAC 8183-1 3HAC 8183-2 3HAC 8183-3 3HAC 8183-4
80

2.5.3. Customer connections on the robot

General For connection of equipment on the robot, there are cables integrated into the robot cabling. This section specifies recommendations for the customer connections. The air and electrical connectors are shown in the figure Connectors on the robot on page 77. Air connection Connection
Air inlet (at the base) Air outlet (at the upper arm housing) 1/4"
Dimension
The integrated air hose is sized as specified in the table below. Inner diameter
8 mm
Max. pressure
0.8 MPa / 115 psi
Customer connectors R2.CS and R2.CP The customer connectors R2.CS and R2.CP can be used with either: specified connector components from Souriau, or connectors that meet Military standard MIL-C-26482 series 1.
These connectors are further detailed in following sections.
81

Specified connector components from Souriau The components specified below are from connector manufacturer Souriau and can be used for connection to R2.CS and R2.CP.
xx0400001339
A B C
Pin connector Pin Backshell
Recommended pin connectors Pin connector

Pin connector, standard connection, CS (Customer Signal) Pin connector, standard connection, CP (Customer Power) Pin connector, integrated wirefeeder cabling, CS Pin connector, Integrated wirefeeder cabling, CP
Souriau art. no.

UT0W6 1626 P-H UT0W6 1210 P-H UT0W6 1626P-H UT06 1412P-H
Recommended pins (turned) Turned pins for cable area...

0.21 - 0.93 mm2 (standard connection, CP/CS and integrated wirefeeder cabling, CS) 0.13 - 0.25 mm2 (integrated wirefeeder cabling, CP) 0.25 - 0.5 mm (integrated wirefeeder cabling, CP) 0.5 - 1.5 mm (integrated wirefeeder cabling, CP)
2 2
Souriau art. no.

RM24M9K RM24M9K RM20M12K RM16M23K
Recommended backshell Backshell

Backshell, standard connection, CS Backshell, standard connection, CP Backshell, integrated wirefeeder cabling, CS Backshell, integrated wirefeeder cabling, CP
Souriau art. no.

UT0 16JC UT0 12JC UT0 16JC UT0 14JC
82

Connectors that meet Military standard The connectors specified below meet Millitary standard MIL-C-26482 series 1 and can be used for connection to R2.CS and R2.CP (only for standard customer connection). The figure below shows a complete connector, including pin connector and backshell.
xx0400001340
Connector for crimping The complete pin connectors for crimping include pin connector and backshell. Connector for crimping
Complete pin connector, CS Complete pin connector, CP Turned pin 0.2 - 0.5 mm2 Turned pin 0.5 - 1.5 mm
2
Military standard MIL-C-26482

MS3126*1626S MS3126*1210S M39029/31-240 M29029/31-228
Connector for soldering The complete pin connectors for soldering include pin connector, backshell and pins. Connector for soldering
Complete pin connector, CS Complete pin connector, CP
Military standard MIL-C-26482

MS3116*1626S MS3116*1210S
83

84
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. Each procedure contains all information required to perform the activity, e.g. required tools and materials. The procedures are gathered in different sections, divided according to the maintenance activity. Safety information Before any service work is commenced, it is extremely important that all safety information is observed! There are general safety aspects that must be read through, as well as more specific safety information that describe danger and safety risks when performing the procedures. Make sure to read through the chapter Safety on page 11.
85
3 Maintenance
3.2.1. Specification of maintenance intervals
3.2 Maintenance schedule and expected component 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: Calendar time: specified in months regardless of whether the robot system is run or not Operating time: specified in operating hours. More frequent running of the robot means more frequent maintenance activities.
86
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. Maintenance schedule The table below specifies the required maintenance activities and intervals: Maintenance activity
Change Change
Equipment
Interval
Detailed in section
Oil change, gearbox axes 5 and 6 on page 92. Replacement of measurement system battery pack on page 95. Cleaning, complete robot on page 97.
Gearbox oil, axes 5 and 6 20,000 hrs Battery, measurement system Complete robot 12 - 36 mths 2)
Cleaning
Regular 1)
1. A regular interval implies that the activity is to be performed regularly, but the actual interval may not be specified by the robot manufacturer. The interval depends on the operation cycle of the robot, its working environment and movement pattern. Generally, the more contaminated environment, the closer the intervals. The more demanding movement pattern (sharper bending cable harness), the closer the intervals. 2. The battery is used as a back-up when the robot system is switched off. Therefore, the life of a lithium battery depends on how frequently the power to the system is switched off and also if the environment temperature is higher than recommended operating temperature. The life varies from 12 - 36 mths, depending on current conditions. An alert is given on the TPU or the FlexPendant when the battery is nearly discharged and it must then be replaced within a month.
87
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
Robot cable harness Cabling for position switch Gearbox
Expected life
2,000,000 cycles 2,000,000 cycles 40,000 hrs
Note
See note 1) See note 1)
1. The expected life can also be affected by grouping harnesses/cables other than standard options. The life expectancy is based on a test cycle that for every axis goes from the calibration position to minimum angle, to maximum angle and back to the calibration position. Deviations from this test cycle will result in differences in expected life!
88
3 Maintenance
3.3.1. Inspection, damper axes 2, 3 and 5
3.3 Inspection activities 3.3.1. Inspection, damper axes 2, 3 and 5

Location of dampers The figure below shows the location of all the dampers to be inspected.
xx0400001217
A B
Damper, axis 2 Attachment screw
xx0400001215
A B
Damper, axis 3 Cast tab
89
3 Maintenance
3.3.1. Inspection, damper axes 2, 3 and 5
xx0200000429
A B
Damper, axis 5 Recess

Standard toolkit
Art. no.
-
Note
The contents are defined in section Standard toolkit in the Product manual, reference information.
Inspection, dampers The procedure below details how to inspect the dampers. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Check all dampers for damage, such as Shown in the figure in section cracks or existing impressions that are larger Location of dampers on page 89. than 1 mm. Check attachment screws for deformation. If any damage is detected, the damper must be replaced with a new one! Replacement is detailed in sections: Replacement of damper, axis 2 on page 124 Replacement of damper, axis 3 on page 126 Replacement of damper, axis 5 on page 128.
3. 4.
90
3 Maintenance
3.4.1. Oil in gearboxes
3.4 Replacement activities 3.4.1. Oil in gearboxes

Location of gearboxes
xx0500001427
A B C D E
Gearbox, axis 1 Gearbox, axis 2 Gearbox, axis 3 Gearbox, axis 4 Gearboxes, axes 5 and 6
Type and amount of oil in gearboxes Gearbox

Axis 1 Axis 2 Axis 3 Axis 4 Axis 5-6 (wrist unit)
Type of oil
Mobil Gearlube X320 Mobil Gearlube X320 Mobil Gearlube X320 Mobil Gearlube X320 Optimol BM 100
Art. no.
11712016-604 11712016-604 11712016-604 11712016-604 3HAC 0860-1
Amount
3,400 ml 3,400 ml 500 ml 350 ml Total amount: 350 ml (new wrist) Amount at oil change: 300 ml 91
3 Maintenance
3.4.2. Oil change, gearbox axes 5 and 6

Location of oil plugs The gearboxes for axes 5 and 6 are 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 Spare parts and exploded views in the Product manual (part 2 of 2), reference information.
xx0200000475
A B
Oil plug, draining and filling Oil plug, vent hole
Required equipment Equipment, etc.

Lubricating oil
Art. no.
3HAC 0860-1
Amount
Note
Total amount: 350 Optimol BM 100 ml (new wrist) Amount at oil change: 300 ml Capacity: 400 ml. The contents are defined in section Standard toolkit in the Product manual, reference information. These procedures include references to the tools required.
Oil collecting vessel Standard toolkit
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
92
3 Maintenance
Draining, wrist unit The procedure below details how to drain oil from the gearboxes in the wrist unit. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2.
Warning! Handling gearbox oil involves several safety risks. Before proceeding, please observe the safety information in section WARNING - Safety risks during work with gearbox oil on page 34. 3. Position the robot as shown in the figure to the Vessel capacity is specified in right: section Required equipment on upper arm: upwards for a standing robot page 92! axis 4: 180, to a position where the oil plug (A), faces downwards. Note! The total amount of oil will not be drained. There will remain approximately 50 ml in the wrist unit.
xx0500001434
A: Oil plug, draining and filling The position for an inverted robot is the opposite! 4. Remove the both oil plugs. Shown in the figure Location of oil Both oil plugs must be removed in order to drain plugs on page 92. the wrist unit properly. Refit the oil plug, vent hole.
5.
93
3 Maintenance
Filling oil, wrist unit The procedure below details how to fill oil in the gearboxes in the wrist unit. Step
1.
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 34. 3. 4. Remove the oil plug, draining and filling. Shown in the figure Location of oil plugs on page 92!
Position the robot as shown in the figure to The oil quality and amount is specified the right: in section Required equipment on page 92! upper arm: downwards for a standing robot axis 4: 90, to a position where the oil plug (A), faces upwards. Fill oil in the wrist unit through the oil plug.
xx0500001435
A: Oil plug, draining and filling The position for an inverted robot:, is the opposite. 5. Refit the oil plug.
94
3 Maintenance
3.4.3. Replacement of measurement system battery pack

Location of battery pack The battery pack for the measurement system is located inside the base of the robot, as shown in the figure below.
xx0500001390
Base cover, including gasket. Battery pack is located beneath the cover.
Battery pack on serial measurement unit The battery pack is attached to the serial measurement unit as shown in the figure below.
xx0500001393
A B C
Battery pack Velcro strap Connector X3
95
3 Maintenance

Battery pack Gasket, base cover Standard toolkit
Spare part no.

3HAC 16831-1 3HAC 022047-001 -
Note
Replace if damaged. The contents are defined in section Standard toolkit in the Product manual, reference information. See chapter Circuit diagram in the Product manual, reference information.
Circuit diagram
Replacement, battery pack The procedure below details how to replace the battery pack. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. 4. 5. Remove the base cover from the robot by Shown in the figure Location of battery unscrewing its attachment screws. pack on page 95. Disconnect the battery from the serial measurement unit. Remove the battery pack. Fit the new battery pack and connect it to the serial measurement unit (X3). Spare part no. is specified in Required equipment on page 96. Shown in the figure Battery pack on serial measurement unit on page 95. Spare part no. is specified in Required equipment on page 96. Shown in the figure Location of battery pack on page 95. Detailed in section Updating revolution counters on page 176.
6. 7. 8.
Check the base cover gasket, replace if damaged. Refit the base cover to the robot. Update the revolution counters.
96
3 Maintenance
3.5.1. Cleaning, complete robot
3.5 Cleaning activities 3.5.1. Cleaning, complete robot

General The protection class of Foundry and Wash versions is IP 67, i.e. the robot is watertight. Required equipment Equipment, etc.
May be used on Foundry versions only! Steam cleaner
Art. no. Note

Water pressure at nozzle: max. 2,500 kN/ m 2 (25 bar) Type of nozzle: fan jet, min. 45 spread Flow: max. 100 litres/min. Water temperature: max. 80 C Max. water pressure on enclosures: 50 kN/ m 2 (0.5 bar) Fan jet nozzle should be used, min. 45 spread Flow: max. 100 litres/min.
May be used on Foundry versions only! High pressure water cleaner
Vacuum cleaner Cloth with mild detergent
May be used on Standard version
Dos and donts! The section below specifies some special considerations when cleaning the robot. Always! Never! Never point the water jet at bearing seals, contacts, and other seals! Never spray from a distance closer than 0.4 m! Never remove any covers or other protective devices before cleaning the robot! Never use any cleaning agents, e.g. compressed air or solvents, other than those specified above! Never spray connectors and similar items with a high pressure cleaner! Always use cleaning equipment as specified above! Any other cleaning equipment may shorten the life of paintwork, rust inhibitors, signs, or labels! Always check that all protective covers are fitted to the robot before cleaning!
97
3 Maintenance
3.5.1. Cleaning, complete robot
98
4 Repair
4.1. Introduction
4 Repair
4.1. Introduction
Structure of this chapter This chapter details all repair activities recommended for the robot and any external units of the robot. It is made up of separate procedures, each detailing a specific repair activity. Each procedure contains all information required to perform the activity, e.g. spare parts numbers, required special tools and materials. The procedures are gathered in sections, divided according to the component location on the robot. Required equipment All equipment required to perform a specific repair activity is listed together with the current procedure. The equipment is also gathered in different lists in the Product manual, reference information. Safety information Before any service work is commenced, it is extremely important that all safety information is observed! There are general safety aspects that must be read through, as well as more specific safety information that describe danger and safety risks when performing specific steps in a procedure. Make sure to read through the chapter Safety on page 11 before commencing any service work.
99
4 Repair
4.2.1. Performing a leak-down test
4.2 General procedures 4.2.1. Performing a leak-down test

General After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equipment Equipment, etc.
Leakdown tester Leak detection spray
Art. no.
3HAC 0207-1 -
Note
Procedure Step
1. 2.
Action
Finish the refitting procedure of the motor or gear in question.
Note/Illustration
Remove the topmost oil plug on the gear in question, Art. no. is specified above! and replace it with the leakdown tester. Adapters may be required, which are included in the leakdown tester kit. Apply compressed air, and raise the pressure with the Recommended value: 0.2 knob until the correct value is shown on the 0.25 bar (20 - 25 kPa) manometer. Disconnect the compressed air supply. Wait for approx. 8-10 minutes. No pressure loss must If the compressed air is be detected. significantly colder or warmer than the gearbox to be tested, a slight pressure increase or decrease respectively may occur. This is quite normal. Was any pressure drop evident? Localize the leak as detailed below. Remove the leakdown tester, and refit the oil plug. The test is complete. Spray suspected leak areas with leak detection spray. Bubbles indicate a leak. When the leak has been localized: take the necessary measures to correct the leak. Art. no. is specified above!
3.
4. 5.
6.
7.
8.
100
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 manipulator. Equipment Equipment, etc.
Grease
Art. no.
3HAB 3537-1
Note
Used to grease the bearings, if not specified otherwise.
Assembly of all bearings Follow the instructions below when mounting a bearing on the manipulator. 1. To avoid contamination, let a new bearing remain in its wrapping until it is time for fitting. 2. Ensure that all parts included in the bearing fitting are free from burrs, grinding waste and other contamination. Cast components must be free from foundry sand. 3. Bearing rings, inner rings and roller elements must under no circumstances be subjected to direct impact. Furthermore, the roller elements must not be exposed to any stresses during the assembly work. Assembly of tapered bearings Follow the previous instructions for assembly of all bearings, when mounting a tapered bearing on the manipulator. In addition to those instructions, the procedure below must be carried out to enable the roller elements to adjust to the correct position against the race flange. 1. Tension the bearing gradually until the recommended pre-tension is achieved. Note! The roller elements must be rotated a specified number of turns before pretensioning is carried out and also rotated during the pre-tensioning sequence. 2. Make sure the bearing is properly aligned, as this will directly affect the lifespan of the bearing. 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. During operation, the bearing should be filled to 70-80% of the available volume. Ensure that grease is handled and stored properly, to avoid contamination.
Grease the different types of bearings as detailed below: Grooved ball bearings must be filled with grease from both sides. Tapered roller bearings and axial needle bearings must be greased in the split condition.
101
4 Repair
4.2.3. Mounting instructions for seals

General This sections details how to mount different types of seals to the manipulator. Equipment Equipment, etc.
Grease
Art. no.
3HAB 3537-1
Note
Used to lubricate the seals.
Rotating seals The procedure below details how to fit rotating seals. CAUTION! Please observe the following before commencing any assembly of seals: Protect the sealing surfaces during transport and mounting. Keep the seal in its original wrappings or protect it well before actual mounting. The fitting of seals and gears must be carried out on clean workbenches. Use a protective sleeve for the sealing lip during mounting, when sliding over threads, keyways, etc. Action
Check the seal to ensure that: the seal is of the correct type (provided with cutting edge). there is no damage to the sealing edge (feel with a fingernail). Inspect the sealing surface before mounting. If scratches or damage are found, the seal must be replaced, as it may result in future leakage. Lubricate the seal with grease just before fitting. (Not too Art. no. is specified in early as there is a risk of dirt and foreign particles adhering Equipment on page to the seal.) 102. Fill the space between the dust tongue and sealing lip to 2/ 3 with grease. The rubber coated external diameter must also be greased, unless otherwise specified. Mount the seal correctly with a mounting tool. Never hammer directly on the seal as this may result in leakage.
Step
1.
Note
2.
3.
4.
102
4 Repair
Flange seals and static seals The procedure below details how to fit flange seals and static seals. Step
1.
Action
Check the flange surfaces. They must be even and free from pores. It is easy to check flatness using a gauge on the fastened joint (without sealing compund). If the flange surfaces are defective, the parts may not be used beacuse leakage could occur. Clean the surfaces properly and in accordance with ABB ROBOTICS PRODUCTS recommendations. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Note
2. 3. 4.
O-rings The procedure below details how to fit o-rings. Step

1. 2. 3.
Action
Ensure that the correct o-ring size is used.
Note
Check the o-ring for surface defects, burrs, shape accuracy, etc. Defective o-rings may not be used. Check the o-ring grooves. Defective o-rings The grooves must be geometrically correct and free from pores may not be used. and contamination. Lubricate the o-ring with grease. Tighten the screws evenly when assembling.
4. 5.
103
4 Repair
4.3.1. Replacement of cable harness
4.3 Complete manipulator 4.3.1. Replacement of cable harness

Location of cable harness The cable harness is run through the robot from the base to the upper arm housing. A more detailed view of the component and its position may be found in chapter Spare parts and exploded views in the Product manual (part 2 of 2), reference information. Required equipment Equipment
Cable harness IRB 1600/1.45 Cable harness IRB 1600/1.2 Cable harness IRB 1600/1.45, Customer connections Cable harness IRB 1600/1.2, Customer connections Cable harness IRB 1600/1.45, Wire feeder Cable harness IRB 1600/1.2, Wire feeder Gasket, upper arm cover Gasket, customer connections Gasket, base cover Gasket, gearbox axis 1-2 VK-cover VK-cover Cable ties Standard toolkit The contents are defined in section Standard toolkit in the Product manual, reference information. See chapter Circuit diagram in the Product manual, reference information.
Spare part no.

3HAC 021827-001 3HAC 021827-008 3HAC 021828-001 3HAC 021828-002 3HAC 021830-001 3HAC 021830-002 3HAC 022049-001 3HAC 022050-001 3HAC 022047-001 3HAC 022048-001 3HAA 2166-23 3HAA 2166-21
Note
No application interface. No application interface.
Replace if damaged. Replace if damaged. Replace if damaged. Replace if damaged. Upper and lower covers. 2 pcs Middle cover.
Circuit diagram
104
4 Repair
Illustration, covers to remove The figure below shows all the covers that must be removed from the robot in order to get access to the cable harness and all the brackets.
xx0400001248
A B C D E
Upper and lower VK-cover Arm housing cover, with gaskets VK-cover (also shown with the cover removed) Cover, frame, with gasket Base cover, with gasket
105
4 Repair
Removal, cable harness The procedure below details how to remove the complete cable harness from the robot. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove all the covers: All the covers are shown in the figure Illustration, covers to remove Remove the covers of the upper arm on page 105. housing, frame and base. Push out the upper and lower VK-cover from the inside. Remove the middle VK-cover from the lower arm. Caution! Be careful not to damage the cabling and cable bracket inside the lower arm when removing the middle VK-cover! The figure to the right shows the space underneath the cover. The gray areas are safe for insertion of a tool that may be inserted with a maximum depth of 20 mm! xx0400001247 The cable bracket inside the lower arm is attached to the cable harness. Move the bracket to the new cabling. Disconnect all the connectors inside the upper Shown in the figure Illustration, arm housing. cabling inside upper arm housing on page 107. Remove all cable ties, clamps and brackets inside the upper arm housing. Attachment points inside the upper arm housing are shown in the figure Illustration, cabling inside upper arm housing on page 107.
3.
4.
5.
6. 7.
Disconnect all the connectors inside the frame. Shown in the figure Illustration, cabling inside frame on page 109. Remove the fastening plate, all cable ties and brackets from inside the frame. Remove the cable clamp unit from the fastening plate. Disconnect all the connectors at the base and remove the SMB unit from the base. Attachment points inside the frame are shown in the figure Illustration, cabling inside frame on page 109. Shown in the figure Illustration, cabling inside base on page 110.
8. 9.
Remove all cable ties and brackets at the base. Shown in the figure Illustration, cabling inside base on page 110.
10. Pull out the cabling from the upper arm housing and pull it down through the lower arm. 11. Continue pulling down the cable harness through the frame and pull it out at the rear of the base.
106
4 Repair
Illustration, cabling inside upper arm housing The figure below shows how the cabling is run inside the upper arm housing.
xx0400001250
A B C D E F G H I J K L
Signal cabling; connectors for motors on axes 3, 4, 5 and 6: R3.FB3, R3.FB4, R3.FB5 and R3.FB6 Power cabling; connectors for motors on axes 3, 4, 5 and 6: R3.MP3, R3.MP4, R3.MP5 and R3.MP6 Optional connector: R2.CP Optional connector: R2.CS Distance console with contact panel Cable clamp unit Attachment screws, cable clamp unit (2 pcs, only one shown) Clamp, signal cabling Clamp, motor cabling Connector plate Connector holder Cable tie, connector holder
107
4 Repair
Refitting, cable harness in upper arm housing and lower arm The procedure below details how to refit the cabling inside the upper arm housing. The cable layout is shown in the figure Illustration, cabling inside upper arm housing on page 107. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. Insert the cabling to axes 3, 4, 5 and 6 up through the lower arm and into the upper arm housing. Place the cable bracket correctly inside the lower Spare part no. is specified in arm and secure it by refitting the VK-cover. Required equipment on page 104.
xx0400001247
Cable bracket is attached to the cabling with 2 screws, M6x8. 4. Fasten the cabling inside the upper arm housing Shown in the figure Illustration, by fitting the cable clamp unit to the distance cabling inside upper arm housing console with two attachment screws. on page 107. Fit the motor and signal cabling to the connector Hexagon nut: M5. 1 pc for each plate with clamps. clamp. Reconnect the signal cable connectors and slide Shown in the figure Illustration, them into the connector holder. cabling inside upper arm housing Notice that one of the cable ties in the connector on page 107. holder plate must be removed in order to insert the cables into the holder. Refit it when the connectors are inserted. Reconnect the motor cable connectors. Reconnect optional connectors, if any, at the contact panel. Place the cabling correctly inside the housing and secure it with cable ties. The cable layout is shown in the figure Illustration, cabling inside upper arm housing on page 107.
5. 6.
7. 8. 9.
108
4 Repair
Step
Action
Note
10. Refit the arm housing cover with eight attachment 8 pcs, M6. screws. Check the two gaskets and replace, if Shown in the figure Illustration, damaged. covers to remove on page 105. Spare part no. is specified in Required equipment on page 104. 11. Fit new VK-covers to the lower arm. Spare part no. is specified in Required equipment on page 104.
12. Continue refitting the cable harness according to procedure Refitting, cable harness in frame and base on page 111.
Illustration, cabling inside frame The figure below shows how the cabling is run inside the frame.
xx0400001249
A B C D E
Power cabling; connectors for motors on axes 1 and 2: R3.MP1 and R3.MP2 Signal cabling; connectors for motors on axes 1 and 2: R3.FB1 and R3.FB2 Cable clamp unit (attachment screws behind the fastening plate) Fastening plate Attachment screws and nuts
109
4 Repair
Illustration, cabling inside base The figure below shows how the cabling is run inside the base. Optional cabling is also shown in the figure, but not further specified.
xx0500001388
A B C D E F G H
Power cabling Signal cabling Clamp with hexagon nut Attachment screws, cable clamp unit Hexagon nut, SMB plate Fastening plate SMB unit Cable clamp unit
110
4 Repair
Refitting, cable harness in frame and base The procedure below details how to refit the cabling inside the frame and the base. The cable layout is shown in the figures Illustration, cabling inside frame on page 109 and Illustration, cabling inside base on page 110. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. Run the cables from the lower arm into the frame. Fit the cable clamp unit to the fastening plate with two attachment screws, but do not secure the plate to the frame yet. Run the cabling down to the base. Pull it out at the rear of the base. Connect all the connectors inside the frame and Shown in the figure Illustration, secure all plates and cable brackets inside the cabling inside frame on page 109. frame with attachment screws and nuts. In the base, secure the cabling to the bottom fastening plate: fit the cable clamp unit with two attachment screws (M6). fit the separate cables with clamps and hexagon nuts. Refit the SMB unit to the fastening plate with hexagon nuts. Connect the: signal cable connectors to the SMB board power cable connector to the housing in the base optional cabling, if any ground cable. Refit the covers to the frame and to the base. Replace the gaskets, if damaged. Shown in the figure Illustration, cabling inside base on page 110. Shown in the figure Illustration, cabling inside frame on page 109.
4. 5.
6.
7. 8.
Shown in the figure Illustration, cabling inside base on page 110. Shown in the figure Illustration, cabling inside base on page 110.
9.
Shown in the figure Illustration, covers to remove on page 105. Spare part no. is specified in Required equipment on page 104. Calibration is detailed in a separate calibration manual. Art. no. for the manual is specified in section Document references in the Product manual, reference information.
10. Recalibrate the robot!
111
4 Repair
4.4.1. Replacement of complete upper arm
4.4 Upper and lower arm 4.4.1. Replacement of complete upper arm
General The complete upper arm is considered a spare part, including wrist, gearboxes and motors. Location of upper arm The figure below shows the location of the upper arm on the robot and some of the upper arm components. A more detailed view of the component and its position may be found in chapter Spare parts and exploded views in the Product manual (part 2 of 2), reference information.
xx0400001218
A B
Arm housing cover, including gaskets for the cover and the contact panel VK cover. Upper arm attachment screws inside
112
4 Repair

Upper arm, spare
Spare part no.

3HAC 023630-001
Art. no.
Note
Includes the wrist unit. All gearboxes are filled with oil at delivery. Replace if damaged. Replace if damaged. Replace if damaged.
VK-cover Sealing ring (V-ring) Gasket, upper arm cover Gasket, customer connections Grease Locking liquid Lifting slings Standard toolkit
3HAA 2166-23 3HAB 3732-19 3HAC 022049-001 3HAC 022050-001
3HAB 3537-1 To lubricate the sealing ring (V-ring). The contents are defined in section Standard toolkit in the Product manual, reference information. These procedures include references to the tools required. Loctite 574
Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.
113
4 Repair
Removal, complete upper arm The procedure below details how to remove the complete upper arm from the robot. Step
1.
Action
Note/Illustration
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. 4. Move the upper arm to a horizontal position. Remove the arm housing cover from the upper Shown in the figure Location of arm. upper arm on page 112. Disconnect all connectors inside the arm housing and loosen the cabling from straps and brackets. The cabling and all connectors inside the upper arm housing are shown in the figure Illustration, cabling inside upper arm housing on page 107. Shown in the figure Location of upper arm on page 112.
5.
Remove the VK-cover from the lower arm by pushing it out from the inside. Pull out the cabling from the arm housing. Secure the weight of the arm with lifting slings.
6. 7.
Caution! The complete upper arm weighs 34 kg without any additinal equipment fitted! Use a suitable lifting device to avoid injury to personnel! 8. Remove the 10 attachment screws (A) and the one washer (B).
xx0400001219
9.
Remove the upper arm, lift it away and place it securely.
114
4 Repair
Refitting, complete upper arm The procedure below details how to refit the complete upper arm to the robot. Step
1.
Action
Note/Illustration
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. Wipe the contact surfaces clean on both the upper and lower arm.
Caution! The complete upper arm weighs 34 kg without any additinal equipment fitted! Use a suitable lifting device to avoid injury to personnel! 4. 5. Attach lifting slings to the upper arm and lift it. Lubricate the sealing ring (A) with grease and fit it to the upper arm. Replace the sealing ring, if damaged.
xx0400001220
6. 7. Lubricate the the contact surface, upper arm, with Loctite 574.
A: Sealing ring, spare part no. is specified in Required equipment on page 113. B: Contact surface.
Lift the upper arm to mounting position, fit the 10 pcs: M10 x 40. washer (B) and secure the upper arm with the Tightening torque: 70 Nm. 10 attachment screws (A).
xx0400001219
115
4 Repair
Step
8. 9.
Action
Run the cabling through the lower arm and into the arm housing.
Note/Illustration
Connect all the connectors in the arm housing Refitting of the cabling in the upper and secure the cabling with brackets and arm house is further detailed in straps. section Refitting, cable harness in upper arm housing and lower arm on page 108.
10. Refit the arm housing cover to the upper arm. Shown in the figure Location of upper arm on page 112. Check the two gaskets in the cover and replace them, if damaged. Spare part no. is specified in section Required equipment on page 113. 11. Refit a new VK-cover to the lower arm. Shown in the figure Location of upper arm on page 112. Spare part no. is specified in section Required equipment on page 113. Calibration is detailed in a separate calibration manual. Art. no. for the manual is specified in section Document references in the Product manual, reference information.
DANGER! When performing the first test run after a service activity (repair, installation or maintenance, it is vital that: all the service tools and other foreign objects are removed from the manipulator! all normal safety equipment is installed properly, e.g. TPU enabling device. all personnel are standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc. special attention is paid to the function of the part previously serviced.
116
4 Repair
4.4.2. Replacement of complete lower arm

Location of lower arm The lower arm is located on the robot as shown in the figure below.
xx0400001246
A B C
Lower arm VK-cover VK-cover, middle

Lower arm, spare Lower arm, short, spare VK-cover VK-cover
Spare part no.

3HAC 023558-001 3HAC 023559-001 3HAA 2166-23 3HAA 2166-21
Note
IRB 1600 - 7/.12 IRB 1600 - 7/1.45 IRB 1600 - 5/1.2 IRB 1600 - 5/1.45 In the middle of the lower arm.
117
4 Repair
Equipment
Sealing ring (V-ring) Isopropanol Locking liquid Standard toolkit
Spare part no.

3HAB 3732-13
Note
Replace if damaged. Used to clean the mating surfaces. Loctite 574 The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.
Removal, lower arm The procedure below details how to remove the complete lower arm. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. Remove the complete upper arm. Remove the VK-covers. Caution! Be careful not to damage the cabling and cable bracket inside the lower arm when removing the middle VK-cover! The figure to the right shows the space underneath the cover. The gray areas are safe for insertion of a tool that may be inserted with a maximum depth of 20 mm! Detailed in section Removal, complete upper arm on page 114. Shown in the figure Location of lower arm on page 117.
xx0400001247
4. 5.
Pull down the cabling through the lower arm and pull it out.
Caution! The lower arm weighs 20 kg! Use a suitable lifting devie to avoid injury to personnel! 6. Fit the lifting device to the lower arm to secure the weight of the arm.
118
4 Repair
Step
7. 8.
Action
Unscrew the 12 attachment screws and remove the one washer. Gently pull out the cabling while lifting away the lower arm. Be careful with the connectors, they are sensitive to damage! Check the sealing ring. Replace it if damaged.
Note
9.
Spare part no. is specified in Required equipment on page 117.
Refitting, lower arm The procedure below details how to refit the complete lower arm. Step
1.
Action
Note/Illustration
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Clean the mating surfaces on both the lower arm and on the frame with isopropanol. Also clean the area where the sealing ring is fitted. Fit the sealing ring properly to the frame. Replace it if damaged. Spare part no. is specified in Required equipment on page 117.
3.
xx0400001245
4. 5. Lubricate the mating surface on the frame with Loctite 574.
A: Sealing ring B: Mating surface
Caution! The lower arm weighs 20 kg! Use a suitable lifting devie to avoid injury to personnel! 3HAC 023637-001 Revision: 119
4 Repair
Step
6. 7. 8.
Action
Fit the lifting device to the lower arm and lift it into position. Insert the cabling into the lower arm.
Note/Illustration
Fit the lower arm against the frame, fit the one 12 pcs; M10 x 40, tightening torque: washer and secure with the 12 attachment 70 Nm. screws. Push the cabling up through the lower arm and place the cable bracket inside the lower arm correctly.
9.
10. Fit new VK-covers to the lower arm. Spare part no. is specified in Required equipment on page 117. Make sure that the cable bracket inside the lower arm is secured beneath the middle VKcover. 11. Refit the upper arm. 12. Recalibrate the robot! Detailed in section Refitting, complete upper arm on page 115. Calibration is detailed in a separate calibration manual. Art. no. for the manual is specified in section Document references in the Product manual, reference information.
120
4 Repair
4.4.3. Replacement of wrist unit

Location of wrist unit The wrist unit is located in the frontmost part of the upper arm. A more detailed view of the component and its position may be found in chapter Spare parts and exploded views in the Product manual (part 2 of 2), reference information.
xx0200000438
A B C
Attachment screws, wrist unit (3 pcs) Oil plug (only one shown) Wrist unit

Wrist, Standard/ Foundry O-ring sealingplate Grease Standard toolkit
Spare part no. Art. no.

3HAC 10475-1 3HAC 7191-1
Note
Standard and Foundry versions. O-ring sealing plate not included! Must be replaced.
3HAC 3537-1 For lubricating the o-ring sealing plate. The contents are defined in section Standard toolkit in the Product manual, reference information. These procedures include references to the tools required.
Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below. 3HAC 023637-001 Revision: -
121
4 Repair
Removal, wrist unit The procedure below details how to remove the complete wrist unit. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. Drain the oil from the wrist unit. Remove the wrist unit by unscrewing its three attachment screws. Detailed in section Oil change, gearbox axes 5 and 6 on page 92. Shown in the figure in section Location of wrist unit on page 121.
Refitting, wrist unit The procedure below details how to refit the complete wrist unit. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. 4. Run the robot to a position where the upper arm is vertical and points upward. Lightly lubricate the o-ring sealing plate with grease. Art. no. is specified in section Required equipment on page 121.
In order to release the brake, connect the Connect to connector R3.MP5 or 6: 24 VDC power supply to motors: +: pin 7 -: pin 8 Fit the o-ring sealing plate to the upper arm. Fit the wrist unit to the upper arm with the three attachment screws, while making sure that the gears mate properly. Perform a leak-down test. Refill the wrist unit with oil. Recalibrate the robot! Use a new o-ring! Spare part no. is specified in Required equipment on page 121. 3 pcs, M8 x 25, tightening torque: 28 Nm. Detailed in section Leak-down test. Detailed in section Oil change, gearbox axes 5 and 6 on page 92. Calibration is detailed in a separate calibration manual. Art. no. for the manual is specified in section Document references in the Product manual, reference information.
5.
6. 7. 8.
122
4 Repair
123
4 Repair
4.4.4. Replacement of damper, axis 2

Location of damper, axis 2 The damper, axis 2, is located as shown in the figure below! A more detailed view of the component and its position may be found in chapter Spare parts and exploded views in the Product manual (part 2 of 2), reference information.
xx0400001217
A B
Damper, axis 2 Attachment screw and washer

Damper, axis 2 Standard toolkit
Spare part no.

3HAC 022013-001
Note
The contents are defined in section Standard toolkit in the Product manual, reference information. These procedures include references to the tools required.
124
4 Repair
Removal, damper axis 2 The procedure below details how to remove the damper, axis 2. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. Run the robot to a position that enables you to access the attachment screw of damper, axis 2. Remove the damper by unscrewing the single attachment screw and washer.
Refitting, damper axis 2 The procedure below details how to refit the damper, axis 2. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. Run the robot to a position that enables access to the attachment screw of the damper, axis 2. Secure the damper with the attachment screw and washer. 1 pc: M6 x 16.
125
4 Repair

Location of damper, axis 3 The damper, axis 3, is shown in the figure below! A more detailed view of the component and its position may be found in chapter Spare parts and exploded views in the Product manual (part 2 of 2), reference information.
xx0400001215
A B
Damper, axis 3 Cast tab

Spare part no.

3HAC 022260-001
Note
126
4 Repair
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. Run the robot to a position that enables access to Shown in the figure Location of damper, axis 3. damper, axis 3 on page 126. Remove the damper by gently prying it from the cast tab.
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Run the robot to a position that enables access to the Shown in the figure Location location where the damper, axis 3, is fitted. of damper, axis 3 on page 126. Refit the damper by gently pressing it onto the cast tab on the upper arm.
3.
127
4 Repair

Location of damper, axis 5 The damper, axis 5, is located as shown in the figure below!
xx0200000429
A B
Damper, axis 5 Recess

Spare part no.

3HAB 8964-1
Note
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Run the robot to a position that enables the end of the Shown in the figure in damper to be pushed into the recess in the wrist unit. section Location of damper, axis 5 on page 128. Unhook the end of the damper, and push it into the recess. Manually move the wrist (robot axis 5) away from the damper to pull it out.
3. 4.
128
4 Repair
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. 4. Push the end of the damper into the gap between the Make sure the damper is wrist unit and upper arm. turned the correct way! Manually move the wrist (robot axis 5) in order to pull the damper into position. Fold out the damper hooks to secure it in position.
DANGER! When performing the first test run after a service activity (repair, installation or maintenance), it is vital that: - all the service tools and other foreign objects are removed from the manipulator! - all normal safety equipment is installed properly, e.g. TPU enabling device. - all personnel is standing at a safe distance from the manipulator, i.e. out of its reach behind any safety fences, etc. - special attention is paid to the function of the part previously serviced.
129
4 Repair
4.5.1. Replacement of base
4.5 Frame and base 4.5.1. Replacement of base

Location of base The base is located at the bottom of the robot as shown in the figure below. A more detailed view of the component and its position may be found in chapter Spare parts and exploded views in the Product manual (part 2 of 2), reference information.
xx0500001453
A B
Base Attachment screws and washer, base-gearbox unit (VK-cover removed)

Base, spare V-ring (sealing ring) VK-cover Lifting slings
Spare part no.

3HAC 023552-001 3HAB 3732-21 3HAA 2166-26
Art. no.
Note
Standard and Foundry versions. Replace if damaged.
130
4 Repair
Equipment
Locking liquid
Spare part no.
Art. no.
Note
Loctite 574 For sealing the base to the gearbox 1-2.
Grease Isopropanol Standard toolkit
3HAB 3537-1
For lubricating the V-ring. For cleaning the mating surfaces.
The contents are defined in section Standard toolkit in the Product manual, reference information. These procedures include references to the tools required.
Removal, base The procedure below details how to remove the base from the robot. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. 4. Remove the cabling inside the base and pull The cable layout in the base is shown it up to the gearbox unit. in the figure . Remove the serial measurement unit. Unfasten the base from the installation site by removing the attachment bolts from the foundation. Detailed in section Removal, serial measurement unit on page 135.
5.
Caution! The robot weighs 250 kg! All lifting equipment must be sized accordingly! 6. Fit the lifting slings to the robot, lift it and place it with the side of the lower arm downwards on a work bench. Be careful not to damage the motor connectors! Art. no. is specified in Required equipment on page 130.
131
4 Repair
Step
7.
Action
Remove the VK-cover from the base. Tip! Push out the cover from inside or drill a hole in the cover through which a tool can be inserted in order to bend out the cover.
Note
8.
Caution! The base weighs 81 kg! All lifting equipment used must be sized accordingly! 9. Secure the weight of the base and remove the gearbox/base attachment screws and washer. Shown in the figure Location of base on page 130.
10. Separate the base from the gearbox unit.
Refitting, base The procedure below details how to refit the base to the robot. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Place the robot with the side of the lower arm downwards on a workbench. Be careful not to damage the motor connectors. Clean the mating surfaces between the base and the gearbox unit with isopropanol. Check the V-ring on the gearbox unit. Spare part no. is specified in Required Lubricate with grease if needed. Replace it if equipment on page 130. damaged! Lubricate the mating surface on the base with Loctite 574.
3. 4.
5. 6.
Caution! The base weighs 81 kg! All lifting equipment used must be sized accordingly! 7. Lift the base to mounting position.
132
4 Repair
Step
8.
Action
Note
Secure the base to the gearbox unit with the Shown in the figure Location of base gearbox/base attachment screws and on page 130. washer. 16 pcs, M10 x 40, tightening torque: 70 Nm. Refit a new VK-cover to the base. Spare part no. is specified in Required equipment on page 130.
9. 10.
Caution! The robot weighs 250 kg! All lifting equipment must be sized accordingly! 11. Turn the robot to stand upright. 12. Secure the base to the foundation. Attachment bolts and tightening torque are specified in section Attachment bolts, specification on page 51. The cable layout inside the base is shown in the figure . Detailed in section Refitting, serial measurement unit on page 136. Calibration is detailed in a separate calibration manual. Art. no. for the manual is specified in section Document references in the Product manual, reference information.
13. Pull down the cabling and refit it inside the base. 14. Refit the serial measurement unit. 15. Recalibrate the robot.
133
4 Repair
4.5.2. Replacement of serial measurement unit

Location of serial measurement unit The serial measurement unit is located inside the base of the robot, as shown in the figure below.
xx0500001390
Base cover, including gasket. Serial measurement unit is located beneath the cover.
Serial measurement unit layout The complete spare part of the serial measurement unit is shown in the figure below.
xx0500001391
A B C D E
Connector SMB Connector SMB1-4 Connector SMB 3-6 Hexagon nuts (totally 4 pcs) Battery pack
134
4 Repair

Serial measurement unit Gasket, base cover Standard toolkit Circuit diagram See chapter Circuit diagram in the Product manual, reference information.
Spare part no.

3HAC 023424-001 3HAC 022047-001
Note
Removal, serial measurement unit The procedure below details how to remove the serial measurement unit from the robot. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. 4. Remove the base cover from the robot. Disconnect all the connectors from the serial measurement unit. Unscrew the four hexagon nuts on the Shown in the figure Serial measurement serial measurement unit enough to enable unit layout on page 134. lifting the unit. Do not remove the nuts. Lift and pull the serial measurement unit backwards, over the lip (A), and lift it away. Shown in the figure Location of serial measurement unit on page 134.
5.
xx0500001455
135
4 Repair
Refitting, serial measurement unit The procedure below details how to refit the serial measurement unit to the robot. Step
1.
Action
Note/Illustration
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Fit the serial measurement unit on to the four pins (A).
xx0500001392
3. 4. 5. 6. 7.
Slide the unit into position, within the lips, and secure with the four hexagon nuts. Reconnect all the connectors to the unit. Check the gasket of the base cover. Replace it if damage. Refit the base cover. Update the revolution counters! Shown in the figure Serial measurement unit layout on page 134. Spare part no. is specified in Required equipment on page 135. Shown in the figure Location of serial measurement unit on page 134. Detailed in section Updating revolution counters on page 176.
136
4 Repair
4.5.3. Replacement of push button unit

Location of push button unit The push button unit for brake release is located inside the base of the robot, as shown in the figure below.
xx0500001390
Base cover, including gasket. Push button unit is located beneath the cover.
Push button unit on serial measurement unit The push button unit is attached to the serial measurement unit as shown in the figure below.
xx0500001394
A B C
Push button unit Hexagon nuts (2 pcs) Hexagon nuts, SMB unit (4 pcs)
137
4 Repair

Push button unit Gasket, base cover Standard toolkit
Spare part no.

3HAC 020967-001 3HAC 022047-001
Note
Includes brake release board and push buttons. The contents are defined in section Standard toolkit in the Product manual, reference information.
Removal, push button unit The procedure below details how to remove the push button unit from the robot. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. 4. Remove the base cover from the robot. Disconnect all the connectors from the brake release board. Unscrew the four hexagon nuts on the SMB unit and move the SMB unit backwards. The nuts do not need to be removed. Remove the two hexagon nuts from the push button unit. Remove the push button unit by lifting it up. Shown in the figure Push button unit on serial measurement unit on page 137. Shown in the figure Location of push button unit on page 137.
5. 6.
Shown in the figure Push button unit on serial measurement unit on page 137.
138
4 Repair
Refitting, push button unit The procedure below details how to refit the push button unit to the robot. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Fit the new push button unit to the serial measurement unit in the robot base. Spare part no. is specified in Required equipment on page 138. Shown in the figure Push button unit on serial measurement unit on page 137. Shown in the figure Push button unit on serial measurement unit on page 137. Shown in the figure Push button unit on serial measurement unit on page 137. Spare part no. is specified in Required equipment on page 138. Shown in the figure Location of push button unit on page 137.
3. 4. 5. 6. 7.
Secure the unit with two hexagon nuts. Push in and secure the SMB unit with the four hexagon nuts. Reconnect all the connectors to the board. Check the gasket of the base cover. Replace it if damaged. Refit the base cover.
139
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 axis 1 motor is located on the frame, as shown in the figure below.
xx0400001256
A B C D E
Motor, axis 1 Connector plate for motor cabling Cover, frame Attachment screws, motor (4 pcs) Motor cover
Required equipment Equipment Spare part no. Art. no. Note
Rot. ac motor incl. pinion, 3HAC 023557-001 spare O-ring 21522012-428 O-ring, motor. Replace if damaged. Replace if damaged.
Gasket, gearbox axis 1-2 3HAC 022048-001
140
4 Repair
Equipment
Power supply
Spare part no.
Art. no.
-
Note
24 VDC, max 1.5 A For releasing the brakes. Used to clean mating surfaces.
Isopropanol Grease Rotation tool, motor Standard toolkit
3HAB 3537-1 3HAC 022266-003
The contents are defined in section Standard toolkit in the Product manual, reference information. See chapter Circuit diagram in the Product manual, reference information.
Circuit diagram
Removal, motor axis 1 The procedure below details how to remove the motor, axis 1. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. 4. 5. Remove the cover, frame. Disconnect the connectors for the motor, axis 1. Loosen the connector plate from the frame and pull out the motor cabling. In order to release the brakes, connect the 24 VDC power supply to the motor. Connect to connector R3.MP1: +: pin 7 -: pin 8 Shown in the figure Location of motor on page 140.
6. 7.
Unscrew the four attachment screws from the motor. Shown in the figure Location of motor on page 140. Remove the motor by gently lifting it straight up, making sure the motor pinion is not damaged against the gear. Disconnect the brake release voltage from the motor connector.
8.
141
4 Repair
Refitting, motor axis 1 The procedure below details how to refit the motor, axis 1. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. Clean the mating surface on the frame. Make sure the o-ring on the circumference of the motor is seated properly. Lubricate the oring with grease. Art. no. is specified in Required equipment on page 140.
4. 5.
Remove the motor cover from top of the motor. Shown in the figure Location of motor on page 140. In order to release the brakes, connect the 24 VDC power supply to the motor. Connect to connector R3.MP1: +: pin 7 -: pin 8
6. 7.
Fit the rotation tool to the end of the motor shaft. Art. no. is specified in Required equipment on page 140. Fit the motor, making sure the motor pinion is properly mated to the gear of gearbox, axis 1. Use the rotation tool to rotate the motor pinion, when mating it to the gear. Secure the motor with four attachment screws and washers, but do not tighten yet. 4 pcs, M8 x 25.
8. 9.
Adjust the motor in relation to the gear in the There should be a barely noticable gearbox: gear play. use the rotation tool to wiggle the motor shaft back and forth to feel the play. Tap with a plastic mallet. position the motor pinion at at least two other positions by turning axis 1 manually and check the gear play again. Tightening torque: 35 Nm. Shown in the figure Location of motor on page 140.
10. Tighten the motor attachment screws. 11. Disconnect the brake release voltage. 12. Refit the motor cover to top of the motor.
13. Insert the motor cabling through the frame and 4 pcs. secure the connector plate with attachment screws. 14. Connect all the connectors inside the frame. The cable layout is shown in the figure Illustration, cabling inside frame on page 109. Spare part no. is specified in Required equipment on page 140.
15. Refit the cover, frame. Replace the gasket, if damaged.
142
4 Repair
Step
Action
Note
Calibration is detailed in a separate calibration manual. Art. no. for the manual is specified in section Document references in the Product manual, reference information.
143
4 Repair

Location of motor axis 2 The motor axis 2 is located on the front of the robot as shown in the figure below. A more detailed view of the component and its position may be found in chapter Spare parts and exploded views in the Product manual (part 2 of 2), reference information.
xx0400001257
A B C D E
Motor, axis 2 Cover, frame Connector plate for motor cabling Bracket and cable tie Motor cover
Required equipment Equipment, etc. Spare part no.

Rot. ac motor incl. pinion, spare O-ring Gasket, gearbox axis 1-2 Grease Isopropanol Standard toolkit 3HAC 023557-001 21522012-428 3HAC 022048-001 3HAB 3537-1 Must be replaced when replacing motor. Replace if damaged. For lubricating the o-ring. For cleaning mating surfaces. The contents are defined in section Standard toolkit in the Product manual, reference information.
Art. no.
Note
144
4 Repair
Equipment, etc. Spare part no.

Rotation tool, motor Power supply Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit Diagram
Art. no.
3HAC 022266003 -
Note
For adjusting the gear play, motor/pinion 24 VDC, 1.5 A. For releasing the brakes. These procedures include references to the tools required.
See chapter Circuit diagram in the Product manual, reference information.
Removal, motor axis 2 The procedure below details how to remove the axis 2 motor. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. Remove the cover, frame. Disconnect the motor connectors inside the frame. Shown in the figure Location of motor axis 2 on page 144. Connectors: R3.MP2 R3.FB2
4. 5.
Cut any cable ties and remove any brackets or clamps securing the cables. Remove the connector plate by removing its attachment screws, and pull the cables out from the frame. Shown in the figure Location of motor axis 2 on page 144.
6.
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!
145
4 Repair
Step
7.
Action
In order to release the brakes, connect the 24 VDC power supply to the motor.
Note
Connect to connector R3.MP2 +: pin 7 -: pin 8
8.
Warning! Oil will be running out of the motor attachment hole when removing the motor! It may also be hot! Take any necessary measures to collect the oil. 9. Remove the motor by unscrewing its four attachment Shown in the figure Location screws and plain washers. of motor axis 2 on page 144.
10. Remove the motor by gently pulling it out, making sure the motor pinion does not get damaged while moving it away from the gear. 11. Disconnect the brake release voltage. 12. Remove any remaining oil from the gearbox by siphoning it off.
Refitting, motor axis 2 The procedure below details how to refit the axis 2 motor. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Make sure the mating surfaces on the motor and the gearbox are clean and free from burrs. If necessary, clean the surfaces with isopropanol. Make sure the o-ring on the circumference of Art. no. is specified in section the motor is seated properly. Required equipment on page 144. Lightly lubricate the o-ring withgrease. In order to release the brakes, connect the 24 Connect to connector R3.MP2: VDC power supply to the motor. +: pin 7 -: pin 8 Remove the motor cover from top of the motor. Shown in the figure Location of motor axis 2 on page 144. Fit the rotation tool to the end of the motor shaft. Art. no. is specified in section Required equipment on page 144.
3.
4.
5. 6.
146
4 Repair
Step
7.
Action
Fit the motor, making sure the motor pinion is properly mated to gearbox 2. Use the rotation tool to rotate the motor pinion, when mating it to the gear.
Note
Make sure the motor is turned the right way, i.e. connections upwards. Make sure the motor pinion does not get damaged!
8. 9.
Secure the motor with four attachment screws 4 pcs, M8 x 25. and plain washers, but do not tighten yet. Tightening torque: approx 2 Nm. Adjust the motor in relation to the gear in the There should be a barely noticable gearbox. gear play. Use the rotation tool to wiggle the motor shaft back and forth to feel the play. Tap with a plastic mallet.
10. Refit the motor cover to the top of the motor. Be careful not to damage the cables! 11. Tighten the motor attachment screws. 12. Disconnect the brake release voltage. 13. Refit the connector plate with its attachment screws. 14. Reconnect the motor connectors inside the frame. Shown in the figure Location of motor axis 2 on page 144. Cable layout is shown in the figure Illustration, cabling inside frame on page 109. Tightening torque: 35 Nm.
15. Refit all cable ties, and the bracket underneath Shown in the figure Location of the frame. motor axis 2 on page 144. 16. Refit the cover, frame. Replace the gasket, if damaged. Shown in the figure Location of motor axis 2 on page 144. Art. no. for the gasket is specified in section Required equipment on page 144. Detailed in section Performing a leak-down test on page 100. Type of oil and amount is specified in section Oil in gearboxes on page 91. Calibration is detailed in a separate calibration manual. Art. no. for the manual is specified in section Document references in the Product manual, reference information.
17. Perform a leak-down test. 18. Refill the gearbox with oil.
147
4 Repair

Location of motor The motor of axis 3 is located inside the upper arm housing, as shown in the figure below.
xx0400001258
A B C D E F G
Motor, axis 3 Attachment screws and washers of the motor (4 pcs) Signal connector R3.FB3 Power connector R3.MP3 Connector holder Upper arm housing cover Cable tie

Rot. ac motor incl pinion O-ring Gasket, upper arm cover Gasket, customer connections
Spare part no.

3HAC 021798-001 21522012-426 3HAC 022049-001 3HAC 022050-001
Art. no.
Note
Replace if damaged. Replace if damaged. Replace if damaged.
148
4 Repair
Equipment
Isopropanol Grease Rotation tool, motor Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit diagram
Spare part no.
Art. no.
3HAB 3537-1
Note
Used for cleaning the mating surfaces. Used for lubricating the oring.
3HAC 022266-003 For adjusting the gear play. These procedures include references to the tools required.
Removal, motor axis 3 The procedure below details how to remove the axis 3 motor. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. Remove any additional mechanical stops from axis 3. Move: axis 2 to calibration position upper arm backwards against the mechanical stop. This position enables removal of the motor without draining of the gearbox, axis 3.
xx0500001447
4.
Remove the upper arm house cover.
Shown in the figure Location of motor on page 148.
149
4 Repair
Step
5. 6.
Action
Disconnect the motor connectors R3.MP3 and R3.FB3.
Note
Danger! Secure the weight of the upper arm properly before releasing the brakes of motor, axis 3. When releasing the holding brakes of the motor, the upper arm will be movable and may fall down! 7. In order to release the brakes, connect the 24 VDC power supply to the motor. Connect to connector R3.MP3: +: pin 7 -: pin 8
8.
Remove the motor, axis 3, by unscrewing its attachment screws and washers. Lift the motor gently straight out, making sure the motor pinion is not damaged. Disconnect the brake release voltage.
9.
Refitting, motor axis 3 The procedure below details how to refit the axis 3 motor. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. Clean the mating surfaces inside the upper arm housing and on the motor with isopropanol. Make sure the o-ring on the circumference of the Replace the o-ring if damaged. motor is seated properly. Ligthly lubricate it with Art .no. is specified in section grease. Required equipment on page 148. In order to release the brakes, connect the 24 VDC power supply to the motor. Fit the motor to the upper arm housing, making sure the motor pinion is properly mated to the gear of axis 3. Fit the attachment screws and washers but do not tighten them yet. 4 pcs, M6 x 20. Shown in the figure Location of motor on page 148. Connect to connector R3.MP3: +: pin 7 -: pin 8.
4.
5.
6.
150
4 Repair
Step
7. 8.
Action
Note
Fit the rotation tool to the end of the motor shaft. Art. no. is specified in Required equipment on page 148. Adjust the motor in relation to the gear. Use the rotation tool to wiggle the motor shaft back and forth to feel the play. Tighten the motor attachment screws. There should be a barely noticable gear play. Tightening torque: 10 Nm.
9.
10. Disconnect the brake release voltage. 11. Reconnect the motor connectors, run and secure Cable layout is shown in the the cabling correctly inside the upper arm figure Illustration, cabling inside housing. upper arm housing on page 107. 12. Refit the cover, upper arm housing. Check both the gaskets and replace, if damaged. Shown in the figure Location of motor on page 148. Art. no. is specified in section Required equipment on page 148. Detailed in section Installation of additional mechanical stops on axis 3 on page 72. Calibration is detailed in a separate calibration manual. Art. no. for the manual is specified in section Document references in the Product manual, reference information.
13. Refit any additional mechanical stops.
151
4 Repair

Location of motor The axis 4 motor is located inside the upper arm housing, as shown in the figure below. A more detailed view of the component and its position may be found in chapter Spare parts and exploded views in the Product manual (part 2 of 2), reference information.
xx0400001273
A B C D E F
Motor, axis 4 Cover, upper arm housing Connector plate Signal connector, R3.FB4 Power connector, R3.MP4 Attachment screw and washer, motor (4 pcs)

O-ring Gasket, customer connections 152
Spare part no.

3HAB 3772-81 3HAC 022050-001
Art. no.
Note
Replace if damaged. Replace if damaged. Replace if damaged.
Rot. ac motor incl pinion 3HAC 021799-001 Gasket, upper arm cover 3HAC 022049-001
4 Repair
Equipment, etc.
Grease Standard toolkit
Spare part no.
Art. no.
3HAB 3537-1
Note
Used for lubricating the oring. The contents are defined in section Standard toolkit in the Product manual, reference information.
Power supply Rotation tool, motor Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit Diagram
24 VDC, max. 1,5 A. For releasing the brakes.
3HAC 022266- For adjusting the gear play. 003 These procedures include references to the tools required.
Removal, motor axis 4 The procedure below details how to remove the motor, axis 4. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Manually move the robot to a position where the upper arm points straight down. Remove the cover from the upper arm housing. Remove the connector plate to get access to the axis 4 motor. Disconnect the connectors R3.MP4 and R3.FB4 from the axis 4 motor. In order to release the brakes, connect the 24 VDC Connect to connector R3.MP4 power supply to the motor. +: pin 7 -: pin 8 Remove the motor, axis 4 by unscrewing the motor Shown in the figure Location of attachment screws. motor on page 152. Lift the motor to get the pinion away from the gear and disconnect the brake release voltage. Remove the motor by gently lifting it out. Make sure the motor pinion is not damaged! Shown in the figure Location of motor on page 152. This will enable the motor 4 to be removed without draining the oil in the gearbox.
3. 4. 5. 6.
7. 8. 9.
153
4 Repair
Refitting, motor axis 4 The procedure below details how to refit the motor, axis 4. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. Clean the mating surfaces on the motor and the gearbox. Shown in the figure Location of motor on page 152.
Make sure the o-ring on the circumference of Art. no. is specified in section the motor is seated properly. Lightly lubricate Required equipment on page 152. the o-ring with grease . In order to release the brakes, connect the 24 Connect to connector R3.MP4 VDC power supply to the motor. +: pin 7 -: pin 8 Fit the motor with the attachment screws and washers. Until the motor shaft is adjusted to the gear, as described in following steps, only tighten the screws lightly. Fit the rotational tool to the end of the motor shaft. Adjust the motor in relation to the gear in the gearbox. Use the arm tool to wiggle the motor shaft back and forth to feel the play. Tighten the motor attachment screws. Shown in the figure Location of motor on page 152. Tightening torque: approx. 2 Nm. 4 pcs, M6 x 20. Art. no. is specified in section Required equipment on page 152. There should be a barely noticable gear play.
4.
5.
6. 7.
8.
Shown in the figure Location of motor on page 152. Tightening torque: 10 Nm.
9.
Reconnect the motor connectors R3.MP4 and R3.FB4. Shown in the figure Location of motor on page 152. Cable layout is shown in the figure Illustration, cabling inside upper arm housing on page 107. Art. no. is specified in Required equipment on page 152. Detailed in section Performing a leak-down test on page 100. Calibration is detailed in a separate calibration manual. Art. no. for the manual is specified in section Document references in the Product manual, reference information. 3HAC 023637-001 Revision: -
10. Refit the connector plate. 11. Make sure all the cabling is placed correctly inside the upper arm housing. 12. Refit the cover to the upper arm housing. Check both the gaskets and replace, if damaged. 13. Perform a leak-down test. 14. Recalibrate the robot!
154
4 Repair
155
4 Repair
4.6.5. Replacement of motor and timing belt, axis 5

Location of motor The motor and timing belt of axis 5 is located inside the upper arm housing, as shown in the figure below.
xx0400001279
A B C D E F G H
Motor, axis 5 Cover, upper arm housing Connector plate Signal cable, motor 5. R3.FB5 Power cable, motor 5: R3.MP5 Attachment screws and washers, motor bracket (2 pcs) Motor bracket Attachment screws and washers, motor (3 pcs)
156
4 Repair

Rot. ac motor incl pinion Timing belt Gasket, customer connections Belt tightener Dynamometer Salter Super Samson 100N Standard toolkit
Spare part no.

3HAC 021800-001 3HAC 021304-001
Art. no.
Note
Gasket, upper arm cover 3HAC 022049-001 3HAC 022050-001 3HAC 024044-001 -
Supplier: Ahlsell The contents are defined in section Standard toolkit in the Product manual, reference information. These procedures include references to the tools required.
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit diagram
Belt tightener, 3HAC 024044-001 The belt tightener is a special tool that is used when adjusting the tension of the timing belt of axis 5. The length of the tool is important, since the tool is pulled with a given force.
xx0500001457
157
4 Repair
Removal, motor axis 5 and timing belt The procedure below details how to remove the motor and the timing belt of axis 5. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. 4. 5. 6. Remove the axis 4 motor. Remove the motor and timing belt of axis 6. Disconnect the axis 5 motor connectors: R3.MP5 and R3.FB5. Move aside all cabling that is hindering access to the axis 5 motor. Remove the motor bracket, including the motor, by unscrewing the two attachment screws and washers. Remove the timing belt of axis 5. Remove the motor bracket from the motor. Shown in the figure Location of motor on page 156. Detailed in section Removal, motor axis 4 on page 153. Detailed in section Removal, motor and timing belt, axis 6 on page 162.
7. 8.
158
4 Repair
Refitting, motor and timing belt axis 5 The procedure below details how to refit the motor and timing belt of axis 5. Step
1.
Action
Note/Illustration
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. 4. Clean the mating surfaces on the motor and in the upper arm housing. Fit the new motor to the motor bracket, previously removed from the old motor. 3 pcs, M6 x 20.
Follow the steps below when fitting the Art. no. is specified in Required motor: equipment on page 157. Place the timing belt (B) round the motor pinion and place the belt round the axis 5 as fitting the motor in the upper arm housing. Fasten the motor bracket with two attachment screws (C), but do not tighten the screws yet. Use correct attachment holes, shown in the figure to the right! Adjust the belt tension by pulling the motor bracket, using the belt tightener and dynamometer, as shown in the figure to the right. Tighten the two attachment screws of the bracket (C) with a torque of 10 Nm.
xx0400001280
5. 6. 7. Refit the motor and timing belt of axis 6. Refit the motor of axis 4. Reconnect all connectors and place the cabling correctly inside the upper arm housing.
A: Motor axis 5 B: Timing belt, axis 5 C: Attachment screws and washers, motor bracket, 2 pcs, M6 x 20 D: Belt tightener, the dimensions are shown in the figure . F: 24 N.
Detailed in section Refitting, motor and timing belt, axis 6 on page 163. Detailed in section Refitting, motor axis 4 on page 154. Cable layout shown in the figure Illustration, cabling inside upper arm housing on page 107.
159
4 Repair
Step
8.
Action
Refit the cover to the upper arm housing. Check both the gaskets and replace, if damaged. Recalibrate the robot!
Note/Illustration
Art.no. is specified in Required equipment on page 157. Calibration is detailed in a separate calibration manual. Art. no. for the manual is specified in section Document references in the Product manual, reference information.
9.
160
4 Repair

Location of motor The motor and timing belt of axis 6 are located inside the upper arm housing, as shown in the figure below. A more detailed view of the component and its position may be found in chapter Spare parts and exploded views in the Product manual (part 2 of 2), reference information.
xx0400001281
A B C D E F G H
Motor, axis 6 Cover, upper arm housing Connector plate Signal cable, axis 6 motor: R3.FB6 Power cable, axis 6 motor: R3.MP6 Attachment screws and washers, motor (3 pcs) Distance console with cable bracket and contact panel Cable tie
161
4 Repair

Rot. ac motor incl pinion Timing belt Gasket, customer connections Hook Dynamometer Salter Super Samson 100N Standard toolkit
Spare part no.

3HAC 021800-001 3HAC 6779-1
Art. no.
Note
Gasket, upper arm cover 3HAC 022049-001 3HAC 022050-001 3HAC 024045-001 -
Supplier: Ahlsell The contents are defined in section Standard toolkit in the Product manual, reference information. These procedures include references to the tools required.
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit diagram
Removal, motor and timing belt, axis 6 The procedure below details how to remove the motor and timing belt of axis 6. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. 4. 5. 6. 7. Remove the cover from the upper arm housing. Remove the connector plate. Remove the complete distance console with cable brackets and contact panel. Disconnect the motor cables for the axis 6 motor; R3.MP6 and R3.FB6. Remove the axis 6 motor by unscrewing its three attachment screws and washers. Remove the timing belt. Shown in the figure Location of motor on page 161. Shown in the figure Location of motor on page 161.
162
4 Repair
Refitting, motor and timing belt, axis 6 The procedure below details how to refit the motor and timing belt of axis 6. Step
1.
Action
Note/Illustration
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. Clean the mating surfaces on the motor and in the upper arm housing. Follow the steps below when fitting the motor: Place the timing belt (B) round the motor pinion and place the belt round the axis 6 as fitting the motor in the upper arm housing. Secure the motor with its tree attachment screws and washers (C), but do not tighten them yet. Attach the hook round the motor pinion (underneath the motor) and adjust the belt tension with a force of 80 N, using a dynamometer. Shown in the figure to the right. Tighten the motor attachment screws with a torque of 10 Nm.
xx0400001282
4. 5. 6. 7. Refit the complete distance console.
A: Motor, axis 6 B: Timing belt, axis 6 C: Attachment screws and washers, motor, 3 pcs, M6 x 20 D: Hook (motor pinion: 24.07 mm) F: 80 N.
Refit the connector plate. Refit the cable Shown in the figure Location of motor on tie. page 161. Reconnect the motor cables: R3.MP6 and R3.FB6. Place all the cabling correctly inside the Cable layout is shown in the figure upper arm housing. Illustration, cabling inside upper arm housing on page 107. Refit the cover to the upper arm housing. Art. no. is specified in Required equipment Check both the gaskets and replace, if on page 162. damaged.
8.
163
4 Repair
Step
9.
Action
Recalibrate the robot!
Note/Illustration
Calibration is detailed in a separate calibration manual. Art. no. for the manual is specified in section Document references in the Product manual, reference information.
164
4 Repair
4.7.1. Replacement of gearbox, axes 1-2
4.7 Gearboxes 4.7.1. Replacement of gearbox, axes 1-2

Location of gearbox unit, axes 1-2 The gearboxes of axes 1 and 2 are located as shown in the figure below. Note that both gearboxes, 1 and 2, are a single unit! A more detailed view of the component and its position may be found in chapter Spare parts and exploded views in the Product manual (part 2 of 2), reference information.
xx0500001400
A B
Gearbox unit, axes 1-2 Attachment screws and washer, base-gearbox unit (VK-cover is removed)

Gearbox axis 1-2, spare
Spare part no.

3HAC 023555-001
Art. no.
Note
Includes: gearbox axis 1-2 V-ring (sealing ring) lubricating oil in vessel stop arm.
165
4 Repair
Equipment
VK-cover Isopropanol Grease Locking liquid Lifting slings Standard toolkit
Spare part no.

3HAA 2166-26
Art. no.
3HAB 3537-1 -
Note
For cleaning the mating surfaces before fitting. For lubricating the V-ring. Loctite 574 The contents are defined in section Standard toolkit in the Product manual, reference information. These procedures include references to the tools required.
Removal, gearbox unit axes 1-2 The procedure below details how to remove the complete gearbox unit, axes 1-2. Step
1.
Action
Note
Danger! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. 3. 4. 5. 6. Remove the motor, axis 1. Remove the motor, axis 2. Remove the complete arm system. Drain the oil from gearbox, axis 1. Unfasten the base from the installation site by removing the attachment bolts from the foundation. Detailed in section Removal, motor axis 1 on page 141. Detailed in section Replacement of motor, axis 2 on page 144. Detailed in section Removal, complete arm system.
7.
Caution! The complete gearbox unit and base weighs 201 kg together! (Base: 81 kg, gearbox unit: 120 kg.) All lifting equipment used must be sized accordingly!
166
4 Repair
Step
8.
Action
Fit the lifting slings to the base/gearbox unit and place it with the lower arm side downwards, on top of a suitable workbench. Remove the VK-cover from the bottom of the robot base. Tip! When the cabling is removed, it may be easier to drill a hole through the cover or to try and push it out from the inside.
Note
9.
10. Secure the weight of the base with lifting slings. 11. Remove the gearbox/base attachment screws Shown in the figure Location of and washer. gearbox unit, axes 1-2 on page 165. 12. Separate the base from the gearbox unit.
Refitting, gearbox unit axes 1-2 The procedure below details how to refit the complete gearbox unit, axes 1-2. Step
1.
Action
Note
Caution! The complete gearbox unit weighs 120 kg (without the base)! All lifting equipment used must be sized accordingly! 3. 4. 5. 6. 7. Place the gearbox unit with the lower arm side downwards on a suitable workbench. Clean the mating surfaces of the base and of the gearbox unit with isopropanol. Lubricate the V-ring with grease and fit it to Art. no. is specified in Required the gearbox unit. equipment on page 165. Fit a small amount of Loctite 574 on the mating surface in the gearbox unit. Fit the base to the gearbox unit and secure Shown in the figure Location of it with the attachment screws and the gearbox unit, axes 1-2 on page 165. washer. 16 pcs, M10 x 40, tightening torque: 70 Nm. Fit a new VK-cover to the base of the robot. Shown in the figure Location of gearbox unit, axes 1-2 on page 165. Spare part no. is specified in Required equipment on page 165. 167
8.
4 Repair
Step
9.
Action
Note
Caution! The complete gearbox unit and base weighs 201 kg together! (Base: 81 kg, gearbox unit: 120 kg.) All lifting equipment used must be sized accordingly! 10. Fit the lifting slings to the base/gearbox unit, turn it right side up and move it to the installation site. 11. Secure the base to the foundation. Attachment bolts and the tightening torque are specified in section Attachment bolts, specification on page 51. Detailed in section Refitting, complete arm system. Detailed in sections: Refitting, motor axis 1 on page 142 Refitting, motor axis 2 on page 146. Detailed in section Performing a leakdown test on page 100. Type of oil and amount is specified in section Oil in gearboxes on page 91. Calibration is detailed in a separate calibration manual. Art. no. for the manual is specified in section Document references in the Product manual, reference information.
12. Refit the complete arm system. 13. Refit the motors, axes 1 and 2.
14. Perform a leak-down test. 15. Fill the two gearboxes with oil. 16. Recalibrate the robot.
168
4 Repair
4.7.2. Service work on gearboxes, axes 3, 4, 5 and 6

Gearboxes, replacement The gearboxes of axes 3, 4, 5 and 6 are intended to run without requiring any repairs or maintenance work. This implies that they must under no circumstances be opened or serviced. If the gearboxes require replacement: axes 3 and 4: the complete upper arm is to be replaced. This procedure is detailed in section Replacement of complete upper arm on page 112. axes 5 and 6: the complete wrist unit is to be replaced. This procedure is detailed in section Replacement of wrist unit on page 121.
169
4 Repair
170
5.1. Introduction
5.1. Introduction
General This chapter includes general information about different calibration methods and also details procedures that do not require specific calibration equipment. When the robot system must be recalibrated, it is done according to documentation enclosed with the calibration tools. When to calibrate The system must be calibrated if any of the below occurs. 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 172, and further detailed in separate Calibration manuals. If the robot has Absolute Accuracy calibration, it is also recommended but not always needed to be calibrated for new Absolute Accuracy. The resolver values will change when parts affecting the calibration position are replaced on the robot, e.g. motors, wrist or part of transmission. Contents of the revolution counter memory are lost If the contents of the revolution counter memory are lost, the counters must be updated as detailed in section Updating revolution counters on page 176. This will occur when: the battery is discharged a resolver error occurs the signal between a resolver and measurement board is interrupted a robot axis is moved with the control system disconnected
The revolution counters must also be updated after the robot and controller are connected at the first installation. The robot is rebuilt If the robot has been rebuilt, e.g. after a crash or when the robot has been changed for other reachability, it needs to be recalibrated for new resolver values. If the robot has Absolute Accuracy calibration, it needs to be calibrated for new Absolute Accuracy.
171
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 calibration
Standard calibration
Description
The calibrated robot is positioned at home position, i.e. the axes positions (angles) are set to 0. Standard calibration data is found in the file calib.cfg, supplied with the robot at delivery. The file identifies the correct resolver/motor position corresponding to the robot home position. From deliveries together with RobotWare 5.0.5 and higher, the data will instead be found on the SMB (serial measurement board) in the robot, and not in a separate file.
Calibration method
Calibration Pendulum (standard method) or Levelmeter calibration (alternative method)
Absolute Accuracy calibration (optional)
Based on standard calibration, and besides CalibWare positioning the robot at home position, the Absolute Accuracy calibration also compensates for: mechanical tolerances in the robot structure deflection due to load. Absolute Accuracy calibration focuses on positioning accuracy in the Cartesian coordinate system for the robot. Absolute Accuracy data is found in the file absacc.cfg, supplied with the robot at delivery. The file replaces the calib.cfg file and identifies motor positions as well as absacccompensation parameters. From deliveries together with RobotWare 5.0.6 and higher, the data will instead be found on the SMB (serial measurement board) in the robot, and not in a separate file. A robot calibrated with AbsAcc has a sticker next to the identification plate of the robot. To regain 100% Absolute Accuracy performance, the robot must be recalibrated for Absolute Accuracy!
xx0400001197
172
Calibration methods Each calibration method is detailed in a separate manual. Below is a brief description of the methods available. 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. The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the manual Calibration Pendulum Instruction. Levelmeter Calibration - alternative method Levelmeter Calibration is referred to as the alternative method for calibration of ABB robots, because of the less accurate values obtained during calibration. The method uses the same principles as Calibration Pendulum but does not have as good of mechanical tolerances to the toolkit parts as the standard method with Calibration Pendulum. This method may, after calibration, require modifications in the robot program, and is therefore not recommended. The calibration equipment for Levelmeter Calibration is ordered as separate parts for each robot and the manual Instruction for Levelmeter Calibration is enclosed with the Levelmeter 2000. CalibWare - Absolute Accuracy calibration In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy is used as a TCP calibration. The tool CalibWare guides through the calibration process and calculates new compensation parameters. This is detailed further in the manual CalibWare 2.0 Users Guide. If a service operation is done to a robot with Absolute Accuracy, a new absolute accuracy calibration is required in order to establish full performance. For most cases after motor and transmission replacements that do not include taking apart the robot structure, standard calibration is sufficient. Standard calibration also supports wrist exchange. References The article numbers for the Calibration manuals are listed in section Document references in the Product manual (part 2 of 2), reference information. Article numbers for the calibration tools are also listed in part 2 of the Product manual.
173
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 marks, IRB 1600 The illustration below shows the calibration marks and correct positions of the six axes of the robot. The marks shown in the figure are numbered according to the number of the axes.
xx0500001423
174
5.4. Calibration movement directions for all axes
5.4. Calibration movement directions for all axes

Calibration movement directions 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. This is normally handled by the robot calibration software. Note! The figure shows an IRB 7600, but the positive direction is the same for all robots, except the positive direction of axis 3 for IRB 6400R which is in the opposite direction!
xx0200000089
175
5.5. Updating revolution counters

General This section details how to perform a rough calibration of each robot axis, i.e. 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; manually running the robot to the calibration position. Step
1. 2. 3.
Action
Select axis-by-axis motion mode. Jog the robot so that the calibration marks lie within the tolerance zone. When all axes are positioned, store the revolution counter settings.
Note
Shown in section Calibration scales and correct axis position on page 174. Detailed in sections: Step 2 - Storing the revolution counter setting with the FlexPendant on page 176 (RobotWare 5.0).
Correct calibration position of axis 4 and 6 When running the robot to calibration position, it is extremely important to make sure that axes 4 and 6 of the below mentioned robots are positioned correctly. The axes do not have any mechanical stops and can therefore be calibrated at the wrong turn. Make sure the axes are positioned according to the correct calibration values, not only according to the calibration marks. The correct values are found on a label, located either on the lower arm or underneath the flange plate on the base. At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before the revolution counters are updated. If one of the below mentioned axes are rotated one or more turns from its calibration position before updating the revolution counter, the exact calibration position will be lost due to uneven gear ratio. This affects the following robots:
Robot variant
IRB 1600
Axis 4
Yes
Axis 6
Yes
Step 2 - Storing the revolution counter setting with the FlexPendant This procedure details the second step when updating the revolution counter; storing the revolution counter setting with the FlexPendant (RobotWare 5.0). Step
1.
Action
On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status.
176
Step
2.
Action
Tap the mechanical unit in question. A screen is displayed: tap Rev. Counters.
en0400000771
3.
Tap Update revolution counters.... A dialog box is displayed, warning that updating the revolution counters may change programmed robot positions: Tap Yes to update the revolution counters. Tap No to cancel updating the revolution counters. Tapping Yes displays the axis selection window. 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. A dialog box is displayed, warning that the updating operation cannot be undone: Tap Update to proceed with updating the revolution counters. Tap Cancel to cancel updating the revolution counters. Tapping Update updates the ticked revolution counters and removes the tick from the list of axes.
4.
5.
6.
Caution! If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury! Check the calibration position very carefully after each update. See section Checking the calibration position on page 178.
177
5.6. Checking the calibration position
5.6. Checking the calibration position

General Check the calibration position before beginning any programming of the robot system. This may be done in one of two ways: Using a MoveAbsJ instruction with argument zero on all axes Using the Jogging window on the teach pendant
Using a MoveAbsJ instruction on the FlexPendant, IRC5 This section describes how to create a program, which runs all the robot axes to their zero position. Step
1. 2. 3. 4.
Action
On ABB menu tap Program Editor. Create a new program. Use MoveAbsJ in the Motion&Proc menu. Create the following program: MoveAbsJ [[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E9]]\NoEOffs, v1000, z50, Tool0 Run the program in manual mode. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!
Note
5. 6.
The calibration marks are shown in section Calibration scales and correct axis position on page 174. How to update the revolution counters is detailed in section Updating revolution counters on page 176.
Using the Jogging window on the FlexPendant, IRC5 This section describes how to jog the robot to all axes zero position. Step
1. 2. 3. 4.
Action
Tap Jogging in the ABB menu. Tap Motion mode to choose group of axes to jog. Tap axes 1-3 to jog axes 1, 2 or 3. Manually run the robots axes to a position where the axis position value read on the FlexPendant, is equal to zero. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!
Note
5.
The calibration marks are shown in section Calibration scales and correct axis position on page 174. How to update the counters is detailed in section Updating revolution counters on page 176.
178
Index
A Absolute Accuracy, calibration 173 Absolute Accuracy, guiding sleeves 51 air connections, pressure 81 attachment bolts, robot-foundation 51 B backshells, customer connection 81 base brake release buttons 47 hole configuration 49 replacing 130 screws, tightening torque 133 spare part number 130 battery pack replacing 95 replacing, interval 87 spare part number 96 belt tightener axis 5 article number 157 measure 157 brake release unit releasing the brakes 47 replacing 137 spare part number 138 brakes, releasing external power supply to connector R1.MP 48 manually 47 power supply on motor axis 1 141 power supply to motor axis 2 146 power supply to motor axis 3 150 power supply to motor axis 4 153 brakes, testing function 26 C cable harness inside base, figure 110 inside frame, figure 109 inside upper arm, figure 107 replacing 104 spare part number 104 cabling inside base, figure 110 inside frame, figure 109 inside upper arm, figure 107 replacing 104 spare part number 104 cabling, position switch 79 cabling, robot 78 calibration Absolute Accuracy type 172 alternative method 173 Calibration Pendulum 173 Levelmeter calibration 173 standard method 173 standard type 172
when to calibrate 171 calibration manuals 173 Calibration Pendulum 173 calibration position 176 calibration position, checking 178 calibration position, jog to 178 calibration, Absolute Accuracy 173 CalibWare 172 check, installation site 38 cleaning robot, interval 87 cleaning, robot 97 Connection of external safety devices 12 connectors air 81 customer 81 MIL-C-26482 series 1 83 on robot, figure 77 R2.CS and R2.CP
pins, customer connection 81

Souriau 82 cracks, damper 90 customer connections 77 D damage, damper 90 damper, axis 2 89 attachment screw 125 replacing 124 spare part number 124 damper, axis 3 inspection 89 replacing 126 spare part number 126 damper, axis 5 inspection 89 replacing 128 spare part number 128 dimensions guiding sleeves 50 mounting surface 50 robot 58 direction of axes 175 E environment 39 equipment, robot 58 ESD sensitive equipment 33 ESD, damage elimination 33 explanation, safety symbols 30 extra equipment 58 extra loads 57
179
Index
F figures base, hole configuration 49 brake release buttons 47 cabling inside base 110 cabling inside frame 109 cabling inside upper arm housing 107 connectors on robot 77 gearboxes 91 mounting surface 50 power supply to connector R1.MP 48 fitting, equipment 58 foundation loads 39 requirements 39 frame replacing 165 spare part number 165 G gaskets, spare part number base cover 138 gearbox axis 1-2 140 upper arm cover 162 upper arm customer connections 162 gearbox, axes 1-2 replacing 165 spare part number 165 gearboxes location on robot, figure 91 type of oil and amount 91 gearboxes, axes 3-6 replacing 169 service work 169 gearboxes, axes 5 and 6 amount and type of oil 92 oil change 92 H hole configuration base 49 I illustrations base, hole configuration 49 brake release buttons 47 cabling inside base 110 cabling inside frame 109 cabling inside upper arm housing 107 connectors on robot 77 gearboxes 91 mounting surface 50 power supply to connector R1.MP 48 inspection 89 installation checking site prior robot installation 38
180
equipment 58 mechanical stop axis 2 69 mechanical stops axis 3 72 mechanical stops, axis 1 66 position switch axis 1 75 robot, attachment bolts 51 signal lamp 62 intervals, maintenance 87 L lamp unit article number 63 installation 62 Levelmeter calibration 173 lifting, robot 45 Limitation of Liability 13 load diagrams 52 loads 57 loads, foundation 39 location of connectors 77 lower arm replacing 117 screws, tightening torque 120 spare part number 117 M maintenance intervals 87 maintenance schedule 87 measurement system battery pack, replacing 95 measurement system battery pack, spare part number 96 mechanical stop axis 2 article number 70 installation 69 mechanical stop axis 3 article number 74 screws, tightening torque 74 mechanical stops axis 1 article number 67 installation 66 screws, tightening torque 68 mechanical stops axis 2 screws, tightening torque 71 mechanical stops axis 3 installation 72 motor axis 1 brake release with power supply 141 replacing 140 spare part number 140 tightening torque 142 motor axis 2 brake release with power supply 146 replacing 144 spare part number 144 tightening torque 147 motor axis 3 brake release with power supply 150
Index
replacing 148 screws, tightening torque 151 spare part number 148 motor axis 4 brake release with power supply 153 replace 152 screws, tightening torque 154 spare part number 152 motor axis 5 replacing 156 screws, tightening torque 159 spare part number 157 motor axis 6 replacing 161 screws, tightening torque 163 spare part number 162 motor connectors 77 mounting, equipment 58 N negative directions, axes 175 O oil change gearbox axes 5 and 6 92 gearboxes, axes 5 and 6, intervals 87 safety risks 34 wrist unit 92 wrist unit, intervals 87 oil in gearboxes amount 91 article numbers 91 type 91 operating, conditions 39 orienting, robot 49 P permitted extra loads 57 position switch axis 1 article number 75 installation 75 position, robot when draining wrist unit 93 when filling oil in wrist unit 94 positive directions, axes 175 protection classes, IP class 40 push button unit releasing the brakes 47 replacing 137 spare part number 138 R releasing brakes external power supply to connector R1.MP 48 manually 47 requirements, foundation 39 restricting working range
axis 1 66, 75 axis 2 69 axis 3 72 Revolution counters 176 robot cleaning 97 connectors 77 dimensions 58 equipment, fitting 58 lifting 45 orienting and securing 49 robot position when draining wrist unit 93 when filling oil in wrist unit 94 RobotLoad 52 S Safety, service 12 safety, symbols 30 schedule, maintenance 87 securing, robot 49, 51 serial measurement unit battery pack, replacing 95 battery pack, spare part number 96 replacing 134 spare part number 135 signal connectors 77 signal lamp article number 63 installation 62 SMB unit battery pack, replacing 95 battery pack, spare part number 96 replacing 134 spare part number 135 Souriau, connector 82 storage, conditions 39 symbols, safety 30 T testing, brakes 26 tightening torques, attachment screws base-gearbox unit 133 lower arm-frame 120 mechanical stop axis 1 68 mechanical stop axis 2 71 mechanical stop axis 3 74 motor axis 1 142 motor axis 2 147 motor axis 3 151 motor axis 4 154 motor axis 5 159 motor axis 6 163 robot to foundation, attachment bolts 51 upper arm 115 wrist unit 122
181
Index
timing belt axis 5 adjusting the tension 159 replacing 156 spare part number 157 timing belt axis 6 adjusting the tension 163 replacing 161 spare part number 162 tools belt tightener axis 5, article number 157 belt tightener axis 5, measure 157 dynamometer axis 5 and 6 162 hook axis 6, article number 162 rotational tool, article number 152 U Updating revolution counters 176 upper arm replacing 112 screws, tightening torque 115 spare part number 113 V Validity and responsibility 12 VK-covers, spare part number at base 130 lower arm, lower 117 lower arm, middle 117 lower arm, upper 113 W weight base 132 gearbox unit 167 lower arm 118, 119 robot 39, 46, 131, 133 upper arm 114, 115 wrist unit amount and type of oil 92 oil change 92 replacing 121 screws, tightening torque 122 spare part number 121
182

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Product manual (part 1 of 2), procedures

2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2.2.2 Working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

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2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

3.3.1 Inspection, damper axes 2, 3 and 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

3.5.1 Cleaning, complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 4 Repair 99

4.3.1 Replacement of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

112 117 121 124 126 128

4.5 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

140 144 148 152 156 161

4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

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Organization of chapters The manual is organized in the following chapters: Chapter

Installation and commissioning Maintenance

Repair Calibration information Decommissioning

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Product documentation, M2004

Product documentation, M2004

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Product documentation, M2004

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How to read the product manual

How to read the product manual

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1.2.1.2. Limitation of Liability

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1.2.1.3. Related information

Restricting the working space Product manual for the robot

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Cabling Safety risk

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Gearboxes and motors Safety risk

Balancing device Safety risk

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1.2.2.2. Safety risks related to gripper

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1.2.2.3. Safety risks related to tools/workpieces

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1.2.2.4. Safety risks related to pneumatic/hydraulic systems

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1.2.2.5. Safety risks during operational disturbances

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1.2.2.6. Safety risks during installation and service

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1.2.2.7. Risks associated with live electric parts

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1.2.3. Safety actions 1.2.3.1. Safety fence dimensions

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1.2.3.2. Fire extinguishing

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1.2.3.3. Emergency release of the robots arm

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1.2.3.4. Brake testing

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1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"

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1.2.3.6. Safe use of the Teach Pendant Unit

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1.2.3.7. Work inside the manipulators working range