Professional Documents
Culture Documents
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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 ABB’s 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.
Sweden
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Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Safety 15
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.2.1 Safety, service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.2.2 Limitation of Liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.2.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.3.1 Safety risks during service work on robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.3.2 Safety risks related to gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.3.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.3.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.3.6 Safety risks during installation and service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.3.7 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2.4.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2.4.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2.4.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.2.4.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.2.4.7 Work inside the manipulator’s working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
1.3.3 WARNING - The brake release buttons may be jammed after service work . . . . . . . . . . . . . . . . 39
1.3.4 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3.5 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.3.6 WARNING - Mixed oils may cause severe damage to gearbox! . . . . . . . . . . . . . . . . . . . . . . . . . 43
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Table of Contents
3 Maintenance 107
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
3.2 Maintenance schedule and expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4 Repair 195
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
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Table of Contents
6 Decommissioning 349
6.1 Environmental information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
6.2 Decommissioning of balancing device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
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Table of Contents
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Overview
Overview
Usage
This manual should be used during
• installation, from lifting the manipulator to its work site and securing it to the
foundation to making it ready for operation
• maintenance work
• repair work.
Prerequisites
The reader should...
• be a trained maintenance/repair craftsman
• have the required knowledge of mechanical and electrical installation/repair/
maintenance work.
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Overview
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Safety Safety information
Installation and Information about installation of the manipulator.
commissioning
Maintenance Information about maintenance work, including maintenance
schedules.
Repair Information about repair work.
Calibration Information Procedures that does not require specific calibration
equipment.
Decommissioning Environmental information about the manipulator.
Revisions
Revision Description
- First edition.
Replaces previous manuals:
• Installation and Commssioning Manual
• Maintenance Manual
• Repair Manual, part 1
• Repair Manual, part 2.
Changes made in the material from the previous manuals:
• Previous separate Removal and Refitting sections combined to one
Replacement section.
• New spare part number for the balancing device, section Replacement of
balancing device on page 263.
• New spare part numbers for the motors, section Motors on page 278.
• Updated instructions for calibration that describe the use of the Wyler
calibration equipment, chapter Calibration information on page 337.
• Modified maintenance intervals for oil change and lubrication of
balancing device bearing, section Maintenance schedule on page 109.
• Corrected information about the weight of the wrist unit, section
Replacement of complete wrist unit on page 225.
• More detailed instructions of how to use special tools when removing and
refitting the lower arm shaft, new section Replacement of lower arm shaft
on page 246.
• More detailed information about how to use special tools when securing
the lower arm with a fixture, new section Securing the lower arm on page
251.
• Information about a cable protection at the lower arm, section Installation
of position switch, axis 2 on page 102.
• Various corrections and editing made in text and figures due to technical
revisions, changes in the toolkits etc.
A • Model M2004 implemented.
• New spare part number for axis 6 motor.
• Removed section Alternative calibration .
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Overview
Revision Description
B Changes made in chapter Calibration:
• Chapter Calibration is replaced with chapter Calibration information.
• Chapter Safety, Service is replaced with a new Safety chapter.
C • New lubricating oil in the gearboxes. Changes are made in the chapter:
Maintenance .
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Product documentation, M2000/M2000A
General
The complete product documentation kit for the M2000 robot system, including controller,
robot and any hardware option, consists of the manuals listed below:
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
• Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
• Part list
• Foldouts or exploded views
• Circuit diagrams
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.
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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:
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.
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Product documentation, M2004
Application manuals
Specific applications (e.g. software or hardware options) are described in Application
manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful)
• 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
Operator’s 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:
• Operator’s manual - IRC5 with FlexPendant
• Operator’s manual - RobotStudio Online
• Trouble shooting manual for the controller and robot
Miscellaneous
A number of manuals provide generic descriptions of the robot and robot system. These
include:
• Robot fundamentals (describing the fundamental aspects, functions, concept and
similar, of a robot system to provide a basic understanding of the robot system)
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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 an procedure.
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
15.
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How to read the product manual
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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 16.
• specific safety information, pointed out in the procedure at the moment of the danger.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in section Safety related instructions on
page 36.
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1 Safety
1.2.1. Introduction
1.2.1. Introduction
Definitions
This section details general safety information for service personnel i.e. personnel performing
installation, repair and maintenance work.
Sections
The general safety information is divided into the following sections:
1. General information contains lists of:
• Safety, service
• Limitation of liability
• Referenced documents
2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split
into different categories:
• Safety risks during service work on robot
• Safety risks related to gripper/end effector
• Safety risks related to tools/workpieces
• Safety risks related to pneumatic/hydraulic systems
• Safety risks during operational disturbances
• Safety risks during installation and service
• Risks associated with live electric parts
3. Safety actions details actions which may be taken to remedy or avoid dangers.
• Safety fence dimensions
• Fire extinguishing
• Emergency release of the manipulator´s arm
• Brake testing
• Risk of disabling function "Reduced speed 250 mm/s"
• Safe use of the Teach Pendant Unit enabling device
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1 Safety
1.2.2.1. Safety, service
Personnel working with robots must be familiar with the operation and handling of the
industrial robot, described in the applicable documents, e.g. User’s Guide and Product
Manual.
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1 Safety
1.2.2.2. 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
have been complied with.
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1 Safety
1.2.2.3. Related information
General
The list below specifies documents which contain useful information:
Documents
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1 Safety
1.2.3.1. 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.
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1 Safety
1.2.3.1. Safety risks during service work on robot
Complete robot
Caution!
Warning!
Cabling
Caution!
Caution!
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1 Safety
1.2.3.1. Safety risks during service work on robot
Balancing device
Warning!
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1 Safety
1.2.3.2. Safety risks related to gripper
CAUTION!
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1 Safety
1.2.3.3. Safety risks related to tools/workpieces
Safe handling
It must be possible to turn off tools, such as milling cutters, etc., safely. 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
1.2.3.4. 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.
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1 Safety
1.2.3.5. Safety risks during operational disturbances
General
• The industrial robot is a flexible tool which can be used in many different industrial
applications.
• All work must be carried out professionally and in accordance with the applicable
safety regulations.
• Care must be taken at all times.
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.
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
1.2.3.6. Safety risks during installation and service
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1 Safety
1.2.3.7. Risks associated with live electric parts
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1 Safety
1.2.4.1. 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
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1 Safety
1.2.4.2. Fire extinguishing
NOTE!
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulator
or controller)!
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1.2.4.3. Emergency release of the robot’s arm
Description
In an emergency situation, any of the robot’s axes may be released manually by pushing the
brake release buttons on the robot or on an optional external brake release unit.
How to release the brakes is detailed in section:
• Manually releasing the brakes on page 67.
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!
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1.2.4.4. 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.
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1.2.4.5. 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.
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1.2.4.6. 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 over
the robot without the programmer knowing.
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1.2.4.7. Work inside the manipulator’s working range
WARNING!
If work must be carried out within the robot’s work envelope, the following points must be
observed:
• The operating mode selector on the controller must be in the manual mode position to
render the enabling device operative and to block operation from a computer link or
remote control panel.
• 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 32.
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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.
Electrical shock
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1.3.1. Safety signals, general
Electrostatic discharge
(ESD)
Note
Tip
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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
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1.3.3. WARNING - The brake release buttons may be jammed after service work
1.3.3. WARNING - The brake release buttons may be jammed after service work
Description
The brake release unit has push buttons for brake release of each axis motor. When service
work is performed inside the SMB recess that includes removal and refitting of the brake
release unit, the brake release buttons may be jammed after refitting!
In case the power is turned on while a brake release button is jammed in depressed position,
the affected motor brake is released! This may cause serious personal injuries and damage to
the robot!
Elimination
To eliminate the danger after service work has been performed inside the SMB recess, follow
the procedure below:
Step Action
1. Make sure the power is turned off.
2. Remove the push button guard, if necessary.
3. Check the push buttons of the brake release unit by pressing them down, one by
one.
Make sure none of the buttons are jammed in the tube.
4. If a button gets jammed in the depressed position, the alignment of the brake release
unit must be adjusted so that the buttons can move freely in their tubes!
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1.3.4. WARNING - The unit is sensitive to ESD!
Description
ESD (electro static discharge) is the transfer of electrical static charge between two bodies at
different potentials, either through direct contact or through an induced electrical field. When
handling parts or their containers, personnel not connected to ground potential may transfer
high static charges. This discharge may destroy sensitive electronics.
Elimination
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1.3.5. WARNING - Safety risks during work with gearbox oil
Description
When handling the gearbox oil, there are several dangers to both personal injuries and product
damages! Following safety information must be regarded before performing any work with
the oil in the gearboxes!
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!
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1.3.5. WARNING - Safety risks during work with gearbox oil
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1.3.6. WARNING - Mixed oils may cause severe damage to gearbox!
Description
The six gearboxes of the robot are historically filled with different types of oil. When refilling
a gearbox it is extremely important to fill with exactly the same type of oil that is currently
used! In case the gearbox oil is contaminated with an other type of oil, the gearbox may be
severely damaged and must therefor be rinsed.
1. Flush the gearbox properly three times with the correct type
of oil. Use a service program when flushing.
2. Refill the gearbox with the correct type of oil.
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1.3.6. WARNING - Mixed oils may cause severe damage to gearbox!
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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.
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2.2.1. Pre-installation procedure
2.2 Unpacking
General
This section is 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.
Weight, robot
The table below shows the weights of the different models:
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2.2.1. Pre-installation procedure
Parameter Value
Min. ambient temperature -25° C
Max. ambient temperature +55°C
Max. ambient temperature (less than 24 hrs) +70°C
Max. ambient humidity Max. 95% at constant temperature
Parameter Value
Min. ambient temperature +5° C
Max. ambient temperature +50°C
Max. ambient humidity Max. 95% at constant temperature
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2.2.1. Pre-installation procedure
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2.2.2. Working range
Working range
This section details the working ranges of the manipulator models.
xx0200000025
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2.2.2. Working range
xx0200000026
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2.2.2. Working range
xx0200000338
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2.2.2. Working range
xx0200000339
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2.2.3. Risk of tipping / stability
Risk of tipping
When the robot is not fastened to the foundation and standing still, the robot is not stable in
the whole working area. Moving the arms will displace the center of gravity, which may cause
the robot to tip over. Do not change the robot position before securing it to the foundation.
Stabililty
The figure below shows the robot in its shipping position, which also is its most stable
position.
xx0100000103
WARNING!
The robot is likely to be mechanically unstable while not secured to the foundation!
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2.3.1. Lifting robot with fork lift
General
The robot may be moved using a fork lift, provided that available special aids are used.
This section describes how to attach the fork lift equipment to the robot.
Different designs
There are two different versions of the fork lift that fit one design of the frame respectevily.
The different designs of the frame and of the fork lift attachments are shown in the figure
below. Determine which fork lift set fits the current robot.
Note! The distance between the attachment holes for the fork lift pockets, shown in the figure
below, are different depending on the design of the frame. This means that the fork lift sets
are unique for one type of frame and not compatible!
Except for the shorter distance between the attachment holes, the later design of the frame
also includes an extra oil plug, located as shown in the figure below.
xx0200000386
1 Frame version without an oil plug, use the fork lift set: 3HAC 0604-2
2 Frame version with an oil plug (C), use the fork lift set: 3HAC 0604-1
A Attachment holes, fork lift 3HAC 0604-2
B Attachment holes, fork lift 3HAC 0604-1
C Oil plug
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2.3.1. Lifting robot with fork lift
Attachment points
The attachment points for the fork lift equipment are shown in the figure below.
xx0400000707
Required equipment
To determine which fork lift set to use, see the section Different designs on page 54.
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2.3.1. Lifting robot with fork lift
xx0100000102
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2.3.1. Lifting robot with fork lift
xx0200000379
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2.3.1. Lifting robot with fork lift
xx0400001068
• A: horizontal attachment
screws, 4 pcs, M16 x 60.
Tightening torque: 60 Nm.
• B: spacers, 2 pcs.
6. Make sure the securing screw is removed
from the fork lift pocket!
It is only used for robot model IRB 6650S.
xx0400000977
• A: securing screw
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2.3.1. Lifting robot with fork lift
xx0300000464
Caution!
Caution!
The fork lift pocket weighs 22 kg!
9. Secure the shorter fork lift pocket on the 4 pcs, M16x60; tightening torque: 60
other side of the robot with the four Nm.
remaining horizontal attachment screws . Make sure the original screws are
always used (or replacements of
equivalent quality: M16, quality 12.9)!
Attachment points on the robot are
shown in the figure Attachment points
on page 55.
10. Double-check that the pockets are
properly secured to the robot! Insert the
xx0200000380
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2.3.1. Lifting robot with fork lift
Caution!
Caution!
The robot weighs 1725 kg! All lifting
equipment used must be dimensioned
accordingly!
12. Carefully lift the robot and move it to its
installation site.
13.
Warning!
WARNING!
Personnel must not, under any
circumstances, be present under the
suspended load!
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2.3.2. Lifting robot with roundslings
General
The robot may be lifted with roundslings according to the illustration below. The illustration
is identical with the label attached to the robot’s lower arm.
Attachment points
The figure below shows how to attach the roundslings to the robot.
xx0200000282
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2.3.2. Lifting robot with roundslings
Sling specification
2.
Caution!
Caution!
The robot weighs 1725 kg! All lifting equipment used
must be dimensioned accordingly!
3.
Warning!
WARNING!
Personnel must not, under any circumstances, be
present under the suspended load!
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2.3.3. Lifting robot with lifting slings
General
This section contains a general overview of how to lift the complete robot using special lifting
equipment. More detailed instructions are included with the equipment.
xx0200000153
A Load hook
B Swivelling lifting eyes, 4 pcs
C Shortening hook
D Chain
E M12 lifting eye
F Lifting device´s eye
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2.3.3. Lifting robot with lifting slings
Required equipment
xx0100000103
3. Fit the lifting device, manipulator to the Art. no. is specified in Required
robot as described in the enclosed equipment on page 65!
instruction!
4.
Caution!
Caution!
The robot weighs 1725 kg! All lifting
equipment used must be dimensioned
accordingly!
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2.3.3. Lifting robot with lifting slings
Warning!
WARNING!
Personnel must not, under any
circumstances, be present under the
suspended load!
6. Raise the overhead crane to lift the Make sure all hooks and attachments
robot. maintain their correct positions while
lifting the robot!
Always move the robot at very low
speeds, making sure it does not tip.
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2.3.4. Manually releasing the brakes
General
This section details how to release the holding brakes of each axis motor.
xx0300000044
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!
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2.3.4. Manually releasing the brakes
Danger!
Incorrect connections, such as
supplying power to the wrong pin, may
cause all brakes to be released
simultaneously!
2. Supply 0V on pin 12 and 24V on pin
11.
xx0300000565
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2.3.5. Lifting the base plate
General
This section details how to lift the base plate
Hole configuration
xx0200000096
Caution!
The base plate weighs 353 kg! All lifting equipment
used must be dimensioned accordingly!
2. Fit the lifting eyes in the three lifting holes. Shown in the figure Hole
configuration on page 69!
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2.3.6. Securing the base plate
General
This section details how to secure the base plate.
xx0100000105
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2.3.6. Securing the base plate
xx0400000715
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2.3.6. Securing the base plate
xx0300000045
Required equipment
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2.3.6. Securing the base plate
Recommendations, quality
The table specifies any recommendations made by ABB:
Variable Recommendation
Recommended foundation quality 1 Steel fibre reinforced concrete foundation, 30 kg/m3,
class K30, t=250 mm
Recommended foundation quality 2 Sturdy concrete foundation, double reinforced by ø10
mm steel bars, distance 140 mm, class K25, t=250
Recommended bolt quality and Hilti HDA-P, M20 x 250/50 (maximum thickness of
dimension base plate = 50 mm)
Hilti HDA-P, M20 x 250/100 (maximum thickness of
base plate = 100 mm)
Base plate
This section details how to secure the base plate to the foundation.
CAUTION!
The base plate weighs 353 kg! All lifting equipment used must be dimensioned accordingly!
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2.3.7. Orienting and securing the robot
General
This section details how to orient and secure the robot to the base plate in order to run the
robot safely. The requirements made on the foundations are shown in the following tables and
figures.
xx0300000566
Attachment screws
The table below specifies the type of securing screws and washers to be used for securing the
robot to the base plate/foundation.
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2.3.7. Orienting and securing the robot
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2.3.7. Orienting and securing the robot
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2.3.8. Fitting equipment on robot
General
The robot features mounting holes for additional equipment.
Access to any of the following mounting holes may be obstructed by any additional cabling,
equipment, etc., fitted by the robot user. Make sure the required mounting holes are accessible
when planning the robot cell.
Under certain conditions, mounting holes may be added on the robot.
xx0200000195
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2.3.8. Fitting equipment on robot
xx0300000571
xx0300000572
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2.3.8. Fitting equipment on robot
xx0300000573
xx0200000196
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2.3.8. Fitting equipment on robot
xx0200000198
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2 Installation and commissioning
2.3.8. Fitting equipment on robot
xx0200000397
- Mounting flange for robot version IRB 6600 175/2.55. Use every other of the bolt
holes for six attachment bolts, as numbered in the figure.
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2.3.8. Fitting equipment on robot
xx0200000197
- Mounting flange for robot version IRB 6600 225/2.55 and 175/2.8, IRB 6650 125/
3.2 and 200/2.75
Fastener quality
When fitting tools on the mounting flange (see the figures above), use only screws with
quality 12.9. When fitting other equipment, standard screws with quality 8.8 can be used.
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2.3.9. Installation of chip and dust protection (option)
General
This section details how to install the optional chip and dust protection. It also details how to
remove the proctection, when necessary.
xx0400001071
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2.3.9. Installation of chip and dust protection (option)
xx0400001078
xx0400001079
xx0400001098
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2.3.9. Installation of chip and dust protection (option)
xx0400001080
• C: Attachment screws: 2 pcs, M6x25.
6. Remove the rear bracket from the
upper shield.
xx0400001099
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2.3.9. Installation of chip and dust protection (option)
xx0400001082
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2.3.9. Installation of chip and dust protection (option)
xx0400001085
xx0400001087
• J: Bushing
• K: Hub
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2.3.9. Installation of chip and dust protection (option)
xx0400001100
• L: Rubber cloth
• M: Upper shield
• N: Rear bracket
12. Fit the cover, lower arm to the
robot, using the enclosed screws.
If the attachment holes are used
for other equipment, the cover
may be fitted beneath the
equipment.
xx0400001088
Removing parts
In case the chip and dust protection must be removed, for example in order to perform certain
repair activities, read and follow the information below. If removing the complete protection,
follow the removal order below. If only removing some parts, follow the actions detailed for
the specific part.
Stop -
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2.3.9. Installation of chip and dust protection (option)
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2.3.10. Loads
2.3.10. 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.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified in the
Product Specification. The loads must also be defined in the software as detailed in User’s
Guide (RobotWare 4.0), or Operator’s manual (RobotWare 5.0).
Robot motor brake performance depends on any loads attached. For further information about
brake performance, please contact ABB.
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2.4.1. Introduction
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 software (signal from adjustable position
switch)
• Axis 2, hardware (mechanical stop) and software (signal from adjustable position
switch)
• Axis 3, hardware (mechanical stop) and software (signal from adjustable position
switch)
As standard configuration, axis 1 is allowed to move ± 180º. The working range may however
be increased to ± 220º with option 561-1 "Extended working range axis 1". Notice that this
option also requires installation of a position switch on axis 1.
This section describes how to install hardware that restricts the working range.
Notice that adjustments must be made also in the software, references to software manuals
are given in following installation procedures.
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2.4.2. Mechanically restricting the working range of axis 1
General
The working range of axis 1 is limited by fixed mechanical stops and can be reduced by
adding additional mechanical stops giving 7.5 or 15 graduation in both directions.
xx0300000049
Required equipment
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2.4.2. Mechanically restricting the working range of axis 1
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Warning!
If the mechanical stop has been deformed
after a hard collision, it must be replaced!
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2.4.3. Mechanically restricting the working range of axis 2
General
The working range of axis 2 is limited by fixed mechanical stops and can be reduced by
adding up to six additional mechanical stops with 15 graduation in respective direction.
xx0300000047
Required equipment
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2.4.3. Mechanically restricting the working range of axis 2
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Warning!
If the mechanical stop has been deformed
after a hard collision, it must be replaced!
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2.4.4. Mechanically restricting the working range of axis 3
General
The working range of axis 3 is limited by fixed mechanical stops and can be reduced by
adding additional mechanical stops with 20 graduation in respective direction.
xx0300000048
Required equipment
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2.4.4. Mechanically restricting the working range of axis 3
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Warning!
If the mechanical stop has been deformed
after a hard collision, it must be replaced!
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2.4.5. Position switches
General
Position switches can be installed on axes 1-3. The position switches include cams as shown
in the figures below.
The position switch kits may be delivered in one of two ways:
• Fitted by ABB Robotics on delivery. In this case, the cams must still be fitted and
locked by the user. For axis 1, the cover for the cams must also be fitted.
• As kits to be completely fitted to the robot and adjusted by the user.
Required equipment
Axis 1
The illustration below shows the position switch for axis 1:
xx0100000158
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2.4.5. Position switches
D Protection sheet
E Rail
F Rail attachment
Axis 2
The illustration below shows the position switch for axis 2:
xx0100000159
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2.4.5. Position switches
Connections
The position switches may be connected to different points on the robot system:
• XT8, screw terminal in the controller cabinet when position switch cables are used.
• R1.SW1 at the robot base. Customer connection kit is recommended, art. no. is
specified in Required equipment on page 99!
• R1.SW2/3 at the robot base. Customer connection kit is recommended, art. no. is
specified in Required equipment on page 99!
Further information about the cables and connection points, see section Robot cabling and
connection points on page 104.
Step Action
1. Remove the cable protection from the lower arm.
2. Fit the rail by pushing it against the support surface on the lower arm and tightening
the two screws.
3. Fit the cam and the position switch unit.
4. Refit the cable protection to the lower arm with two screws.
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2.4.5. Position switches
xx0100000113
The illustration below show how to cut the position switch cam.
xx0100000114
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2.5.1. Robot cabling and connection points
General
Connect the robot and controller to each other after securing them to the foundation. The lists
below specify which cables to use for each respective application.
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.
Connection Connection
Cable sub-category Description
point, cabinet point, robot
Robot cable, power Transfers drive power from the XS1 R1.MP
drive units in the control cabinet
to the robot motors.
Robot cable, signals Transfers resolver data from the XS2 R1.SMB
serial measurement board and
power supply to the SMB.
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2.5.1. Robot cabling and connection points
Connection
Connection
Cable Art. no. point,
point, robot
cabinet
Position switch cable, axis 1, 7 m 3HAC 13175-1 XS8 R1.SW
Position switch cable, axis 1, 15 m 3HAC 13175-2 XS8 R1.SW
Position switch cable, axis 1, 30 m 3HAC 13175-4 XS8 R1.SW
Position switch cable, axes 2 and 3, 7 m 3HAC 13176-1 XS8 R1.SW2/3
Position switch cable, axes 2 and 3, 15 m 3HAC 13176-2 XS8 R1.SW2/3
Position switch cable, axes 2 and 3, 30 m 3HAC 13176-4 XS8 R1.SW2/3
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3 Maintenance
3.1. Introduction
3 Maintenance
3.1. Introduction
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 15.
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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.
Values for these are specified in Expected component life on page 112.
Maintenance
Equipment Interval Detailed in section
activity
Cleaning Robot - Cleaning, robot on page
181
1)
Inspection Axis 1 gear, oil level 12 mths Inspection, oil level
gearbox axis 1 on page
113
1)
Inspection Axis 2 gear, oil level 12 mths Inspection, oil level
gearbox axis 2 on page
116
1)
Inspection Axis 3 gear, oil level 12 mths Inspection,
gearbox axisoil3 level
on page
119
Inspection Axis 4 gear, oil level 12 mths Inspection, oil level
gearbox axis 4 on page
121
Inspection Axis 5 gear, oil level 12 mths Inspection, oil level,
gearbox axis 5 on page
123
1)
Inspection Axis 6 gear, oil level 12 mths Inspection, oil level
gearbox axis 6 on page
125
Inspection Balancing device 12 mths Inspection, balancing
device on page 127
Inspection Robot harness 12 mths Inspection, cable
harness on page 134
Inspection Information labels 12 mths Inspection, information
labels on page 138
Inspection Damper axes 2-5 12 mths Inspection, damper axes
2-5 on page 144
Inspection Mechanical stop, axis 1 12 mths Inspection, mechanical
stop, axis 1 on page 140
1)
Changing Axis 1 gear, oil: Optimol 12 000 h Oil change, gearbox axis
Optigear RMO 150 1 on page 156
Changing Axis 1 gear oil: Shell - 7) -
Tivela S 150
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3.2.2. Maintenance schedule
Maintenance
Equipment Interval Detailed in section
activity
1)
Changing Axis 2 gear, oil: Optimol 12 000 h Oil change, gearbox axis
Optigear RMO 150 2 on page 160
Changing Axis 2 gear oil: Shell - 7) -
Tivela S 150
1)
Changing Axis 3 gear, oil: Optimol 12 000 h Oil change, gearbox, axis
Optigear RMO 150 3 on page 164
Changing Axis 3 gear oil: Shell - 7) -
Tivela S 150
1)
Changing Axis 4 gear, oil 12 000 h Oil change, gearbox, axis
4 on page 167
1)
Changing Axis 5 gear, oil 12 000 h Oil change, gearbox, axis
5 on page 170
1)
Changing Axis 6 gear, oil: Optimol 12 000 h Oil change, gearbox axis
Optigear RMO 150 7) 6 on page 173
Changing Axis 6 gear oil: Shell - 7) -
Tivela S 150
Replacement Axis 1 gearbox As specified by the SIS, Replacement of gearbox,
or typically 96 mths axis 1 on page 308
Replacement Axis 2 gearbox As specified by the SIS, Replacement of gearbox
or typically 96 mths axis 2 on page 316
Replacement Axis 3 gearbox As specified by the SIS, Replacement of gearbox,
or typically 96 mths axis 3 on page 324
Replacement Axis 4 gearbox 5) 96 mths 2)
Replacement of upper
arm on page 231
Replacement Axis 5 gearbox 6) 96 mths 2)
Replacement of
complete wrist unit on
page 225
Replacement Axis 6 gearbox As specified by the SIS, Replacement of gearbox,
or typically 96 mths axis 6 on page 330
Replacement Robot harness See note below 3) Replacement of cable
harness, axes 1-4 on
page 200
Replacement of cable
harness, axes 5-6 on
page 209
Replacement SMB Battery pack 36 mths Replacement of SMB
battery on page 176
4)
Lubrication Balancing device 12 000 h Lubrication, balancing
bearing device bearing on page
179
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3.2.2. Maintenance schedule
1)
• If the robot is run at ambient temperatures higher than 50°C, the equipment may
require maintenance more frequently.
2)
• The service time for gearboxes, axes 4 and 5, is not calculated by the SIS, see
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3.2.3. Expected component life
General
The expected life of a component can vary greatly depending on how hard it is run.
Expected life
1)The expected life can also be affected by assemblage of cabling other than standard options.
The given life is based on a test cycle that for every axis starts from the calibration position
to minimum angle to maximum angle and back to the calibration position. Deviations from
this cycle will result in differences in expected life!
2)
The given life for the balancing device is based on a test cycle that starts from the initial
position and goes to maximum extension, and back. Deviations from this cycle will result in
differences in expected life!
3)
The robot is dimensioned for a life of 8 years (350,000 cycles per year) in a normal spot
welding application. Depending on the actual application, the life of individual gearboxes
may vary greatly from this specification. The Service Information System (SIS), integrated
in the robot software, keeps track of the gearbox life in each individual case and will notify
the user when a service is due. The SIS is described in section Service Information System,
SIS .
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3 Maintenance
3.3.1. Inspection, oil level gearbox axis 1
Location of gearbox
The axis 1 gearbox is located between the frame and base. The oil plugs are shown in the
figure below.
xx0200000228
A Gearbox axis 1
B Oil plug, inspection
C Motor, axis 1
D Oil plug, filling
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3.3.1. Inspection, oil level gearbox axis 1
Required equipment
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 41.
2.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Open the oil plug, inspection. Shown in the figure Location of
gearbox on page 113!
4. Required oil level: max. 10 mm below the oil
plug hole!
5. Add oil if required. Art. no. is specified in Required
equipment on page 114!
Further information about how to
fill the oil may be found in section
Filling, oil on page 158.
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3.3.1. Inspection, oil level gearbox axis 1
Warning!
Do not mix the oil types! If wrong oil is refilled,
the gearbox must be rinsed as detailed in
section WARNING - Mixed oils may cause
severe damage to gearbox! on page 43!
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3.3.2. Inspection, oil level gearbox axis 2
Different designs
Between the axis 2 motor and gearbox there is a motor attachment which exists in two
different designs.
• The early design of the motor attachment is attached directly to the gearbox, with the
front gearbox attachment screws.
• The later design of the motor attachment is attached directly to the frame. This design
also includes an additional cover that overlaps the motor attachment and holds the oil
plugs.
The correct oil level varies, depending on the design of the motor attachment.
Location of gearbox
The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor
attachment.
The figure below shows the later design of the motor attachment.
xx0200000229
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3.3.2. Inspection, oil level gearbox axis 2
Required equipment
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 41.
2.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Open the oil plug, filling. Shown in the figure Location of
gearbox on page 116!
4. Measure the oil level at the oil plug, filling. Shown in the figure Location of
Required oil level with the early designof the gearbox on page 116!
motor attachment: approx. 65 mm ± 5 mm. Read more about the variations in
Required oil level with the later designof the design in Different designs on page
motor attachment: max. 10 mm below the oil 116.
plug hole.
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3.3.2. Inspection, oil level gearbox axis 2
Warning!
Do not mix the oil types! If wrong oil is refilled,
the gearbox must be rinsed as detailed in
section WARNING - Mixed oils may cause
severe damage to gearbox! on page 43!
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3.3.3. Inspection, oil level gearbox axis 3
Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
xx0200000230
A Gearbox axis 3
B Oil plug, filling
C Oil plug, draining
Required equipment
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3 Maintenance
3.3.3. Inspection, oil level gearbox axis 3
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 41.
2. Move the robot to the calibration position. Detailed in section Calibration scales
and correct axis position on page 340.
3.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
4. Open the oil plug, filling. Shown in the figure Location of
gearbox on page 119!
5. Required oil level: max 10 mm below the oil
plug hole.
6. Add oil if required. Art. no. is specified in Required
equipment on page 119!
Further information about how to fill
the oil may be found in section Filling,
oil on page 166.
7. Refit the oil plug, filling. Tightening torque: 24 Nm.
8.
Warning!
Do not mix the oil types! If wrong oil is
refilled, the gearbox must be rinsed as
detailed in section WARNING - Mixed oils
may
pagecause
43! severe damage to gearbox! on
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3 Maintenance
3.3.4. Inspection, oil level gearbox axis 4
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 41.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
4. Open the oil plug, filling. Shown in the figure Location of
gearbox on page 121!
5. Required oil level: max 10 mm below the oil plug
hole.
6. Add oil if required. Art. no. is specified in Required
equipment on page 121.
Further information about how to
fill the oil may be found in section
Filling, oil on page 169.
7. Refit the oil plug. Tightening torque: 24 Nm.
8.
Warning!
Do not mix the oil types! If wrong oil is refilled,
the gearbox must be rinsed as detailed in
section WARNING - Mixed oils may cause
severe damage to gearbox! on page 43!
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3 Maintenance
3.3.5. Inspection, oil level, gearbox axis 5
Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below.
xx0200000232
Required equipment
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3 Maintenance
3.3.5. Inspection, oil level, gearbox axis 5
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 41.
2.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Turn the wrist unit so that the both oil plugs face
upwards.
4. Open the oil plug, filling. Shown in the figure Location of
gearbox on page 123!
5. Measure the oil level.
Required oil level: 30 mm to the oil plug hole.
6. Add oil if required. Art. no. is specified in Required
equipment on page 123.
Further information about how
to fill the oil may be found in
section Filling, oil on page 172.
7. Refit the oil plug. Tightening torque: 24 Nm.
8.
Warning!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe
damage to gearbox! on page 43!
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3 Maintenance
3.3.6. Inspection, oil level gearbox axis 6
Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
xx0200000233
A Gearbox axis 6
B Oil plug, filling
C Oil plug, draining
Required equipment
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3 Maintenance
3.3.6. Inspection, oil level gearbox axis 6
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 41.
2.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Make sure the oil plug, filling is facing Shown in the figure Location of
upwards and open it. gearbox on page 125!
4. Measure the oil level.
Required oil level: 55 mm ± 5 mm to oil plug
hole, filling.
5. Add oil if required. Art. no. is specified in Required
equipment on page 125!
Further information about how to fill
the oil may be found in section Filling,
oil on page 175.
6. Refit the oil plug, filling. Tightening torque: 24 Nm.
7.
Warning!
Do not mix the oil types! If wrong oil is
refilled, the gearbox must be rinsed as
detailed in section WARNING - Mixed oils
may cause severe damage to gearbox! on
page 43!
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3 Maintenance
3.3.7. Inspection, balancing device
General
Several points are to be checked on the balancing device during the inspection. This section
details how to perform the inspection regarding:
• dissonance
• damage
• leakage
• contamination / lack of free space.
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3 Maintenance
3.3.7. Inspection, balancing device
xx0300000580
A Balancing device
B Piston rod (inside)
C Shaft, including securing screw
D Ear, bearing and o-rings
E Label with article number
F Inspect the surroundings
G Bearing, balancing device attachments
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3.3.7. Inspection, balancing device
Required equipment
The table below specifies the equipment used if damage is detected on the balancing device.
See section Action at detected faults on page 127 to determine whether to perform
maintenance or upgrade!
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3 Maintenance
3.3.7. Inspection, balancing device
instructions below.
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3 Maintenance
3.3.7. Inspection, balancing device
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3 Maintenance
3.3.7. Inspection, balancing device
xx0300000284
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3 Maintenance
3.3.7. Inspection, balancing device
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
4. Check the o-rings at the front ear for leakage. The o-rings are included in the
Replace the o-rings, if any leaks are detected. Maintenance kit, bearings and
Excessive grease from between the shaft and seals , already assembled with
the sealing spacer is normal and is not sealing spacers and sealing
considered as a leak! rings.
Art. no. for the kit is specified in
Required equipment on page
129!
Step Action
1.
-
Danger!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2. Check that there are no obstacles inside the frame, that could prevent the balancing
device from moving freely. See the figure Inspection points, balancing device on
page 128.
Keep the areas around the balancing device clean and free from objects, such as
service tools.
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3 Maintenance
3.3.8. Inspection, cable harness
xx0200000097
A Lower arm
B Cables attached with velcro straps and mounting plate
C Connectors at cable harness division point, R2.M5/6
D Connectors at base
Required equipment
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3 Maintenance
3.3.8. Inspection, cable harness
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Make an overall visual inspection of the cable
harness, in order to detect wear and damage.
3. Check the connectors at the division point Shown in the figure Location of
and at the base. cable harness, axes 1-4 on page
134!
4. Check that velcro straps and the mounting Location is shown in the figure
plate are properly attached to the frame. Also Location of cable harness, axes 1-4
check the cabling, leading into the lower arm. on page 134!
Make sure it is attached by the straps and not A certain wear of the hose at the
damaged. entrance to the lower arm is natural.
5. Replace the cable harness if wear or damage Detailed in section Replacement of
is detected. cable harness, axes 1-4 on page
200!
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3 Maintenance
3.3.8. Inspection, cable harness
xx0200000234
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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3 Maintenance
3.3.8. Inspection, cable harness
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3 Maintenance
3.3.9. Inspection, information labels
Location of labels
The figures below show the location of the information labels to be inspected.
xx0200000236
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3 Maintenance
3.3.9. Inspection, information labels
xx0400000786
Required equipment
Inspection, labels
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Check the labels, located as shown in the
figures Location of labels on page 138.
3. Replace any missing or damaged labels. Art. no. is specified in Required
equipment on page 139!
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3 Maintenance
3.3.10. Inspection, mechanical stop, axis 1
xx0200000151
Required equipment
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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3 Maintenance
3.3.10. Inspection, mechanical stop, axis 1
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3 Maintenance
3.3.11. Inspection, additional mechanical stops
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
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3 Maintenance
3.3.12. Inspection, damper axes 2-5
Location of dampers
The figure below shows the location of all the dampers to be inspected.
xx0300000040
Required equipment
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3 Maintenance
3.3.12. Inspection, damper axes 2-5
Inspection, dampers
The procedure below details how to inspect the dampers, axes 2-5
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Check all dampers for damage, and for cracks or Shown in the figure Location
existing impressions larger than 1 mm. of dampers on page 144!
To inspect the damper, axis 4, remove the two covers
on top of the upper arm!
3. Check attachment screws for deformation.
4. If any damage is detected, the damper must be Art. no. is specified in
replaced with a new one! Required equipment on
page 144!
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3 Maintenance
3.3.13. Inspection, position switch axes 1, 2 and 3
xx0100000159
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3 Maintenance
3.3.13. Inspection, position switch axes 1, 2 and 3
xx0100000160
Required equipment
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3 Maintenance
3.3.13. Inspection, position switch axes 1, 2 and 3
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Check the position switch!
• Check that the rollers are easy to push in and
that they roll freely.
3. Check the rail!
• Check that the rail is firmly attached with the
attachment screws.
4. Check the cams!
• Check that the rollers have not caused any
impressions on the cams.
• Check that the cams are clean. Wipe them if
necessary!
• Check that the set screws holding the cams in
position are firmly attached.
5. Check the protection sheets on axis 1!
• Check that the three sheets are in position and
not damaged. Deformation can result in
rubbing against the cams!
• Check that the area inside of the sheets is
clean enough not to interfere the function of
the position switch.
6. If any damage is detected, the position switch must Art. no. is specified in
be replaced! Required equipment on
page 148!
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3 Maintenance
3.3.14. Inspection, signal lamp
xx0200000240
A Signal lamp
B Clamp
C Position for cable gland
D Warning label on motor cover
E Warning sign on motor cover
Required equipment
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3 Maintenance
3.3.14. Inspection, signal lamp
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
3. If the lamp is not lit, trace the fault by: Art. no. is specified in
• Checking whether the signal lamp is broken. If Required equipment on
so, replace it. page 150!
• Checking the cable connections.
• Measuring the voltage in connectors motor
axis 3 (=24V).
• Checking the cabling. Replace cabling if a
fault is detected.
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3.4.1. Oil in gearboxes
Location of gearboxes
The gearboxes are located as shown in the figure below.
xx0400000798
A Axis 1 gearbox
B Axis 2 gearbox
C Axis 3 gearbox
D Axis 4 gearbox
E Axis 5 gearbox
F Axis 6 gearbox
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3 Maintenance
3.4.1. Oil in gearboxes
Type of oil
The table below specifies the types of oil used in the gearboxes of each axis. For some of the
axes, there are two different types specified. Normally, the same oil should be refilled as the
one drained. Read the section Which type of oil does the gearbox contain? on page 154 in
order to determine which type of oil is currently used in the gearbox.
As the Shell Tivela S 150 is not compatible with mineral oil, contamination with other types
of oils used in the gearboxes is not accepted. Equipment used in handling of Tivela S 150
must be carefully cleaned. In case of changing the type of oil to another, the gearbox must
therefor be thoroughly rinsed! Contact ABB for further instructions.
The Shell Global Product Code for Shell Tivela S 150 is specified within parentheses in table.
Axis 6 Optimol Optigear RMO 150 / 3HAC 16843-1 / 300 ml (IRB 6600-
Shell Tivela S 150 (001A9646) 3HAC 021469-001 175/2.55)
450 ml
WARNING!
When filling gearbox oil, do not mix different types of oil as this may cause severe damage
to the gearbox! Always use the type of oil specified by the manufacturer!
If the oils are mixed, the gearbox must be thoroughly rinsed! Contact ABB for further
instructions!
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3 Maintenance
3.4.1. Oil in gearboxes
Notice that robots with earlier serial numbers might have been changed to Tivela after
delivery!
xx0500001398
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3 Maintenance
3.4.1. Oil in gearboxes
xx0500001396
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3 Maintenance
3.4.2. Oil change, gearbox axis 1
xx0200000228
A Gearbox axis 1
B Oil plug, inspection
C Motor axis 1
D Oil plug, filling
Required equipment
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3 Maintenance
3.4.2. Oil change, gearbox axis 1
Draining
The procedure below details how to drain the oil in gearbox axis 1.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 156.
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 41.
3. Remove the rear cover on the base by
unscrewing its attachment screws.
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3.4.2. Oil change, gearbox axis 1
xx0200000237
Filling, oil
The procedure below details how to fill the oil in gearbox axis 1.
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
during work in section
with WARNING
gearbox - Safety
oil on page 41. risks
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3 Maintenance
3.4.2. Oil change, gearbox axis 1
Warning!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe
damage to gearbox! on page 43!
6. Refit the oil plug, filling. Tightening torque: 24 Nm.
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3 Maintenance
3.4.3. Oil change, gearbox axis 2
Required equipment
Draining, oil
The procedure below details how to drain the oil in gearbox axis 2.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 161.
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 41.
3. Remove the plug of the vent hole . Shown in the figure Location of oil
plugs on page 160!
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3 Maintenance
3.4.3. Oil change, gearbox axis 2
Filling, oil
The procedure below details how to fill oil into the gearbox, axis 2.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 161.
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 41.
3. Remove the oil plug, filling and the plug from the Shown in the figure Location of
vent hole. oil plugs on page 160!
4. Refill the gearbox with lubricating oil. Art. no. and total amount are
Warning!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe
damage to gearbox! on page 43!
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3 Maintenance
3.4.3. Oil change, gearbox axis 2
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3 Maintenance
3.4.4. Oil change, gearbox, axis 3
Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
xx0200000230
A Gearbox axis 3
B Oil plug, filling
C Oil plug, draining
Required equipment
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3 Maintenance
3.4.4. Oil change, gearbox, axis 3
Draining, oil
The procedure below details how to drain oil from the gearbox, axis 3.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 164.
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 41.
3. Remove the oil plug, draining, and drain the Shown in the figure Location of
gearbox oil using a hose with nipple and an gearbox on page 164!
oil collecting vessel. Vessel capacity is specified in
Remove the oil plug, filling in order to drain Required equipment on page 164!
the oil quicker! Draining is time-consuming. Elapsed
time varies depending on the
temperature of the oil.
4. Refit the oil plug. Tightening torque: 24 Nm.
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3.4.4. Oil change, gearbox, axis 3
Filling, oil
The procedure below details how to fill oil to the gearbox, axis 3.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 164.
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 41.
3. Remove the oil plug, filling. Shown in the figure Location of
gearbox on page 164!
4. Refill the gearbox with lubricating oil. Art. no. and total amount are
The amount of oil to be refilled depends on the specified in Required equipment
amount previously being drained. The correct oil on page 164!
level is detailed in section Inspection, oil level
gearbox axis 3 on page 119.
5.
Warning!
Do not mix
gearbox thebe
must oil rinsed
types! Ifaswrong oil is
detailed inrefilled,
sectionthe
WARNING - Mixed oils may cause severe
damage to gearbox! on page 43!
6. Refit the oil plug. Tightening torque: 24 Nm.
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3.4.5. Oil change, gearbox, axis 4
Location of gearbox
The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure
below.
xx0200000231
Required equipment
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3 Maintenance
3.4.5. Oil change, gearbox, axis 4
Draining, oil
The procedure below details how to drain the oil in the gearbox, axis 4.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 167.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.
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 41.
4. Drain the oil from the gearbox into an vessel Shown in the figure Location of
by opening theoil plug, draining. gearbox on page 167!
Remove the oil plug, filling in order to drain Vessel capacity is specified in
the oil quicker! Required equipment on page 167!
5. Run the upper arm back to its calibration Shown in section Calibration scales
position (horizontal position). and correct axis position on page
340.
6. Refit the oil plug, draining. Tightening torque: 24 Nm.
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3.4.5. Oil change, gearbox, axis 4
Filling, oil
The procedure below details how to fill the oil in the gearbox, axis 4.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 167.
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 41.
3. Refill the gearbox with lubricating oil through the oil Shown in the figure Location of
plug, filling. gearbox on page 167!
The amount of oil to be refilled depends on the Art. no. and total amount are
amount previously being drained. The correct oil specified in Required
level is detailed in section Inspection, oil level equipment on page 167.
gearbox axis 4 on page 121.
4.
Warning!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe damage
to gearbox! on page 43!
5. Refit the oil plug, filling. Tightening torque: 24 Nm.
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3.4.6. Oil change, gearbox, axis 5
Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below.
xx0200000232
Required equipment
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3.4.6. Oil change, gearbox, axis 5
Draining, oil
The procedure below details how to change the oil in gearbox, axis 5.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 170.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.
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 41.
4. Drain the oil from the gearbox by opening the Shown in the figure Location of
oil plug, draining. gearbox on page 170!
Remove the oil plug, filling in order to drain Vessel capacity is specified in
the oil quicker! Required equipment on page 170!
5. Refit the oil plug, draining. Tightening torque: 24 Nm.
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3.4.6. Oil change, gearbox, axis 5
Filling, oil
The procedure below details how to change the oil in gearbox, axis 5.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 170.
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 41.
2. Run axis 4 to a position where the oil plug, Calibration position is shown in
filing, is facing upwards. section Calibration scales and
correct axis position on page 340.
3.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
4. Refill the gearbox with lubricating oil through Shown in the figure Location of
the oil plug, filling. gearbox on page 170!
The amount of oil to be refilled depends on Art. no. and total amount are
the amount previously being drained. The specified in Required equipment on
correct oil level is detailed in section page 170.
Inspection, oil level, gearbox axis 5 on page
123.
5.
Warning!
Do not mix the oil types! If wrong oil is refilled,
the gearbox must be rinsed as detailed in
section WARNING - Mixed oils may cause
severe damage to gearbox! on page 43!
6. Refit the oil plug, filling. Tightening torque: 24 Nm.
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3.4.7. Oil change, gearbox axis 6
Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
The different robot versions have different gearbox designs. The amount of oil in the gearbox
therefor varies depending on robot version.
xx0200000233
A Gearbox axis 6
B Oil plug, filling
C Oil plug, draining
Required equipment
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3.4.7. Oil change, gearbox axis 6
Draining, oil
The procedure below details how to drain oil from the gearbox, axis 6.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 173.
-
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.
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 41.
4. Drain the oil from gearbox into a vessel by Vessel capacity is specified in
removing the oil plug. Required equipment on page
173!
5. Refit the oil plug, draining. Tightening torque: 24 Nm.
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3.4.7. Oil change, gearbox axis 6
Filling, oil
The procedure below details how to fil oil in the gearbox, axis 6.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 173.
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 41.
3. Remove the oil plug, filling. Shown in the figure Location of
gearbox on page 173!
4. Refill the gearbox with lubricating oil. Art. no. and the total amount are
The amount of oil to be refilled depends on the specified in Required equipment
amount previously being drained. The correct oil on page 173!
level is detailed in section Inspection, oil level
gearbox axis 6 on page 125.
5.
Warning!
Do not mix
gearbox thebe
must oil rinsed
types! Ifaswrong oil is
detailed in refilled,
section the
WARNING - Mixed oils may cause severe
damage to gearbox! on page 43!
6. Refit the oil plug. Tightening torque: 24 Nm.
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3.4.8. Replacement of SMB battery
xx0200000238
Required equipment
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3.4.8. Replacement of SMB battery
Removal, battery
The procedure below details how to remove the SMB battery.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
Warning!
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety
information in section WARNING - The unit
is sensitive to ESD! on page 40
3. Remove the SMB battery cover by Shown in the figure Location of SMB
unscrewing its attachment screws. battery on page 176!
4. Pull out the battery and disconnect the Shown in the figure Location of SMB
battery cable . battery on page 176!
5. Remove the SMB battery. Shown in the figure Location of SMB
Battery includes protection circuits. Replace battery on page 176!
it only with the specified spare part or with
an ABB approved eqvivalent.
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3 Maintenance
3.4.8. Replacement of SMB battery
Refitting, battery
The procedure below details how to refit the SMB battery.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
Warning!
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the safety
information in section WARNING - The unit
is sensitive to ESD! on page 40
3. Reconnect the battery cable to the SMB Art. no. is specified in Required
battery pack and fit it to the frame. equipment on page 176!
Shown in the figure Location of SMB
battery on page 176!
4. Secure the SMB battery cover with its Shown in the figure Location of SMB
attachment screws. battery on page 176
5. Update the revolution counter. Detailed in chapter Calibration -
section Updating revolution counters
on page 342.
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.
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3.5.1. Lubrication, balancing device bearing
Location of bearing
The figure below shows the location of the lubrication nipple etc.
Note! The balancing device must be mounted on the manipulator when lubricating the
bearing!
xx0200000109
Required equipment
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3.5.1. Lubrication, balancing device bearing
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Lubricate the spherical roller bearing through Art. no. is specified in Required
the lubrication nipple in the ear, with grease. equipment on page 179!
Fill until excessive grease is forced out Shown in the figure Location of
between the shaft and the sealing spacer. bearing on page 179!
The balancing device must be
mounted on the manipulator when
lubricating the bearing!
3. Clean the area from any excessive grease Read more about the inspection in
and check the area once again after section Inspection, balancing device
operation of the robot, in order to make sure - Check for leakage on page 132.
there is no incorrect leakage from the o-rings.
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3.6.1. Cleaning, robot
General
The protection class is IP 67, i.e. the robot is watertight.
Activities
This instruction specifies how to clean the robot.
Periodicity
The periodicity of cleaning the robot varies a great deal depending on the actual environment
and function of the robot. Clean a contamined robot as required.
Special points
Special points to be observed are shown in the figure below:
xx0200000239
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3.6.1. Cleaning, robot
Required equipment
Foundry versions
In working environments, e.g. foundries, where the robot may be exposed to fluids that dry
to make a crusty surface, e.g. release agents, clean the cable harnesses to prevent the crust
damaging the cables:
• Clean the spiral wound cables to motor 6 (item A in the figure Special points on page
181) with water and a cloth!
• Clean the remaining sections of the cable harnesses as detailed above!
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3 Maintenance
3.7.1. Using the SIS system
General
This is a brief description of how to use the Service Information System, SIS. Details may be
found in:
• Service Information System, SIS
• Defining the SIS input parameters
• Setting the SIS parameters
• Importing/exporting SIS data
• Reading the SIS output logs
Basic procedure
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3.7.2. Description of Service Information System (SIS)
General
Service Information System (SIS) is a software function within the robot controller, which
simplifies maintenance of the robot system. It supervises the operating time and mode of the
robot, and alerts the operator when a maintenance activity is scheduled.
Maintenance is scheduled by setting the system parameters of the type SIS Parameters, see
section Setting the SIS parameters on page 189. All system parameters are described in
Technical reference manual - System Parameters.
Supervised functions
The following counters are available:
• Calendar time counter, a general alarm based on calendar time
• Operation time counter, a general alarm based on operational time
• Gearbox 1 operation time counter, based on percentage of the axis 1 gearbox service
interval
• Gearbox 2 operation time counter, based on percentage of the axis 2 gearbox service
interval
• Gearbox 3 operation time counter, based on percentage of the axis 3 gearbox service
interval
• Gearbox 6 operation time counter, based on percentage of the axis 6 gearbox service
interval
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3.7.2. Description of Service Information System (SIS)
Remaining time Remaining operation time for axis x until the service time parameter
value has been reached.
Reset values
Counters may be reset at any time by running the service routine.
When resetting, the counter variables are reset. The variables are described in section
Exporting the SIS data on page 193!
No data available
When no data is available for the selection made, a message (No data available!) is displayed
when trying to display the data.
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3.7.3. SIS system parameters
General
This section details the system parameters that may be set with estimated values. The values
can be defined by the operating organization as knowledge of the robot’s working conditions
are accumulated.
Since the counters are to be used for purposes defined by the user, ABB cannot give any
recommendations regarding their definitions.
The figures below shows the options of parameters to be set.
en0200000049
en0400001266
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3.7.3. SIS system parameters
Gearbox warning
A percentage of the gearbox service interval as calculated by the system.
E.g. by setting the value "90", the SIS will alert the operator after 90% of the expected service
interval of each gearbox.
The robot system automatically detects and stores all required variables to calculate the
expected service interval of each gearbox. This is done by extrapolating data from earlier
operation into a function of time, using a formula including:
• input and output torque
• gearbox spindle speed
• other variables
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3.7.4. Setting the SIS parameters
General
If the SIS system is to function properly, a number of parameters must be set. This is detailed
below.
Procedure M2000
This is an instruction of how to enter SIS parameters to the M2000 robot system.
2. Go to "System parameters/
Manipulator/types 2".
xx0200000045
en0200000046
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3.7.4. Setting the SIS parameters
en0200000047
xx0100000200
en0200000048
en0200000049
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3 Maintenance
3.7.4. Setting the SIS parameters
Procedure M2004
This is an instruction of how to enter SIS parameters to the M2004 robot system.
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3 Maintenance
3.7.5. Reading the SIS output logs
General
Whenever a set condition has expired (e.g. max allowed operation time before service), a
message to this effect will be shown in the Operational log (M2000 robot system) or the event
log (M2004 robot systems).
Access to logs
How to open a log and show its contents is detailed in the User’s Guide, chapter Service
(M2000 robot systems) and in Trouble shooting - IRC 5 (M2004 robot systems).
Available messages
The following messages may be shown:
SIS message in
Available in: Meaning:
the log:
Calendar time Service Message The manually set calendar time limit has expired.
Service is due! How to set the limit is detailed in section Setting the
X calendar days SIS parameters on page 189.
since last service. Proceed with the required service as detailed in
chapter Repair on page 195 or chapter
Maintenance on page 107 depending on which
type of service.
Calendar time Service Message X number of calendar days remain until the
manually set calendar time limit expires.
X calendar
next days to
service. How to set the value determining when the
message is to be shown, is detailed in section
Setting the SIS parameters on page 189.
Operation time Service Message The manually set operation time limit has expired.
Service is due! How to set the limit is detailed in section Setting the
X production hours SIS parameters on page 189.
since last service. Proceed with the required service as detailed in
chapter Repair on page 195 or chapter
Maintenance on page 107 depending on which
type of service.
Operation time Service Message X number of operation hours remain until the
X production hours manually set operation time limit expires.
to next service. How to set the value determining when the
message is to be shown, is detailed in section
Setting the SIS parameters on page 189.
Gearbox time Service Message The automatically calculated gearbox time limit has
Gearbox x requires expired.
service! Proceed with the required service as detailed in
chapter Repair on page 195 or chapter
Maintenance on page 107 depending on which
type of service.
Gearbox time Service Message X percent of gearbox hours remain until the
X% of the service automatically calculated gearbox time limit expires.
interval has expired How to set the value determining when the
for gearbox x! message is to be shown, is detailed in section
Setting the SIS parameters on page 189.
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3 Maintenance
3.7.6. Exporting the SIS data
General
This section describes the available variables for entering SIS parameters as well as showing
any values of exceeded time limits as detected by the SIS counters.
In a M2004 robot system, the values can be read using OPC Server or RAB. The values can
also be read in RobotStudio Online (Controller and System Properties) or on the FlexPendant
(System Info).
In a M2000 robot system, the values can be read on a PC using "Webware SDK". How to
access these variables and how to perform the actual programming sequences are detailed in
the robot system User’s Guide.
Definitions
The table below defines the names and functions of all software variables available for
communication between the SIS and an external computer.
sisRunT hrs* Operation time The number of operation hours since start/
last reset of the operation time counter.
Corresponds to the operating time counter on
the control cabinet.
sisL10h_1 hrs Gearbox time Estimated life of gearbox axis 1
sisL10h_Time_1 hrs* Gearbox time Operation time of gearbox axis 1
sisL10h_2 hrs Gearbox time Estimated life of gearbox axis 2
sisL10h_Time_2 hrs* Gearbox time Operation time of gearbox axis 2
sisL10h_3 hrs Gearbox time Estimated life of gearbox axis 3
sisL10h_Time_3 hrs* Gearbox time Operation time of gearbox axis 3
sisL10h_6 hrs Gearbox time Estimated life of gearbox axis 6
sisL10h_Time_6 hrs Gearbox time Operation time of gearbox axis 6
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3.7.6. Exporting the SIS data
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4 Repair
4.1. Introduction
4 Repair
4.1. Introduction
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 15 before commencing any
service work.
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4 Repair
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
Procedure
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4 Repair
4.2.2. Mounting instructions for bearings
General
This section details how to mount and grease different types of bearings on the manipulator.
Equipment
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 pre-
tensioning 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.
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4 Repair
4.2.3. Mounting instructions for seals
General
This sections details how to mount different types of seals to the manipulator.
Equipment
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.
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4 Repair
4.2.3. Mounting instructions for seals
O-rings
The procedure below details how to fit o-rings.
and contamination.
4. Lubricate the o-ring with grease.
5. Tighten the screws evenly when assembling.
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4 Repair
4.3.1. Replacement of cable harness, axes 1-4
xx0300000561
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4 Repair
4.3.1. Replacement of cable harness, axes 1-4
Required equipment
The procedure below details how to remove the cable harness, axes 1-4.
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4 Repair
4.3.1. Replacement of cable harness, axes 1-4
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Remove the rear cover plate on the manipulator Shown in the figure Location of
by removing its attachment screws. cable harness on page 200.
4. Disconnect the earth cable . Attachment point is shown in the
figure Location of cable harness
on page 200!
xx0200000118.wmf
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4 Repair
4.3.1. Replacement of cable harness, axes 1-4
xx0300000560
• A: Cable gland
• B: Attachment screws,
cable gland
• C: Attachment plate
• D: Velcro strap
11. Remove the cable gland securing the cables
inside the lower arm.
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4 Repair
4.3.1. Replacement of cable harness, axes 1-4
xx0100000143.wmf
13. Remove the velcro strap from the harness at the Shown in the figure Location of
cable fixing bracket at the arm house. cable harness on page 200.
14. Disconnect connector R2.M5/6 at the cable Shown in the figure Location of
division point. cable harness on page 200!
15. Disconnect all connectors at motor 3 and motor 4. Specified and shown in the figure
Location of cable harness on
page 200!
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4 Repair
4.3.1. Replacement of cable harness, axes 1-4
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. In order to facilitate refitting of cable harness, Axes 2 and 3 may be tilted slightly to
move the manipulator to the specified position: improve access.
• Axis 1: 0 degrees
• Axis 2: 0 degrees
• Axis 3: 0 degrees
• Axis 4: 0 degrees
• Axis 5: +90 degrees
• Axis 6: no significance
3. Pull the cable and connectors down through Make sure the cables are not
the cable guide in the center of the frame. twisted with each other or with
eventual customer harnesses!
Make a note of the correct positions
of the connectors!
4. Reconnect connectors R1.MP and R1.SMB at Make a note of the correct positions
the rear cover plate. of the connectors!
Attachment point is shown in the
figure Location of cable harness on
page 200.
5. Reconnect the earth cable. Attachment point is shown in the
figure Location of cable harness on
page 200!
6. Refit the rear cover plate on the manipulator Shown in the figure Location of
with its attachment screws. cable harness on page 200.
7. Reconnect all connectors at motor 1 and Specified and shown in the figure
motor 2. Location of cable harness on page
200!
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4 Repair
4.3.1. Replacement of cable harness, axes 1-4
xx0300000560
• A: Cable gland
• B: Attachment screws, cable
gland
• C: Attachment plate
• D: Velcro strap
9. Reconnect connectors R2.SMB, R1.SMB1-3,
R1.SMB4-6 to the SMB unit.
Reconnect X8, X9 and X10 to the brake
release unit.
Reconnect R1.G if it has been disconnected.
10. Secure
screws. the SMB cover with its attachment
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4 Repair
4.3.1. Replacement of cable harness, axes 1-4
Warning!
Before continuing any service work, please
observe the safety information in section
WARNING - The brake release buttons may
be jammed after service work on page 39!
12. Pull the cable harness through the lower arm.
13. Refit the cable gland securing the cables
inside the lower arm.
xx0100000142
xx0100000143
15. Reconnect all connectors at motor 3 and Specified and shown in the figure
motor 4. Location of cable harness on page
200!
16. Reconnect the connector R2.M5/6 gently at Shown in the figure Location of
the cable division point. cable harness on page 200!
Be careful not to bend the attachment plate M6, 2 pcs.
when fastening the screws!
17. Secure the cable harness to the upper arm Shown in the figure Location of
house by refitting the velcro strap to the cable cable harness on page 200!
bracket at the upper arm house.
18. If the connection between the SMB battery Detailed in the Calibration chapter -
and the SMB unit has been broken, the section Updating revolution
revolution counters must now be updated! counters on page 342.
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4 Repair
4.3.2. Replacement of cable harness, axes 5-6
xx0200000213
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4 Repair
4.3.2. Replacement of cable harness, axes 5-6
Note!
Axis 5 must be oriented in the correct
position (+90º) to allow the motor 6
cover to open!
4. Remove the cover of motor, axis 6 and Specified in the figure Location of cable
disconnect all connectors beneath. harness ax 5-6 on page 209!
5. Loosen the cable bracket on top of the Shown in the figure Location of cable
wrist unit by undoing the three harness ax 5-6 on page 209!
attachment screws.
Two of the attachment screws are
visibly located at the rear attachment
and the third is located at the bottom of
the cable bracket, in the center.
xx0200000254
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4 Repair
4.3.2. Replacement of cable harness, axes 5-6
xx0200000185
xx0200000254
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4 Repair
4.3.2. Replacement of cable harness, axes 5-6
-
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Reconnect all connectors at motor, axis 5.
3. Refit the cable gland cover at the cable exit
with its two attachment screws.
4. Refit the cover of motor, axis 5.
5. Refit the complete wrist unit. Detailed in section Refitting, wrist
unit on page 228.
6. Recalibrate the robot! Calibration is detailed in separate
calibration manuals.
Art. no. for the manuals are
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.
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4 Repair
4.3.3. Replacement of complete arm system
xx0200000224
A Upper arm
B Lower arm
C Frame
D Gearbox, axis 1
E Base attachment screws
F Balancing device
G Block for calibration
H Motor axis 1
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4 Repair
4.3.3. Replacement of complete arm system
Required equipment
chain.
Standard toolkit 3HAC 15571-1 The contents are defined in section
Standard toolkit in the Product manual,
reference information !
Other tools and procedures These procedures include references to
may be required. See the tools required.
references to these procedures
in the step-by-step instructions
below.
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4 Repair
4.3.3. Replacement of complete arm system
Danger!
Turn off all electric power, hydraulic
and pneumatic pressure supplies to
the robot!
2. Make sure the manipulator is Release the brakes if necessary, as
positioned as shown in figure to the detailed in section Manually releasing the
right. If it is not, position it that way. brakes on page 67.
xx0100000103
3. Drain the oil from gearbox axis 1. Detailed in section Oil change, gearbox
axis 1 on page 156.
4. Loosen the cable connectors from the
base and pull up the cabling from the
base, through the hole in the center of
the frame.
5. Remove the motor, axis 1. Detailed in section Removal, motor on page
279.
6. Run the overhead crane to a position
above the manipulator.
7. Fit the lifting device and adjust it as Art. no. is specified in Required equipment
detailed in the enclosed instructions. on page 216!
Make sure the lift is done completely level!
How to adjust the lift is described in the
enclosed instruction to the lifting device!
Follow the instructions before lifting!
8. Remove the block for calibration from Shown in the figure Location of arm system
the bottom of the frame. on page 215!
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4 Repair
4.3.3. Replacement of complete arm system
Caution!
The complete arm system weighs
1300 kg! All lifting equipment used
must be dimensioned accordingly!
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Fit the lifting device as detailed in enclosed Art. no. is specified in Required
instruction. equipment on page 216!
Also fit a hoisting block to the front chain,
used to adjust the balance of the arm system
in order to lift it completely level!
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4 Repair
4.3.3. Replacement of complete arm system
Caution!
The complete arm system weighs 1300 kg!
All lifting equipment used must be
dimensioned accordingly!
4. Lift the complete arm system and move it at Make sure all the hooks and
very low speed, making sure it does not tip! attachments stay in the correct
Make sure the lift is done completely level. position while lifting the manipulator!
Adjust the length of the chains as detailed in
enclosed instruction or with a hoisting block!
xx0300000070
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4 Repair
4.3.3. Replacement of complete arm system
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.
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4 Repair
4.4.1. Replacement of turning disk
xx0300000473
E Attachment screws (6 pcs) , turning disk for robot version IRB 6600 175/2.55
xx0200000217
A Turning disk
B Wrist unit
C Oil plug, draining
D Oil plug, filling
F Attachment screws (12 pcs)turning disk for all robot versions except IRB 6600
175/2.55
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4 Repair
4.4.1. Replacement of turning disk
Required equipment
-
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Remove any equipment fitted to the turning disk.
3. Run the robot to a position where the oil plug, Shown in the figure Location of
draining of axis 6 gearbox faces downwards. turning disk on page 221!
4. Drain the oil from gearbox 6. Detailed in section Oil change,
gearbox axis 6 on page 173.
5. Remove the turning disk by unscrewing its Shown in the figure Location of
attachment screws . turning disk on page 221!
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4 Repair
4.4.1. Replacement of turning disk
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Lubricate the turning disk o-ring with Art. no. is specified in Required
grease. equipment on page 222!
Fit the o-ring to the rear of the turning disk.
Fit also the 6 or 12 o-rings (depending on
robot version), when refitting the
attachment screws.
xx0200000218
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4 Repair
4.4.1. Replacement of turning disk
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.
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4 Repair
4.4.2. Replacement of complete wrist unit
xx0200000184
A Wrist unit
B Turning disk
C Cover, wrist unit
D Cover, upper arm tube
E Connectors, upper arm tube, with cable bracket (R3.FB5, R3.MP5)
F Cable bracket
G Attachment point for lifting tool, wrist unit
H Wrist unit attachment screws and washers
I Upper arm tube
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4 Repair
4.4.2. Replacement of complete wrist unit
Required equipment
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Remove all equipment fitted to the turning disk.
3. Turn axis 4 to a position where the cover, upper arm Shown in the figure Location
tube and wrist unit, faces upwards. Also turn axis 5 of wrist unit on page 225!
so that the turning disk faces to the side in order to
allow access to the motor 6 cover.
4. Remove the cover, wrist unit . Shown in the figure Location
of wrist unit on page 225!
5. Remove the cover, upper arm tube. Shown in the figure Location
of wrist unit on page 225!
6. Remove the cover of motor, axis 6 and disconnect
all connectors beneath.
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4 Repair
4.4.2. Replacement of complete wrist unit
xx0200000254
• B: Attachment screws,
rear of cable bracket, 2
pcs
• C: Attachment screw,
bottom of cable
bracket, 1 pc
8. Pick out the cabling from motor, axis 6 and place it
safely on the tube.
9. Loosen the cable bracket in the upper arm tube by Shown in the figure Location
undoing the two screws on top of the tube. of wrist unit on page 225!
10. Disconnect the motor axis 5 by disconnecting the Shown in the figure Location
two connectors in the upper arm tube (R3.FB5, of wrist unit on page 225!
R3.MP5).
11. Fit the lifting tool to the wrist unit. Art. no. is specified in
Required equipment on page
226!
12.
Caution!
The complete wrist unit weighs 130 kg! All lifting
equipment used must be dimensioned accordingly!
13. Slightly raise the wrist unit to unload the screw joint,
facilitating removing the attachment screws.
14. Remove the wrist unit attachment screws and Shown in the figure Location
washers . of wrist unit on page 225!
15. Pull the wrist unit out, lift it away and place it on a
secure surface.
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4 Repair
4.4.2. Replacement of complete wrist unit
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Fit two guide pins, M12 in the upper arm Art. no. is specified in Required
tube, in two of the holes for the wrist unit equipment on page 226!
attachment screws. Shown in the figure Location of wrist
unit on page 225!
3. Fit the lifting tool to the wrist unit. Art. no. is specified Location of wrist
unit on page 225!
4.
Caution!
The complete wrist unit weighs 130 kg! All
lifting equipment used must be
dimensioned accordingly!
5. Lift the wrist unit and guide it to the upper
arm tube with help of the guide pins.
Make sure the cabling from motor, axis 5 is
safely run into the arm tube and does not
get jammed.
6. Secure the wrist unit with 10 of the 12 Shown in the figure Location of wrist
attachment screws and washers. unit on page 225!
12 pcs: M12 x 50, 12.9 quality
UNBRAKO, tightening torque: 115 Nm.
Reused screws may be used,
providing they are lubricated as
detailed in section
Product manual, Screw joints
reference in the
information
before fitting.
7. Remove the guide pins and secure the two
remaining attachment screws as detailed
above.
8. Remove the lifting tool from the wrist unit.
9. Reconnect the motor axis 5 by connecting Shown in the figure Location of wrist
the two connectors inside the upper arm unit on page 225!
tube (R3.FB5, R3.MP5) and secure the
cable bracket with the two attachment
screws to the tube.
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4 Repair
4.4.2. Replacement of complete wrist unit
Note!
Axis 5 must be oriented in the correct
position (+90º) to allow the motor 6 cover to
open!
11. Place the cabling to motor, axis 6, correctly
on the upper arm and gently pull the
connectors through the hole on top of wrist
unit to motor, axis 6.
xx0200000185
xx0200000254
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4 Repair
4.4.2. Replacement of complete wrist unit
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.
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4 Repair
4.4.3. Replacement of upper arm
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4 Repair
4.4.3. Replacement of upper arm
xx0200000163
A Attachment hole for lifting eye, M12 (if wrist unit is mounted)
B Attachment for lifting device, upper arm (2 pcs if there is no wrist unit mounted)
C Oil plug, draining, gearbox axis 3
D Cable harness division; connector R2.M5/6
E Motor, axis 3
F Motor, axis 4
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4 Repair
4.4.3. Replacement of upper arm
Required equipment
power supply.
Lifting eye VLBG M12 3HAC 16131-1
Lifting device, upper arm 3HAC 15994-1
Lifting tool (chain) 3HAC 15556-1 To be used together with lifting
eye, M12 and lifting device, upper
arm.
Standard toolkit 3HAC 15571-1 The contents are defined in
section Standard toolkit in the
Product manual, reference
information !
Other tools and procedures may be These procedures include
required. See references to these references to the tools required.
procedures in the step-by-step
instructions below.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Remove all equipment fitted to turning disk.
3. Move the manipulator upper arm to a horizontal Shown in the figure Location of
position. upper arm on page 231!
Run axis 4 so that the attachment hole for lifting
eye is faced upwards!
4. Upper arm including wrist unit: Fit the lifting Art. no. is specified in Required
eye, VLBG M12 to the attachment hole for equipment on page 233!
lifting eye on the upper arm tube. Shown in the figure Location of
upper arm on page 231!
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4 Repair
4.4.3. Replacement of upper arm
Caution!
The complete upper arm weighs 380 kg without
any additional equipment fitted! Use a suitable
lifting device to avoid injury to personnel!
12. Raise the lifting equipment to take the weight of
the upper arm.
13. In order to release the brake of the axis 3 motor, Connect to connector R2.MP3
connect the 24 VDC power supply. • +: pin 2
Note! When releasing the brake, the position of • -: pin 5
the upper arm is adjusted to the position given
by the lifting equipment.
14. Carefully remove the attachment screws and Shown in the figure Location of
washers, upper arm. upper arm on page 231!
15. Lift the upper arm and place it on a secure
surface.
Make sure the lift is done completely level! In
case of necessary adjustments, use the
shortening loops on the lifting tool (chain), but
make sure to place the chain the right way
through the loops!
16. Remove the sealing, axis 2/3 from the lower Shown in the figure Location of
arm. upper arm on page 231!
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4 Repair
4.4.3. Replacement of upper arm
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Fit the two guide pins, sealing axis 2/3 in Always use a new sealing when
two of the attachment screw holes on reassembling!
gearbox 3, see figure to the right. Art. no. is specified in Required
Guide the new sealing, axis 2/3 into equipment on page 233!
position on gearbox 3, using the guide
pins.
xx0200000166
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4 Repair
4.4.3. Replacement of upper arm
6. Fasten the lifting tool (chain) onto the Art. no. is specified in Required
lifting eye, the lifting device and an equipment on page 233!
overhead crane.
7.
Caution!
The complete upper arm weighs 380 kg
without any additional equipment fitted!
Use a suitable lifting device to avoid injury
to personnel!
8. Lift the upper arm and run to its mounting
position.
Make sure the lift is done completely level!
9. Fit in the gearbox attachment holes with Art. no. is specified in Required
the attachment holes on the lower arm with equipment on page 233!
the guide pins.
It may be necessary to turn the gear by
rotating the motor pinion with a rotation
tool, motor beneath the motor cover.
xx0200000165
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4 Repair
4.4.3. Replacement of upper arm
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.
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4 Repair
4.4.4. Replacement of complete lower arm
xx0200000255
A Lower arm
B Pivot point, axis 2
C Front shaft, balancing device, including securing screw
D Attachment for lifting equipment, balancing device
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4 Repair
4.4.4. Replacement of complete lower arm
xx0200000031
A Gearbox
B Lower arm
C Balancing device piston rod ear
D Frame
E Shaft hole
201 Sealing, axis 2/3
202 Attachment screw
204 Washer
401 Bearing
402 Thrust washer
403 Bushing
404 Retaining ring
405 Shaft, lower arm
406 Protection plug
409 Protection washer
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4 Repair
4.4.4. Replacement of complete lower arm
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Remove the upper arm. Detailed in section Removal, upper
arm on page 233.
3. Disconnect and remove the cables from Detailed in section Removal, cable
inside the lower arm. harness, axes 1-4 on page 201.
Release any cable attachments.
4. Apply the lifting eye, M12 orshackle to the Art. no. is specified in Required
balancing device and raise to unload the equipment on page 240.
weight of the device. Attachment is shown in the figure
Location of lower arm on page 238.
5. Unload the balancing device in order to make Detailed in sectionUnloading the
the piston rod and front ear adjustable when balancing device on page 271.
pulling the front shaft out.
6. Remove the securing screw from the Shown in the figure Location of lower
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4 Repair
4.4.4. Replacement of complete lower arm
xx0300000015
10. Apply the lifting tool to the lower arm. Art. no. is specified in Required
equipment on page 240!
11. Drain the oil from gearbox 2. Detailed in section Oil change,
gearbox axis 2 on page 160.
12.
Caution!
The lower arm weighs 160 kg! All lifting
equipment used must be dimensioned
accordingly!
13. Raise the tool to unload the lower arm.
14. Remove the lower arm shaft and all additional
components, as detailed in section Removal,
lower arm shaft on page 248!
15. Remove the attachment screws and Shown in the figure Internal
washers that attach the lower arm to the components, lower arm on page 239!
gearbox axis 2.
16. Lift the lower arm and place it on a secure
surface.
17. Remove the bearing and thrust washer from Shown in the figure Internal
the shaft hole in the lower arm. components, lower arm on page 239!
On reassembly a new bearing must
be used!
18. Remove the both sealings, axis 2/3 from the Shown in the figure Internal
lower arm. components, lower arm on page 239!
On reassembly new sealings must
be used!
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4 Repair
4.4.4. Replacement of complete lower arm
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Fit a new VK-cover on a new lower arm or Part no. is specified in Required
replace the existing if damaged. equipment on page 240!
3. Fit two guidings in the attachment holes of Art. no. is specified in Required
the lower arm. equipment on page 240!
xx0200000262
Caution!
The lower arm weighs 160 kg! All lifting
equipment used must be dimensioned
accordingly!
7. Lift the lower arm and move it to its mounting
position.
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4 Repair
4.4.4. Replacement of complete lower arm
xx0200000165
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4 Repair
4.4.4. Replacement of complete lower arm
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.
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4 Repair
4.4.5. Replacement of lower arm shaft
Prerequisites
This section details how to remove and refit the lower arm shaft as a step in the procedure of
removing/refitting the complete lower arm. To perform the procedure described in this
section, it is required that the preceding instructions in section Replacement of complete lower
arm on page 238 are followed! These include:
• removing the upper arm
• removing the cabling in the lower arm
• unloading the balancing device and removing the front eye shaft
• draining the oil in gearbox axis 2
• unloading the lower arm with specific lifting equipment.
xx0300000487
A Protection plug
B Lower arm shaft (axis 2 shaft)
C Thrust washer
D Bearing
E Protection washer
F Retaining ring
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4 Repair
4.4.5. Replacement of lower arm shaft
Required equipment
xx0400001029
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4 Repair
4.4.5. Replacement of lower arm shaft
xx0300000485
Warning!
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4 Repair
4.4.5. Replacement of lower arm shaft
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4 Repair
4.4.6. Securing the lower arm
General
This section details how to secure the lower arm with a specific fixture prior to performing
certain service activities to the manipulator.
xx0400000708
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4 Repair
4.4.6. Securing the lower arm
Required equipment
C A B
D
xx0400000709
A Locking screw
B Adjusters, 2 pcs
C M16 bolts, 4 pcs
D Ring nuts, 2 pcs
E M12 bolts and washers, 2 pcs
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4 Repair
4.4.6. Securing the lower arm
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Remove any
upper arm or load or equipment
turning disk. fitted to the
3. Move the robot to the calibration position. The
upper arm can be directed in three different
ways, shown in the figure to the right.
The lowered position, as in figure A, is
recommended as it gives the least load on the
tool.
xx0200000260
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4 Repair
4.4.6. Securing the lower arm
A
xx0400000710
Warning!
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4 Repair
4.5.1. Replacement of SMB unit
xx0200000203
A SMB cover
B SMB unit
C Pins
D Battery cable
Required equipment
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4 Repair
4.5.1. Replacement of SMB unit
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
Warning!
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to ESD!
on page 40
3. Remove the SMB cover by unscrewing its Shown in the figure Location of
attachment screws. SMB unit on page 255!
4. Remove the connectors X8, X9 and X10 from the
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4 Repair
4.5.1. Replacement of SMB unit
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
Warning!
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to ESD!
on page 40
3. Connect the battery cable to the SMB unit. Shown in the figure Location of
SMB unit on page 255.
4. Connect all connectors to the SMB board and fit Art. no. is specified in Required
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.
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4 Repair
4.5.2. Replacement of brake release unit
xx0200000226
D SMB cover
E Push button guard
Required equipment
frame.
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4 Repair
4.5.2. Replacement of brake release unit
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
Warning!
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the
safety information in section WARNING -
The unit is sensitive to ESD! on page 40
3. Remove the push button guard from the Shown in the figure Location of brake
SMB cover. release unit on page 258.
The guard must be removed to ensure a
correct refitting of the brake release unit.
4. Open the SMB cover by unscrewing the Shown in the figure Location of brake
attachment screws. release unit on page 258!
Let the battery stay connected, to avoid
the need of synchronization of the robot!
5. Remove the complete brake release unit
(including brake release unit and bracket)
from the SMB recess, by removing its two
attachment screws.
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4 Repair
4.5.2. Replacement of brake release unit
xx0200000129
• A: Connector X8
• B: Connector X9
• C: Connector X10
• D: Push buttons
Location of brake release unit is shown
in the figure Location of brake release
unit on page 258!
7. Remove the brake release unit from the
bracket by removing the four attachment
screws.
Danger!
Turn off all electric power, hydraulic and
Warning!
WARNING!
The unit is sensitive to ESD, before
handling the unit please observe the safety
information in section WARNING - The unit
is sensitive to ESD! on page 40
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4 Repair
4.5.2. Replacement of brake release unit
xx0200000129
• A: Connector X8
• B: Connector X9
• C: Connector X10
• D: Push buttons
5. Refit the complete brake release unit
(including brake release unit and bracket)
to the SMB recess with the two attachment
screws.
6. Refit the SMB cover with its attachment Shown in the figure Location of brake
screws. release unit on page 258!
The push button guard must not be
mounted on the cover before the check
described below is made!
7.
Warning!
Before continuing any service work,
please observe the safety information in
section WARNING - The brake release
buttons may be jammed after service work
on page 39!
8. Refit the push button guard to the SMB Shown in the figure Location of brake
cover. release unit on page 258.
9. If the battery has been disconnected the Detailed in the Calibration chapter -
revolution counter must be updated. section Updating revolution counters on
page 342.
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4 Repair
4.5.2. Replacement of brake release unit
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.
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4 Repair
4.5.3. Replacement of balancing device
xx0200000223
A Balancing device
B Rear cover
C Support shaft inside
D Attachment screws, rear cover
E Balancing device shaft, including securing screw
F Bearing attachment
G Parallel pin (inside bearing attachment)
H Attachment screws, bearing attachments
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4 Repair
4.5.3. Replacement of balancing device
xx0300000482
C Securing screw attachment hole, secures the bearing attachment to the balancing
device (remove the protection plug)
D Hole in the frame to access the balancing device shaft with the puller/press tool
E Locking screw attachment hole, secures the lower arm to the frame
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4 Repair
4.5.3. Replacement of balancing device
Required equipment
roller
of new bearing in ear,
balancing in case
device.
Locking liquid - Loctite 243
To apply to the securing
screw in the shaft.
Grease pump - To lubricate spherical roller
bearing.
Guide pins M16 x 300 3HAC 13120-5 Always use guide pins in
pairs!
Lifting eye M12 3HAC 14457-3 Used if the balancing
device is equipped with a
threaded hole.
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4 Repair
4.5.3. Replacement of balancing device
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Run the lower arm to a position close to the
calibration position.
3. Secure the lower arm to the frame by inserting Attachment hole for the locking
the locking screw into the attachment hole in screw is shown in the figure
the frame. Attachment points, balancing
device on page 264.
Art. no. is specified in Required
equipment on page 265!
4.
Caution!
The balancing device weighs 210 kg! All lifting
equipment used must be dimensioned
accordingly!
5. Apply the lifting eye or the shackle to the Art. no. is specified in Required
balancing device, and raise to unload the equipment on page 265!
device. Attachments are shown in the figure
Attachment points, balancing
device on page 264.
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4 Repair
4.5.3. Replacement of balancing device
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4 Repair
4.5.3. Replacement of balancing device
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Secure the lower arm to the frame by Art. no. is specified in Required
inserting the locking screw into the equipment on page 265!
attachment hole in the frame. Attachment hole is shown in the
figure Attachment points, balancing
device on page 264.
3. Secure the bearing attachments to the Shown in the figure Attachment
balancing device with securing screws . points, balancing device on page
264!
Dimension of the securing screws is
specified in Required equipment on
page 265.
4. Refit the two parallel pins in the frame. Shown in the figure Location of
balancing device on page 263!
5. Fit two guide pins to the upper holes in the
frame, where the bearing attachments are to
be attached.
6. Fit the lifting eye to the balancing device. Art. no. is specified in Required
equipment on page 265!
Attachments are shown in the
figureAttachment points, balancing
device on page 264.
7.
Caution!
The balancing device weighs 210 kg! All
lifting equipment used must be dimensioned
accordingly!
8. Lift the balancing device and bring it forward, Note! Make sure not to burden the
gliding the bearing attachments on to the guide pins with the weight of the
guide pins. balancing device!
9. Remove the guide pins.
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4 Repair
4.5.3. Replacement of balancing device
where the
inserted balancing
through deviceshaft
the piston shaftfront
may eye.
be
13. Unload the balancing device with the press Detailed in section Unloading the
tool. balancing device on page 271.
Art. no. is specified in Required
equipment on page 265!
For an easier reassembling of the
shaft, the piston rod may be pressed
out more than necessary and then
pressed in when fitting the shaft.
14. Lubricate the shaft with grease. Art. no. is specified in Required
equipment on page 265!
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4 Repair
4.5.3. Replacement of balancing device
Danger!
The rear cover of the balancing device is a
safety device for the piston rod during
operation! Make sure the cover is properly
secured before commissioning of the robot!
20. Remove the locking screw that secures the
lower arm to the frame.
xx0300000483
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.
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4 Repair
4.5.4. Unloading the balancing device
Required equipment
xx0300000600
xx0300000601
Art.
(IRBno: 3HAC 17117-2 (IRB 6600), 3HAC 17117-3
6650) Art. no: 3HAC 18100-1
Description: balancing device with lifting eye.
xx0300000599
xx0300000602
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4 Repair
4.5.4. Unloading the balancing device
device.
Note! Make sure the bolt is secured properly!
3. Remove the rear cover of the balancing
device, by unscrewing the attachment screws
(E).
xx0200000175
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4 Repair
4.5.4. Unloading the balancing device
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4 Repair
4.5.5. Restoring the balancing device
Overview
This section details how to restore the balancing device and how to remove the press tool
from the device.
xx0200000174
A Press block
B Hydraulic cylinder
C Press device
D Bolt, press device
E Moving pin with marking
F Bolt (4 pcs)
G Pin, attached to the fix plate
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4 Repair
4.5.5. Restoring the balancing device
xx0200000175
Danger!
The rear cover of the balancing device is a
safety device for the piston rod during
operation! Make sure the cover is properly
secured before commissioning of the robot!
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4 Repair
4.6.1. Replacement of motor, axis 1
4.6 Motors
Location of motor
The motor axis 1 is located on the left hand side of the manipulator as shown in the figure
below.
xx0200000200
A Motor, axis 1
B Motor attachment screws and washers
Required equipment
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4 Repair
4.6.1. Replacement of motor, axis 1
Removal, motor
The procedure below details how to remove motor, axis 1.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Remove the cover for connector access on top of the
motor by unscrewing its four attachment screws.
3. Remove the cable gland cover at the cable exit by
unscrewing its two attachment screws.
xx0200000199
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4 Repair
4.6.1. Replacement of motor, axis 1
Caution!
The motor weighs 25 kg! All lifting equipment used
must be dimensioned accordingly!
10. Lift the motor to get the pinion away from the gear and
disconnect the brake release voltage.
11. Remove the motor by gently lifting it straight up.
Refitting, motor
The procedure below details how to refit motor, axis 1.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Make sure the o-ring on the circumference of the Art no. is specified in
motor is seated properly. Lightly lubricate the o-ring Required equipment on
with grease. page 278!
3.
Caution!
The motor weighs 25 kg! All lifting equipment used
must be dimensioned accordingly!
4. Apply the lifting tool, motor axis 1, 4, 5 to the motor. Art no. is specified in
Required equipment on
page 278!
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4 Repair
4.6.1. Replacement of motor, axis 1
Document references
Product manual, in the
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.
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4 Repair
4.6.2. Replacement of motor axis 2
Location of motor
The motor, axis 2, is located on the left hand side of the manipulator as shown in the figure
below.
xx0200000169
A Motor axis 2
B Hole for lock screw
C Cable gland cover (located on the lower side of the motor)
D Motor attachment holes (4 pcs)
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4 Repair
4.6.2. Replacement of motor axis 2
Required equipment
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4 Repair
4.6.2. Replacement of motor axis 2
Removal, motor
The procedure below details how to remove the motor, axis 2.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Run the manipulator to a position close Shown in the figure Location of
enough to its calibration position, to allow the motor on page 282!
lock screw to be inserted into the hole for lock
screw.
3. Lock the lower arm by inserting the lock screw Art. no. is specified in Required
into the hole. equipment on page 283!
4. Drain the oil from gearbox, axis 2. Detailed in section Oil change,
gearbox axis 2 on page 160.
5. Remove the cover on top of the motor by
unscrewing its four attachment screws.
6. Remove the cable gland cover at the cable Shown in the figure Location of
exit by unscrewing its two attachment screws. motor on page 282!
Make sure the gasket is not
damaged!
7. Disconnect all connectors beneath the motor
cover.
8. In order to release the brake, connect the 24 Connect to connector R2.MP2
VDC power supply. • +: pin 2
• -: pin 5
9. Remove the motor by unscrewing its four
attachment screws and plain washers.
10. Fit the two guide pins in two of the motor Art. no. is specified in Required
attachment holes. equipment on page 283!
Shown in the figure Location of
motor on page 282!
11. If required, press the motor out of position by Art. no. is specified in Required
fitting the removal tool, motor to the remaining equipment on page 283!
motor attachment holes. Shown in the figure Location of
motor on page 282!
Always use the removal tools in
pairs!
12. Remove the removal tools and fit the lifting Art. no. is specified in Required
tool, motor axis 2, 3, 4 to the motor. equipment on page 283!
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4 Repair
4.6.2. Replacement of motor axis 2
Caution!
The motor weighs 27 kg! All lifting equipment
used must be dimensioned accordingly!
14. Lift the motor to get the pinion away from the Make sure the motor pinion does
gear. not get damaged!
15. Remove the motor by gently lifting it straight
out and place it on a secure surface.
Disconnect the brake release voltage.
Refitting, motor
The procedure below details how to refit the motor axis 2.
Danger!
Caution!
The motor weighs 27 kg! All lifting
equipment used must be dimensioned
accordingly!
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4 Repair
4.6.2. Replacement of motor axis 2
xx0200000165
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4 Repair
4.6.2. Replacement of motor axis 2
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.
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4 Repair
4.6.3. Replacement of motor, axis 3
Location of motor
The motor axis 3 is located on the left hand side of the robot as shown in the figure below.
xx0200000186
A Motor axis 3
B Cable gland cover, motor axis 3
C Motor attachment holes (4 pcs)
Required equipment
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4 Repair
4.6.3. Replacement of motor, axis 3
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4 Repair
4.6.3. Replacement of motor, axis 3
Removal, motor
The procedure below details how to remove motor, axis 3.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Unload the upper arm of the robot by either:
• Use a fork lift to rest the upper arm onto.
• Use lifting slings and an overhead crane
to rest the upper arm.
• Use a mechanical stop to rest the upper
arm. Fit the mechanical stop in the
attachment hole (A) with tightening
torque: 115 Nm.
The upper arm must be positioned as horizontal
as possible!
xx0300000051
7. Disconnect
cover. all connectors beneath the motor
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4 Repair
4.6.3. Replacement of motor, axis 3
Caution!
The motor weighs 27 kg! All lifting equipment
used must be dimensioned accordingly!
14. Lift the motor to get the pinion away from the
gear.
15. Remove the motor by gently lifting it straight out Make sure the motor pinion is not
and disconnect the brake release voltage. damaged!
Refitting, motor
The procedure below details how to refit motor, axis 3.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Make sure the o-ring on the circumference Art no. is specified in Required
of the motor is seated properly. Lightly equipment on page 288!
lubricate it with grease .
3. Fit the lifting tool, motor axis 2, 3, 4 to the Art no. is specified in Required
motor. equipment on page 288!
4. Fit the two guide pins in the two lower Art no. is specified in Required
motor attachment holes. equipment on page 288!
Shown in the figure Location of motor
on page 288!
5.
Caution!
The motor weighs 27 kg! All lifting equipment
used must be dimensioned accordingly!
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4 Repair
4.6.3. Replacement of motor, axis 3
xx0200000165
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4 Repair
4.6.3. Replacement of motor, axis 3
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.
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4 Repair
4.6.4. Replacement of motor, axis 4
Location of motor
The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below.
xx0200000202
A Motor, axis 4
B Cable gland cover, motor axis 4
C Motor attachment holes (4 pcs)
Required equipment
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4 Repair
4.6.4. Replacement of motor, axis 4
Removal, motor
The procedure below details how to remove the motor, axis 4.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Run the robot to a position where the upper arm is Draining of oil is described in
pointed straight up. section Draining, oil on page
This position enables the motor to be replaced 168.
without draining the gear oil, which in turn saves time.
Any other position of the upper arm requires a
draining of oil from the gearbox for axis 4.
3. Remove the cable gland cover at the cable exit of the Shown in the figure Location
motor by unscrewing its two attachment screws. of motor on page 294!
Make sure the gasket is not
damaged!
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4 Repair
4.6.4. Replacement of motor, axis 4
Refitting, motor
The procedure below details how to refit motor, axis 4.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Make sure the o-ring on the Art. no. is specified in Required
circumference of the motor is seated equipment on page 294!
properly. Lightly lubricate the o-ring with
grease.
3. In order to release the brakes, connect the Connect to connector R2.MP4:
24 VDC power supply. • +: pin 2
• -: pin 5
4. Fit the two guide pins, M8 in two of the Art. no. is specified in Required
motor attachment holes. equipment on page 294!
Shown in the figure Location of motor
on page 294!
5. Fit the motor, with guidance of the pins, Make sure the motor pinion does not
making sure the motor pinion is properly get damaged!
mated to the gear of gearbox 4.
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4 Repair
4.6.4. Replacement of motor, axis 4
xx0200000165
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4 Repair
4.6.4. Replacement of motor, axis 4
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.
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4 Repair
4.6.5. Replacement of motor, axis 5
Reused pinion
The pinion in the motor, axis 5, is matched with the beveral gear for axis 5. When the motor
is replaced the pinion must therefor be removed from the dismounted motor and fitted onto
the new motor shaft as detailed in this section.
Location of motor
The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown
in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information .
xx0200000204
A Motor, axis 5
B Upper arm tube
C Wrist unit
Required equipment
Spare part
Equipment, etc. Art. no. Note
no.
Motor axis 5 (175/2.55) 3HAC 17484-7 Does not include pinion. Use
the pinion from the motor to be
replaced.
Includes o-ring 2152 2012-430.
Motor axis 5 3HAC 17484-10 Does not include pinion. Use
(125/3.2, 200/2.75, the pinion from the motor to be
175/2.8, 225/2.55) replaced.
Includes o-ring 2152 2012-430.
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4 Repair
4.6.5. Replacement of motor, axis 5
Spare part
Equipment, etc. Art. no. Note
no.
Set of shim, motor 3HAC 7941-28 Used to obtain the correct
distance between motor flange
and outer surface of motor
pinion.
O-ring 2152 2012-430 Must be replaced when
reassembling motor!
Grease 3HAC 3537-1 For lubricating the o-ring.
Isopropanol 1177 1012-208 For cleaning motor pinion and
motor pinion hole.
Mineral oil CS 320 For lubrication of pinion shaft
and pinion hole.
Removal tool, motor 3HAC 14972-1 Always use the removal tools in
M10x pairs!
Oil injector / max 500 3HAC 021590- For pressing out the pinion,
MPa 001 motor 5.
Motor press pinion 3HAC 021883- For pressing the pinion on to
001 the new motor.
Measuring tool 6896 134-GN
Guide pins M8 x 100 3HAC 15520-1 For guiding the motor.
Guide pins M8 x 150 3HAC 15520-2 For guiding the motor.
Power supply - 24 VDC, 1.5 A
For releasing the brakes.
Standard toolkit 3HAC 15571-1 The contents are defined in
ProductStandard
section toolkit in the
manual, reference
information !
Other tools and These procedures include
procedures may be references to the tools required.
required. See
references to these
procedures in the step-
by-step instructions
below.
Circuit Diagram See chapter Circuit diagram in
the Product manual, reference
information .
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4 Repair
4.6.5. Replacement of motor, axis 5
Removal, motor
The procedure below details how to remove motor, axis 5.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Drain the oil from gearbox axis 5. Detailed in section Oil change,
gearbox, axis 5 on page 170.
3. Remove the wrist unit. Detailed in section Removal, wrist
unit on page 226.
4. Place the wrist unit safely on a workbench, in
a fixture or similar.
5. Remove the cover on top of the motor by
unscrewing its four attachment screws.
6. Remove the cable gland cover at the cable
exit by unscrewing its two attachment screws.
7. Disconnect all connectors beneath the motor
cover and remove the separate cable of the
axis 5 motor.
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4 Repair
4.6.5. Replacement of motor, axis 5
Refitting, motor
The procedure below details how to refit motor, axis 5.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Make sure the o-ring on the circumference of Art. no. is specified in Required
the motor is seated properly. Lightly lubricate equipment on page 299!
the o-ring with grease.
3. Clean the motor pinion and the motor pinion Art. no. is specified in Required
hole in the motor, with isopropanol. equipment on page 299!
Note!If the pinion is damaged the complete Replacing the complete wrist unit is
wrist unit must be replaced! detailed in section Replacement of
complete wrist unit on page 225.
4. Apply a thin film of mineral oil to the pinion Art. no. is specified in Required
shaft and the pinion hole in order to make the equipment on page 299!
pinion run smoothly and to achieve an even
friction torque when assembling the pinion.
5. Place the motor and pinion in the press Art. no. is specified in Required
fixture . equipment on page 299!
6. Press the pinion onto the new motor and If the pressing force is outside the
check the pressing force. given range or if the pinion "jumps"
For an axis diameter of 15.5 mm, use min. in bit by bit, it must be dismounted,
pressing force: 18.5 kN and max. pressing checked, cleaned and oiled before it
is assembled once again!
force: 39.5 kN.
7. Measure the distance between the motor Art. no. is specified in Required
flange and the outer surface of the pinion with equipment on page 299.
the measuring tool.
Modify the distance with shims in order to
obtain the same distance as measured when
dismounting the old motor (+ 0-0,05 mm).
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4 Repair
4.6.5. Replacement of motor, axis 5
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.
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4 Repair
4.6.6. Replacement of motor, axis 6
Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.
xx0200000222
A Wrist unit
B Motor, axis 6
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4 Repair
4.6.6. Replacement of motor, axis 6
Required equipment
Removal tool, motor 3HAC 14972-1 Always use the removal tools
M10x in pairs!
Guide pins M8 x 100 3HAC 15520-1 For guiding the motor.
Guide pins M8 x 150 3HAC 15520-2 For guiding the motor.
Power supply - 24 VDC, 1.5 A
For releasing the brakes.
Grease 3HAB 3537-1 For lubricating the o-ring.
Standard toolkit 3HAC 15571-1 The contents are defined in
section Standard toolkit in the
Product manual, reference
information !
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4 Repair
4.6.6. Replacement of motor, axis 6
Removal, motor
The procedure below details how to remove the motor, axis 6.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Run the robot to a position where the motor in axis
6 is pointed straight up. This position enables the
motor to be replaced without draining the gear oil,
which in turn saves time.
3. Remove the rear motor cover by unscrewing the
six attachment screws.
4. Disconnect all connectors beneath the cover.
5. In order to release the brake, connect the 24 VDC Connect to connector R3.MP6
power supply. • +: pin 2
• -: pin 5
6. Remove the motor by unscrewing its four
attachment screws and plain washers.
7. If required, press the motor out of position by fitting Art. no. is specified in Required
removal tool, motor to the motor attachment equipment on page 305!
screw holes. Always use the removal tools in
pairs!
8. Lift the motor carefully to get the pinion away from Make sure the motor pinion is
the gear and disconnect the brake release voltage. not damaged!
9. Remove the motor by gently lifting it straight out.
Refitting, motor
The procedure below details how to refit motor, axis 6.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Make sure the o-ring on the circumference of Art. no. is specified in Required
the motor is seated properly. Lightly lubricate equipment on page 305!
the o-ring with grease.
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4 Repair
4.6.6. Replacement of motor, axis 6
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.
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4 Repair
4.7.1. Replacement of gearbox, axis 1
4.7 Gearboxes
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.
xx0300000015
A Gearbox, axis 1
B Frame
C Base
- Attachment screws, gearbox axis 1 (not shown in figure)
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4 Repair
4.7.1. Replacement of gearbox, axis 1
Required equipment
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4 Repair
4.7.1. Replacement of gearbox, axis 1
Danger!
Turn off all electric power, hydraulic
and pneumatic pressure supplies to
the robot!
2. Move the robot to its most stable
position, shown in the figure to the
right.
xx0300000022
Caution!
The base (without gearbox 1) weighs
263 kg! All lifting equipment used must
be dimensioned accordingly!
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4 Repair
4.7.1. Replacement of gearbox, axis 1
xx0300000612
• A: Bottom plate
• B: Rear connector plate
• C: Attachment screw
• D: Groove
13. Unscrew the 18 attachment screws
and remove the 3 washers, shown in
the figure to the right.
xx0200000227
• B: Attachment
1, 18 pcs screws, gearbox axis
• C: Washers, 3 pcs
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4 Repair
4.7.1. Replacement of gearbox, axis 1
xx0200000256
Caution!
The gearbox weighs 160 kg! All lifting
equipment used must be dimensioned
accordingly!
16. Lift the gearbox away with the already
mounted lifting tools.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. If the base is not supported with support, Mounting of the support, base and gear
base and gear 1, this should be done first. 1 is detailed in section Removal,
gearbox axis 1 on page 310.
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4 Repair
4.7.1. Replacement of gearbox, axis 1
xx0200000055
• A: Guide pin
• C: O-ring 3HAB 3772-54
• D: O-ring 3HAB 3772-55
• E: Sealing ring 3HAC 11581-4
4. Refit the cable guide in the center of
gearbox 1 with its attachment screws.
xx0200000256
Caution!
The gearbox weighs 160 kg! All lifting
equipment used must be dimensioned
accordingly!
7. Lift the gearbox to its mounting position in
the center of the base.
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4 Repair
4.7.1. Replacement of gearbox, axis 1
xx0200000227
xx0300000612
• A: Bottom plate
• B: Rear connector plate
• C: Attachment screw
• D: Groove
11.
Caution!
The base (without gearbox 1) weighs 263
kg! All lifting equipment
dimensioned used must be
accordingly!
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4 Repair
4.7.1. Replacement of gearbox, axis 1
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.
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4 Repair
4.7.2. Replacement of gearbox axis 2
Location of gearbox
The gearbox for axis 2 is located in the lower arm rotational center, underneath the cover.
The figure below shows design 2 of the cover.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.
xx0200000171
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4 Repair
4.7.2. Replacement of gearbox axis 2
Required equipment
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4 Repair
4.7.2. Replacement of gearbox axis 2
Removal, gearbox
The procedure below details how to remove the gearbox, axis 2.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Secure the lower arm with the special fixture
equipment according to section Securing the lower
arm on page 251.
3. Unload the balancing device shaft by using the press Art. no. is specified in
tool, balancing device , according to section Required equipment on
Unloading the balancing device on page 271! page 317!
4. Drain the gearbox, axis 2. Notice! Time-consuming
activity!
Detailed in section Oil
change, gearbox axis 2 on
page 160.
5. Remove the motor, axis 2. Detailed in section Removal,
motor on page 284.
6. Remove the rear attachment screws, gearbox from Shown in the figure Location
inside of the lower arm. of gearbox on page 316!
7. Remove the cover, axis 2 by unscrewing the Read more about the
• design 1: 24 front attachment screws, variations in design in
gearbox, shown in the figure below. section Different designs,
• design 2: 15 attachment screws, cover. cover axis 2 on page 316.
• design 3: 14 attachment screws, cover. Shown in the figure Location
of gearbox on page 316!
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4 Repair
4.7.2. Replacement of gearbox axis 2
xx0200000172
• A: Front attachment
screws, gearbox (24
pcs)
• B: M12 holes for
pressing the gearbox
out
9. Fit two guide pins in 180° relation to each other in the Art. no. is specified in
empty holes of the front gearbox attachment screws. Required equipment on
page 317!
10. If required, apply two M12 screws to the holes, shown
in the figure above, to press it free.
11. Fit the lifting tool, gearbox axis 2 to the gearbox. Art. no. is specified in
Required equipment on
page 317!
12.
Caution!
The gearbox weighs 53 kg! All lifting equipment used
must be dimensioned accordingly!
13. Remove the gearbox axis 2 using an overhead crane
or similar, with guidance from the mounted guide
pins.
14. Remove the friction washer and clean it.
15. Remove the sealing from the lower arm.
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4 Repair
4.7.2. Replacement of gearbox axis 2
Refitting, gearbox
The procedure below details how to refit the gearbox axis 2.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Make sure the both o-rings are fitted to the gearbox Art. no. is specified in
as shown in the figure to the right. Lightly lubricate Required equipment on
them with grease. page 317!
xx0200000173
• A: O-ring, gearbox
axis 2
3. Fit the lifting tool, gearbox axis 2 to the gearbox. Art. no. is specified in
Required equipment on
page 317!
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4 Repair
4.7.2. Replacement of gearbox axis 2
xx0300000553
• A: Rear attachment
screws, gearbox (33
pcs)
• B: Holes for the guide
pins, sealing axis 2/3
on the gearbox
5. Fit the new sealing, axis 2/3 on to the guide pins on Art. no. is specified in
the gearbox. Required equipment on
Note! Do not remove the guide pins for the sealing page 317!
until the rear attachment screws are secured.
6. Fit two guide pins, M12 in 180°relation to each other Art. no. is specified in
in the frame, in the screw holes for the gearboxes Required equipment on
front attachment screws. page 317!
7. Fit the cleaned friction washer onto the guide pins,
M12.
8.
Caution!
The gearbox weighs 53 kg! All lifting equipment used
must be dimensioned accordingly!
9. Lift the gearbox to its mounting position and slide it
onto the guiding pins attached in the frame, through
the front attachment screw holes.
10. Align the gearbox attachment screw holes to the hole Art. no. is specified in
patterns in the lower arm, with help from the guide Required equipment on
pins, sealing axis 2/3. page 317!
If necessary, use a gearbox crank to turn the gear!
Use the gearbox crank with caution! The gearbox
may be damaged if the crank is inserted too far into
the gear!
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4 Repair
4.7.2. Replacement of gearbox axis 2
15. Insert
screws,and secure
gearbox 31the
on of the 33 rear
inside of theattachment
lower arm. Shown in the
of gearbox pageLocation
onfigure 316!
33 pcs: M12 x 50, 12.9
quality UNBRAKO,
tightening torque: 115 Nm.
Reused screws may be
used, providing they are
lubricated as detailed in
section Screw joints in the
Product manual, reference
information before fitting.
16. Remove the guide pins, sealing axis 2/3, and tighten
the two remaining screws as detailed above.
17. Refit the motor. Detailed in section Refitting,
motor on page 285.
18. Perform a leak-down test. Detailed in section
Performing a leak-down test
on page 196.
19. Refill the gearbox with oil. Detailed in section Oil
change, gearbox axis 2 on
page 160.
20. Restore the balancing device. Detailed in section Restoring
the balancing device on
page 275!
21. Remove the fixture, lower arm.
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4 Repair
4.7.2. Replacement of gearbox axis 2
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.
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4 Repair
4.7.3. Replacement of gearbox, axis 3
Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.
xx0200000194
A Gearbox, axis 3
B Motor, axis 3
C Upper arm
D Attachment screws, gearbox (24 pcs)
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4 Repair
4.7.3. Replacement of gearbox, axis 3
Required equipment
arm.
3HABUse attachment
3409-86 (M16 xscrews
60).
Washers for mech 3HAA 1001-186
stop axis 3
Lifting eye M12 3HAC 14457-3
Guide pins M12 x 200 3HAC 13056-3 For guiding the gearbox.
Use guides in pairs!
Guide pins M12 x 250 3HAC 13056-4 For guiding the gearbox.
Use guides in pairs!
Guide pins, sealing 3HAC 14628-1 For guiding the sealing, axis
ax 2/3, 80mm 2/3.
Use guides in pairs!
Guide pins, sealing 3HAC 14628-2 For guiding the sealing, axis
ax 2/3, 100mm 2/3.
Use guides in pairs!
Standard toolkit 3HAC 15571-1 The contents are defined in
section Standard toolkit in the
Product manual, reference
information !
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the
step-by-step
instructions below.
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4 Repair
4.7.3. Replacement of gearbox, axis 3
Removal, gearbox
The procedure below details how to remove gearbox, axis 3.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Secure the upper arm in a horizontal position Art. no. is specified in Required
using a mechanical stop. equipment on page 325.
Fit the mechanical stop to the third and final
attachment hole (A), below the fixed
mechanical stop (B) in the upper arm, shown in
the figure to the right.
Tightening torqure: 115 Nm.
xx0300000051
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4 Repair
4.7.3. Replacement of gearbox, axis 3
xx0200000201
free.
11.
Caution!
The gearbox weighs 60 kg! All lifting equipment
used must be dimensioned accordingly!
12. Remove the gearbox, with guidance from the
guide pins, using an overhead crane or similar.
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4 Repair
4.7.3. Replacement of gearbox, axis 3
Refitting, gearbox
The procedure below details how to refit gearbox, axis 3.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Turn the upper arm in such a position that the gear
mating surface faces upwards.
3. Fit two guide pins in 180°relation to each other in the Art. no. is specified in
holes in the upper arm, used for the gearbox Required equipment on
attachment screws. page 325!
4.
Caution!
The gearbox weighs 60 kg! All lifting equipment used
must be dimensioned accordingly!
5. Fit the lifting eye, M12 to the gearbox. Art. no. is specified in
Required equipment on
page 325!
6. Make sure the o-rings are fitted to the gearbox. Art. no. is specified in
Apply grease to the o-rings to make sure they stick Required equipment on
in their grooves during assembly. page 325!
Replace them if damaged!
xx0200000173
• A: O-rings, gearbox
axis 3
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4 Repair
4.7.3. Replacement of gearbox, axis 3
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.
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4 Repair
4.7.4. Replacement of gearbox, axis 6
Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.
The different robot versions result in two different designs of the gearbox.
xx0300000555
A Gearbox, axis 6
E Attachment screws and washers, gearbox for robot version IRB 6600 - 175/2.55
(8 pcs)
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4 Repair
4.7.4. Replacement of gearbox, axis 6
xx0200000219
A Gearbox, axis 6
B Attachment screws and washers, gearbox for robot version IRB 6600 225/2.55
and 175/2.8, IRB 6650 125/3.2 and 200/2.75 (18 pcs)
C Oil plug, draining
D Oil plug, filling
- O-ring (not shown in figure)
Required equipment
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4 Repair
4.7.4. Replacement of gearbox, axis 6
Removal, gearbox
The procedure below details how to remove gearbox, axis 6.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Drain the oil from gearbox, axis 6. Detailed in section Oil change, gearbox
axis 6 on page 173.
3. Remove the turning disk. Detailed in section Removal, turning
disk on page 222.
4. Remove the gearbox by unscrewing its 8 Shown in the figure Location of gearbox
or 18 attachment screws (amount on page 330!
depends on robot version).
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4 Repair
4.7.4. Replacement of gearbox, axis 6
xx0200000220
Refitting, gearbox
The procedure below details how to refit gearbox, axis 6.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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4 Repair
4.7.4. Replacement of gearbox, axis 6
xx0100000132
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4 Repair
4.7.4. Replacement of gearbox, axis 6
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.
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4 Repair
4.7.4. Replacement of gearbox, axis 6
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5 Calibration information
5.1. Introduction
5 Calibration information
5.1. Introduction
General
This chapter includes general information about different calibration methods and details also
procedures that does 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.
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.
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5 Calibration information
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
Description Calibration method
calibration
Standard The calibrated robot is positioned at home Calibration Pendulum
calibration position, i.e. the axes positions (angles) are (standard method)
set to 0º. or
Standard calibration
calib.cfg, supplied data
with theisrobot
foundatindelivery.
the file Levelmeter
(alternative calibration
method)
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.
Absolute Accuracy Based on standard calibration, but besides CalibWare
calibration positioning the robot at home position, the
(optional) Absolute Accuracy calibration also
compensates for:
xx0400001197
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5 Calibration information
5.2. Calibration methods
Calibration methods
Each calibration method is detailed in separate manuals. Below is a brief description of the
methods available.
because of the less accurate values obtained during calibration. The method uses the same
principles as Calibration Pendulum but has not as good 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.
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5 Calibration information
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.
xx0200000176
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5 Calibration information
5.4. Calibration movement directions for all axes
xx0200000089
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5 Calibration information
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 either the TPU or the FlexPendant.
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5 Calibration information
5.5. Updating revolution counters
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4. Select the desired axis and press Incl to include it (it will
be marked with an x) or press All to select all axes.
5. Press OK when all axes that are to be updated are marked
with an x.
CANCEL returns to the Calibration window.
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5 Calibration information
5.5. Updating revolution counters
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.
How to perform the check is detailed in section Checking the
calibration position on page 346.
Step Action
1. On the ABB menu, tap Calibration.
All mechanical units connected to the system are shown along with their calibration
status.
2. Tap the mechanical unit in question.
A screen is displayed: tap Rev. Counters.
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5 Calibration information
5.5. Updating revolution counters
Step Action
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.
4. Select the axis to have its revolution counter updated by:
• Ticking in the box to the left
• Tapping Select all to update all axes.
Then tap Update .
5. A dialog box is displayed, warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the ticked revolution counters and removes the tick from
the list of axes.
6.
Caution!
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning,
which in turn may cause damage or injury!
Check the calibration position very carefully after each update.
See section Checking the calibration position on page 346.
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5 Calibration information
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
counters
Updating is detailed in
revolution section
counters
on page 342
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5 Calibration information
5.6. Checking the calibration position
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5 Calibration information
5.6. Checking the calibration position
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6 Decommissioning
5.6. Checking the calibration position
6 Decommissioning
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6 Decommissioning
6.1. Environmental information
Hazardous material
The table specifies some of the materials in the manipulator and their respective use
throughout the product.
Dispose the components properly to prevent health or environmental hazards.
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6 Decommissioning
6.2. Decommissioning of balancing device
General
There is much energy stored in the balancing device. Therefore a special procedure is
required to dismantle it. The coil springs inside the balancing device exert a potentially lethal
force unless dismantled properly.
Required equipment
DANGER!
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Procedure
The instruction below details how to cut open the balancing device housing and removing the
tension in the coil springs before opening the device.
Contact ABB Robotics for further consultation.
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6 Decommissioning
6.2. Decommissioning of balancing device
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Index
C
cabling, position switch 105
cabling, robot 104
cabling, robot axes 1-4 201
cabling, robot axes 5-6 210
calibration position 342
calibration position, checking 346
calibration position, jog to 347
Connection of external safety devices 17
D
direction of axes 341
G
gearbox oil 152
L
Limitation of Liability 18
N
negative directions, axes 341
O
oil, amount 152
oil, types 152
P
positive directions, axes 341
R
Revolution counters 342
S
Safety, service 17
securing, base plate 70
securing, lower arm 251
securing, robot 74
securing, upper arm 290
U
Updating revolution counters 342
V
Validity and responsibility 17
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