Repairs Axis 4

6 Axis 4

6.1 Replacing motor

Refer to foldout no. 8

Dismounting:

1. Drain the gearbox by removing oil plugs <31.26>.

2. Unscrew the 4 cable inlet cover screws.
3. Unscrew the 3 screws on the top of motor 4. Remove the cover.
4. Disconnect connectors R3.MP4 and R3.FB4.
5. Secure axis 4 so it cannot rotate when the motor is removed.
6. Remove cover <31.28>.
7. Remove the screws <31.14> and nuts <31.18>.
8. Unscrew screws <31.25> and pull out the motor.
Be careful not to tap or hit the shaft axially, nor displace the shaft axially in any
way, as this could give rise to an incorrect air gap in the brake.

9. To press the gear off the motor shaft, oil must be injected into the centre of the
gear. Mount SKF Oil injector 226270 + SKF nipple 725 870 + 234 063 in the
centre and press the gear off the shaft.

Caution: Make sure that the oil injector is filled with oil.

Mounting:

10. Press the gear on to the motor shaft. Use tools 3HAA 7601-070 and
3HAB 5674-1.

Remove the B-side cover at the rear of the motor and place support 3HAA 7601-
070 under the motor shaft, to avoid axial loading of the bearings in the motor.

11. Mount O-ring <31.2> and insert motor, tighten screws <31.25>, torque 22 Nm.
12. Adjust the intermediate wheel as described in Chapter 6.2, Replacing and adjust-
ing intermediate gear.
13. Mount a new cork seal <31.29> on the cover.
14. Fill the gearbox with oil, type ABB 1171 2016 -604, volume 6 litres. Regarding
replacement oils see the Maintenance Manual IRB 6400.

15. Reconnect connectors R3.MP4 and R3.FB4. Mount the cover.

16. Calibrate the robot as described in Chapter 9, Calibration.

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Axis 4 Repairs

Tightening torque:

Screws for motor, item 31.25: 22 Nm

6.2 Replacing and adjusting intermediate gear

Refer to foldout no. 8.

Dismounting:

1. Drain the gearbox of oil.

2. Secure axis 4 mechanically.

3. Remove the cover <31.28>.

4. Remove the motor as described in Chapter 6.1, Replacing motor.

5. Unscrew the screws <31.14>.

6. Unscrew nuts <31.18> and remove the wedges <31.17> and remove screws
<31.14>.

7. Pull out the intermediate gear unit.

Mounting:

8. Mount the gear and tighten screws <31.14> only very slightly.

9. Refit the motor.

10. Adjust the play by moving the intermediate wheel to obtain the minimum play
between the final gear and the motor gear, at four points, by turning axis 4. Ensure
that when axis 4 is turned, the gears do not “scrape” together.

11. Tighten screws <31.14> with a torque of 69 Nm.

12. Insert the 3 wedges <31.17> with 3 tension washers <31.43> and the nut <31.18>
on <31.16>, tighten with a torque of 8 Nm.

Note! Fit the tension washers with their concave sides facing each other.

NOTE! Check the play.

13. Mount cover <31.28> with a new seal <31.29>.

14. Fill the gearbox with oil, ABB 1171 2016-604, volume 6 litres. Regarding
replacements oils, see the Maintenance Manual IRB 6400.

15. Calibrate the robot as described in Chapter 9, Calibration.

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Repairs Axis 4

Tightening torque:

Screw joint intermediate wheel, item 31.14: 69 Nm

Nuts/wedge joints, item 31.18: 8 Nm

Fixing screws for motor, item 31.25: 22 Nm

6.3 Replacing final gear

Refer to foldout no. 8.

Dismounting:

1. Dismount cabling in the upper arm as in Chapter 3.8, Dismounting cables,

lower arm/upper arm
2. Dismount adjustable intermediate gear as in Chapter 6.2, Replacing and adjust-
ing intermediate gear.
3. Mount the special hydraulic tool, ABB 6896 134-AN, to the tubular shaft end.
4. Remove the cover in the gear <31.11> and mount nipple, SKF 234 063, with
NIKE quick coupling, I-AQU 8.
5. Mount tool, ABB 6396 134-AT with hydraulic cylinder NIKE I-CH 612, on the
gear <31.11> with three hexagon screws M12x70 10.9.
6. Connect pump 6369 901-286 to the cylinder and nipple in the gear.
7. Pump up the pressure, with both taps on the valve open. When the gear moves
sufficiently so that the pressure disappears between the gear and the shaft, close
one of the taps. Continue pumping in this way until the gear has been removed.

Be careful with the surface at the end of the shaft.

Otherwise there may be oil leakage.

Mounting:

8. Heat up the gear <31.11> to 160 oC using an induction heater or oven.

9. Mount tool ABB 6896 134-BU on the end of the tube shaft.
The following steps must be carried out in sequence while the gear is still hot.

10. Mount gear on the tube shaft.

11. Mount tool, ABB 6896 134-FK.

12. Mount hydraulic cylinder NIKE I-CH 612 with regulator.

13. Press the gear on the shaft with a force of 16 000 N, equivalent to 8.7-9.2 MPA,
check the pressure gauge (part of pump 6369 901-286).

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Axis 4 Repairs

14. Check that the distance ring <31.12> is pressed in position behind the gear.

15. The pressure must be retained until the gear has cooled down and shrunk on to
the shaft.

16. Mount intermediate wheel as in Chapter 6.2, Replacing and adjusting intermedi-
ate gear.

17. Mount the cabling in the upper arm as in Chapter 3.8, Dismounting cables,
lower arm/upper arm.

18. Calibrate the robot as described in Chapter 9, Calibration.

6.4 Dismounting tube shaft, upper arm

Refer to foldout no. 8.

Dismounting:

1. Dismount wrist as in Chapter 7.1, Dismounting the wrist.

2. Dismount cabling in upper arm as in Chapter 3.8, Dismounting cables, lower

arm/upper arm

3. Dismount the motor axis 4 as in Chapter 6.1, Replacing motor.

4. Dismount the adjustable intermediate gear as in Chapter 6.2, Replacing and

adjusting intermediate gear.

5. Dismount final gear as in Chapter 6.3, Replacing final gear.

6. Remove the mechanical stop <31.23> for axis 4.

7. Rotate axis 4 so that the damper <31.22> is visible and can be removed.

8. Remove the stop on shaft <31.20>.

9. Press the tube shaft out with tool 3HAB 8079-1.

N.B. The extender 3HAB 8008-1, included in 3HAB 8079-1, can also be used
to get the tube through the second bearing.

10. Knock the bearing <31.6> out.

Mounting:

11. Cover the sliding surfaces, for the seal rings, with some tape.

12. Apply some grease on the diameters of the tubular shaft where the seals must
pass.

13. “Fix” the NILOS-ring <31.7> in the upper arm housing with some grease.

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Repairs Axis 4

14. Mount the seal <31.8> on tube shaft.

15. Mount bearing <31.6>. Use tool 6896 134-S + 6896 134-S + NIKE 1-CH-612.
Alternatively, heat up the bearing to 120°C and mount on the shaft. Let the bear-
ing cool down before further assembly.

16. Grease the bearing.

17. Press the shaft into the housing using the tool 6896 134-FL with holder on -BU
+ NIKE 1-CH-612.

18. Mount the distance ring <31.12> on the tube.

19. Mount the final gear according to Chapter 6.3, Replacing final gear.

20. Mount the motor and intermediate wheel as in Chapter 6.1, Replacing motor
and Chapter 6.2, Replacing and adjusting intermediate gear.

21. Mount the stop <31.20> on the tube shaft. Lock the screws <31.21> with Loc-
tite 242 and tighten with a torque of 84 Nm.

22. Mount the damper <31.22> and the mechanical stop <31.23> with seal and
tighten screws <31.25> with a torque of 22 Nm. Use Loctite 242. Apply some
grease on the sliding surfaces.

23. Mount the cabling as in Chapter 3.8, Dismounting cables, lower arm/upper arm

24. Calibrate the robot as described in Chapter 9, Calibration.

Tightening torque:

Screws for stop, item 31.21: 84 Nm

Screws mechanical stop, item 31.25: 22 Nm

6.5 Replacing seals and bearings, upper arm

Refer to foldout no. 8.

Dismounting:

1. Dismount the tube shaft as in Chapter 6.4, Dismounting tube shaft, upper arm.

2. Knock bearing <31.6> off the tube shaft <5>.

3. Knock bearing <31.6> out, inside housing <31.3>.

4. Knock out the sealing <31.10>.

Mounting:

5. Mount a new sealing ring <31.10>, apply some grease on the diameter inside

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Axis 4 Repairs

the upper arm house. Use tool 6896 134-FA.

6. Mount seal ring <31.8> on to the tube shaft.

7. Mount bearing <31.6> according to Chapter 6.4, Dismounting tube shaft, upper
arm, point 15.

NOTE! Let the bearing cool down before mounting the shaft.

8. Apply grease in the bearing.

9. Mount the tube shaft as described in Chapter 6.4, Dismounting tube shaft, upper
arm.

40 Product Manual IRB 6400