Mechanical Repair: TR-510 / TR-5000

Mechanical
Repair
TR-510 / TR-5000
Publication No.: 3HNT 105 004R1701
ABB Flexible Automation AS

Mechanical Repair
TR-510 / TR-5000
3HNT 105 004R1701
Mechanical Repair
The information in this document is subject to change without notice and should not be construed as a commitment by
ABB Flexible Automation AS. ABB Flexible Automation AS assumes no responsibility for any errors that may appear in
this document.
In no event shall ABB Flexible Automation AS be liable for incidental or consequential damages arising from use of this
document or of the software and hardware described in this document.
This document and parts thereof must not be reproduced or copied without ABB Flexible Automation AS’s written
permission, and the 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 document may be obtained from ABB Flexible Automation AS at its then current charge.
© 1995 ABB Flexible Automation AS

ABB Flexible Automation AS
4341 Bryne - Norway
3 May 1995
Table of Contents
1 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 General considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Commutation and synchronization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Using Loctite glue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.5 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Flexi wrist procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.1 Flexi wrist replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.2 Flexi wrist driveshaft axis 6 replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.3 Flexi wrist pushrods axis 4-5 replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2.4 Flexi wrist drive unit axis 4-6 replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.5 Flexi wrist axis 6 gear unit replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 Hollow wrist procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.1 Hollow wrist replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.2 Hollow wrist drive unit replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.3 Hollow wrist seals replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.4 Hollow wrist inner tube replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.5 Hollow wrist gearwheel replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4 Arm replacement procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.1 Horizontal arm replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.2 Vertical arm replacement, ME502 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.3 Vertical arm replacement, ME512 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.4 Parallel rod replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
4.5 Parallel rod lever arm replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
5 Turning unit components replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.1 Turning unit replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5.2 Balancing springs replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3 Balancing spring replacement, ME512 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.4 Gearbox shaft seals replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6 Axis 1, 2, 3, 7 component replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

6.1 Drive motor axis 1, 2, 3 replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.2 Brakes axis 1, 2 and 3 replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.3 Gearbox axis 1 replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.4 Measuring system replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.5 Replacing motor for axis 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
7 ME504 repair procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

7.1 Axis 3 arm replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.2 Gear box axis 3 replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7.3 Axis 2 arm replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.4 Gear box axis 2 replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.5 Axis 1 arm and cable unit replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
7.6 Motor axis 1 replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8 ME505 repair procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

8.1 Vertical arm parallel rod replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.2 Horizontal arm parallel rod replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.3 Rear leveller arm replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
9 Misc. procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9.1 Disengage balancing springs, ME502, 503, 505 . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
9.2 Disengage balancing springs, ME512 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.3 Flexi wrist balancing adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.4 Hollow wrist gearwheel adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.5 Balancing spring adjustment, ME512 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
1 - Introduction
1 Introduction
This manual provides mechanical repair procedures for the following manipulator types:
ME512 for TR-510
ME502 for TR-5002 Stand alone robot
ME503 for TR-5003 Trolley robot
ME504 for TR-5004 Door opener robot
ME505 for TR-5005 Hood/Lid opener robot
The manual is divided into the following chapters:
1 - Introduction
2 - Flexi wrist procedures
3 - Hollow wrist procedures
4 - Arm replacement procedures
5 - Turning unit components replacement
6 - Axis 1, 2, 3, 7 component replacement
7 - ME504 repair procedures
9 - Misc. procedures
The following sections provide general information and safety precautions for
performing mechanical repair on the robot. These sections must always be read before
performing any work on the robot.
WARNING!
No work must be performed on the robot before the Safety Manual, the
Introduction to Service Manual and the safety regulations below have been studied
carefully.
WARNING!
Repair work on the robot must only be performed by skilled personnel with proper
training.
• Make sure that the Mains Switch is switched OFF and locked in OFF position
before performing any work on the robot.
• Make sure that the area where the repair work is to be performed is tested to be
free from explosive gases.
• Make sure that no person or obstacles is within the reach of the manipulator arm
whenever starting the robot for test run etc.
• Some of the manipulator components are heavy. Make sure that proper lifting
device is used when necessary.
• Ensure that any person in the area of the robot are aware that service work on
the robot system is being performed.
• Manipulator panels are equipped with ground connection. These connections
must not be removed.
• Never change any ground connections in the system.
3HNT 105 004R1701 © 1995 ABB Flexible Automation AS Mechanical Repair 5

General considerations
1.1 General considerations

In addition to the above safety regulations, following points should be observed.
• Make sure that any replacement items are available before performing any repair
procedures. Use only replacement items listed in the spare parts catalogue.
• During operation, the manipulator is supplied by an over pressure. For this reason, the
robot can not operate unless all panels are in place and properly sealed. Missing
screws will cause air leaks and result in increased air consumption or failure in the
over pressure system.
1.2 Commutation and synchronization

Whenever work has been performed that has altered the setting of a drive motor or
measuring system for the motor, commutation and/or synchronization must be
performed. Commutation means to set-up the motor to give maximum torque, and
synchronization is used to set-up correct mathematical model for the robot. A mastering
fixture is required to perform these operations.
Commutation and synchronization is described in the Commutation and Synchronization
manual, and referred to in the procedures whenever required.
1.3 Using Loctite glue
Loctite 243 Glue (Blue)

Add a drop of Loctite 243 to screws which you
can see have Loctite when dismounted (old
designation 242).
Loctite 270 Glue (Green)
Must be used on screws where it is especially
important that the screws are firmly fixed.
Screws with green Loctite are much harder to
open than screws with blue Loctite. It may be
required to heat screws to be able to loosen!
Do not use Loctite on following:
Hexagon socket head cap screws (guide
screws) with grinded sylindrical stem
BS 4168 - ISO 7379, and all swivels.
1.4 Special tools

For information on special tools, see Introduction to Service Manual.
6 Mechanical Repair © 1995 ABB Flexible Automation AS 3HNT 105 004R1701

1 - Introduction
1.5 Tightening torques

All screws on the robot except screws for covers and adjusting screws should be
tightened with torque according to following tables unless otherwise specified.
Screw quality
Nominal 8.8 12.9
Diameter Nm Nm
M4 2.5 4.3
M5 4.9 8.5
M6 8.5 14.5
M7 14.0 24.0
M8 20.5 35.0
M10 44.0 75.0
M12 75.0 130.0
M14 120.0 205.0
M16 180.0 310.0
Galvanized screws are of 8.8 quality and untreated screws (black oxide) are of 12.9
quality. Torques apply to lightly lubricated screws.
Nominal Tightening torque - Nm

Diameter class 4.8 “Dry”
M 2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0

Tightening torques

2 Flexi wrist procedures

This chapter includes procedures for replacing components associated with the flexi
wrist.
Following procedures are included:
2.1 - Flexi wrist replacement
2.3 - Flexi wrist pushrods axis 4-5 replacement
2.3 - Flexi wrist pushrods axis 4-5 replacement
2.4 - Flexi wrist drive unit axis 4-6 replacement
2.5 - Flexi wrist axis 6 gear unit replacement

Flexi wrist replacement
2.1 Flexi wrist replacement

The following procedure describes how to replace the complete wrist unit.
Robot Types: All robots with flexi wrist arm
Required Tools and Items:
- Mastering fixture
- Grease type Omega 77
- Normal hand tools
6 7 8 9 10 11
1 2 3 4 5
12
WARNING!
Watch fingers whenever flexi wrist sleeve is removed.
IMPORTANT
Read chapter 1 - Introduction, before performing following steps.
1. Remove tool bracket / spraygun assy’ (5) by unscrewing 3 ea. attachment screws on
front of wrist. Release axes brakes.
2. Remove lock pin from nut (4) on ball stud assy’, and loosen nut 2 - 3 revolutions. Do
not remove nut.
3. Remove PG nipple (12) and loosen screw on spline (8).
4. Unscrew 3 ea. screws (1) securing wrist to horizontal arm.
5. Bend wrist upwards and activate brakes. Bend wrist downwards to extract from arm.
6. Install new wrist in reverse order as follows.
7. Refer to illustration below and pull rear end of wrist sleeve a little bit forwards to
expose inner ring. Align the small notch (14) on this ring with allen screw (13) on
top of arm.
8. Pull pushrods (2) for axes 4 and 5 and center guide (3) fully forwards.

9. Bend wrist down and move into position while guiding center shaft (9) into
attachment on front of axis 6 drive shaft (6). The shaft can be guided by removing
arm rear cover to get access to the shaft.
10. Enter ball studs into position. Move wrist up (alternatively down) and move shaft
spline (7) into position.
13 14
15 15
16
Wrist/arm - top view Wrist - front view
11. Rotate wrist fully to one end position. Mark position of alignment notch (14) in
relation to ball race (16).
12. Rotate wrist to the opposite end position and mark as above.
13. Check that the rotation in both directions is the same (15). If not, bend wrist down to
free spline connection. Rotate wrist as required and move wrist up to re-enter spline.
Repeat operation until correct by eye-measure. Note that if the robot is equipped
with a 2:1 gear, the rotation will be more than a full revolution. When correct,
re-align notch (14) and cross tighten.
14. Move complete wrist carefully in/out while looking into the attachment hole (10) on
top of the horizontal arm. When slot (11) in attachment ring can be seen, insert
screw. Enter the other 2 screws and cross tighten.
15. Tighten nuts (4) on ball stud assy’s until no play can be observed. Insert lock pins. If
lock pin does not fit directly, loosen until first free slot is reached. Do not tighten to
next free slot.
16. Lubricate ball stud assy’s, center guide, grease nipple on underside of ball race and
flexi wrist bevel gears. Refer to Maintenance Manual for accomplishment
instructions.
17. Install gun bracket assy’ in the same position as before removal.
18. Check the balancing of the wrist. If not as required, adjust balancing springs as
described in section 9.3 - Flexi wrist balancing adjustment procedure.
19. Perform synchronization as described in the Commutation and Synchronization
Manual.

Flexi wrist driveshaft axis 6 replacement
2.2 Flexi wrist driveshaft axis 6 replacement

The following procedure describes how to replace the drive shaft for axis 6. To replace
the drive shaft, the flexi wrist must first be removed.
- Mastering fixture
- Normal hand tools
1 2
3 4
IMPORTANT:
1. Remove flexi wrist as described in section 2.1 - Flexi wrist replacement procedure.
2. Remove cover (4) on underside of horizontal arm to get access to pushrod
attachment.
3. Loosen screws (3) for shaft attachment.
4. Pull shaft (2) out through front of arm.
5. If required, shift shaft attachment (1) to new shaft.
6. Install new shaft in reverse order. When entering the shaft attachment over the
actuator splines, open the attachment slightly by carefully pressing a screwdriver
into slot.
7. Re-install flexi wrist according to procedure.
8. Perform synchronization for axis 6 as described in the Commutation and
Synchronization Manual.

2.3 Flexi wrist pushrods axis 4-5 replacement

The following procedure describes how to replace the pushrods for axis 4-5. To replace
the pushrods, the flexi wrist must first be removed.
- Mastering fixture
- Normal hand tools
1 2 3 4
IMPORTANT:
2. Remove cover (3) on underside of horizontal arm to get access to pushrod
attachment.
3. Loosen screw (4) for spring attachment, and pull spring (2) forwards to get access to
pushrod attachment.
4. Using 2 open ring keys, unscrew pushrod from front of drive motor shaft (1).
5. Pull rod out through front of arm.
6. Install new rod in reverse order.
8. Check the balancing of flexi wrist. If not as required, adjust balancing springs as
described in section 9.3 - Flexi wrist balancing adjustment procedure.
9. Due to possible difference in length of pushrod, perform synchronization as
described in the Commutation and Synchronization Manual.

Flexi wrist drive unit axis 4-6 replacement
2.4 Flexi wrist drive unit axis 4-6 replacement

The following procedure describes how to replace the drive unit for axis 4-6. The drive
unit is located in the rear end of the horizontal arm. To be able to replace the drive unit,
the flexi wrist must first be removed.
- Mastering fixture
- Loctite 242
- Normal hand tools
5 7
8
1 2 3 4
IMPORTANT:
2. Remove horizontal arm rear top and bottom covers to get access to drive unit and
attachment to axis 4-5 pushrods and axis 6 driveshaft.
3. Loosen set screw (4) on both sides for balancing spring attachment and push springs
forwards.
4. Unscrew connection (3) between pushrod and drive unit shaft.
5. Loosen screw (2) for driveshaft connection.
6. Remove 3 ea. screws (8) for axis 6 shaft seal.

7. Disconnect electrical connectors for drive unit.

8. Unscrew attachment screws (1) on both sides, securing drive unit to arm.
9. Lift out complete drive unit.
10. On the new drive unit, adjust axes 4 and 5 shaft until length (6) is 55 mm (center of
stroke). Check o-rings (5). Replace as required.
11. Rotate axis 6 until slot (7) in shaft is pointing straight upwards.
12. Remove seal (9) and check if damaged. Replace as required.
13. Install new drive unit and install attachment screws (1).
14. Add grease in hole for seal. Slide seal (9) over axis 6 shaft. Move seal into correct
position. Add Loctite 242 and install seal attachment screws (8)
CAUTION:
Do not tighten seal attachment screws too hard. This may deform the seal
housing surface and make it impossible to replace the seal at another time.
NOTE: Due to the purging system, it is important that there are no air leaks from the
rear compartment.
16. As the shafts for axes 4 and 5 were positioned in center position, you may now
position flexi wrist until it is pointing straight forwards. This may be checked by
using the mastering fixture.
17. Install electrical connectors.
18. If commutation values are shipped with the new drive unit, these values may be
entered into the system. If values are not available, perform commutation as
described in the Commutation and Synchronization Manual.
19. Perform synchronization according to same manual.
20. Re-install covers.

Flexi wrist axis 6 gear unit replacement
2.5 Flexi wrist axis 6 gear unit replacement

The following procedure describes how to replace the gear unit for axis 6. The gear unit
is located on the front of the flexi wrist drive unit. To replace the gear unit, the flexi wrist
and the complete drive unit must first be removed from the manipulator.
- Mastering fixture
- Normal hand tools
1 2 3
4 5
IMPORTANT
2. Remove drive unit as described in section 6.1 - Drive motor axis 1, 2, 3 replacement
procedure.
3. Place drive unit on a work bench.
4. Remove 4 screws (3) securing gear unit to drive unit. Remove old drive unit.
5. Loosen adjustment screw (2) on new drive unit and install.
6. Move axis 6 from side to side using a suitable tool attached to the output shaft.
7. Tighten adjustment screw until a small play can be felt between the motor gear
wheel (1) and the first gear wheel (4) in the gear unit. Complete a full rotation to
check that the play is even in all positions. If not, adjust so that a very small play
(hardly no play at all) can be observed on the tightest point.
NOTE: Adjustment screw (5) is used to adjust the front gear wheels. This screw
should normally not need any adjustment.
8. Re-install drive unit and flexi wrist.
9. Perform synchronization as described in Commutation and Synchronization Manual.

3 Hollow wrist procedures

This chapter includes procedures for replacing components associated with the hollow
wrist.
3.1 - Hollow wrist replacement
3.2 - Hollow wrist drive unit replacement
3.3 - Hollow wrist seals replacement
3.4 - Hollow wrist inner tube replacement
3.5 - Hollow wrist gearwheel replacement

Hollow wrist replacement
3.1 Hollow wrist replacement

The following procedure describes how to replace the wrist on front of the hollow wrist
arm.
Robot Types: All robots with hollow wrist arm
- Mastering fixture
- Normal hand tools
1 2 3 4 5
3 2 3 2
IMPORTANT
Read chapter 1 - Introduction before performing following steps.
1. Before starting the replacement operation, all wrist axes must be moved to center
position. This can be performed in 2 ways as described below. Center position is
when the notches (6) on front of axis 6, studs (5) on axis 5 are placed horizontally,
and the hole (4) on axis 4 is up.
Release brakes for axes 4 - 6 and move each axis manually to center position. To
make sure that center position is found, each axis must first be moved to end position
as each axis makes approximately 3 revolutions.
Apply mains power to the robot (brakes must be activated). Select JOG menu and
jog wrist until axes 4 - 6 shows quadrant 0 and position approximately 0 for all axes
(+/- 5).
2. If brakes have been released, activate brakes.
3. Remove covers (1) on each side on front of the arm.

CAUTION
When performing the next step, the wrist will be free. The wrist must be
supported through the next steps to avoid wrist from dropping.
4. Remove 8 screws (7) securing wrist to arm.
5. While one person is holding the wrist, insert one screwdriver through each of the
arm side access holes.
6. Insert screwdrivers between rear gear wheel and arm bracket. Bend screwdriver
carefully backwards to push wrist forwards until free.
7. Check small gearwheels for axes 4 - 6 for signs of wear. Replace as required as
described in section 3.5 - Hollow wrist gearwheel replacement procedure.
8. Check rear gasket and inner protection tube for paint hoses. Replace as required as
described in section 3.4 - Hollow wrist inner tube replacement procedure.
9. Check that axes of new wrist are placed in center position as described earlier in this
procedure.
10. Slide new wrist into position and install screws (7). Do not tighten screws too hard as
this may damage the threads on the arm flange.
11. Adjust hollow wrist gear wheel as described in section 9.4 - Hollow wrist gearwheel
adjustment procedure.
manual.

Hollow wrist drive unit replacement
3.2 Hollow wrist drive unit replacement

The following procedure describes how to replace the complete drive unit on the hollow
wrist arm.
- Mastering fixture
- Normal hand tools
2
1
3 4 5 6 7 8
IMPORTANT
1. Before starting the replacement operation, all wrist axes must be moved to center
position. This can be performed in 2 ways as described below. Center position is
when the notches (8) on front of axis 6, studs (7) on axis 5 are placed horizontally,
and the hole (6) on axis 4 is up.
Release brakes for axes 4 - 6 and move each axis manually to center position. To
make sure that center position is found, each axis must first be moved to end position
as each axis makes approximately 3 revolutions.
Apply mains power to the robot (brakes must be activated). Select JOG menu and
jog wrist until axes 4 - 6 shows quadrant 0 and position approximately 0 for all axes
(+/- 5).
2. Move arm to a good working position. A good position is when the vertical arm is
moved to extreme forward position and horizontal arm is placed horizontally.
3. Remove rear cover (1) and 2 front side covers (2).
4. Disconnect connectors for motors, motor brakes and measuring system.

CAUTION
Performing next step will release the complete arm. Make sure that the arm is
properly suspended before removing the arm attachment screws. Weight of
arm is approximately 45 kg.
5. Remove 4 ea. arm attachment screws (4). Remove arm assembly and place on a
work bench.
6. Remove 2 screws (3) securing drive unit to arm.
7. Open set screws (5) for front drive shaft attachments for axes 4, 5, 6. If set screws
can not be accessed, release brakes for motor by applying 24VDC directly on motor
brake release connector. Rotate motor until set screw can be reached.
8. When all set screws have been opened, remove complete drive unit and drive shafts.
Check that the shaft attachments at front comes off properly. If necessary, lift a little
with finger to release attachments.
9. Check that new motors are set to the commutation marks on the housing/brake disk.
(If necessary, refer to Commutation and Synchronization manual for information).
If setting for some reason has been disturbed, move each of the motors to one end
position. Then move 7 revolutions backwards. Then move to the nearest
commutation mark (any direction will do).
10. Open set screws and remove drive shafts from old drive unit. Note that the length of
the shafts are different, and that they must be placed correctly. (Axis 4 is the longest,
axis 6 shortest).
11. Install rods on new drive unit and secure set screws.
12. The front shaft couplings have 3 slots/studs. To simplify installation, mark position
of slot in drive shaft and stud on front attachment using a felt tip marker etc.
13. Move drive unit into position while engaging front couplings. Rotate wrist axes a
little to locate studs. This operation is best performed by 2 persons.
14. Install 2 screws (3) and tighten.
15. Move arm/drive unit assembly into position. Install screws (4) and tighten.
16. Insert connectors for drive unit.
17. Perform commutation as described in the Commutation and Synchronization
manual.
18. Tighten adjustment screws (5) at front coupling until play is close to nothing. (The
wrist may need rotating to access screws).
manual.
20. Re-install covers.

Hollow wrist seals replacement
3.3 Hollow wrist seals replacement

The following procedure describes how to replace the seals in the hollow wrist. The wrist
has 4 seals which must be replaced if worn. 3 of the seals may be replaced directly, while
the inner seal requires removal of the wrist to be replaced.
- Medium size screwdriver
IMPORTANT
1. If the inner seal is to be replaced, remove wrist as described in section 3.1 - Hollow
wrist replacement procedure before continuing.
2. Carefully, not to damage seal seat, insert screwdriver to lift seal from seat. Remove
seal. (Screwdriver is not required for inner seal).
3. Add a little grease to seat. Install new seal making sure that the seal is installed in the
correct direction.
4. Re-install wrist if inner seal has been replaced.

3.4 Hollow wrist inner tube replacement

The following procedure describes how to replace the plastic tube which protects the
paint hoses leading through the hollow wrist. This tube should be replaced if worn. To
replace the tube, the wrist must be removed. It is therefore a good idea to check the tube
if the wrist is removed for other reasons.
- Normal hand tools
3
2
IMPORTANT
1. Place wrist in straight forward position and remove wrist as described in section 3.1
- Hollow wrist replacement procedure.
2. Loosen 2 screws (2) at front of wrist to release front tube attachment. The 2 screws
securing the tube can be distinguished from the other screws (1) on the front ring as
they are located further inwards as shown in the upper right illustration.
3. Remove rear end o-ring (3) using a small screwdriver.
4. Slide old tube backwards and discard.
5. Insert new tube from rear end. Check that o-ring is properly positioned.
6. Pull front end of tube until it is positioned even with the flange front (4).
7. Tighten screws (2) to secure front end of tube.
8. Re-install wrist according to procedure.

Hollow wrist gearwheel replacement
3.5 Hollow wrist gearwheel replacement

This procedure describes how to replace the drive gearwheels on front of the drive shaft
for axes 4 - 6 controlling the hollow wrist. Most of the procedure refers to the Hollow
Wrist Drive Unit Replacement- and Hollow Wrist Gear Wheel Adjustment Procedure.
- Mastering fixture
- Normal hand tools
1 2
1
2 1 2
3 4 1 2 5
IMPORTANT
1. Remove drive unit as described in section 3.2 - Hollow wrist drive unit replacement
procedure, steps 1 - 10.
2. Loosen gearwheel adjustment screw (2) and tighten gearwheel release screw (1) for
gearwheel(s) to be replaced.
3. Remove gearwheel (5) by removing complete gearwheel assembly (4). Note position
of studs (3) on coupling.
4. Install new gearwheel, making sure to place studs on coupling in same position.
5. Tighten adjustment screws (2) and release screw (1) lightly.
6. Re-install drive unit as described in section 3.2 - Hollow wrist drive unit replacement
procedure, steps 14 - 18.
7. Adjust set screws for gearwheel as described in section 9.4 - Hollow wrist gearwheel
adjustment procedure.
manual.

4 Arm replacement procedures

This chapter includes procedures for replacing components associated with the arm.
4.1 - Horizontal arm replacement
4.2 - Vertical arm replacement, ME502
4.3 - Vertical arm replacement, ME512
4.4 - Parallel rod replacement
4.5 - Parallel rod lever arm replacement

Horizontal arm replacement
4.1 Horizontal arm replacement

This procedure provides information for replacing the horizontal arm or to remove the
arm temporarily to replace the vertical arm etc.
Robot Types: ME512, ME502, ME503, ME505
Required Tools and Items
- (Mastering fixture)
- Lifting Device
- Normal hand tools
Horizontal
arm
Bearings
3
2 Vertical arm
IMPORTANT
1. Remove horizontal arm rear cover (1) and disconnect all electrical connectors
including PE-wire connection. For ME505, remove quick disconnect couplings for
sensors on side of vertical arm.
2. Release balancing spring tension as described in section 9.1 - Disengage balancing
springs, ME502, 503, 505 or section 9.2 - Disengage balancing springs, ME512. It is
EXTREMELY IMPORTANT that this is done before performing this procedure.
3. Make sure that arm is properly supported, and unscrew 2 screws (2) for brackets on
each side of the upper parallel rod attachment. For ME505, remove vertical arm
parallel rod upper attachment (extra parallel rod at back).
4. Loosen 2 set screws (3) for cable inlet and pull out cable/purging tube assembly.
5. Refer to illustration below and remove 4 ea. 6 x M16 screws (4) for cap (5) on each
side of the horizontal arm/vertical arm joint. Remove caps. Note that there is one
illustration for ME512 and one for ME502/ME503/ME505.
6. Unscrew 4 ea. M8 x M40 screws (6) for bearing support (8) inside caps.
7. Install one of the removed M8 screws (7) in hole in center of bearing support.

CAUTION
Suspend horizontal arm with strap and lifting device before performing the
following steps. The weight of the arm is 40-45 kg).
8. Pull out bearing support (8) on each side 6-7 mm to free horizontal arm, using the
screw installed in center as puller.
4 5 6 7 8 9 4 5 6 7 8
ME502/503/505 ME512
9. Remove complete horizontal arm.

10. Note the seal ring (9) (not used on ME512) and install new if necessary.
11. Install new arm in reverse order.
12. Install bearing support (8). Add Loctite glue to all screws. Install screws and press
bearing / bearing assembly into position by cross tightening screws.
NOTE: When installing the bearing support, the support will center the horizontal
arm. Ensure that the bearing assembly enter into the rear part correctly.
13. Apply grease to bearing.
14. Install caps and screws (4), and cross tighten.
15. Install cable and parallel rod. Check that rod bearing is located in center of gap.
16. If new arm has been installed, it may be required to perform synchronization as
described in the Commutation and Synchronization manual. If commutation values
are shipped with the new arm, these values must be entered into the control system.
If values are not available, commutation must be performed as described in the same
manual.
If the arm has only been temporarily removed, commutation and synchronization is
not required.

Vertical arm replacement, ME502
4.2 Vertical arm replacement, ME502

The following procedure describes how to replace the vertical arm. The procedure may
be used to replace the arm, or to remove the arm temporarily, e.g. to replace the turning
unit. To replace the vertical arm, the horizontal arm and balancing spring arrangement
must first be removed.
Robot Types: ME502, ME503, (ME505)
- Torque key with range 10 - 145 NM
- (Lifting Device)
- Normal hand tools
1
2 5
4
ME502 ME502V ME503 ME505 base rear view
IMPORTANT
1. Remove horizontal arm as described in section 4.1 - Horizontal arm replacement
procedure.
2. Remove balancing spring assembly on both sides as described in section 5.2 -
Balancing springs replacement procedure.
3. Move parallel rod (4) to rear position to get easier access to lower end of vertical
arm.
4. Remove vertical arm front covers and right side cover and disconnect electrical
connectors for cable leading through bottom end of arm.
5. Remove 2 screws (1) securing cable plate to bottom of vertical arm. Pull cables out
of arm.
6. Remove front- and rear clamp attachment screw (2).

CAUTION
following steps. Weight approx. 25 kg.
7. Remove 12 ea. M14 screws (3).
8. The arm may now be lifted out.
9. Clean big bearing (5) on the axis 3 side of the gearbox.
Mount the vertical arm.
10. Prepare vertical arm by removing clamp (7), and shims (6).
11. Use Loctite 270 on the outside of bearing (5).
12. Lift vertical arm on to the gear box. Fasten vertical arm with 12 e.a. M14x30 screws
(3). Add Loctite 243 to screws. Secure screws using a torque key, with a torque of
145 NM.
Mount clamp (7) with correct pressure on the bearing.
13. The clamp (7) must be fasten with 2 e.a. 10x40 screws (2). Add Loctite 243 to the
screws.
14. Tighten one of the screws (2) with a torque of 52.5 NM, and 10 NM on the other
screw (Note: Don’t insert the Shims yet).
15. Measure clearance between vertical arm and clamp using a measuring blade at the
position of the screw with the 10 NM torque.
16. Unscrew the screw which is tightened with 10 NM.
17. Insert Shims which is 0.1 mm thicker, compare to what you measured with the
measuring blade. E.g. if you measured a clearance of 0.2 mm, you must insert
0.3 mm Shims.
18. Tighten screw (2) with a torque of 52.5 NM.
manual.

Vertical arm replacement, ME512
4.3 Vertical arm replacement, ME512

The following procedure describes how to replace the vertical arm. The procedure may
be used to replace the arm, or to remove the arm temporarily, e.g. to replace the turning
unit. To replace the vertical arm, the horizontal arm and balancing spring arrangement
must first be removed.
Robot Types: ME512
- Torque key with range 0 - 10 NM
- (Lifting Device)
- Normal hand tools
5 2
6
Screw (6) is located
on front end 3
ME512 base rear view
IMPORTANT
procedure.
2. Disengage balancing spring assembly on both sides by performing steps 1-6 in
procedure in section 5.3 - Balancing spring replacement, ME512.
3. Move parallel rod (4) to rear position to get easier access to lower end of vertical
arm.
4. Remove vertical arm left side cover and disconnect electrical connectors for cable
leading through bottom end of arm.

5. Remove 2 screws (1) securing cable plate to bottom of vertical arm. Pull cables out
of arm.
6. Loosen front clamp attachment screw (2).
CAUTION
8. The arm may now be lifted out.
9. Clean big bearing (5) on the axis 3 side of the gearbox.
Mount the vertical arm.
10. Lift vertical arm into position. Make sure that arm is placed in same position as the
old arm.
11. Secure vertical arm to vertical arm drive shaft with 12 e.a. screws (3).
12. Add loctite to outer ring of support bearing. Secure other side of arm to vertical arm
support plate using 7 e.a. screws (7). Move support plate as required to engage
screws.
13. Tighten vertical arm support plate clamp screw (6) with 1 NM torque. Add loctite to
screw before tightening.
manual.

Parallel rod replacement
4.4 Parallel rod replacement

The following procedure describes how to replace the parallel rod.
- 6 mm Grease Nipple (Not used for ME512)
- (Small Puller)
- Normal hand tools
ME512 ME502, ME503
2 3 4 5 5 4 3 6
IMPORTANT
CAUTION:
following procedure. The weight of the arm is 40-45 kg.
1. Release balancing spring tension as described in section 9.1 - Disengage balancing
springs, ME502, 503, 505 or section 9.2 - Disengage balancing springs, ME512. It is
EXTREMELY IMPORTANT that this is done before performing this procedure.
2. Unscrew 2 screws (1) for brackets on each side of the upper parallel rod attachment.
3. Insert medium size screwdriver in slot on cover plate (5) for lower bearing. Bend
screwdriver to remove cover.
4. Open lip on lock ring (3) to free lock nut.
5. Following points are different for ME512 and ME502, ME503, ME505

ME512: Unscrew lock nut (4) until even with front of bearing cone (2). Using a
plastic hammer, carefully knock the nut / bearing cone to free bearing. If cone will
not free, use puller to remove parallel rod from shaft.
ME502, ME503, ME505: Remove lock nut (4). Install grease nipple (6) in end of
parallel rod shaft. Using a grease pump, press grease into nipple to free bearing from
cone. When free, remove parallel rod by hand. If cone will not free, use puller to
remove parallel rod from shaft.
6. Install new parallel rod in reverse order.

Parallel rod lever arm replacement
4.5 Parallel rod lever arm replacement

The following procedure describes how to replace the lever arm for the parallel rod. The
lever arm must be replaced as a complete assembly.
Robot Types: ME512, ME502, ME503, (ME505)
- Normal hand tools
1
2
4
ME512 base rear view ME502 ME502V ME503 ME505 base rear view
IMPORTANT
1. Disengage balancing spring assembly on axis 3 side (1) as described in section 9.1 -
Disengage balancing springs, ME502, 503, 505 or section 9.2 - Disengage balancing
springs, ME512.
2. Remove parallel rod (4) as described in procedure section 4.4 - Parallel rod
replacement.
CAUTION
4. Lift out lever arm (3).
Mount the lever arm.
5. Lift new lever arm on to the gear box. Fasten lever arm with 12 e.a. M14x30 screws
(3). Add Loctite 243 to screws. Secure screws using a torque key, with a torque of
145 NM. Install parallel rod and engage balancing.
manual.

5 Turning unit components replacement

This chapter includes procedures for replacing components associated with the turning
unit.
5.1 - Turning unit replacement
5.2 - Balancing springs replacement
5.3 - Balancing spring replacement, ME512
5.4 - Gearbox shaft seals replacement

Turning unit replacement
5.1 Turning unit replacement

The following procedure describes how to replace the complete turning unit. To replace
the unit, the horizontal arm, vertical arm and balancing spring arrangement must first be
removed.
Robot Types: ME502, ME503, ME505
- Mastering fixture
- 4 ea. 8 mm screws, 50 - 80 mm long
- Normal hand tools
- Loctite 574 or 510 liquid seal
1 5
3 4
IMPORTANT
1. Remove balancing spring arrangement on both sides as described in section 5.2 -
Balancing springs replacement procedure.
procedure.
3. Remove vertical arm as described in section 4.2 - Vertical arm replacement, ME502
procedure.
4. Open base cover(s) and disconnect cables leading through center of turning unit.
Also disconnect cables for measuring system and drive motor for axes 2 and 3.
5. Remove front attachment screw (7) for plate securing cables to top of turning unit.
6. Rotate axis 1 as required to get access to electrical junction box inside base.
7. Remove screws securing purging air hose (8) for horizontal arm. Disconnect hose.

8. Lift rear end of lever arm (2). Remove rear attachment screw (4) for cable securing
plate.
9. Carefully not to damage connectors, pull out complete cable assembly from top of
turning unit.
NOTE: The attachment plate may stick to the mounting surface due to the liquid seal
used during installation. Bending lightly with a screwdriver will release the plate.
10. Clean attachment plate and mounting surface for liquid seal remains.
11. Remove lever arm by removing 12 ea. M14 screws (1) and 8 ea. M10 screws (6).
12. Remove shafts (5) for balancing springs for installation on new turning unit.
13. Remove 12 ea. 8 x 22 mm screws (3) securing tuning unit to bearing.
14. Attach lifting device to eye-bolts on top of gear boxes.
15. Carefully lift complete turning unit.
NOTE. The turning unit may stick to the surface due to the liquid seal used during
installation. Using a screwdriver, bend a little under each of the 4 lower spring
attachments to free unit. Do not bend any other places.
16. Clean all mounting surfaces for old liquid seal remains. Apply new liquid seal.
17. Attach lifting device to new turning unit and carefully lift into position.
By stopping when the turning unit is approximately 5 cm above mounting surface
and installing 4 ea. 8 mm screws as guides, the turning unit may be easily guided
into correct position.
18. Lower tuning unit into position, and remove guide screws.
19. Install cables, arms, springs etc. in reverse order.
20. If commutation values for axes 2 and 3 are shipped with the new turning unit, these
values may be entered into the system. If not, perform commutation as described in
the Commutation and Synchronization manual.
21. Perform synchronization as described in the same manual.

Balancing springs replacement
5.2 Balancing springs replacement

The following procedure describes how to remove and re-install the spring assembly, to
replace springs or to remove springs temporarily to get access to gearbox shaft seals etc.
The balancing springs are used to counter balance the vertical and horizontal arm when
the axes brakes are released. The springs are located in pairs on each side of the turning
unit.
- Lever arm extraction tool
- 22 mm ring key
- 32 mm ring key
- 32 mm pipe wrench with T-shaped handle (crossbar).
- Normal hand tools
5
1
6 7 6
4 9

IMPORTANT
WARNING!
The springs are tightened to a considerable force. Attempts to release this force
without having the required qualification and knowledge may cause serious
personnel injuries. For this reason: Do not attempt to loosen spring force unless you
know exactly what you are doing.
1. Remove spring cover to get access to spring assembly.
2. Remove spring cap attachment screws (5), one for each spring.
3. Remove lock screw (1) on top of each spring using 22 mm ring key. Use 32 mm ring
key to hold spring tightening screw (2) in position.
4. Tighten spring tightening screws (2) on both sides to press springs together, thus
relieving spring tension from cross bar (7). Screw as far down as required to free
conex pin (6) from crossbar.
5. Remove 8 ea. M10 screws (8) securing crank shaft (9) to vertical arm (axis 2) or
parallel rod lever arm (axis 3) from inner side of vertical arm assy’.
6. Pull out complete crank shaft / lever arm / crossbar assy’.
WARNING!
Be absolutely sure that the counter nut and set screw (4) are secured to prevent
screw rod (3) to be unscrewed instead of spring tightening screw (2).
7. Release spring tension by unscrewing spring tightening screw (2). Use the 32 mm
pipe wrench with T-shaped handle to avoid bending the screw rod (3). After tension
has been released, continue until screw is free.
8. Install new springs and spring caps. Tighten spring force to enable installation of
crossbar / lever arm assembly.
9. Install crossbar / lever arm. Engage conex pin by rotating spring cap and releasing
spring tension.
10. When engaged, use a plastic hammer to position cap screw hole. Install screw.
11. Release spring force until force is fully applied to crossbar / lever arm.
12. Continue unscrewing spring attachment screw until lock screw (1) can be fully
installed.
13. Tighten lock screw / spring tightening screw.
14. Re-install spring cover.

Balancing spring replacement, ME512
5.3 Balancing spring replacement, ME512

The following procedure describes how to replace the spring assembly on the ME512
manipulator.
the axes brakes are released. One spring assembly is located on each side of the
manipulator base. Note that the 2 spring assemblies are different. Check that you have
the correct type before continuing.
Robot Types: ME512
- 17 mm ring key
- 10 mm hex torque wrench
- Loctite 243 glue
- Omega 77 grease
1 1
2 2
3 3
4 4
5 5
Spring assembly axis 3 Spring assembly axis 2
Left side - rear view Right side - rear view
IMPORTANT
WARNING!
The springs are tightened to a considerable force. Attempts to replace the spring
assembly without having the required qualification and knowledge may cause
serious personnel injuries. For this reason: Do not replace spring assembly unless
you know exactly what you are doing.
2. Compress spring (1) by moving vertical- or horizontal arm as follows:

Axis 2: Locate spring on right hand side of base as seen from the rear. Move vertical
arm backwards (or forwards) to compress spring. Verify that spring is compressed
Axis 3: Locate spring on left hand side of base as seen from the rear. Move
horizontal arm down to compress spring. Verify that spring is compressed
3. Remove spring compression screw (2) from suspension beside spring. Remove
screw and insert in center of spring (5) from underneath.
4. Tighten screw until it hits the bottom surface (4) of the spring assembly.
5. Move horizontal arm up (for axis 3) or vertical arm to center position (axis 2) to
transfer spring force from crankshaft to screw. Check visually that there is clearance
between the crankshaft bearing and top of spring assembly.
6. Unscrew 4 spring assembly attachment screws (3) and remove spring assembly. Do
not remove spring compression screw.
NOTE: The spring assembly includes one guide pin on each side and you may have
to bend carefully to loosen assembly.
WARNING!
The spring is still loaded even if the spring compression screw is removed. Do not
loosen any screws inside the spring assembly unless the spring load is taken care of
by special equipment (hydraulic press). This also applies to the replacement spring
unit.
7. Install new spring assembly and tighten attachment screws (3) with 9.12 kpm torque.
8. Add grease of specified type to crankshaft gliding surface.
9. Move horizontal arm down (for axis 3) or vertical arm backwards or forwards
(axis 2) to transfer spring force from spring compression screw to crankshaft. Check
visually that there is clearance between the spring compression screw and the bottom
of the spring assembly.
10. Remove spring compression screw and install in suspension.
11. Move horizontal arm or vertical arm to center position as required. Re-install spring
cover.

Gearbox shaft seals replacement
5.4 Gearbox shaft seals replacement

Following procedure describes how to replace the gearbox shaft seals on the inside and
outside of the gear unit. 2 different seal arrangements are present, the old style using 2
seals on each side (seal width 15 mm) and the new style using 1 seal on each side (seal
width 25 mm). To replace the seals, spring arrangement and vertical arm must first be
removed.
- Special tool for inserting seals
- Torque key
- Loctite 270
- Normal hand tools
1 2 New style
4 5
3
Old style
4 5
7
6
IMPORTANT
1. Place a tray under gear oil drain screw and remove oil from gearbox. When finished,
re-install drain screw.
Note: If it is not necessary to remove all of the oil, just lowering the level below the
shaft will be sufficient (draining approximately 0.5 - 1 litre).

WARNING!
The springs are tightened to a considerable force and may cause serious personnel
injuries. For this reason, the spring arrangement MUST be removed according to
the procedure stated below.
2. Remove spring arrangement as described in section 5.2 - Balancing springs
replacement procedure.
3. Remove vertical arm as described in section 4.2 - Vertical arm replacement, ME502
procedure.
4. Remove 8 screws (1) from the inside to be able to retract spring shaft (2). Note
position of spring lever arm attachment shaft (3) to simplify later re-installation.
5. Remove seals (4) by carefully using a screwdriver and plastic hammer as shown in
illustration (7).
CAUTION
Be extremely careful not to damage seal gliding surface. This applies especially
to the inner surface (6). Scratching or adding dents this surface will make it
impossible to avoid oil leaks.
NOTE 1. For the old style seals, 2 seals are used on both sides. Both seals must be
replaced.
NOTE 2. If the outer seals for the old style version are to be replaced, removing the
glide ring will simplify the removal of the old seals. Accomplishment instructions
for removal and installation of this ring is available at the end of this procedure.
6. Clean surface (5) for loctite remains using a small knife or similar.
7. Lubricate seal gliding surface (6) of ring using a light grease type.
8. Place new seals on seal insertion tool. Make sure that the seal(s) is placed correctly
as shown in illustration on previous page. (Note that the 2 old style seals are different
from each other).
9. Add Loctite 270 (Green) on outer surface of seals.
Inner seal Outer seal

10. Install insertion tool as shown in illustration. Check that seals will be properly
engaged. Tighten screw fully to press seals into position.
11. Leave insertion tool in this position for approximately 5 minutes to let Loctite dry.
12. Remove insertion tool.
Vertical arm (Holes located

Parallel rod on back side)
lever arm
Lever arm shaft
Lever arm shaft

Axis 2 Axis 3
13. Re-install shaft. Make sure that the balancing spring lever arm shaft is correctly
positioned as shown in the illustration.
Axis 2: When vertical arm is in upright position, lever arm shaft is up.
Axis 3: When parallel rod lever arm is in horizontal position, lever arm shaft is ’one
screw hole’ above center line in forward direction.
14. Re-install vertical arm according to procedure.
WARNING!
Do not omit procedure stated below when re-installing spring assembly.
15. Re-install spring assembly according to procedure section 5.2 - Balancing springs
replacement.
16. Refill oil drained from gear box.
Old style outside seals

1. Remove 12 ea. 6 x M16 screws, securing ring to shaft.
2. Insert 2 ea. M6 screws in M6 threaded holes in ring and tighten lightly. These holes
lies one on each side of the ring. The length of the screws must be minimum 20 mm.
3. The 6 mm screws are used as extractor for the ring. Tighten the screws to remove the
ring. Tighten little by little on each side to remove ring evenly.
CAUTION
Be extremely careful when handling the ring. It is of utmost importance that the
outer surface of the ring is not scratched or damaged in any way.
4. Remove ring and shims and retain for later re-installation.
CAUTION
The shims are carefully adapted during assembly. It is therefore essential that

the same shims (one or more) are used during re-installation. If the thickness is
altered, pressure will be applied to the gearwheels causing damage.
5. You may now remove the old seals.
6. Before returning to the procedure, re-install shims and ring. Make sure that the
un-threaded hole is positioned to give access to the set screw. (The set screw is not to
be touched in this procedure).
7. Insert screws and tighten lightly.
CAUTION
Mechanical property class of the ring attachment screws is 12.9. It is important
that this strength is used. If a screw is lost, is should NOT be substituted by a
’normal’ strength screw (8.8).
8. Cross tighten screws to 1.9 kpm using a torque key.


6 Axis 1, 2, 3, 7 component replacement

This chapter includes procedures for replacing components associated with the axis 1, 2,
3 and 7.
6.1 - Drive motor axis 1, 2, 3 replacement
6.2 - Brakes axis 1, 2 and 3 replacement
6.3 - Gearbox axis 1 replacement
6.4 - Measuring system replacement
6.5 - Replacing motor for axis 7

Drive motor axis 1, 2, 3 replacement
6.1 Drive motor axis 1, 2, 3 replacement

This procedure describes how to replace drive motor for axis 1 (arm rotation), axis 2
(vertical arm motion) and axis 3 (horizontal arm motion). Note that 2 different sizes of
drive motors are used. For ME502V robot, drive motor for axis 1 is not to be replaced by
the user.
Robot Types: ME512, ME502, ME503, ME504 (axis 1), ME505
- Disk for checking play in gear wheels
- Motor adjustment tool
- Gauge on magnetic foot
- Mastering fixture
1 2 3
5 6 7
IMPORTANT
WARNING!
This procedure (axis 2 and 3) must not be performed if the balancing springs has
been disengaged unless the robot arm is properly suspended.
1. Remove necessary covers to get access to motor to be replaced.
2. Place a tray under drain screw at lower part of gear box. Remove drain plug and
drain oil. Clean drain plug and re-install. (It is not necessary to drain oil for axis 1).
3. If required, rotate arm/gear to get access to motor to be replaced.
4. Remove measuring system on end of motor as described in section 6.4 - Measuring
system replacement procedure.
5. Disconnect electrical connector on motor. Unscrew 4 ea. attachment screws (1) on
motor flange and remove motor unit.

6. Remove rear end cover from new motor by removing 3 attachment screws (3).
7. Check that o-ring (5) is undamaged and correctly positioned, alternatively install
new o-ring. Place new motor in position. Install 3 of the 4 attachment screws and
tighten fairly hard (motor must be in contact with mounting flange to enable
adjustment).
8. Install adjustment tool (8) and secure screw (7) in position of 4th motor attachment
screw. By rotating the center section of the tool, the motor may now be rotated
around the guide pin (2).
9. Install disk (4) on end of motor and place gauge as shown in illustration. Place gauge
sensor in one of the disk gaps.
10. Move disk by hand to measure play between motor gear wheel and gear unit gear
wheel (6). When motor is correctly positioned, play should be 0.05 mm (0.02 - 0.08
and NOT more than 0.08 mm).
11. Tighten adjustment tool if play is to be reduced and vice versa.
12. Repeat above steps until play is as specified. All 4 slots on the disk must be checked.
13. When motor is correctly adjusted, remove adjustment tool and install the 4th
attachment screw. Cross tighten attachment screw Then verify that the adjustment is
correct.
14. When adjustment is correct, remove disk and gauge and install motor end cover.
15. Refer to procedure and install measuring system.
16. Connect motor connector.
17. Re-fill oil in gearbox.
18. Perform commutation as described in the Commutation and Synchronization
manual.
19. Perform synchronization as described in the same manual.
20. Re-install panels.

Brakes axis 1, 2 and 3 replacement
6.2 Brakes axis 1, 2 and 3 replacement

The following procedure describes how to replace the brakes for axis 1, 2 and 3. To
replace the brakes, the motor must be removed from the manipulator.
Robot Types: ME512, ME502, ME503, ME504 (axis 1), ME505
- Notch Key for Brake Adapter
- Burndy Pin Extractor
- Feeder Gauge 0.20, 0.25 and 0.30 mm
- 2 ea. 8X25 mm screws
- Loctite
1 2 3 4 5 6 7 8 9 10 11
2 4 6 12 13 14 5 7 15
IMPORTANT
1. Remove affected motor from manipulator as described in section 6.1 - Drive motor
axis 1, 2, 3 replacement procedure.
2. Remove measuring system (11) as described in section 6.4 - Measuring system
3. Remove mounting plate for measuring system by loosening attachment screws (10)
and swinging eccentric washers (9) aside.
4. Remove screw (8) and adapter (7) using brake adapter key (15). If necessary, insert a
screwdriver or similar into hole (12) on brake disk to prevent disk from rotating.
5. Install 2 e.a 8 mm screws in holes (13) on brake disk (5). Pull off brake disk by
cross-tightening these screws.

6. Using Burndy Pin Extractor, remove pins for electrical connection of brake from
connector (1). For more information on position of pins etc., refer to Releasing the
Axes Brakes document.
7. Remove 4 screws (4) and remove brake magnet (2/3).
Installing new brake
8. Install pins on brake release wires in electrical connector.
9. Install new brake magnet (2/3). Add a little Loctite 242 to screws (4). Insert screws
and cross tighten.
10. Read IMPORTANT note below and add a SMALL AMOUNT of Loctite 270 in hole
and cotter slot of brake disk.
IMPORTANT: It is extremely important that the loctite does not come into
contact with the motor bearing or other components. For this reason, loctite
MUST be added to the brake disk and NOT to the motor shaft. Thereby, excess
loctite will be pushed off the shaft rather then into the motor when pressing the
brake disk into position.
11. Place the motor in vertical position so that the output shaft of the motor (motor front)
is placed on the surface of the working table. This is necessary to avoid damaging
the motor bearings and other internal components during the next steps.
12. Insert 0.3 mm feeler gauge between brake magnet (3) and brake disk (5). Press brake
disk into position by carefully knocking on the disk using a plastic hammer or
similar. Remove feeler gauge.
13. Remove 2 screws (6). These screws are used to hold the magnet springs compressed
during transportation.
14. Apply +24VDC to activate brake magnet.
NOTE: As the distance above (0.3 mm) is to great for the magnet (2) to pull the
solenoid disk (3), the magnet will not pull at this stage. To check that the magnet is
powered, a metal tool etc. may be placed on the magnet.
15. Install adapter (7) and hand tighten.
16. Using brake adapter notch key (15), slowly tighten adapter until distance between
magnet (2) and magnet solenoid disk (3) is short enough for the magnet to pull. If
necessary, insert screwdriver or similar into hole (12) to prevent disk from rotating.
Insert feeler gauge between magnet and solenoid disk and check that gap is between
0.2 and 0.25 mm.
17. Switch brake power on and off a few times to check that the brake is operating
properly.
18. Rotate adapter (7) to closest attachment hole (14). Install screw (8) and tighten.
19. Install measuring system mounting plate. Swing eccentric washers (9) into position
and tighten screws (10).
20. Install resolver according to procedure.
21. Perform synchronization and commutation as described in the Commutation and
Synchronization manual.

Gearbox axis 1 replacement
6.3 Gearbox axis 1 replacement

The following procedure describes how to replace the gearbox for axis 1, and to perform
necessary adjustments. The gearbox for axis 1 transfers the force from the axis 1 drive
motor to the turning unit rotating the complete arm assembly.
- Measuring gauge on magnetic foot
- (Mastering fixture)
- Grease
- Normal hand tools
1 2 6 7
3 4 5
Top view Side view
IMPORTANT
1. Remove manipulator base rear cover and left side cover (rear view).
2. Place a tray under gear box. Open drain screw and drain oil. The gearbox contains
approximately 1 litre of oil.
3. Remove axis 1 drive motor as described in section 6.1 - Drive motor axis 1, 2, 3
4. Open lock nut (4) and loosen gear wheel adjustment screw (5).
5. Remove 4 ea. 10 x 30 mm screws (9) securing gearbox to attachment shaft (8).
Lower gearbox and let it rest on bottom of manipulator base.
6. Remove 8 screws (7) (2 ea. 8 x 16 mm, 6 ea. 8 x 22 mm) securing attachment shaft to
base. Note location of 2 shorter screws (1).

7. Lift out attachment shaft and remove gearbox unit. Clean shaft and all mounting
surfaces for liquid seal remains.
8. Apply liquid seal on mounting surface for attachment shaft.
9. Place new gear box inside base. Apply grease on lower section of attachment shaft.
10. Slide shaft into position. Check that the flat surface of the shaft is facing the
gearwheel.
11. Insert screws, checking that the 2 shorter screws (1) are installed at the location of
the gearwheel.
CAUTION
It is important that the longer screws are NOT installed in this position as these
screws will lock the gearwheel.
12. Cross tighten screws with 2 kpm (short screws) and 3 kpm (long screws).
13. Lift gearbox and install 4 screws from underside. Do not apply loctite at this step.
Tighten screws lightly.
14. Tighten adjustment screw fully so that no play is present between upper gearwheel
and gear ring (6).
15. Install motor according to procedure making sure that play between lower gearbox
gearwheel and motor gearwheel is correct.
16. Install measuring device as shown in illustration (2). With the brakes for axis 1
activated, manually move rotating unit (complete arm assembly) sideways. The play
shown on the gauge should now be 3-4/100 mm which represents the 12/100 mm
play between lower gearbox and motor gearwheel (upper and lower gearwheels are
different).
17. Open adjustment screw and pull gearbox backwards to give play between upper
gearbox gearwheel and gear ring.
18. Remove 4 screws from underside of attachment shaft. Add loctite to screws and
re-install. Tighten screws fairly hard but not so hard that adjustment screw is not able
to move gearbox forwards.
19. Move turning unit manually, and rotate adjustment screw until play is 7/100 mm
(3-4/100 of the 7/100 mm represents motor gearwheel).
20. Tighten shaft securing screws with approximately 5 kpm.
21. Tighten adjustment screw counter nut.
22. With installation completed, check that above play is as specified.
manual.
24. If measuring system has been removed from motor, commutation must be performed
as described in the same document.

Measuring system replacement
6.4 Measuring system replacement

The following procedure describes how to replace the complete measuring system
unit.The measuring system consists of 2 resolvers and a tachometer assembled as a unit.
One measuring system unit is installed on the end of each axis drive unit.
Robot Types: ME512, ME502, ME503, ME504, ME505
- Mastering fixture
- Normal hand tools
Allen key
1
2
IMPORTANT
1. Locate drive unit for measuring system to be replaced and remove necessary covers
to get access to drive unit.
2. Remove electrical connector (1).
3. Rotate motor by manually moving the axis, to get access to one of the 2 set screws
(2) attaching the measuring system to the motor shaft. Loosen screw.
4. Repeat operation for second set screw (3).
5. Unscrew 4 attachment screws (4) for measuring system unit. Remove unit.
6. Install new unit in reverse order.
7. Install covers.
manual.
9. Perform commutation as described in the same manual.

6.5 Replacing motor for axis 7

This procedure describes how to replace the drive motor and gearbox for axis 7.
Robot Types: ME503
- Normal hand tools
3 5
IMPORTANT
1. Remove cover on front side (1) and rear side (9). Retain cover, gasket and screws for
re-installation.
2. Disconnect 3 e.a. electrical connectors (5) for motor and measuring system.
3. Remove 2 e.a. connectors (3) for DSQC253 board.
4. Remove 2 e.a. screws (4) securing DSQC253 board. Remove board to make room
for suspension for motor.
8
6 9
7 10
11

Replacing motor for axis 7
5. Remove 4 allen screws (2) securing motor to trolley. Retain screws for
re-installation.
6. Loosen set screw (6). Suspend motor unit by placing a support such as a wooden
block etc. under the unit where the DSQC253 board was located.
WARNING!
Be careful during the next point as the motor unit is heavy (40 kg).
7. Unscrew motor adjustment screw (8) while lowering motor towards support.
Remove screw and lift motor unit out.
8. Remove 8 screws (7) securing pinion to gearbox shaft. Remove pinion. Retain
pinion and screws for re-installation.
Installing new motor
9. Install pinion on new motor and tighten 8 attachment screws (7) with 20.5 Nm
torque.
10. Place support for the motor unit inside the trolley motor unit compartment. Add a
little grease to the motor flange. Insert motor unit and push into position.
11. Install 4 attachment screws (2). Tighten screws with 2 Nm torque.
12. Insert adjustment screw (8). Tighten screw lightly.
13. Connect motor- and measuring system connectors (5) on motor.
14. Install DSQC253 board and install connectors.
15. Rotate adjustment screw (8) until play between pinion (10) and rack (11) is next to
nothing. Release axis brakes. Repeat adjustment at different positions along the rack.
The play must be as described above on the highest point of the rack. Tighten set
screw (6).
16. Tighten 4 motor unit attachment screws (2) with torque 75 Nm.
17. Install front and rear covers.

7 ME504 repair procedures

This chapter includes procedures for replacing components on the ME504 manipulator
which are not described in other sections in this manual.
7.1 - Axis 3 arm replacement
7.2 - Gear box axis 3 replacement
7.3 - Axis 2 arm replacement
7.4 - Gear box axis 2 replacement
7.5 - Axis 1 arm and cable unit replacement
7.6 - Motor axis 1 replacement
The procedures in this chapter all refer to the illustration below.
18
4
Axis 3 arm 5
6
3
7
1 2 17
8
Axis 2 arm 9
19
11 12
10
Axis 1 arm
13
14
15
16

Axis 3 arm replacement
7.1 Axis 3 arm replacement

The following procedure describes how to replace axis 3 arm. Before performing this
procedure, the gear screw (the arm) must be placed approximately in the centre position.
Required tool and items:
- Mastering fixture
- Normal hand tools
IMPORTANT
1. Remove 2 outer and 2 inner covers.
2. Remove screws under tower plate. Lift up top base with extension and disconnect
electrical cable on tower plate.
3. Disconnect electrical cable (3) at bottom of tower plate.
4. Remove screws (18) in tower plate and remove plate.
5. Unscrew screws in tower frame (17) and pull (lift) tower frame up from cylinder.
6. Remove guide rods (6).
7. Unscrew screw (9) in guide ring, and remove the complete lifting cylinder.
IMPORTANT: When dismounting the lifting cylinder, ensure that ball screw
nut and screw are NOT separated.
8. Re-install arm in reverse order. Pay special attention to the following points:
- Check that sleeve (19) on coupling is correctly positioned.
- Check o-rings, and grease parts.
- Mount guide ring (6) to the axis 3 gear.
- Press tower frame (from front) against guide ring before fastening.
manual.
7.2 Gear box axis 3 replacement

The following procedure describes how to replace the gear box for axis 3. To be able to
remove the gear box, the axis 3 arm must first be removed. Please note that it is not
allowed to remove motor from gear box. The reason is that special equipment is used to
put the motor in correct position into the gear box.
An exeption is to remove the motor from the gear box to replace sealings, BUT ensure
that the correct number and sizes of shims are used when re-installing. If gear wheels or
bearings are damaged, the complete gear unit with motor has to be replaced.
- Normal hand tools
IMPORTANT
1. Remove axis 3 arm according to procedure 7.1 - Axis 3 arm replacement.

NOTE: Remove covers and disconnect electrical cable. The tower may remain
fastened to the gear box.
2. Open access panel (2) and disconnect all electrical cables for motor and measuring
system.
3. Remove 6 screws (10) supporting the gear box to the arm.
4. Pull the gear box out of the arm. Be sure not to damage the o-ring.
5. Re-install gear box in reverse order.
7.3 Axis 2 arm replacement

The following procedure describes how to replace the axis 2 arm. To be able to remove
the arm, the axis 3 arm must first be removed.
- Silicone free liquid sealing
- Normal hand tools
IMPORTANT
2. Open access panel (2) and disconnect all electrical cables for motor and measuring
system.
3. Remove screws (1) supporting the arm to the bearing and lift the arm. Note that the
arm can be installed in 2 positions.
4. Clean the surface and add liquid sealing.
5. Re-install arm in reverse order.
7.4 Gear box axis 2 replacement

The following procedure describes how to replace the gear box for axis 2. Please note
that it is not allowed to remove motor from gear box. The reason is that special
equipment is used to put the motor in correct position into the gear box.
An exeption is to remove the motor from the gear box to replace sealings, BUT ensure
that correct number and sizes of shims are used when re-installing. If gear wheels or
bearings are damaged, the complete gear unit with motor has to be replaced.
All sealings may be replaced, BUT ensure that identical parts are re-installed in reverse
order.
If complete gear box is replaced, it is vital that position of stoppers are identical to those
replaced.
- Normal hand tools

Axis 1 arm and cable unit replacement
IMPORTANT
3. Open inner arm access panel (12) and disconnect all electrical cables for motor and
measuring system.
4. Remove screws (13) supporting the gear box to the arm.
5. Pull the gear box out from the arm.
6. Clean the surface and add liquid sealing.
7. Re-install gear box in reverse order.
7.5 Axis 1 arm and cable unit replacement

The following procedure describes how to replace the axis 1 arm. To be able to remove
the arm, the axis 2 and axis 3 arm must first be removed.
Robot types: ME504
- Mastering fixture
- Normal hand tools
IMPORTANT
1. Open inner arm access panel (12) and disconnect all electrical connectors for
measurement systems, motors, power supply and purging air.
2. Remove bracket (11) supporting the turning unit to the cable unit. Note the position.
3. Disconnect all electrical connectors and purging air from exterior to be able to pull
the cable unit out.
4. Disconnect turning unit from foot by removing screws (14).
5. Lift the turning unit with a lifting device. Be careful not to damage the 2 guide pins
(1 in front and 1 in rear).
6. Remove screws underneath the turning unit (15) supporting cable unit to axis 1 arm.
7. Pull the cable unit (16) out.
8. Clean the surface and apply liquid sealing.
9. Re-install in reverse order. Secure turning unit to the foot.
10. Perform synchronization, see Commutation and Synchronization manual.
7.6 Motor axis 1 replacement

Refer to procedure 6.1 - Drive motor axis 1, 2, 3 replacement.

8 ME505 repair procedures

This chapter includes procedures for replacing components on the ME505 which are not
described in other sections in this manual.
8.1 - Vertical arm parallel rod replacement
8.2 - Horizontal arm parallel rod replacement
8.3 - Rear leveller arm replacement
The procedures in this chapter all refer to the illustration below.
Top view Front

Rear 4 lever arm 5
lever arm
1
2
Quick disconnect Horizontal arm Tool fork
coupling parallel rod attachment
for sensors including
grease nipple
Vertical arm
parallel rod
Axis 3
parallel rod
3

Vertical arm parallel rod replacement
8.1 Vertical arm parallel rod replacement

The following procedure describes how to replace the parallel rod on ME505.
- Mastering fixture
- Normal hand tools
IMPORTANT
1. Remove 2 ea. 8 mm screws in top (2) and bottom (3) of the rod. Remove rod.
2. Re-install in reverse order.
3. If new parallel rod has been installed, it may be required to perform synchronization
as described in the Commutation and Synchronization manual.
8.2 Horizontal arm parallel rod replacement

The following procedure describes how to replace the horizontal parallel rod on ME505.
- Mastering fixture
- Normal hand tools
IMPORTANT
1. Remove cover (1) on rear end of horizontal arm.
2. Remove gripper.
3. Loosen 2 ea. 8 mm screws (4) supporting the arm in rear part.
4. Loosen 2 ea. 8 mm screws supporting the arm in front (5).
8.3 Rear leveller arm replacement

The following procedure describes how to replace the rear leveller arm on ME505.
Required tools and items:
-Mastering fixture
-Normal hand tools
IMPORTANT
1. Remove top part of vertical arm parallel rod (2).
2. Remove leveller arm by loosening 2 ea. 8 mm screws (6) supporting the leveller arm
to axis 3 bearing.

9 Misc. procedures
This chapter provides procedures for adjustments which may be necessary to perform
after some of the replacement operations.
9.1 - Disengage balancing springs, ME502, 503, 505
9.2 - Disengage balancing springs, ME512
9.3 - Flexi wrist balancing adjustment
9.4 - Hollow wrist gearwheel adjustment
9.5 - Balancing spring adjustment, ME512

Disengage balancing springs, ME502, 503, 505
9.1 Disengage balancing springs, ME502, 503, 505

The following procedure describes how to disengage the balancing spring assembly on
the ME502, ME503 and ME505 manipulator. This procedure must be performed before
performing some of the procedures in this manual.
the axes brakes are released. The springs are located in pairs on each side of the turning
unit.
- 22 mm ring key
- 32 mm ring key
- Normal hand tools
1 3 4
IMPORTANT
2. Remove lock screw (1) on top of each spring (4) using 22 mm ring key. Use 32 mm
ring key to hold spring tightening screw (2) in position.
3. Tighten spring tightening screws (2) on both sides to compress springs until screw
hits the surface (3) of the crossbar. The crossbar is now blocked for movement
upwards.
IMPORTANT
The spring is now secured when the robot arm is in the current position. If, during the
procedure, the arm needs to be moved so that the spring is compressed (a gap appears
between the spring tightening screw and the crossbar surface), the spring tightening
screw must be further tightened until it again hits the crossbar surface.
WARNING!
Repair work must not be performed unless spring tightening screw is properly
tightened.

9.2 Disengage balancing springs, ME512

The following procedure describes how to disengage the balancing spring assembly on
the ME512 manipulator. This procedure must be performed before performing some of
the procedures in this manual.
the axes brakes are released. The springs are located on each side of the turning unit.
1 1
2 2
3 3
IMPORTANT
2. Remove spring compression screw (1) from suspension beside spring.
3. Insert screw in center of spring (3) from underneath.
4. Tighten screw until it hits the bottom surface (2) of the spring assembly.
IMPORTANT
The spring is now secured when the robot arm is in the current position. If, during the
procedure, the arm needs to be moved so that the spring is compressed (a gap appears
between the spring suspension screw and the bottom surface), the spring compression
screw must be further tightened until it again hits the bottom surface.
WARNING!
Repair work must not be performed unless spring suspension screw is properly
tightened.

Flexi wrist balancing adjustment
9.3 Flexi wrist balancing adjustment

This procedure describes how to balance the flexi wrist. Balancing may need adjustment
as result of having replaced pushrod for axes 4 - 5, or if the weight on the wrist has been
altered.
- Normal hand tools
Spring
attachment
screws
Cover
Screwdriver
IMPORTANT
1. Remove cover on underside of arm to get access to balancing springs.
2. Bend flexi wrist to point upwards.
3. Using a screwdriver as shown in illustration, lock spring in position.
4. Loosen set screw on front spring attachment.
5. Bend flexi wrist a bit up to increase spring tension or vice versa.
6. Tighten set screw.
7. Remove screwdriver. Check balancing. Repeat procedure as required.
8. When finished, install cover.

9.4 Hollow wrist gearwheel adjustment

The following procedure describes how to adjust the gearwheels on the hollow wrist.
- Normal hand tools
Gearwheel axis 4
1 Gearwheel axis 5 Release screw
Gearwheel axis 6
2
4
1 5 6
Adjustment screw
Drive gearwheel
2 1 2
Wrist gearwheel
IMPORTANT
NOTE: Adjustment is best performed with minimum grease on gear wheels.
Before performing adjustment with screws (1) and (2), be sure that the play is related to
the actual gear wheel. If play is related to other parts, look for adequate adjustment
procedure. Play for axes 4 and 5 must be observed through holes in side of arm.
1. Start by adjusting axis 4. Loosen release screws (1) and tighten adjustment screw (2)
lightly to rotate drive gearwheel towards wrist gearwheel.
2. Insert a tool in hole on top of axis 4. The mastering tool is handy for this operation.
(Be careful not to damage hole).
3. Move axis a little from side to side to feel play between gearwheels. Tighten
adjustment screw (2) until no play can be felt. Tighten release screw (1). By
tightening/opening the 2 screws, adjust until a very small play can be felt (hardly no
play at all).
4. Repeat operation for axes 5 and 6. Axis 5 is best moved by hand and axis 6 is best
moved by installing 2 screws on front flange and then bend with a screwdriver or
similar.
5. Rotate corresponding wrist axis and check that play is as required in several
positions.
6. Check that both adjustment screws are tightened when adjustment is completed.

Balancing spring adjustment, ME512
9.5 Balancing spring adjustment, ME512

The effect of the balancing spring force may be adjusted to change the balancing of the
robot vertical and horizontal arm.
Robot types: ME512
Required tools and items:
- 10mm hex torque wrench
Increase force Reduce force Increase force
Lever arm roller Reduce force
Roller Lever arm

attachment
screws

IMPORTANT
1. Before the spring force can be adjusted, the spring must be compressed as described
in procedure section 5.3 - Balancing spring replacement, ME512, step 1 - 5.
2. When spring has been locked in compressed position, loosen screws on the lever arm
roller.
3. Change roller offset by moving roller up/down (axis 2) or sideways (axis 3), see
illustration above. Tighten screws for lever arm roller.
4. Remove spring compression as described in procedure section 5.3 - Balancing spring
replacement, ME512, step 9 - 10.
5. Check that balancing is as required. If not repeat operation.
6. Move vertical- and horizontal arm to extreme positions and check that the springs
does not get fully compressed before the arm reaches the end of the movement. If
this should happen, repeat procedure and reduce spring force accordingly.
7. When finished, re-install spring covers.

3HNT 105 004R1701 Mechanical Repair
Dated: 020212
List of Document Files:

1 - Introductionand safety 140060
2 - Flexi wrist procedures 140061
3 - Hollow wrist procedures 140062
4 - Arm replacement proc. 140063
5 - Turning unit comp. repl. 140064
6 - Axis 1,2,3,7 comp.repl. 140065
7 - ME504 repair procedures 140152
8 - ME505 repair procedures 140153
9 - Adjustment procedures 140166
List of Imported Graphics:

Page: Illustration: Document File:
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11 m3024902.wmf 140061
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32 m30352.wmf 140063
34 M3025901.wmf 140063
36 m30261.wmf 140064
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55 Photo01.jpg @ 300 dpi140065
55 Photo02.jpg @ 300 dpi140065
57 m30491.wmf 140152
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Page 69
3HNT 105 004R1701 Mechanical Repair
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Mechanical Repair: TR-510 / TR-5000

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Mechanical

Publication No.: 3HNT 105 004R1701

ABB Flexible Automation AS

© 1995 ABB Flexible Automation AS

2 Flexi wrist procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

3 Hollow wrist procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4 Arm replacement procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

5 Turning unit components replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

6 Axis 1, 2, 3, 7 component replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

7 ME504 repair procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

8 ME505 repair procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3HNT 105 004R1701 © 1995 ABB Flexible Automation AS Mechanical Repair 5

1.1 General considerations

1.2 Commutation and synchronization

1.3 Using Loctite glue

Loctite 243 Glue (Blue)

1.4 Special tools

6 Mechanical Repair © 1995 ABB Flexible Automation AS 3HNT 105 004R1701

1.5 Tightening torques

Nominal Tightening torque - Nm

3HNT 105 004R1701 © 1995 ABB Flexible Automation AS Mechanical Repair 7

8 Mechanical Repair © 1995 ABB Flexible Automation AS 3HNT 105 004R1701

2 Flexi wrist procedures

3HNT 105 004R1701 © 1995 ABB Flexible Automation AS Mechanical Repair 9

2.1 Flexi wrist replacement

10 Mechanical Repair © 1995 ABB Flexible Automation AS 3HNT 105 004R1701

3HNT 105 004R1701 © 1995 ABB Flexible Automation AS Mechanical Repair 11

2.2 Flexi wrist driveshaft axis 6 replacement

12 Mechanical Repair © 1995 ABB Flexible Automation AS 3HNT 105 004R1701

2.3 Flexi wrist pushrods axis 4-5 replacement

3HNT 105 004R1701 © 1995 ABB Flexible Automation AS Mechanical Repair 13

2.4 Flexi wrist drive unit axis 4-6 replacement

14 Mechanical Repair © 1995 ABB Flexible Automation AS 3HNT 105 004R1701

7. Disconnect electrical connectors for drive unit.

3HNT 105 004R1701 © 1995 ABB Flexible Automation AS Mechanical Repair 15

2.5 Flexi wrist axis 6 gear unit replacement

16 Mechanical Repair © 1995 ABB Flexible Automation AS 3HNT 105 004R1701

3 Hollow wrist procedures

3HNT 105 004R1701 © 1995 ABB Flexible Automation AS Mechanical Repair 17

3.1 Hollow wrist replacement

18 Mechanical Repair © 1995 ABB Flexible Automation AS 3HNT 105 004R1701

3HNT 105 004R1701 © 1995 ABB Flexible Automation AS Mechanical Repair 19

3.2 Hollow wrist drive unit replacement

20 Mechanical Repair © 1995 ABB Flexible Automation AS 3HNT 105 004R1701

3HNT 105 004R1701 © 1995 ABB Flexible Automation AS Mechanical Repair 21

3.3 Hollow wrist seals replacement

22 Mechanical Repair © 1995 ABB Flexible Automation AS 3HNT 105 004R1701

3.4 Hollow wrist inner tube replacement

3HNT 105 004R1701 © 1995 ABB Flexible Automation AS Mechanical Repair 23

3.5 Hollow wrist gearwheel replacement

24 Mechanical Repair © 1995 ABB Flexible Automation AS 3HNT 105 004R1701

4 Arm replacement procedures

3HNT 105 004R1701 © 1995 ABB Flexible Automation AS Mechanical Repair 25

4.1 Horizontal arm replacement

26 Mechanical Repair © 1995 ABB Flexible Automation AS 3HNT 105 004R1701

9. Remove complete horizontal arm.

3HNT 105 004R1701 © 1995 ABB Flexible Automation AS Mechanical Repair 27

4.2 Vertical arm replacement, ME502

28 Mechanical Repair © 1995 ABB Flexible Automation AS 3HNT 105 004R1701

3HNT 105 004R1701 © 1995 ABB Flexible Automation AS Mechanical Repair 29

4.3 Vertical arm replacement, ME512

ME512 base rear view

30 Mechanical Repair © 1995 ABB Flexible Automation AS 3HNT 105 004R1701