工控帮助教小舒QQ2823408167

ABB Robotics

Product manual
IRB 7600

公 司
有 限

育 科技

控帮教
沙 工
长
 工控帮助教小舒QQ2823408167

公 司
有 限

育 科技

控帮教
沙 工
长
 工控帮助教小舒QQ2823408167

Product manual
IRB 7600 - 500/2.55
IRB 7600 - 500/2.3
IRB 7600 - 400/2.55
IRB 7600 - 340/2.8
公司IRB 7600 - 325/3.1
有限 IRB 7600 - 150/3.5
育 科技 M2000

帮 教 M2000A
控 M2004

长 沙工 Document ID: 3HAC022033-001

Revision: K
© Copyright 2004-2011 ABB. All rights reserved.
 工控帮助教小舒QQ2823408167

公 司
有any限errors that
The information in this manual is subject to change without notice and should not be

技
construed as a commitment by ABB. ABB assumes no responsibility for
may appear in this manual.

育 科
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB
or property, fitness for a specific purpose or the帮
教
like.
for losses, damages to persons

控
工 herein.
In no event shall ABB be liable for incidental or consequential damages arising from

This manual and parts thereof长

沙
use of this manual and products described
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.

© Copyright 2004-2011 ABB. All rights reserved.

© Copyright 2004-2011 ABB All rights reserved.

ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
 工控帮助教小舒QQ2823408167
Table of Contents

Overview of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1 Safety 19
1.1 Introduction to safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.1 Safety in the manipulator system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.2 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.2.1 Safety risks during installation and service work on manipulators. . . . . . . . . . . . . . . . . . 21
1.2.2.2 CAUTION - Hot parts may cause burns! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.2.3 Safety risks related to tools/work pieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.2.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.2.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.2.6 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.3 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2.3.3 Emergency release of the manipulator’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

公 司
1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.2.3.6 Safe use of the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

有 限
1.2.3.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.2.3.8 Signal lamp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

育 科技
1.2.4 Safety stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
1.2.4.1 What is an emergency stop? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

帮教
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

工 控
1.3.1 Safety signals in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
1.3.2 Safety symbols on manipulator labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

长 沙
1.3.3 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
1.3.4 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
1.3.5 WARNING - The brake release buttons may be jammed after service work . . . . . . . . . . . . . . . . 48
1.3.6 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
1.3.7 WARNING - Safety risks during work with gearbox lubricants (oil or grease) . . . . . . . . . . . . . . 51
© Copyright 2004-2011 ABB. All rights reserved.

2 Installation and commissioning 53

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.2 Robot transportation precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.3 Securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.4 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.4.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.4.2 Working range, IRB 7600 - 150/3.5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.4.3 Working range, IRB 7600 - 340/2.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
2.4.4 Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.4.5 Working range, IRB 7600 - 500/2.3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.4.6 Risk of tipping/stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
2.5 On-site Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.5.1 Lifting robot with fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.5.2 Lifting robot with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.5.3 Lifting robot with roundslings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.5.4 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
2.5.5 Manually releasing the brakes, external brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
2.5.6 Lifting the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

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2.5.7 Securing the base plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

2.5.8 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.5.9 Fitting equipment on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.5.10 Installation of base spacers (option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.5.11 Installation of cooling fan for motors, axes 1-3 (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
2.5.12 Installation of Foundry Plus Cable guard (option no. 908-1) . . . . . . . . . . . . . . . . . . . . . . . . . . 112
2.5.13 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
2.6 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
2.6.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
2.6.3 Mechanically restricting the working range of axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
2.6.4 Mechanically restricting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
2.6.5 Installation of position switches (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
2.7 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.7.1 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
2.8 Making robot ready for operation (Foundry Prime). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.8.1 Additional installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
2.8.2 Commissioning (Foundry Prime). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

3 Maintenance 141
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

公 司
3.2 Maintenance schedule and expected life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

有 限
3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

科技
3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

育
3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

帮教
3.3.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.3.2 Inspection, oil level gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

工 控
3.3.3 Inspection, oil level gearbox axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

长 沙
3.3.4 Inspection, oil level gearbox axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3.5 Inspection, oil level, gearbox axis 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
158
161
3.3.6 Inspection, oil level gearbox axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3.3.7 Inspection, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.3.8 Inspection, cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3.3.9 Inspecting, mechanical stop pin, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.3.10 Inspection, mechanical stop, axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 © Copyright 2004-2011 ABB. All rights reserved.
3.3.11 Inspection, damper axes 2-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.3.12 Inspection, position switch axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3.3.13 Inspection, information labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
3.3.14 Inspection, UL-lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
3.3.15 Inspection of air hoses (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
3.4 Changing/replacement activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3.4.1 Type of oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
3.4.2 Oil change, gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
3.4.3 Oil change, gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
3.4.4 Oil change, gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
3.4.5 Oil change, gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
3.4.6 Oil change, gearbox, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
3.4.7 Oil change, gearbox axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
3.4.8 Replacing SMB battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
3.5 Lubrication activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3.5.1 Lubrication of spherical roller bearing, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
3.5.2 Rust preventive measures, bearing axis 1 (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

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3.5.3 Rust preventive measures, sealing axis 4 (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

3.5.4 Rust preventive measures, support bearing in wrist (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . 229
3.6 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
3.6.1 Flushing a contaminated gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
3.6.2 Cleaning, robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
3.7 Service Information System, M2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
3.7.1 Using the SIS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
3.7.2 Description of Service Information System (SIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
3.7.3 SIS system parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
3.7.4 Setting the SIS parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
3.7.5 Reading the SIS output logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
3.7.6 Exporting the SIS data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

4 Repair 245
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 247
4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249
4.3 Complete robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251
4.3.1 Replacement of cable harness, axes 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 251

公 司
4.3.2 Replacement of cable harness, axes 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

有 限
4.3.3 Replacement of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
4.3.4 Replacement of air nipple and hose (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268

育 科技
4.4 Upper and lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
4.4.1 Replacing turning disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

帮教
4.4.2 Replacement of complete wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
4.4.3 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
控
4.4.4 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
工
长
4.5.1 Replacement of
沙
4.5 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
SMB unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297
4.5.2 Replacement of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301
4.5.3 Replacement of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
4.5.4 Replacement of spherical roller bearing, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
© Copyright 2004-2011 ABB. All rights reserved.

4.5.5 Unloading the balancing device using hydraulic press tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
4.5.6 Restoring the balancing device using a hydraulic press tool.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
4.6.2 Replacement of motor axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333
4.6.3 Replacement of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
4.6.4 Replacement of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348
4.6.5 Replacement of motor, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355
4.6.6 Replacement of motor, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
4.7 Gearboxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
4.7.1 Replacement of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
4.7.2 Replacement of gearbox, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 373
4.7.3 Replacement of gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380
4.7.4 Replacement of gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 386
4.7.5 Replacement of gearbox, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
4.7.6 Replacement of gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397

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5 Calibration information 403

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
5.3 Calibration scale and correct axis position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
5.4 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
5.6 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 412

6 Decommissioning 415
6.1 Environmental information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
6.2 Decommissioning of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

7 Reference information 419

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419
7.2 Applicable safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 420
7.3 Unit conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422
7.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
7.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 426
7.6 Standard toolkit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427
7.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
7.8 Lifting accessories and lifting instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431

8 Spare part / part list 公 司 433

有 限
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 433

8.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 科
技
8.2 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 434
8.2.2 Spare part list . . . . . . . . . . . . . . . . . . . . . . . .育
8.3 Part list. . . . . . . . . . . . . . . . . . . . . . . . . . .帮
教 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 435
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
8.3.1 Introduction . . . . . . . . . . . . . . 控 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 437
8.3.2 Rebuilding parts . . . . . . . .工
8.3.3 Part list, overview. . . .沙
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 438
长 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 439
8.3.4 Mechanical stop axis 1, 3HAC12812-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 441
8.3.5 Base incl frame axis 1, 3HAC12304-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 442
8.3.6 Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/2.55). . . . . 443
8.3.7 Axis 3-4, 3HAC13063-2 (IRB 7600 - 500/2.3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 446
8.3.8 Axis 3-4, Foundry, 3HAC13063-4 (IRB 7600 -150/3.5, - 325/3.1, - 340/2.8, - 400/2.55, - 500/2.55) © Copyright 2004-2011 ABB. All rights reserved.
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 447
8.3.9 Axis 3-4 Foundry, 3HAC13063-5 (IRB 7600 - 500/2.3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 448
8.3.10 Wrist, 3HAC16628-4 / 3HAC16628-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 449
8.3.11 Material set robot, 3HAC13079-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 455
8.3.12 Material set axis 1-2, 3HAC13077-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 456
8.3.13 Material set balancing device, 3HAC13082-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 459
8.3.14 Arm extension set, 956 mm, 3HAC12311-1 (IRB 7600 - 150/3.5) . . . . . . . . . . . . . . . . . . . . . . 460
8.3.15 Arm extension set, 250 mm, 3HAC12311-2 (IRB 7600 - 340/2,8) . . . . . . . . . . . . . . . . . . . . . . 461

9 Exploded views 463

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463
9.2 Base incl. Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 464
9.3 Frame-Lower arm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465
9.4 Frame-Lower arm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 466
9.5 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 467
9.6 Wrist complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 468

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10 Circuit Diagram 469

10.1 About circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 469
10.2 Circuit diagram 3HAC 025744-001. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
10.2.1 Validity of circuit diagram 3HAC 025744-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 471
10.3 Circuit diagram 3HAC 13347-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472
10.3.1 Validity of circuit diagram 3HAC 13347-1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472

Index 473

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

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公 司
有 限

育 科技

控帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

8 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167

Overview of this manual

Overview of this manual

About this manual

This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.
The manual also contains reference information for all procedures detailed in the manual.

Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the foundation, to
making it ready for operation
• maintenance work
• repair work.

Who should read this manual?

This manual is intended for:
公 司
• installation personnel
有 限
科技
• maintenance personnel
• repair personnel.
育
Prerequisites
控 帮教
工
A maintenance/repair/installation craftsman working with an ABB Robot must:
沙
•
长beinstallation/repair/maintenance
trained by ABB and have the required knowledge of mechanical and electrical
work.

Organization of chapters
© Copyright 2004-2011 ABB. All rights reserved.

The manual is organized in the following chapters:

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

Continues on next page

3HAC022033-001 Revision: K 9
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Overview of this manual

Continued

Chapter Contents
Reference information Useful information when performing installation, maintenance or
repair work. Includes lists of necessary tools, additional documents,
safety standards etc.
Spare part list Complete spare part list shown in exploded views.
Exploded views Detailed illustrations of the robot with reference numbers to the part
list.
Circuit diagram Reference to the circuit diagram for the robot.

References
Procedures in this product manual contain references to the following manuals:

Document name Document ID Note

Product specification - IRB 7600 3HAC023934-001
Product specification - IRB 7600 M2000/M2000A 3HAC13491-1
Circuit diagrams IRB 7600 3HAC13347-1
3HAC025744-001
Product manual - IRC5 3HAC021313-001
Product manual - S4Cplus M2000 司
3HAC021333-001
公
Product manual - S4Cplus M2000A
Operating manual - IRC5 with FlexPendant 有 限 3HAC022419-001
3HAC16590-1
User’s guide - S4Cplus
育 科技
Operating manual - Calibration Pendulum
3HAC7793-1
3HAC16578-1

控 帮教
Operating manual - Service Information System 3HAC025709-001 M2004

工
Operating manual - Levelmeter Calibration 3HAC022907-001 M2000/M2000A

沙 - Additional axes and stand

Technical reference manual - System parameters
长manual
Application
3HAC17076-1
3HAC021395-001 M2004
alone controller
Application manual - External axes 3HAC9299-1 M2000

© Copyright 2004-2011 ABB. All rights reserved.

Additional document references

Document name Document ID

Application manual - CalibWare Field 5.0 3HAC030421-001

Continues on next page

10 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167

Overview of this manual

Continued

Revisions

Revision Description
- First edition.
Replaces previous manuals:
• Installation and Commissioning Manual
• Maintenance Manual
• Repair Manual, part 1
• Repair Manual, part 2.
Changes made in the material from the previous manuals:
• Model M2004 implemented.
• Various corrections due to technical revisions, changes in the toolkits
etc.
A Chapter Calibration replaced with chapter Calibration information.
Following corrections are made:
• In chapter 3: Maintenance in section Exporting the SIS data, the unit
seconds for different SIS parameters is replaced by the unit hours. The
change is only valid for RobotWare release 5.0.
Following updates are made:
• In chapter 4: Repair, the sections Removal of complete lower arm and

公 司
Refitting of complete lower arm are completed with more detailed
information about how to use the glycerin pump.

有 限
• Section Document references is completed with article numbers for

科技
calibration manuals.
• Section Part list is completed with the spare part number for a variant of
育
the cable harness/brake release unit.
B
帮教
New lubricating oil in the gearboxes. Changes made in the chapter

控
Maintenance and Part list.
C
沙 工 • New variant of the robot (IRB 7600 - 500/2.55) implemented throughout
the manual.
长 • Wrist unit updated, new spare part number is specified in Replacement
of complete wrist unit on page 279 and Spare part list on page 435.
• Insulated wrist unit implemented, new spare part number is specified in
Replacement of complete wrist unit on page 279 and Spare part list on
© Copyright 2004-2011 ABB. All rights reserved.

page 435. Amount of oil differs from non-insulated wrist unit, changes
made in sections Type of oil and Oil change, gearbox axis 6 on page
215.
• New section that describes how to replace the bearing at the front eye
of the balancing device, Replacement of spherical roller bearing,
balancing device on page 316.
• Incorrect article numbers for position switches are corrected, section
Installation of position switches (option) on page 122.
• New section: Installation of cooling fan for motors, axes 1-3 (option) on
page 104.
• New section: Installation of base spacers (option) on page 102
• New section that specifies all the recommended spare parts: Spare part
list on page 435.
• Repair sections for removal/refitting are restructured into replacement
sections.
• Various corrections made, due to technical revisions etc.
D Foundry Prime option included.

Continues on next page

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Overview of this manual

Continued

Revision Description
E • New variant of the robot (IRB 7600 - 325/3.1) implemented throughout
the manual.
• In chapter 3 Maintenance section Oil in gearboxes type of oil and art.
no. in gearbox axes 1 has been added.
• New product name has been implemented throughout the manual:
"Mobilgear 600 XP 320". Replaces "Mobil Gearlube X320".
• Interval for change of Shell Tivela S 150 has been changed in section
Maintenance schedule.
• Section Service Information System has been removed from the
manual. There is a specific manual for SIS. See References.
• Section Chip and dust protection has been removed from the manual.
This option is no longer available.
• Standard tightening torque for M24 Allen head screws has been added
in section Screw joints.
• Prerequisites in section Overview
F This revision includes the following additions and/or changes:
• Section "WARNING! - Mixed oils may cause severe damage to
gearboxes" in chapter Safety, has been integrated in section "Type of oil
in gearboxes" in the Maintenance chapter.

公 司
• The oil Shell Tivela S150 in gearboxes 1, 2, 3 and 6 has been replaced
by Kyodo Yushi TMO 150. Changes made in chapters Maintenance and
Spare Parts.
有 限
• The section "Type of oil in gearboxes" in chapter Maintenance has been

科技
updated according to changes made in oil types and intervals for oil
change.
育
帮教
• Sections "Robot transportation precaution" and "Securing the robot" are
added to the Installation chapter.

工 控
• Modified maintenace intervals for oil change in gearboxes.
• Chapter Maintenance, section "Mainenance Schedule": interval for

长 沙 replacement of battery pack changed.

• Section "Type of oil" changed.
G This revision include the following addition:
• New WARNING! added in Safety chapter section Work inside the
robot´s working range.
• New WARNING! added in Safety chapter section WARNING! - Safety © Copyright 2004-2011 ABB. All rights reserved.
risks during work with gearbox oil.
• The text in the introduction to chapters Installation, Maintenance and
Repair has been uppdated concerning the robot being connected to
earth when power connected.
• Section Expected component life in chapter Maintenance: The lifetime
of certain parts has been updated.
• Section Type of oil in chapter Maintenance has been updated.
• Section Foundry Plus, Cable guard added to Installation chapter.

Continues on next page

12 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167

Overview of this manual

Continued

Revision Description
H This revision includes the following additions and/or changes:
• Circuit diagrams are not included in this document but delivered as
separate files. See Circuit diagram.
• List of standards updated, see Applicable safety standards on page 420.
• Interval changed for inspection and lubrication of balancing device
(Foundry Prime). See chapter Maintenance section Maintenance
schedule on page 143.
The chapter Safety updated with:
• Updated safety signal graphics for the levels Danger and Warning, see
Safety signals in the manual on page 39.
• New safety labels on the manipulators, see Safety symbols on
manipulator labels on page 41.
• Revised terminology: robot replaced with manipulator.
J This revision includes the following updates:
• Maximum deviation changed, see Securing the base plate on page 90.
• Corrected part numbers, see Wrist, 3HAC16628-4 / 3HAC16628-3 on
page 449.
• Corrected exploded view, see Wrist complete on page 468.
• Added inspection of oil level in gearboxes and inspection of surface

公 司
treatment in maintenance schedule for Foundry Prime. See section
Activities and intervals, Foundry Prime on page 146.
限
• Text in maintenance schedules concering lubrication of balancing
有
科技
device bearing changed into concerning all bearings of the balancing
device, see Maintenance schedule on page 143.

育
• Replacement of cable harness in Foundry Prime robots added to

帮教
maintenance schedule, see Activities and intervals, Foundry Prime on
page 146.
This控
K

沙 工 revision includes the following updates:

• Removed incorrect article number for fork lift, see Lifting robot with fork
长 •
lift on page 71.
Information about restricting and extending the working range of axis 1
is now separated, see Mechanically restricting the working range of axis
1 on page 115 and the new section Extended working range, axis 1
(option 561-1). Also added signal about option 561-1 in section
© Copyright 2004-2011 ABB. All rights reserved.

Inspecting, mechanical stop pin, axis 1 on page 177.

3HAC022033-001 Revision: K 13
 工控帮助教小舒QQ2823408167

Product documentation, M2000/M2000A

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:

Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware will be delivered
with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or electrical
connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare parts).
• Calibration.
• Decommissioning.
•
公 司
Reference information (safety standards, unit conversions, screw joints, lists of tools ).
•
有 限
Spare parts list with exploded views (or references to separate spare parts lists).

科技
• Circuit diagrams (or references to circuit diagrams).

育
Software manuals
教
帮consists of a wide range of manuals, ranging from manuals for
控
The software documentation

operation. 沙
工
basic understanding of the operating system to manuals for entering parameters during

长
A complete listing of all available software manuals is available from ABB.

Controller hardware option manual

© Copyright 2004-2011 ABB. All rights reserved.

Each hardware option for the controller is supplied with its own documentation. Each
document set contains the types of information specified below:
• Installation information
• Repair information
• Maintenance information
In addition, spare part information is supplied for the entire option.

14 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167

Product documentation, M2004

Product documentation, M2004

Categories for manipulator documentation

The manipulator documentation is divided into a number of categories. This listing is based
on the type of information in the documents, regardless of whether the products are standard
or optional.
All documents listed can be ordered from ABB on a DVD. The documents listed are valid for
M2004 manipulator systems.

Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware will be delivered
with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or electrical
connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• 司
Repair (descriptions of all recommended repair procedures including spare parts).
公
• Calibration.
有 限
• Decommissioning.
技
科standards, unit conversions, screw joints, lists of tools ).
• Reference information (safety
• Spare parts list with教
育
exploded views (or references to separate spare parts lists).

控
• Circuit diagrams帮(or references to circuit diagrams).
工
Technical reference manuals沙
长
The technical reference manuals describe the manipulator software in general and contain
relevant reference information.
• RAPID Overview: An overview of the RAPID programming language.
© Copyright 2004-2011 ABB. All rights reserved.

• RAPID Instructions, Functions and Data types: Description and syntax for all
RAPID instructions, functions, and data types.
• RAPID Kernel: A formal description of the RAPID programming language.
• System parameters: Description of system parameters and configuration workflows.

Continues on next page

3HAC022033-001 Revision: K 15
 工控帮助教小舒QQ2823408167

Product documentation, M2004

Continued

Application manuals
Specific applications (for example 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 (for example cables, I/O boards, RAPID instructions, system
parameters, DVD with PC software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.

Operating manuals
The operating manuals describe hands-on handling of the products. The manuals are aimed
at those having first-hand operational contact with the product, that is production cell
operators, programmers, and trouble shooters.
The group of manuals includes (among others):
•
•
Emergency safety information
General safety information 公 司
• Getting started, IRC5 and RobotStudio 有 限
• Introduction to RAPID
育 科技
帮教
• IRC5 with FlexPendant
• RobotStudio
•
工 控
Trouble shooting, for the controller and manipulator.

长 沙

© Copyright 2004-2011 ABB. All rights reserved.

16 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167

How to read the product manual

How to read the product manual

Reading the procedures

The procedures contain references to figures, tools, material, and so on. The references are
read as described below.

References to figures
The procedures often include references to components or attachment points located on the
manipulator/controller. The components or attachment points are marked with italic text in
the procedures and completed with a reference to the figure where the current component or
attachment point is shown.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a procedure.

Action Note/Illustration
8. Remove the rear attachment screws, gearbox. Shown in the figure Location of
gearbox on page xx.

References to required equipment

公 司
限
The procedures often include references to equipment (spare parts, tools, etc.) required for the
有 is marked with italic text in the procedures
and completed with a reference to the
技
different actions in the procedure. The equipment
科 section where the equipment is listed with further
育 and dimensions.
information, that is article number
The designation in the帮
教
procedure for the component or attachment point corresponds to the

工 控
designation in the referenced list.
The table沙 below shows an example of a reference to a list of required equipment from a step
长
in a procedure.

Action Note/Illustration
© Copyright 2004-2011 ABB. All rights reserved.

3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required
equipment on page xx.

Safety information
The manual includes a separate safety chapter that must be read through before proceeding
with any service or installation procedures. All procedures also include specific safety
information when dangerous steps are to be performed.
Read more in the chapter Safety on page 19.

3HAC022033-001 Revision: K 17
 工控帮助教小舒QQ2823408167

How to read the product manual

公 司
有 限

育 科技

控帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

18 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
1 Safety
1.1. Introduction to safety information

1 Safety
1.1. Introduction to safety information

Overview
The safety information in this manual is divided into 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 General safety
information on page 20.
• Specific safety information, pointed out in the procedures. How to avoid and eliminate
the danger is either described directly in the procedure, or in specific instructions in
the section Safety related instructions on page 39.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 19
 工控帮助教小舒QQ2823408167
1 Safety
1.2.1. Safety in the manipulator system

1.2 General safety information

1.2.1. Safety in the manipulator system

Validity and responsibility

The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment that can influence the safety of the entire system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the
manipulator is installed.
The users of ABB industrial manipulators are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the safety devices
necessary to protect people working with the manipulator system are designed and installed
correctly. Personnel working with manipulators must be familiar with the operation and
handling of the industrial manipulator as described in the applicable documents, for example:
• User’s guide - S4Cplus (M2000)
• Operating manual - IRC5 with FlexPendant
• Product manual
公 司
Connection of external safety devices
有 限
科技
Apart from the built-in safety functions, the manipulator is also supplied with an interface for

育
the connection of external safety devices. An external safety function can interact with other

帮教
machines and peripheral equipment via this interface. This means that control signals can act
on safety signals received from the peripheral equipment as well as from the manipulator.

工 控
Limitation of liability
长 沙
Any information given in this manual regarding safety must not be construed as a warranty
by ABB that the industrial manipulator will not cause injury or damage even if all safety
instructions are complied with.

Related information © Copyright 2004-2011 ABB. All rights reserved.

Type of information Detailed in document Section

Installation of safety devices Product manual for the manipulator Installation and
commissioning
Changing operating modes User´s Guide - S4Cplus (RobotWare Start-up
4.0) Operating modes
Operating manual - IRC5 with
FlexPendant
Restricting the working space Product manual for the manipulator Installation and
commissioning

20 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
1 Safety
1.2.2.1. Safety risks during installation and service work on manipulators

1.2.2. Safety risks

1.2.2.1. Safety risks during installation and service work on manipulators

Overview
This section includes information on general safety risks to be considered when performing
installation and service work on the manipulator.

General risks during installation and service

• The instructions in the product manual in the chapter Installation and commissioning
must always be followed.
• Emergency stop buttons must be positioned in easily accessible places so that the
manipulator can be stopped quickly.
• Those in charge of operations must make sure that safety instructions are available for
the installation in question.
• Those who install the manipulator must have the appropriate training for the
equipment in question and in any safety matters associated with it.

Nation/region specific regulations

公 司
限 of the manipulator, the regulations
To prevent injuries and damages during the installation
applicable in the country concerned and the有
with. 科 技 instructions of ABB Robotics must be complied

育
Non-voltage related risks
帮 教
• Safety zones,控
工 working space. Light beams or sensitive mats are suitable devices.
which must be crossed before admittance, must be set up in front of the
沙
manipulator's
•长 Turntables or the like should be used to keep the operator out of the manipulator's
working space.
• The axes are affected by the force of gravity when the brakes are released. In addition
© Copyright 2004-2011 ABB. All rights reserved.

to the risk of being hit by moving manipulator parts, there is a risk of being crushed
by the parallel arm (if there is one).
• Energy stored in the manipulator for the purpose of counterbalancing certain axes may
be released if the manipulator, or parts thereof, are dismantled.
• When dismantling/assembling mechanical units, watch out for falling objects.
• Be aware of stored heat energy in the controller.
• Never use the manipulator as a ladder, which means, do not climb on the manipulator
motors or other parts during service work. There is a serious risk of slipping because
of the high temperature of the motors and oil spills that can occur on the manipulator.

To be observed by the supplier of the complete system

• The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
• The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance with the
applicable standards for the emergency stop function.
Continues on next page
3HAC022033-001 Revision: K 21
 工控帮助教小舒QQ2823408167
1 Safety
1.2.2.1. Safety risks during installation and service work on manipulators

Continued

Complete manipulator

Safety risk Description

Hot components!

CAUTION!
Motors and gears are HOT after running the manipulator!
Touching motors and gears may result in burns!
With a higher environment temperature, more surfaces on
the manipulator will get HOT and may also result in burns.
Removed parts may result in
collapse of manipulator!

WARNING!
Take any necessary measures to ensure that the
manipulator does not collapse as parts are removed, e.g.
secure the lower arm according to repair instruction if
removing motor, axis 2.

Cabling

公 司
Safety risk
Cable packs are sensitive to
Description
有 限
科技
mechanical damage!

育
教 CAUTION!
帮 The cable packs are sensitive to mechanical damage!
工 控 They must be handled with care, especially the
connectors, in order to avoid damaging them!

长 沙
Gearboxes and motors

Safety risk Description

© Copyright 2004-2011 ABB. All rights reserved.

Gears may be damaged if
excessive force is used!

CAUTION!
Whenever parting/mating motor and gearbox, the gears
may be damaged if excessive force is used!

Balancing device

Safety risk Description

Dangerous balancing device!

WARNING!
Do not under any circumstances, deal with the balancing
device in any other way than that detailed in the product
documentation! For example, attempting to open the
balancing device is potentially lethal!

22 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
1 Safety
1.2.2.2. CAUTION - Hot parts may cause burns!

1.2.2.2. CAUTION - Hot parts may cause burns!

Description
During normal operation, many manipulator parts become hot, especially the drive motors
and gears. Sometimes areas around these parts also become hot. Touching these may cause
burns of various severity.
Because of a higher environment temperature, more surfaces on the manipulator get hot and
may result in burns.

Elimination
The instructions below detail how to avoid the dangers specified above:

Action Info
1. Always use your hand, at some distance, to feel if heat is
radiating from the potentially hot component before
actually touching it.
2. Wait until the potentially hot component has cooled if it is
to be removed or handled in any other way.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 23
 工控帮助教小舒QQ2823408167
1 Safety
1.2.2.3. Safety risks related to tools/work pieces

1.2.2.3. Safety risks related to tools/work pieces

Safe handling
It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards
remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).

Safe design
Grippers/end effectors must be designed so that they retain work pieces in the event of a
power failure or a disturbance to the controller.
CAUTION!
Ensure that a gripper is prevented from dropping a work piece, if such is used.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

24 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
1 Safety
1.2.2.4. Safety risks related to pneumatic/hydraulic systems

1.2.2.4. Safety risks related to pneumatic/hydraulic systems

General
Special safety regulations apply to pneumatic and hydraulic systems.

Residual energy
• Residual energy can be present in these systems. After shutdown, particular care must
be taken.
• The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.

Safe design
• Gravity may cause any parts or objects held by these systems to drop.
• Dump valves should be used in case of emergency.
• Shot bolts should be used to prevent tools, etc., from falling due to gravity.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 25
 工控帮助教小舒QQ2823408167
1 Safety
1.2.2.5. Safety risks during operational disturbances

1.2.2.5. Safety risks during operational disturbances

General
• The industrial manipulator is a flexible tool that 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
Corrective maintenance 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.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

26 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
1 Safety
1.2.2.6. Risks associated with live electric parts

1.2.2.6. Risks associated with live electric parts

Voltage related risks, general

• Although troubleshooting may, on occasion, need to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
• The mains supply to the robot must be connected in such a way that it can be turned
off from outside the robot’s working space.

Voltage related risks, controller S4Cplus

A danger of high voltage is associated with the following parts:
• Controller (Be aware of stored electrical energy (DC link)).
• Units inside the controller, e.g. I/O modules, can be supplied with power from an
external source.
• Mains supply/mains switch
• Power unit
•
公 司
Power supply unit for the computer system (230 VAC)
• Rectifier unit (400-480 VAC and 700 VDC.
有 限 Note: Capacitors!)
• Drive unit (700 VDC)
科 技
育
• Service outlets (115/230 VAC)
教tools, or special power supply units for the machining process.
• Power supply unit for
帮
控
• External voltage connected to the control cabinet remains live even when the robot is
工 from the mains.
沙
disconnected
•长Additional connections
© Copyright 2004-2011 ABB. All rights reserved.

Continues on next page

3HAC022033-001 Revision: K 27
 工控帮助教小舒QQ2823408167
1 Safety
1.2.2.6. Risks associated with live electric parts

Continued

Voltage related risks, IRC5 controller

A danger of high voltage is associated with, for example, the following parts:
• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the
controller.
• Units such as I/O modules, can be supplied with power from an external source.
• The mains supply/mains switch
• The transformers
• The power unit
• The control power supply (230 VAC)
• The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
• The drive unit (700 VDC)
• The drive system power supply (230 VAC)
• The service outlets (115/230 VAC)
• The customer power supply (230 VAC)
• The power supply unit for additional tools, or special power supply units for the
machining process.
• 公 司
The external voltage connected to the controller remains live even when the robot is
disconnected from the mains.
有 限
科技
• Additional connections.

育
帮教
Voltage related risks, manipulator

• 工 控
A danger of high voltage is associated with the manipulator in:
The power supply for the motors (up to 800 VDC).
• 长 沙
The user connections for tools or other parts of the installation (max. 230 VAC, see the
chapter Installation and commissioning in the Product manual).

Voltage related risks, tools, material handling devices, etc.

Tools, material handling devices, etc., may be live even if the robot system is in the OFF © Copyright 2004-2011 ABB. All rights reserved.
position. Power supply cables which are in motion during the working process may be
damaged.

28 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
1 Safety
1.2.3.1. Safety fence dimensions

1.2.3. Safety actions

1.2.3.1. Safety fence dimensions

General
Install a safety cell around the manipulator to ensure safe manipulator installation and
operation.

Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the manipulator is dropped or released at maximum speed. Determine the
maximum speed from the maximum velocities of the manipulator axes and from the position
at which the manipulator is working in the work cell (see the section Robot motion in the
Product specification).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 29
 工控帮助教小舒QQ2823408167
1 Safety
1.2.3.2. Fire extinguishing

1.2.3.2. Fire extinguishing

NOTE!
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the manipulator
system (manipulator or controller)!

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

30 3HAC022033-001 Revision: K
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1 Safety
1.2.3.3. Emergency release of the manipulator’s arm

1.2.3.3. Emergency release of the manipulator’s arm

Description
In an emergency situation, any of the manipulator's axes may be released manually by
pushing the brake release buttons on the manipulator.
How to release the brakes is detailed in the section:
• Manually releasing the brakes on page 83.
The manipulator arm may be moved manually on smaller manipulator models, but larger
models may require using an overhead crane or similar equipment.

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!

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 31
 工控帮助教小舒QQ2823408167
1 Safety
1.2.3.4. Brake testing

1.2.3.4. Brake testing

When to test
During operation, the holding brake of each axis normally wears down. A test can be
performed to determine whether the brake can still perform its function.

How to test
The function of the holding brake of each axis motor may be checked as described 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.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

32 3HAC022033-001 Revision: K
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1 Safety
1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"

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

NOTE!
Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant
or a PC. This will affect the safety function "Reduced speed 250 mm/s".

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 33
 工控帮助教小舒QQ2823408167
1 Safety
1.2.3.6. Safe use of the FlexPendant

1.2.3.6. Safe use of the FlexPendant

NOTE!
The enabling device is a push-button located on the side of the FlexPendant which, when
pressed halfway in, switches the system to MOTORS ON. When the enabling device is
released or pushed all the way in, the manipulator switches to the MOTORS OFF state.
To ensure safe use of the FlexPendant, the following must be implemented:
• The enabling device must never be rendered inoperational in any way.
• During programming and testing, the enabling device must be released as soon as
there is no need for the manipulator to move.
• The programmer must always bring the FlexPendant with him/her when entering the
manipulator's working space. This is to prevent anyone else from taking control of the
manipulator without the programmer’s knowledge.

Enabling device
The enabling device is a manually operated, constant pressure push-button which, when
continuously activated in one position only, allows potentially hazardous functions but does
not initiate them. In any other position, hazardous functions are stopped safely.

公 司
The enabling device is of a specific type where you must press the push-button only half-way

有 限
to activate it. In the fully in and fully out positions, manipulator operation is impossible.

Hold-to-run function
育 科技
帮教
The hold-to-run function allows movement when a button connected to the function is
actuated manually and immediately stops any movement when released. The hold-to-run

工 控
function can only be used in manual mode.

长沙
How to operate the hold-to-run function is described in Operating manual - IRC5 with
FlexPendant.

© Copyright 2004-2011 ABB. All rights reserved.

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1 Safety
1.2.3.7. Work inside the manipulator's working range

1.2.3.7. Work inside the manipulator's working range

WARNING!
If work must be carried out within the manipulator’s work area, 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 operational and to block operation from a computer link or
remote control panel.
• The manipulator’s speed is limited to max. 250 mm/s when the operating mode
selector is in the position Manual mode with reduced speed. This should be the normal
position when entering the working space. The position Manual mode with full speed
(100%) may only be used by trained personnel who are aware of the risks that this
entails. Manual mode with full speed (100%) is not available in USA or Canada.
• Pay attention to the rotating axes of the manipulator. Keep away from axes to not 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 the section Brake testing on page 32.

WARNING! 公 司
有 限
NEVER, under any circumstances, stay beneath any of the manipulator’s axes! There is

科技
always a risk that the manipulator will move unexpectedly when manipulator axes are moved
育
using the enabling device or during other work inside the manipulator’s working range.

控 帮教
沙 工
长
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1 Safety
1.2.3.8. Signal lamp (optional)

1.2.3.8. Signal lamp (optional)

Description
A signal lamp with a yellow fixed light can be mounted on the manipulator, as a safety device.

Function
The lamp is active in MOTORS ON mode.

Further information
Further information about the MOTORS ON/MOTORS OFF mode may be found in the
product manual for the controller.

公 司
有 限

育 科技

控 帮教
沙 工
长

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1 Safety
1.2.4.1. What is an emergency stop?

1.2.4. Safety stops

1.2.4.1. What is an emergency stop?

Definition of emergency stop

An emergency stop is a state that overrides any other manipulator control, disconnects drive
power from the manipulator motors, stops all moving parts, and disconnects power from any
potentially dangerous functions controlled by the manipulator system.
An emergency stop state means that all power is disconnected from the manipulator except
for the manual brake release circuits. You must perform a recovery procedure, i.e, resetting
the emergency stop button and pressing the Motors On button, in order to return to normal
operation.
The manipulator system can be configured so that the emergency stop results in either:
• An uncontrolled stop, immediately stopping the manipulator actions by disconnecting
power from the motors.
• A controlled stop, stopping the manipulator actions with power available to the motors
so that the manipulator path can be maintained. When completed, power is
disconnected from the motors.
公 司
有 限
The default setting is an uncontrolled stop. However, controlled stops are preferred since they
minimize extra, unnecessary wear on the manipulator and the actions needed to return the

科技
manipulator system back to production. Please consult your plant or cell documentation to

育
see how your manipulator system is configured.
NOTE!
控 帮教
The emergency stop function may only be used for the purpose and under the conditions for

沙 工
which it is intended.
长
NOTE!
The emergency stop function is intended for immediately stopping equipment in the event of
© Copyright 2004-2011 ABB. All rights reserved.

an emergency.

NOTE!
Emergency stop should not be used for normal program stops as this causes extra,
unnecessary wear on the manipulator. For how to perform normal program stops, see in the
sectionStopping programs inOperating manual - IRC5 with FlexPendant.

Classification of stops
The safety standards that regulate automation and manipulator equipment define categories
in which each type of stop applies:
If the stop is... ... then it is classified as...
uncontrolled category 0 (zero)
controlled category 1

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1 Safety
1.2.4.1. What is an emergency stop?

Continued

Emergency stop devices

In a manipulator system there are several emergency stop devices that can be operated in
order to achieve an emergency stop. There are emergency stop buttons available on the
FlexPendant and on the controller cabinet (on the Control Module on a Dual Cabinet
Controller). There can also be other types of emergency stops on your manipulator. Consult
your plant or cell documentation to see how your manipulator system is configured.

公 司
有 限

育 科技

控 帮教
沙 工
长

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1 Safety
1.3.1. Safety signals in the manual

1.3 Safety related instructions

1.3.1. Safety signals in the manual

Introduction to safety signals

This section specifies all dangers that can arise when doing the work described in this manual.
Each danger consists 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 do not
eliminate the danger.
• Instruction about how to eliminate danger to simplify doing the work.

Danger levels
The table below defines the captions specifying the danger levels used throughout this
manual.

Symbol Designation Significance

DANGER 公 司
Warns that an accident will occur if the instructions

有 限
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to

科技
warnings that apply to danger with, for example,

育 contact with high voltage electrical units, explosion

帮教
or fire risk, risk of poisonous gases, risk of crushing,
danger
impact, fall from height, and so on.

工 控 WARNING Warns that an accident may occur if the instructions

are not followed that can lead to serious injury,

长 沙 possibly fatal, and/or great damage to the product. It

applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
warning
explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
© Copyright 2004-2011 ABB. All rights reserved.

ELECTRICAL Warns for electrical hazards which could result in

SHOCK severe personal injury or death.

Electrical shock

CAUTION Warns that an accident may occur if the instructions

are not followed that can result in injury and/or
damage to the product. It also applies to warnings of
risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping,
impact, fall from height, etc. Furthermore, it applies
caution to warnings that include function requirements when
fitting and removing equipment where there is a risk
of damaging the product or causing a breakdown.

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1 Safety
1.3.1. Safety signals in the manual

Continued

Symbol Designation Significance

ELECTROSTATIC Warns for electrostatic hazards which could result in
DISCHARGE (ESD) severe damage to the product.

Electrostatic discharge
(ESD)

NOTE Describes important facts and conditions.

Note

TIP Describes where to find additional information or

how to do an operation in an easier way.

司
Tip

限 公
有
育 科技

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1 Safety
1.3.2. Safety symbols on manipulator labels

1.3.2. Safety symbols on manipulator labels

Introduction to labels
This section describes safety symbols used on labels (stickers) on the manipulator.
Symbols are used in combinations on the labels, describing each specific warning. The
descriptions in this section are generic, the labels can contain additional information such as
values.

Types of labels
Both the manipulator and the controller are marked with several safety and information
labels, containing important information about the product. The information is useful for all
personnel handling the manipulator system, for example during installation, service, or
operation.
The safety labels are language independent, they only use graphics. See Symbols on safety
labels on page 41.
The information labels can contain information in text (English, German, and French).
The labels are identified and located on the product as shown in the section:
• Inspection, information labels on page 187
公 司
Symbols on safety labels
有 限
Symbol
育 科技
Description

教Warning!
帮 Warns that an accident may occur if the instructions are not
工 控 followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply to

长 沙 danger with, for example, contact with high voltage electrical

units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.

xx0900000812
© Copyright 2004-2011 ABB. All rights reserved.

Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping,
impact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
xx0900000811

Prohibition
Used in combinations with other symbols.

xx0900000839

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1 Safety
1.3.2. Safety symbols on manipulator labels

Continued

Symbol Description
See user documentation
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
• EPS: Application manual - Electronic Position Switches.
xx0900000813

Before dismantling see product manual

xx0900000816

Do not dismantle
Dismantling this part can cause injury.

公 司
xx0900000815
有 限
科技
Extended rotation
This axis has extended rotation (working area) compared to
育
standard.

控 帮教
沙 工
长
xx0900000814

Brake release
Pressing this button will release the brakes. This means that the
manipulator arm can fall down.

xx0900000808 © Copyright 2004-2011 ABB. All rights reserved.

Tip risk when loosening bolts
The manipulator can tip over if the bolts are not securely
fastened.

xx0900000810

Crush
Risk of crush injuries.

xx0900000817

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1 Safety
1.3.2. Safety symbols on manipulator labels

Continued

Symbol Description
Heat
Risk of heat that can cause burns.

xx0900000818

Moving robot
The robot can move unexpectedly.

xx0900000819

公 司
有 限

育 科技
帮教
xx1000001141

工控
Brake release buttons

长沙
© Copyright 2004-2011 ABB. All rights reserved.

xx0900000820

xx1000001140

Lifting bolt

xx0900000821

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1 Safety
1.3.2. Safety symbols on manipulator labels

Continued

Symbol Description
Chain sling with shortener

xx1000001242

Lifting of robot

xx0900000822

Oil
公 司
Can be used in combination with prohibition if oil is not allowed.

有 限
xx0900000823
育 科技
帮教
Mechanical stop

工 控
长 沙
xx0900000824

No mechanical stop

© Copyright 2004-2011 ABB. All rights reserved.

xx1000001144

Stored energy
Warns that this part contains stored energy.
Used in combination with Do not dismantle symbol.

xx0900000825

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1 Safety
1.3.2. Safety symbols on manipulator labels

Continued

Symbol Description
Pressure
Warns that this part is pressurized. Usually contains additional
text with the pressure level.

xx0900000826

Shut off with handle

Use the power switch on the controller.

xx0900000827

公 司
有 限

育 科技

控 帮教
沙 工
长
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1 Safety
1.3.3. DANGER - Moving manipulators are potentially lethal!

1.3.3. DANGER - Moving manipulators are potentially lethal!

Description
Any moving manipulator is a potentially lethal machine.
When running, the manipulator may perform unexpected and sometimes irrational
movements. Moreover, all movements are performed with great force and may seriously
injure any personnel and/or damage any piece of equipment located within the working range
of the manipulator.

Elimination

Action Note
1. Before attempting to run the manipulator, Emergency stop equipment such as gates,
make sure all emergency stop equipment tread mats, light curtains, etc.
is correctly installed and connected.
2. Usually the hold-to-run function is active How to use the hold-to-run function is
only in manual full speed mode. To described in section How to use the hold-
increase safety it is also possible to to-run function in the Operating manual -
activate hold-to-run for manual reduced
公 司
IRC5 with FlexPendant.
speed with a system parameter.

有
The hold-to-run function is used in manual 限
How to use the hold-to-run control in
RobotWare 4.0 is detailed in section The

科技
mode, not in automatic mode. Teach Pendant unit in the User Guide.

育
3. Make sure no personnel are present within

帮教
the working range of the manipullator
before pressing the start button.

工 控
长 沙

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1 Safety
1.3.4. DANGER - First test run may cause injury or damage!

1.3.4. DANGER - First test run may cause injury or damage!

Description
Since performing a service activity often requires disassembly of the robot, there are several
safety risks to take into consideration before the first test run.

Elimination
Follow the procedure below when performing the first test run after a service activity, such
as repair, installation, or maintenance.

Action
1. Remove all service tools and foreign objects from the robot and its working area
2. Install all safety equipment properly
3. Make sure all personnel are standing at a safe distance from the robot, that is out of its
reach behind safety fences, and so on
4. Pay special attention to the function of the part previously serviced

Collision risks

公 司
CAUTION!
有 限
科技
When programming the movements of the manipulator always check potential collision risks
before the first test run.
育
控 帮教
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1 Safety
1.3.5. WARNING - The brake release buttons may be jammed after service work

1.3.5. WARNING - The brake release buttons may be jammed after service work

Description
The brake release unit has push-buttons for the 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.
DANGER!
If 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
manipulator.

Elimination
To eliminate the danger after service work has been performed inside the SMB recess, follow
the procedure below.

Action
1. Make sure the power is turned off.

司
2. Remove the push-button guard, if necessary.

限 公
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.
有
科技
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!
育
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1 Safety
1.3.6. WARNING - The unit is sensitive to ESD!

1.3.6. WARNING - The unit is sensitive to ESD!

Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two bodies at
different potentials, either through direct contact or through an induced electrical field. When
handling parts or their containers, personnel not grounded may potentially transfer high static
charges. This discharge may destroy sensitive electronics.

Elimination

Action Note
1. Use a wrist strap Wrist straps must be tested frequently to ensure
that they are not damaged and are operating
correctly.
2. Use an ESD protective floor mat. The mat must be grounded through a current-
limiting resistor.
3. Use a dissipative table mat. The mat should provide a controlled discharge of
static voltages and must be grounded.

Location of wrist strap button

公 司
限
The location of the wrist strap button is shown in the following illustration.
有
IRC5
The wrist strap button is located in科
技
the top right corner.
育
帮 教
工 控
长沙
© Copyright 2004-2011 ABB. All rights reserved.

xx0500002171

A Wrist strap button

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1 Safety
1.3.6. WARNING - The unit is sensitive to ESD!

Continued

Assemble the wrist strap

The picture illustrates how the ESD wrist strap is assembled in the controller.

司
xx0400001055

A 公
The strap is fastened to a button on the side of the control module.
限
B
有
When not used, the wrist strap is placed on the power supply unit.

科技
C Power supply unit

育
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1 Safety
1.3.7. WARNING - Safety risks during work with gearbox lubricants (oil or grease)

1.3.7. WARNING - Safety risks during work with gearbox lubricants (oil or grease)

Description
When handling gearbox lubricants, there is a risk of both personal injury and product damage
occurring. The following safety information must be regarded before performing any work
with lubricants in the gearboxes.

Warnings and elimination

Warning Description Elimination/Action

Changing and draining gearbox Make sure that protective gear
oil or grease may require like goggles and gloves are
handling hot lubricant heated up always worn during this activity.
to 90 °C.
-

Hot oil or grease

When working with gearbox Make sure that protective gear
lubricant there is a risk of an like goggles and gloves are
allergic reaction. always worn.

司
.

Allergic reaction
When opening the oil or限 公
grease Open the plug carefully and
plug, there may be
present in the技
有 pressure keep away from the opening. Do
gearbox, causing not overfill the gearbox when
lubricant 科
育
to spray from the filling.

教
- opening.
Possible pressure
帮
控 Overfilling of gearbox lubricant Make sure not to overfill the
build-up in gearbox
工
长沙
can lead to internal over- gearbox when filling it with oil or
pressure inside the gearbox grease!
which in turn may: After filling, check the correct
-
• damage seals and level.
Do not overfill gaskets
© Copyright 2004-2011 ABB. All rights reserved.

• completely press out

seals and gaskets
• prevent the robot from
moving freely.
Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the gearbox. mix different types of oil unless
specified in the instructions.
Always use the type of oil
-
specified by the manufacturer!
Do not mix types of oil
Warm oil drains quicker than When changing gearbox oil, first
cold oil. run the robot for a time to heat
up the oil.

Heat up the oil

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1 Safety
1.3.7. WARNING - Safety risks during work with gearbox lubricants (oil or grease)

Continued

Warning Description Elimination/Action

The specified amount of oil or After refilling, check the lubricant
grease is based on the total level.
volume of the gearbox. When
changing the lubricant, the
- amount refilled may differ from
Specified amount the specified amount, depending
depends on drained on how much has previously
volume been drained from the gearbox.

公 司
有 限

育 科技

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2 Installation and commissioning
2.1. Introduction

2 Installation and commissioning

2.1. Introduction

General
This chapter contains information for installing the robot at the working site.
More detailed technical data can be found in the Product specification for the robot, such as:
• Load diagram
• Permitted extra loads (equipment)
• Location of extra loads (equipment).

Safety information
Before any installation 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 describes the danger and safety risks when performing the procedures. Read
the chapter Safety on page 19 before performing any installation work.

公 司
NOTE!
有 限
科技
If the robot is connected to power, always make sure that the robot is connected to earth

育
before starting any installation work!

帮教
For more information see:
• 控
Product manual - IRC5
工
长 沙
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2 Installation and commissioning
2.2. Robot transportation precautions

2.2. Robot transportation precautions

General
This section details ABB approved transportation precautions for ABB robots.
CAUTION!
All transportation in or outside the plant, must be carried out according to description
in method 1. If transportation according to method 1 is not possible, use method 2.
Transportation in any other way than method 1 or 2 can seriously damage the robot. If
the robot is incorrectly transported and the instructions are not followed, the robot is
not covered by the warranty and ABB will not accept any compensation claim.

Method 1
Transportation according to method 1 is strongly recommended by ABB.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0800000030

Always follow these instructions when transporting an ABB robot according to method 1:
• Always remove the tool before transportation of the robot.
• Always place the robot in the ABB recommended transport position, detailed in
section Risk of tipping/stability on page 70.
• Always read and follow the instructions in section Pre-installation procedure.

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2 Installation and commissioning
2.2. Robot transportation precautions

Continued

Method 2
Transportation according to method 2 is approved by ABB, if use of method 1 is not
possible.
Always follow these instructions when transporting an ABB robot according to method 2:
• Always read and follow the instructions in section Securing the robot on page 61
• Always place the robot in the ABB recommended transport position for robot with
tool, detailed in sub section Transport position with a transport support on page 57.
• Always use the recommended transport support detailed in sub section Recommended
transport support on page 59.

IRB7600/IRB66XX

公 司
有 限

育 科技

控 帮教
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长
© Copyright 2004-2011 ABB. All rights reserved.

xx0800000037

A Transport Support
B Hexagon socket head cap screw M16x140
C Threaded bar M10x200
D Nut M10

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2 Installation and commissioning
2.2. Robot transportation precautions

Continued

IRB6620/Foundry Plus

公 司
有 限

育 科技

控 帮教
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长

© Copyright 2004-2011 ABB. All rights reserved.

xx0800000036

A Transport Support
B Hexagon socket head cap screw M10x50
C Threaded bar M10x280
D Nut M10

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2 Installation and commissioning
2.2. Robot transportation precautions

Continued

Transport position with a transport support

All transportation of the robot with tool must follow these instructions.

IRB 7600/IRB 66XX

公 司
有 限

育 科技

控 帮教
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长
© Copyright 2004-2011 ABB. All rights reserved.

xx0800000040

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2 Installation and commissioning
2.2. Robot transportation precautions

Continued

IRB 6620/Foundy Plus

公 司
有 限

育 科技

控帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0800000041

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2 Installation and commissioning
2.2. Robot transportation precautions

Continued

Recommended transport support

Always use the recommended transport support when transporting a robot with tool.

IRB 7600/IRB 66XX

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0800000039

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2 Installation and commissioning
2.2. Robot transportation precautions

Continued

IRB 6620

公 司
有 限

育 科技

控帮教
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长

© Copyright 2004-2011 ABB. All rights reserved.

xx0800000038

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2 Installation and commissioning
2.3. Securing the robot

2.3. Securing the robot

General
This section describes how to secure the robot using the transport support.
DANGER!
Releasing the brakes is a hazardous action that may cause injury and damage property. It must
be done with great care and only when absolutely necessary.

Securing the robot

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0800000062

Action Note
1. Mount the transport support’s lower end Do not tighten the screw.
to the robot using the recommended See attachment point for the specific robot in
screw joint, (A) in figure. the section Transport position with a
transport support on page 57.
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2.3. Securing the robot

Continued

Action Note
2. Jog the robot into a position as near
above as possible to the recommended
transport position for the specific robot,
as specified in section Transport position CAUTION!
with a transport support on page 57. Do not try to jog the robot to the exact
position (max distance 1mm).
3. Use the brake release for axis 3 to reach See attachment point for the specific robot in
the final resting position on the transport the section Transport position with a
support, see the section Manually transport support on page 57
releasing the brakes on page 83.
4. Tighten all the attachment screws, (A)
and (B), in the figure with the brake
release for axis 3 still activated starting
with the lower attachment screw. CAUTION!
Do not attempt to tighten any attachment
screws without first releasing the brakes.
This can seriously damage the robot.
5. Use the brake release for axis 5 and 6 to
reach the final resting position for the
tool, see the section Manually releasing
the brakes on page 83
公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

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2.4.1. Pre-installation procedure

2.4 Unpacking

2.4.1. Pre-installation procedure

General
This instruction is primarily intended for use when unpacking and installing the robot for the
first time. It also contains information useful during later re-installation of the robot.

Checking the pre-requisites for installation

The checklist below details what must be observed before proceeding with the actual
installation of the robot:

Action Note
1. Make sure only qualified installation personnel
conforming to all national and local codes are allowed
to perform the installation.
2. Make sure the robot has not been damaged, by
visually inspecting the robot and control cabinet
exterior.

公 司Specified in Weight, robot on

3. Make sure the lifting device used is dimensioned to
handle the weight of the robot.

有 限 page 63.
4. If the robot is not to be installed directly, it must be Specified in Storage conditions,

科技
stored. robot on page 64.

育
5. Make sure the appointed operating environment of Specified in Operating

帮 教
the robot conforms to the specifications. conditions, robot on page 64.

控
6. Before taking the robot to its installation site, make Specified in Loads on

沙 工
sure the site conforms to the demands. foundation, robot on page 64,
Requirements, foundation on

长 page 64 and Protection classes,

robot on page 65 respectively.
7. Before moving the robot, please observe the risk of Described in Risk of tipping/
tipping! stability on page 70.
© Copyright 2004-2011 ABB. All rights reserved.

8. When these prerequisites have been met, the robot Specified in Lifting robot with
may be taken to its installation site. fork lift on page 71.

Weight, robot
The table below shows the weights of the different models (without DressPack):

Robot model Weight

IRB 7600 - 500/2.55 2400 kg
IRB 7600 - 500/2.3 2400 kg
IRB 7600 - 400/2.55 2400 kg
IRB 7600 - 340/2.8 2450 kg
IRB 7600 - 325/3.1 2440 kg
IRB 7600 - 150/3.5 2450 kg

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2.4.1. Pre-installation procedure

Continued

Loads on foundation, robot

The table below shows the different forces and torques working on the robot during different
kinds of operation.
NOTE! These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum simultaneously!

Force Endurance load (operation) Max. load (emergency stop)

Force xy ± 14000 N ± 31000 N
Force z 32000 ±10000 N 39000 ±16000 N
Torque xy ± 42000 Nm ± 72000 Nm
Torque z ± 11000 Nm ± 19500 Nm

Requirements, foundation
The table below shows the requirements for the foundation where the weight of the installed
robot is included:

Requirement Value Note

Min. levelness
Max. tilt
0.5 mm
5° 公 司
The limit for the maximum payload on the robot
限
is reduced if the robot is tilted from 0°.
有
科技
Contact ABB for further information about
acceptable payload.
Min. resonance 22 Hz 育
帮教
frequency

Storage conditions, robot 工 控

长 沙
The table below shows the allowed storage conditions for the robot:

Parameter Value
Min. ambient temperature -25° C
Max. ambient temperature +55° C © Copyright 2004-2011 ABB. All rights reserved.
Max. ambient temperature (less than 24 h) +70° C
Max. ambient humidity Max. 95% at constant temperature

Operating conditions, robot

The table below shows the allowed operating conditions for the robot:

Parameter Value
Min. ambient temperature +5° C
Max. ambient temperature +50° C
Max. ambient humidity Max. 95% at constant temperature

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2.4.1. Pre-installation procedure

Continued

Protection classes, robot

The table below shows the protection class of the robot:

Equipment Protection class

Robot, IRB 7600 IP 67

公 司
有 限

育 科技

控 帮教
沙 工
长
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2.4.2. Working range, IRB 7600 - 150/3.5

2.4.2. Working range, IRB 7600 - 150/3.5

Illustration
The illustration below shows the unrestricted working range of IRB 7600 - 150/3.5:

公 司
有 限

育 科技

控 帮教
xx0100000101
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

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2.4.3. Working range, IRB 7600 - 340/2.8

2.4.3. Working range, IRB 7600 - 340/2.8

Illustration
The illustration below shows the unrestricted working range of IRB 7600 - 340/2.8:

公 司
有 限

育 科技

控 帮教
xx0300000296

沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

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2.4.4. Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55

2.4.4. Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55

Illustration
The illustration below shows the unrestricted working range of IRB 7600 - 400/2.55 and IRB
7600 - 500/2.55:

公 司
有 限

育 科技

控 帮教
xx0100000100

沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

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2.4.5. Working range, IRB 7600 - 500/2.3

2.4.5. Working range, IRB 7600 - 500/2.3

Illustration
The illustration below shows the unrestricted working range of IRB 7600 - 500/2.3:

公 司
有 限

育 科技
帮教
en0100000099

工 控
长 沙
© Copyright 2004-2011 ABB. All rights reserved.

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2.4.6. Risk of tipping/stability

2.4.6. 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!

Shipping and transport position

This figure shows the robot in its shipping position, which also is a recommended transport
position.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0100000103

WARNING!
The robot is likely to be mechanically unstable if not secured to the foundation! © Copyright 2004-2011 ABB. All rights reserved.

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2.5.1. Lifting robot with fork lift

2.5 On-site Installation

2.5.1. Lifting robot with fork lift

General
The robot may be moved using a fork lift, provided that available special aids are used.
This section describes how to attach the fork lift equipment to the robot.

Different designs
There are two different versions of the fork lift that fit one design of the frame respectively.
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.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0200000386

1 Frame version without an oil plug, use the fork lift set: 3HAC0604-2
2 Frame version with an oil plug (C), use the fork lift set: 3HAC0604-1
A Attachment holes, fork lift 3HAC0604-2
B Attachment holes, fork lift 3HAC0604-1
C Oil plug

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2.5.1. Lifting robot with fork lift

Continued

Attachment points on robot

The attachment points for the fork lift equipment are shown in this figure.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0400000707

A Attachment points, spacer and horizontal attachment screws

B Attachment points, horizontal attachment screws
C Attachment points, vertical attachment screws © Copyright 2004-2011 ABB. All rights reserved.
D Attachment points, horizontal attachment screws

Required equipment
To determine which fork lift set to use, see the section Different designs on page 71.

Equipment, etc. Art. no. Note

Fork lift set, incl. all required 3HAC0604-2 See figure Fork lift set, 3HAC0604-2 on
hardware page 73.
Standard toolkit - Content is defined in section Standard
toolkit on page 427.

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2.5.1. Lifting robot with fork lift

Continued

Fork lift set, 3HAC0604-2

The fork lift set, 3HAC0604-2, is fitted to the robot as shown in the figure below.

公 司
xx0100000102

有 限
A
技
Vertical attachment screws (4 pcs / fork lift pocket)
Fork lift pockets (2 pcs)科
育
B
C Spacer (2 pcs)
帮 教
控
长 沙工
© Copyright 2004-2011 ABB. All rights reserved.

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2.5.1. Lifting robot with fork lift

Continued

Fork lift set, 3HAC0604-1

The fork lift set, 3HAC0604-1, is fitted to the robot as shown in the figure below.

公 司
有 限

育 科技

控 帮教
沙 工
长Fork lift pocket (2 pcs, different from each other)
xx0200000379

A
B Spacer (2 pcs)
C Horizontal attachment screws (4 pcs / fork lift pocket)

© Copyright 2004-2011 ABB. All rights reserved.

D Vertical attachment screws (2 pcs)
E Securing screw, used for IRB 6650S

Lifting robot with fork lift

This section details how to secure the fork lift set to the robot in order to lift and move the
robot using the fork lift ONLY!

Action Note
1. If a cooling fan for the axis 1 motor is used, it
must be removed in order to use the fork lift
device!

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2.5.1. Lifting robot with fork lift

Continued

Action Note
2. Position the robot as shown in the figure to the Release the brakes if required as
right! detailed in section Manually releasing
the brakes on page 83.

NOTE!
No load is permitted on the robot if the fork lift
set 3HAC0604-2 is used!

xx0200000079

When using fork lift set 3HAC0604-2,

no load is permitted on the robot!

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0200000387

3. Fit the two spacers to the robot and secure. Attachment points are shown in figure
© Copyright 2004-2011 ABB. All rights reserved.

Attachment points on robot on page 72.

4.

CAUTION!
The fork lift pocket weighs 60 kg!

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2.5.1. Lifting robot with fork lift

Continued

Action Note
5. Secure the longer fork lift pocket to the spacers Always use original screws (or replace-
with four of the horizontal attachment screws ments of equivalent quality: M16,
and washers. quality 12.9)!
Attachment points on robot are shown
in figure Attachment points on robot on
page 72.
NOTE!
The vertically and the horizontally attached
screws are identical, but tightened with
different torques!

xx0400001068

A. Horizontal attachment screws, 4

pcs, M16 x 60. Tightening
torque: 60 Nm.

6. Make sure the securing screw is removed from 公 司

B. Spacers, 2 pcs.

有
the fork lift pocket! It is only used for robot 限
科技
model IRB 6650S.

育
控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0700000655

• A: Securing screw must be

removed!

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2.5.1. Lifting robot with fork lift

Continued

Action Note
7. Secure fork lift pocket to robot with two vertical
attachment screws and washers.
(only valid for the fork lift set 3HAC 0604-1)

NOTE!
Vertically and the horizontally attached screws
are identical, but tightened with different
torques!

xx0300000464

A. Vertical attachment screws, 2

pcs, M16x60. Tightening torque:
270 Nm.
Always use original screws (or replace-
ments of equivalent quality: M16,
quality 12.9)!
Attachment points on robot are shown
in figure Attachment points on robot on

8. 公 司 page 72.

有 限
CAUTION!
育 科技
The fork lift pocket weighs 22 kg!

控 帮教
9. Secure the shorter fork lift pocket on the other 4 pcs, M16x60.
side of the robot with the four remaining Tightening torque: 60 Nm.

沙 工
horizontal attachment screws. Always use original screws (or replace-
ments of equivalent quality: M16,
长 quality 12.9)!
Attachment points on robot are shown
in figure Attachment points on robot on
page 72.
© Copyright 2004-2011 ABB. All rights reserved.

10. Double-check that pockets are properly

secured to the robot! Insert fork lift forks into
the pockets.

xx0200000380

Reposition harness, if any, before using

a fork lift!

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2.5.1. Lifting robot with fork lift

Continued

Action Note
11.

CAUTION!
The robot weighs 2550 kg! All lifting equipment
used must be sized accordingly!
12. Carefully lift the robot and move it to its instal-
lation site.
13.

WARNING!
Personnel must not, under any circumstances,
be present under the suspended load!
14. Refit the cooling fan to the motor, if any. Detailed in section Installation of
cooling fan for motors, axes 1-3 (option)
on page 104.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

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2.5.2. Lifting robot with lifting slings

2.5.2. Lifting robot with lifting slings

General
This section contains a general overview of how to lift the complete robot using special lifting
equipment. More detailed instructions are included with the equipment.
NOTE!
Move the robot to the recommended position shown in the figure and in the instruction!
Attempting to lift a robot in any other position may result in the robot tipping over, causing
severe damage or injury!

Illustration, lifting slings

The figure below shows how to lift the complete robot with lifting slings.

公 司
有限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0200000153

A Load hook
B Swivelling lifting eyes, 4 pcs
C Shortening hook
D Chain
E M12 lifting eye
F Lifting device´s eye
I Lifting slings, 4 pcs
L Hook

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2.5.2. Lifting robot with lifting slings

Continued

Required equipment

Equipment Art. no. Note

Lifting device, robot 3HAC15607-1 Includes:
• user instructions (3HAC15971-2).

Slings attached directly onto robot

This section details how to lift and move the robot using lifting slings when these are attached
directly onto the robot frame.

Action Note
1. Run the overhead crane to a position above
the robot.
2. Make sure the robot is positioned as shown in Release the brakes if required as
the figure on the right. If it is not, position it that detailed in section Manually releasing
way. the brakes on page 83.

公 司
有 限

育 科技

控 帮教
沙 工
长 xx0100000103

3. Fit lifting device, robot to the robot as Art. no. is specified in Required
described in enclosed instruction! equipment on page 80.

© Copyright 2004-2011 ABB. All rights reserved.

4.

CAUTION!
The robot weighs 2550 kg! All lifting
equipment used must be sized accordingly!
5.

WARNING!
Personnel must not, under any circum-
stances, be present under the suspended
load!
6. Raise overhead crane to lift the robot. Make sure all hooks and attachments
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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2.5.3. Lifting robot with roundslings

2.5.3. Lifting robot with roundslings

General
The figure below shows how to lift the complete robot with roundslings.
Notice the recommended robot position shown in the figure below!

Roundslings attached to the robot

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0200000315

A Chain sling with shortener, 4250 kg, 3 pcs (0.5 m, 0.5 m, 0.265 m)
B Roundsling, 1000 kg, 2 pcs
C Roundsling, 2000 kg, 3 pcs (4 m)

Required equipment

Equipment Note
Chain sling with shortener, 4250 kg, 3 pcs Lengths: 0.5 m (2 pcs), 0.265 m (1 pc).
Roundslings, 1000 kg, 2 pcs
Roundslings, 2000 kg, 3 pcs Lengths: 4 m (3 pcs).

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2.5.3. Lifting robot with roundslings

Continued

Slings attached directly on to robot

The section below details how to attach roundslings to the robot in order to lift the complete
robot.

Action Note
1. Recommended robot position is
described in section Risk of tipping/
stability on page 70.
CAUTION!
Attempting to lift the robot in any other position
than that recommended may result in the robot
tipping over and causing severe damage or
injury!
2.

CAUTION!
The robot weighs 2550 kg! All lifting equipment
used must be sized accordingly!
3. Run the overhead crane to a position above the
robot.
公 司
4. Attach the three chain slings with shorteners to Shown in the figure Roundslings
the overhead crane hook.
有 限
attached to the robot on page 81.

科技
Lengths are specified in Required
equipment on page 81.
育
帮教
5. Fit the three roundslings, 2000 kg to the robot. Shown in the figure Roundslings
Attach the roundslings to the chain slings attached to the robot on page 81.

工 控
hanging from the overhead crane. Lengths are specified in Required
equipment on page 81.

长 沙
6. Attach the two roundslings, 1000 kg to the Shown in the figure Roundslings
upper arm and the overhead crane hook! attached to the robot on page 81.
7. Raise the overhead crane to lift the robot. Make sure all hooks and attachments
maintain correct position while lifting
the robot!
Always move the robot at very low © Copyright 2004-2011 ABB. All rights reserved.
speeds, making sure it does not tip.

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2.5.4. Manually releasing the brakes

2.5.4. Manually releasing the brakes

General
This section details how to release the holding brakes of each axis motor.
The brakes may be released by:
• Internal brake release unit: using push buttons on the robot. This requires either the
controller to be connected or that power is supplied to the R1.MP connector, according
to the section Supplying power to connector R1.MP on page 85.
• External brake release unit: using push buttons on an external brake release unit. This
does NOT require the controller to be connected. The external unit is used when there
are no push buttons on the robot. Read about how to use the external brake release unit
in the section Manually releasing the brakes, external brake release unit on page 86

Location of brake release unit at base

The internal brake release unit is located either at the base or at the frame. The figure below
shows the unit located at the base.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0200000375

- Internal brake release unit with push buttons, located on the robot base
© Copyright 2004-2011 ABB. All rights reserved.

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2.5.4. Manually releasing the brakes

Continued

Location of brake release unit at frame

The internal brake release unit is located either at the base or at the frame. The figure below
shows the unit located at the frame.

xx0200000376

- Internal brake release unit with push buttons, located on the robot frame

公 司
Releasing the brakes
有 限
This procedure details how to release the holding brakes when the robot is equipped with an
internal brake release unit.
育 科技
帮教
Action Note

工 控
1. The internal brake release unit is equipped with six
buttons for controlling the axes brakes. The buttons are
Buttons are shown in figure
Location of brake release

长 沙
numbered according to the numbers of the axes. unit at base on page 83 or
Location of brake release
If the robot is not connected to the controller, power must
be supplied to the connector R1.MP according to the unit at frame on page 84.
section Supplying power to connector R1.MP on page 85.
2.
© Copyright 2004-2011 ABB. All rights reserved.

DANGER!
When releasing the holding brakes, the robot axes may
move very quickly and sometimes in unexpected ways!
Make sure no personnel is near or beneath the robot arm!
3. Release the holding brake on a particular robot axis by
pressing the corresponding button on the internal brake
release unit.
The brake will function again as soon as the button is
released.

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2.5.4. Manually releasing the brakes

Continued

Supplying power to connector R1.MP

If the robot is not connected to the controller, power must be supplied to connector R1.MP on
the robot in order to enable the brake release buttons.

Action Note
1.

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.

公 司
有 限

育 科技
帮教
xx0600002937

工 控
长 沙
© Copyright 2004-2011 ABB. All rights reserved.

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2.5.5. Manually releasing the brakes, external brake release unit

2.5.5. Manually releasing the brakes, external brake release unit

General
The section below details how to release the holding brakes of each axis motor using push
buttons on an external brake release unit. This does not require the controller to be connected.

When to use the external brake release unit

The external brake release unit must only be used when the robot does not have an internal
brake release unit (when there are no push buttons on the robot).

Internal brake release unit

How to use the internal brake release unit, if available, is detailed in section Manually
releasing the brakes on page 83.

Required equipment

Equipment Art. no.

External brake release unit 3HAC12987-1

Connections, robot 公 司
有 限
The illustration below shows where to connect the external brake release unit in order to

科技
release the holding brakes of the robot.

育
控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0100000104

A Connector R1.BU
B Rear connector plate
C Rear cover plate
D External brake release unit
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2.5.5. Manually releasing the brakes, external brake release unit

Continued

Connectors, external brake release unit

The illustration below shows the connectors on the robot and on the external brake release
unit.

公 司
有 限
xx0200000081
育 科技
帮教
A Rear connector plate
B
C 工 控
Connector R1.MP
Connector R1.BU
D
长 沙 External brake release unit
E Connect to R1.BU

Releasing the brakes

© Copyright 2004-2011 ABB. All rights reserved.

This section describes how to release the holding brakes when the robot is equipped with an
external brake release unit.

Action Note
1. Remove the rear cover plate from the base of the Shown in the figure Connec-
robot by unscrewing its attachment screws and plain tions, robot on page 86.
washers.
2. Locate the free connector, connected to the rear of Shown in the figure Connectors,
connector R1.MP, behind the rear connector plate. external brake release unit on
Make sure it is designated R1.BU. page 87.
3. Connect the external brake release unit to the Art. no. is specified in section
connector R1.BU. Required equipment on page
86.

Continues on next page

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2 Installation and commissioning
2.5.5. Manually releasing the brakes, external brake release unit

Continued

Action Note
4.

DANGER!
When releasing the holding brakes, the robot axes
may move very quickly and sometimes in unexpected
ways!
Make sure no personnel is near or beneath the robot
arm!
5. Release the holding brake of each robot axis by
pressing the respective button on the external brake
release unit.
6. Disconnect the external brake release unit.
7. Refit the rear cover plate with its attachment screws.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

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2.5.6. Lifting the base plate

2.5.6. Lifting the base plate

Required equipment

Equipment Art. no. Note

Lifting eye, M16 3HAC14457-4 3 pcs
Lifting slings 3 pcs
Length: approx. 2 m

Hole configuration

公 司
有 限

育 科技

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沙 工
长
xx0200000096

A Attachment holes for lifting eyes (x3)

© Copyright 2004-2011 ABB. All rights reserved.

Lifting, base plate

Action Note
1.

CAUTION!
The base plate weighs 353 kg! All lifting equipment
used must be sized accordingly!
2. Fit lifting eyes in specified holes. Shown in figure Hole configu-
ration on page 89.
3. Fit lifting slings to the eyes and to the lifting device.

3HAC022033-001 Revision: K 89
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2.5.7. Securing the base plate

2.5.7. Securing the base plate

Base plate, dimensions

公 司
有 限

育 科技

控帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx1000001053
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2.5.7. Securing the base plate

Continued

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0400000715

A Four holes for alternative clamping, 4x Ø18

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2.5.7. Securing the base plate

Continued

Base plate, grooves and holes

The illustration below shows the orienting grooves and guide sleeve holes in the base plate.

公 司
有 限

育 科技
教
xx0300000045

A 帮 (2 pcs)
Guide sleeve holes
控
B
C 沙 工bolts, attachment holes (4 pcs)
Orienting grooves (3 pcs)
Levelling
长
Required equipment

Equipment Art. no. Note

Base plate 3HAC 12937-7 Includes © Copyright 2004-2011 ABB. All rights reserved.
• guide sleeves, 3HAC12937-3
• levelling screws, 9ADA120-79
• attachment screws and
washers for securing the robot
to the base plate.
A drawing of the base plate itself may
be ordered from ABB Robotics!
Standard toolkit - Content is defined in section Standard
toolkit on page 427.
Other tools and procedures may These procedures include references
be required. See references to to the tools required.
these procedures in the step-by-
step instructions below.

Continues on next page

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2.5.7. Securing the base plate

Continued

Recommendations, quality
The table specifies any recommendations made by ABB:
Variable Recommendation
Recommended foundation quality 1 Steel fibre reinforced concrete foundation, 30 kg/m3,
class K30, t=250 mm
Recommended foundation quality 2 Sturdy concrete foundation, double reinforced by ø10
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.

Action Note
1. Make sure the foundation is level.
2.

公 司
CAUTION!
有
The base plate weighs 353 kg! All lifting
限
科技
equipment used must be sized accordingly!

育
3. Orient base plate in relation to robot work Shown in figure Base plate, grooves

plate. 帮 教
location using the three grooves in the base and holes on page 92.

控
沙工
4. Lift the base plate to its mounting position. Detailed in section Lifting the base plate
on page 89.
长
5. Use the base plate as a template and drill 16 If possible, observe the recommenda-
attachment holes as required by the selected tions specified in section Recommenda-
bolt dimension. tions, quality on page 93. ABB does not
assume any responsibility for other
foundation qualities, due to great
© Copyright 2004-2011 ABB. All rights reserved.

variations in the foundation properties.

6. Fit the base plate and use the levelling bolts to Shown in figure Base plate, grooves
level the base plate. and holes on page 92.
7. If required, fit strips of sheet metal underneath
the base plate to fill any gaps.
8. Secure the base plate to the foundation with
screws and sleeves.
9. Recheck the four robot contact surfaces on Maximum allowed deviation: 0.1 mm
the base plate to make sure they are level and
flat.
If they are not, pieces of sheet metal or similar
may be used to bring the base plate to a level
position.

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2.5.8. Orienting and securing the robot

2.5.8. Orienting and securing the robot

General
This section details how to orient and secure the robot to the base plate in order to run the
robot safely.

Illustration, robot fitted to base plate

This illustration shows the robot base fitted to the base plate.

公 司
有 限

育 科技

控 帮教
xx0100000107
沙 工
A 长Robot attachment bolts and washers, 12 pcs (M24 x 140)
B Orienting grooves in the robot base and in the base plate
C Levelling screws

© Copyright 2004-2011 ABB. All rights reserved.

D Base plate attachment screws

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.
Suitable screws, lightly lubricated: M24 x 140
Quality: Quality 8.8
Suitable washer: Thickness: 4 mm
Outer diameter: 44 mm
Inner diameter: 25 mm
Tightening torque: 725 Nm

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2.5.8. Orienting and securing the robot

Continued

Securing the robot

Use this procedure to secure robot to base plate after fitting plate to the foundation.

Action Note
1. Lift the robot. Detailed in section Lifting robot with
lifting slings on page 79.
Detailed in section Lifting robot with
roundslings.
2. Move robot to the vicinity of its installation
location.
3. Fit two guide sleeves to the guide sleeve holes Shown in figure Base plate, grooves
in the base plate. and holes on page 92.

NOTE!
One of the guide sleeve holes is
elongated!
4. Guide the robot gently using two M24 screws Make sure the robot base is correctly
while lowering it into its mounting position. fitted onto the guide sleeves!
5. Fit the bolts and washers in the base
公 司
Specified in Attachment screws on
attachment holes.

有 限 page 94.
Shown in figure Illustration, robot fitted

科 技 to base plate on page 94.

育
帮 教
工 控 NOTE!
Lightly lubricate screws before

长 沙 assembly!
6. Tighten bolts in a criss-cross pattern to ensure
that the base is not distorted.
© Copyright 2004-2011 ABB. All rights reserved.

Continues on next page

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2.5.8. Orienting and securing the robot

Continued

Hole configuration, base

This illustration shows the hole configuration used when securing the robot.

公 司
xx0300000046
有 限
Cross section, guide sleeve hole
育 科技
帮教
This illustration shows the cross section of the guide sleeve holes.

工 控
长 沙

© Copyright 2004-2011 ABB. All rights reserved.

xx0100000109

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2.5.9. Fitting equipment on robot

2.5.9. 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.

Illustration, fitting of extra equipment on lower arm

The illustration below shows the mounting holes available for fitting extra equipment on the
lower arm.
Make sure not to damage the robot cabling on the inside of the lower arm when fitting extra
equipment. Always use appropriate attachment screws!

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0700000722

Robot variant A
IRB 7600 - 500/2.55 2442 mm
IRB 7600 - 500/2.3 2192 mm
IRB 7600 - 400/2.55 2442 mm
IRB 7600 - 340/2.8 2692 mm
IRB 7600 - 325/3.1 2942 mm
IRB 7600 - 130/3.5 3398 mm

Continues on next page

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2.5.9. Fitting equipment on robot

Continued

公 司
有 限

育 科技
帮教
xx0100000120

控
Illustration, fitting of extra equipment on upper arm
工
长沙
The illustration below shows the mounting holes available for fitting extra equipment on the
upper arm.

© Copyright 2004-2011 ABB. All rights reserved.

xx0100000116

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2.5.9. Fitting equipment on robot

Continued

xx0300000299

Robot variant A
IRB 7600 - 500/2.55 1056 mm
IRB 7600 - 500/2.3 806 mm
IRB 7600 - 400/2.55 1056 mm
IRB 7600 - 340/2.8 1306 mm
IRB 7600 - 325/3.1 1556 mm
IRB 7600 - 150/3.5 2012 mm

公 司
Illustration, fitting of extra equipment on frame
有 限
科技
The illustration below shows the mounting holes available for fitting extra equipment on the
frame.
育
控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0100000117

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2.5.9. Fitting equipment on robot

Continued

公 司
有 限

育 科技
帮教
xx0100000118

Illustration, fitting on turning disk

工 控
The illustration below shows the mounting holes available for fitting equipment on the
turning disk.
长 沙

© Copyright 2004-2011 ABB. All rights reserved.

xx0100000119

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2.5.9. Fitting equipment on robot

Continued

Fastener quality
When fitting tools on the turning disk (see the figures above), only use screws with quality
12.9. When fitting other equipment to mounting holes standard screws with quality 8.8 may
be used.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 101

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2.5.10. Installation of base spacers (option)

2.5.10. Installation of base spacers (option)

Illustration, installation of base spacers

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0500001570

A Base spacer (4 pcs)

B Guide sleeve (4 pcs)
C Attachment screws and washers (12 pcs)

Required equipment

Equipment Art. no. Note

Base spacers 3HAC 021899-002 Includes mounting set with
attachment screws and
mounting instruction.
Base plate 3HAC 12937-7
Standard toolkit - Content is defined in section
Standard toolkit on page 427.

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2.5.10. Installation of base spacers (option)

Continued

Equipment Art. no. Note

Other tools and procedures These procedures include
may be required. See references to the tools
references to these required.
procedures in the step-by-
step instructions below.

Installation, base spacers

The procedure below details how to fit the base spacers between the robot and the base plate.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not
the air pressure to the gearboxes, motors and
SMB.
2. Unfasten the robot from the foundation, if
公 司 Detailed in section Lifting robot with
fastened, and lift it away with lifting slings.

有
Make sure the robot is positioned in the most 限 lifting slings on page 79.

科技
stable position; the transport position!

育
3. Install the base plate to the foundation, if not Detailed in section Securing the base
used previously.

帮 教 plate on page 90.

4. Fit the four base spacers and guiding sleeves to Shown in the figure Illustration, instal-
the base plate.
工 控 lation of base spacers on page 102.

长 沙
5. Lift the robot with lifting slings and move it to the
prepared base plate.
6. Guide the robot with the guiding sleeves as
lowering it towards the base plate and spacers.
7. Fasten the robot base to the spacers with M24 x 240, tightening torque: 775 Nm.
© Copyright 2004-2011 ABB. All rights reserved.

enclosed attachment screws and washers.

8.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 47.

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2.5.11. Installation of cooling fan for motors, axes 1-3 (option)

2.5.11. Installation of cooling fan for motors, axes 1-3 (option)

General
A cooling fan can be installed on the motors of axes 1, 2 and 3.
Cooling fans for axes 1 and 2 can not be combined!
The cabling for the fans is available in different design:
• complete cabling, including connections for both cooling fans and position switches,
at axes 1, 2 and 3. Installation of this complete cabling is detailed in section
Installation of cable harness for position switches and fans on page 129.
• separate cabling for axis 1 or 2, including only connections for the cooling fans on
axes 1 or 2. Installation of this cabling is detailed in section Installation, separate fan
cabling axis 1 or 2 on page 109.
If both cooling fans and position switches are installed on the robot, the complete cabling
must be used! It can not be combined with the separate cabling.

Location of cooling fans

The fans are installed on the motors, axes 1-3, as shown in the figure below.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0500002157

A Cooling fan, axis 1

B Cooling fan, axis 2
C Cooling fan, axis 3
D Rear cover plate

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2.5.11. Installation of cooling fan for motors, axes 1-3 (option)

Continued

xx0700000671

A Cooling fan, axis 2

B Cooling fan, axis 1
C Rear cover plate
公 司
有 限
Cooling fan
技
育科
The details of the cooling fan are shown in the figure below.

帮 教
工 控
长沙
© Copyright 2004-2011 ABB. All rights reserved.

xx0500002158

A Fanbox
B Attachment screws, fanbox plates (9 pcs)
C Groove in the connector
D Tightening screws, fanbox (3 pcs)
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2.5.11. Installation of cooling fan for motors, axes 1-3 (option)

Continued

司
xx0900000137

A Fanbox
限 公
B Groove in the connector
有
科技
C Back plate
D
育
Part of the fanbox that can be removed, if needed.

Required equipment
控 帮教
Equipment
沙 工 Art. no. Note
Cooling长
fan 3HAC15374-1
Cabling, position switches 3HAC15390-1 Choose this cabling if equipping the robot
and cooling fans, axes 1, 2 withboth position switches and cooling
and 3 fansor with cooling fans on axis 3.
Cabling, cooling fans, axes 3HAC023599-001 Choose this cabling if only equipping the © Copyright 2004-2011 ABB. All rights reserved.
1 or 2. robot with cooling fans on axis 1 or 2 (not
on axis 3and not with position switches).
Plate for customer 3HAC025778-001 An additional connection plate must be
connections fitted to the robot base, if not already
installed. The plate is shown in the figure
Plate for customer connections, at base
on page 107.
Additional cabling to and - Specified in section Position switch and
inside the controller fan cables, robot base to controller
(option) on page 134.
Material set fan axes 1 and 3HAC023999-001 The set includes:
2 • fan axes 1 & 2 cable harness
• plate, customer
• attachment screws and nuts.
Cable harness inside 3HAC025488-001
controller

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2.5.11. Installation of cooling fan for motors, axes 1-3 (option)

Continued

Equipment Art. no. Note

Locking liquid - Loctite 243. Used for the three tightening
screws.
Standard toolkit - Content is defined in section Standard
toolkit on page 427.
Circuit diagram - See chapter Circuit diagram.
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.

Plate for customer connections, at base

公 司
有限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0500002301

A Plate for customer connections

B Attachment screws, 3 pcs, M6x16 quality 8.8-A2F

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2.5.11. Installation of cooling fan for motors, axes 1-3 (option)

Continued

Installation, fan
The procedure below details how to install the cooling fan on any of the motors, axes 1-3 .

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and pneumatic pressure
supplies to the robot!
Turn off all electric power and hydraulic but not the air
pressure to the gearboxes, motors and SMB.
2. Prepare the fanbox for installation: Shown in the figure
• disassemble the two parts of the box by removing the Cooling fan on page 105.
nine attachment screws
• loosen the three tightening screws, to avoid damaging
the surfaces of the motor when fitting the fanbox
• turn the connector to the correct position; axis 1:
groove pointing inwards, as shown in the figure
Cooling fan on page 105. Positions for axis 2 and 3 are
shown in the figureLocation of cooling fans on page
104.
公 司
有限
3. Temporarily lift the motor cabling out of the way of the current
motor to make room for the fanbox.
Fit the parts of the fanbox to the motor 技
4.
the nine attachment screws.
育 科 and reassemble with

Lift the box (axis 1) so that 教

5.

控
and secure the box with 帮the three tightening screws, using
it does not rest directly on the robot

工
locking liquid. Tighten them properly so that the box is firmly

长the沙cabling and make adjustments in RobotWare, as

attached to the motor.
6. Install
described in the following procedures.

Separate cabling for axis 1 or 2

The figure below shows the cabling used only for the fan on axis 1 or 2. © Copyright 2004-2011 ABB. All rights reserved.

xx0500002173

A Cable bracket
B Connector R1.SW2/3, connected to the robot base
C Connector R3.FAN2, connected to the fan of axis 1or 2

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2.5.11. Installation of cooling fan for motors, axes 1-3 (option)

Continued

Installation, separate fan cabling axis 1 or 2

The procedure below details how to install the separate cabling for the cooling fan of axis 1
or 2.

Action Note
1. Move the robot to its calibration position. Shown in section Calibration scale
and correct axis position on page
406.
2.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.
3. Remove the rear cover plate from the robot base. Shown in the figure Location of
cooling fans on page 104.
4. Remove the cable bracket (A) Shown in the figure Separate
cabling for axis 1 or 2 on page 108
5. Fit the plate for customer connections, if not
公 司 Shown in the figure Plate for

base.
有 限
already fitted, to the connection plate of the robot customer connections, at base on
page 107.

科技
Art. no. is specified in Required
equipment on page 106.
育
帮教
6. Run the cabling up through the base and frame,
beneath the balancing device.

工 控
长 沙
© Copyright 2004-2011 ABB. All rights reserved.

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2.5.11. Installation of cooling fan for motors, axes 1-3 (option)

Continued

Action Note
7. Secure the cable bracket to the bracket of the
robot cabling inside the frame.
Run the cable underneath the robot cabling and
out through the side of the frame, at motor, axis 1
. The correct cable run is shown in the figure to the
right!

NOTE!
There is a risk of the balancing device damaging
the cable if it is not protected by the robot cabling!

公 司
有 限 xx0500002174

科技
A. Cable bracket. Also shown
in the figure Separate
育 cabling for axis 1 or 2 on

帮教
page 108.

1or 2.
工 控
8. Connect the connector R3.FAN2 to the fan of axis

长 沙 NOTE!
Fans on both axis 1 and 2 can not
be used at the same time!
9. Connect the connector R1.SW2/3 to the base of

© Copyright 2004-2011 ABB. All rights reserved.

the robot. Make sure that the cabling, run through
the frame and base, is not twisted and runs freely
from the robot cabling.
10. Refit the rear cover plate to the robot base.
11. Install additional cabling to and inside the Cabling is specified in section
controller. Position switch and fan cables,
Also make adjustments in RobotWare, as robot base to controller (option) on
described in the following procedure. page 134.

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2.5.11. Installation of cooling fan for motors, axes 1-3 (option)

Continued

Adjustments in RobotWare

Action Note
1. Modify the settings in RobotWare to RobotWare 4.0: modify the settings in
include the cooling fans. RobInstall. RobotWare 4.063 and older must
be updated with a newer release.
RobotWare 5.0: change the settings in the
Modifying options dialogue, by using the
Modify Controller System Wizard in the
System Builder of RobotStudio. Read more
about modifying the system in Operating
manual - RobotStudio.

公 司
有限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 111

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2.5.12. Installation of Foundry Plus Cable guard (option no. 908-1)

2.5.12. Installation of Foundry Plus Cable guard (option no. 908-1)

Introduction
How to install the Foundry Plus Cable guard is described in the instruction delivered with the
cable guard.
Separate instructions for IRB 140, 4600, 1600, 6620, 6640, 6650S, 6660 and 7600 are
available in English, German, French, Spanish and Italian and can be found on the DVD
delivered with the Cable guard, article number 3HAC035933-001.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

112 3HAC022033-001 Revision: K

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2.5.13. Loads

2.5.13. Loads

General
Any loads mounted on the robot must be defined correctly and carefully (with regard to the
position of center of gravity and mass moments of inertia) in order to avoid jolting
movements and overloading motors, gears and structure.
CAUTION!
Incorrectly defined loads may result in operational stops or major damage to the robot.

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)Operating manual IRC5 with FlexPendant.

Stop time and braking distances

Robot motor brake performance depends on any loads attached. For information about brake
performance, see Product Specification for the robot.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

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2 Installation and commissioning
2.6.1. Introduction

2.6 Restricting the working range

2.6.1. Introduction

General
When installing the robot, make sure that it can move freely within its entire working space.
If there is a risk that it may collide with other objects, its working space should be limited.
The working range of the following axes may be restricted:
• 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. Note that this option
also requires installation of a position switch on axis 1.

公 司
This section describes how to install hardware that restricts the working range.
Note! Adjustments must also be made in the robot 限
configuration software (system
有included in the installation procedures.
技
parameters). References to relevant manuals are

育科
帮 教
工 控
长沙

© Copyright 2004-2011 ABB. All rights reserved.

114 3HAC022033-001 Revision: K

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2 Installation and commissioning
2.6.2. Mechanically restricting the working range of axis 1

2.6.2. Mechanically restricting the working range of axis 1

General
The working range of axis 1 is limited by fixed mechanical stops and adjustment of the
system parameter configuration. The working range can be reduced by adding additional
mechanical stops giving 7.5 or 15 graduation, between 22.5° and 135° in both directions.

Mechanical stops, axis 1

The illustration shows the mounting position of the stop pin and one of the additional
mechanical stops available for axis 1.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0300000049
© Copyright 2004-2011 ABB. All rights reserved.

A Additional mechanical stop

B Stop pin

Required equipment

Equipment, etc. Art. no. Note

Mechanical stop for axis 1, 7.5° 3HAC11076-1 Includes attachment screws
and an assembly drawing.
Mechanical stop for axis 1, 15° 3HAC11076-2 Includes attachment screws
and an assembly drawing.
Standard toolkit - Content is defined in section
Standard toolkit on page 427.
User’s guide - S4Cplus (RobotWare - Art. no. is specified in section
4.0) References on page 10.
Technical reference manual - System
parameters

Continues on next page

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2 Installation and commissioning
2.6.2. Mechanically restricting the working range of axis 1

Continued

Installation, mechanical stops axis 1

Use this procedure to fit mechanical stops to axis 1 of the robot. An assembly drawing is also
enclosed with the product.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but
not the air pressure to the gearboxes, motors
and SMB.
2. Fit the additional mechanical stop to the Tightening torque: 120 Nm.
frame according to the figure Mechanical
stops, axis 1 on page 115.
3. Adjust the software working range limitations How to define the range of movement in
(system parameter configuration) to RobotWare 4.0 is detailed in User’s
correspond to the mechanical limitations. guide - S4Cplus, chapter System

公 司
Parameters - topic Manipulator.
The system parameters that must be

有 限
changed (Upper joint bound and Lower
joint bound) are described in Technical

科技
reference manual - System parameters.
4.
育
WARNING! 控 帮教
沙 工
If the mechanical stop pin is deformed after a
长
hard collision, it must be replaced!
Deformed movable stops and/or additional
stops as well as deformed attachment
screws must also be replaced after a hard
collision.
© Copyright 2004-2011 ABB. All rights reserved.

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2 Installation and commissioning
2.6.3. Mechanically restricting the working range of axis 2

2.6.3. Mechanically restricting the working range of axis 2

General
The working range of axis 2 is limited by fixed mechanical stops and can be reduced by
adding up to six additional mechanical stops with 15 graduation in respective direction.

Mechanical stops, axis 2

The illustration below shows the mounting position of the mechanical stops on axis 2.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0300000047

A Additional mechanical stops

© Copyright 2004-2011 ABB. All rights reserved.

B Fixed mechanical stop

Required equipment

Equipment, etc. Art. no. Note

Mechanical stop set, axis 2 3HAC11077-1 Includes six stops, 3HAC11407-1, each
one restricting the working range by
15°.
Includes attachment screws.
Standard toolkit - Content is defined in section Standard
toolkit on page 427.
User’s guide - S4Cplus - Art. no. is specified in section
(RobotWare 4.0) References on page 10.
Technical reference manual
- System parameters

Continues on next page

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2 Installation and commissioning
2.6.3. Mechanically restricting the working range of axis 2

Continued

Installation, mechanical stops axis 2

The procedure below details how to fit the mechanical stops for axis 2 to the robot. An
assembly drawing is also enclosed with the product.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but
not the air pressure to the gearboxes, motors
and SMB.
2. Fit and tighten the additional stops in a row, Tightening torque: 115 Nm.
starting from the fixed stop. Shown in the figure Mechanical stops,
axis 2 on page 117.
3. The software working range limitations must How to define the range of movement in
be redefined to correspond to the changes in RobotWare 4.0 is detailed in User’s guide
the mechanical limitations of the working - S4Cplus, chapter System Parameters -
range.
司
topic Manipulator.
公
The system parameters that must be

有 限
changed (Upper joint bound and Lower

科技
joint bound) are described in Technical
reference manual - System parameters.
4. 育
控 帮教
WARNING!
沙 工
If the mechanical stop pin is deformed after a
长
hard collision, it must be replaced!
Deformed movable stops and/or additional
stops as well as deformed attachment
screws must also be replaced after a hard
collision.
© Copyright 2004-2011 ABB. All rights reserved.

118 3HAC022033-001 Revision: K

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2 Installation and commissioning
2.6.4. Mechanically restricting the working range of axis 3

2.6.4. Mechanically restricting the working range of axis 3

General
The working range of axis 3 is limited by fixed mechanical stops and can be reduced by
adding additional mechanical stops with 20 graduation in respective direction.

Mechanical stops, axis 3

The illustration below shows the mounting position of the mechanical stops on axis 3.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0300000048

The figure shows IRB 7600 but the principle is the same.
A Additional mechanical stops
© Copyright 2004-2011 ABB. All rights reserved.

B Fixed mechanical stop

C Attachment screw M16x60 quality 12.9

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2 Installation and commissioning
2.6.4. Mechanically restricting the working range of axis 3

Continued

公 司
有 限
科技
xx0600002973

A
育
Mechanical stop pin, axis 3

帮教
B Attachment screw and washer

Required equipment 工 控
长
Equipment, etc.
沙 Art. no. Note
Mechanical stop set, axis 3 3HAC13128-2 Includes six stops, one with 80°
restriction, 3HAC12708-4 (use when
limitation angle >=80), and five with
© Copyright 2004-2011 ABB. All rights reserved.
20°, 3HAC 12708-2.
Includes attachment screws.
Standard toolkit - Content is defined in section Standard
toolkit on page 427.
User’s guide - S4Cplus - Art. no. is specified in section
(RobotWare 4.0) References on page 10.
Technical reference manual -
System parameters

Continues on next page

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2 Installation and commissioning
2.6.4. Mechanically restricting the working range of axis 3

Continued

Installation, mechanical stops axis 3

The procedure below details how to fit the mechanical stops for axis 3 to the robot. An
assembly drawing is also enclosed with the product.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but
not the air pressure to the gearboxes,
motors and SMB.
2. Fit and tighten the additional stops in a row, Tightening torque: 115 Nm.
starting from the fixed stop. Shown in the figure Mechanical stops,
axis 3 on page 119
3. How to define the range of movement in
RobotWare 4.0 is detailed in User’s guide
- S4Cplus, chapter System Parameters -
NOTE!
The software working range limitations 公 司
topic Manipulator.
The system parameters that must be
限
(system parameters) must be redefined to changed (Upper joint bound and Lower
有
科技
correspond to the changes in the joint bound) are described in Technical
mechanical limitations of the working range. reference manual - System parameters.
4. 育
控 帮教
WARNING!
沙
If the
工
mechanical stop pin is deformed after
长
a hard collision, it must be replaced!
Deformed movable stops and/or additional
stops as well as deformed attachment
screws must also be replaced after a hard
© Copyright 2004-2011 ABB. All rights reserved.

collision.

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2 Installation and commissioning
2.6.5. Installation of position switches (option)

2.6.5. Installation of position switches (option)

General
Position switches can be installed on axes 1-3. The position switches include cams as shown
in the figures below. The system parameter configuration must also be updated.
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

Description Art. no. Note

Position switch, axis 1 3HAC15715-1 Includes position swtich and plate for
customer connections.
Position switch, axis 2 3HAC15715-2 Includes only the position switch.
Position switch, axis 3 3HAC15715-3 Includes only the position switch.
Cabling, position switches and 3HAC15390-1 Cabling to be installed on the robot.
cooling fans, axes 1, 2 and 3
公 司
Plate for customer connections 3HAC025778-001
有 限 An additional connection plate must
be fitted to the robot base, if not

科 技 already installed. The plate is shown

in the figure Plate for customer con-
育 nections, at base on page 128.

帮 教-
Additional cabling to and inside Specified in section Robot cabling
the controller
工
Connector kit R1.SW1
控 3HAC17252-1
and connection points on page 133.

长 沙
Connector kit R1.SW2/3 3HAC17253-1

© Copyright 2004-2011 ABB. All rights reserved.

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2 Installation and commissioning
2.6.5. Installation of position switches (option)

Continued

Axis 1
The illustration below shows the position switch for axis 1. There is no extra cabling installed
on the robot, as for axes 2 and 3. Instead the switch is connected directly to the connector in
the base, R1.SW1.

公 司
有 限
科技
xx0100000158

A
育
Position switch, axis 1

帮教
B Cam
C
D 工 控Set screw, cam (cam stop)
Protection sheet
E
长 沙 Rail
F Rail attachment
© Copyright 2004-2011 ABB. All rights reserved.

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2 Installation and commissioning
2.6.5. Installation of position switches (option)

Continued

Axis 2
The illustration below shows the position switch for axis 2. In addition to the shown
components, cabling must also be installed from the switch to the robot base.

公 司
限
xx0100000159

A Position switch, axis 2 有

B
C
Cam
Set screw, cam (cam stop) 育 科技
E
F
Rail
控 帮教
Rail Attachment

沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

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2 Installation and commissioning
2.6.5. Installation of position switches (option)

Continued

Axis 3
The illustration below shows the position switch for axis 3. In addition to the shown
components, cabling must also be installed from the switch to the robot base.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0100000160
© Copyright 2004-2011 ABB. All rights reserved.

A Position switch, axis 3

B Cam
C Set screw, cam (cam stop)
E Rail
F Rail attachment

Specifications
Maximum voltage/current for the position switches:
Parameter Value
Voltage Max. 50 VDC
Current Max. 1 A

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2 Installation and commissioning
2.6.5. Installation of position switches (option)

Continued

Connections
The position switches are connected to different points on the robot system:
• XT8, screw terminal in the controller cabinet when position switch cables are used.
• R1.SW1 at the robot base. Customer connection kit is recommended, art. no. is
specified in Required equipment on page 122!
• R1.SW2/3 at the robot base. Customer connection kit is recommended, art. no. is
specified in Required equipment on page 122!
Further information about the cables and connection points, see section Robot cabling and
connection points on page 133.

Fitting and adjusting cams and stops

The instruction below details how to fit and adjust the parts of the position switches:

Action Note
1. Cut the cam to a suitable length. Use a sharp knife and rubber
hammer or similar.
2. Cut the edge of the cam edge to max 30°! Shown in Illustration, cutting

司
the cam on page 127.

限 公 If the angle is larger, this may

damage the position switch!
有
3. Cut the part of the cam running in the profile to 90°!

below!
育 科技
Also see Illustration, cutting the cam on page 127

帮教
4. Make sure the ends of the profile are chamfered to
enable the cam to run through the profile.

工 控
5. Fit the cam with the M5 screw and nut. Tighten the M5 Shown in Illustration, adjust

长 沙
screw to secure the cam.
6. Install the cabling for axes 2 and/or 3.
and secure cams on page 127.
Detailed in section Installation
of cable harness for position
switches and fans on page
129.

© Copyright 2004-2011 ABB. All rights reserved.

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2 Installation and commissioning
2.6.5. Installation of position switches (option)

Continued

Illustration, adjust and secure cams

The illustration below show how to adjust and secure the position switch cams and profiles.

xx0100000113

A Cam stop, M5 nut and M5 x 6 set screw

B Adjustable cam
C Profile
公 司
Illustration, cutting the cam
有 限
科技
The illustration below show how to cut the position switch cam.

育
控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0100000114

A Remove the gray section

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2.6.5. Installation of position switches (option)

Continued

Plate for customer connections, at base

公 司
有 限
xx0500002301

育 科技
B
A
教
Plate for customer connections
帮 3 pcs, M6x16
Attachment screws,
控
工and fans, axes 1-3
沙
Cable harness for position switches
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0500002305

A Cable bracket, frame

B Cable bracket, lower arm
C Cable bracket, upper arm
R1.SW2/3 Connected to the robot base
R3.FAN2 Connected to the fan of axis 1 or 2

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2.6.5. Installation of position switches (option)

Continued

R3.FAN3 Connected to the fan of axis 3

R2.SW2 Connected to the position switch of axis 2
R2.SW3 Connected to the position switch of axis 3

Installation of cable harness for position switches and fans

The procedure below details how to fit the complete cable harness for position switches and
cooling fans to the robot.

Action Note
1. Move the robot to its calibration position.
2.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but
not the air pressure to the gearboxes,
motors and SMB.
3. Remove the rear cover (A) from the robot
base and replace the protection (B) with a 公 司
plate for customer connections (if not
already mounted). 有 限

育 科技

控 帮教
沙 工
长 xx0500002306

Art. no. for the plate is specified in

Required equipment on page 122.
4. Run the cabling through the base and frame
© Copyright 2004-2011 ABB. All rights reserved.

of the robot, up beneath the balancing

device.

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2 Installation and commissioning
2.6.5. Installation of position switches (option)

Continued

Action Note
5. Run and secure the cabling inside the frame
as detailed below and as shown in the
figure to the right:
• Secure the cable bracket (A) to the
bracket of the robot cabling.
• Run the cable for the fan of axis 1 or
2 under the robot cabling and
through the side of the frame at
motor axis 1.
• Secure the cabling going up to the
axis 3 fan and position switch with
existing velcro strap (B), attached
around the robot cabling.
• Connect the connector R2.SW2 to
the position switch of axis 2.

NOTE!
There is a risk of the balancing device
damaging the fan cable if it is not protected
by correct routing underneath the robot
公 司
cabling!
有 限
xx0500002309

科 技 A. Cable bracket, frame. Also shown

in the figure Cable harness for
育 position switches and fans, axes 1-

帮 教 3 on page 128.

工 控 B. Velcro strap
C. Connector R2.SW2

长 沙
6. Connect the connector R3.FAN2 to the fan
of either axis 1 or axis 2.
If no fan is used, strap the cabling together
with the motor cabling so that the connector
stays close to the frame, as shown in the
© Copyright 2004-2011 ABB. All rights reserved.
figure to the right.

xx0500002312

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2.6.5. Installation of position switches (option)

Continued

Action Note
7. Run the remaining cable harness up
through the lower arm and:
• secure with the bracket, lower arm,
as shown in the figure to the right.
• connect the connector R2.SW3 to
the position switch of axis 3.
• secure the cable going to the fan of
axis 3, together with the robot
cabling with a velcro strap.

公 司
有 限

育 科技
帮教
xx0500002313

A. Bracket, lower arm. Also shown in

工 控 the figure Cable harness for

position switches and fans, axes 1-

长 沙 3 on page 128.
B. Bracket for robot cabling
C. Connector R2.SW3
D. Velcro strap
8. Secure the axis 3 fan cable with the bracket, Shown in the figure Cable harness for
© Copyright 2004-2011 ABB. All rights reserved.

upper arm. position switches and fans, axes 1-3 on

page 128.
9. Connect the connector R3.FAN3 to the fan
of axis 3. If no fan is used, strap the cable
together with the robot cabling.

xx0500002314

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2 Installation and commissioning
2.6.5. Installation of position switches (option)

Continued

Action Note
10. Connect the connector R1.SW2/3 to the
base of the robot. Make sure that the
cabling, run through the base, frame and
lower arm, is not twisted and is running free
from the robot cabling.
11. Refit the rear cover to the robot base.
12. Install additional cabling to and inside the Cabling is specified in section:
control cabinet. • Position switch and fan cables,
robot base to controller (option) on
page 134

公 司
有限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

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2.7.1. Robot cabling and connection points

2.7 Electrical connections

2.7.1. Robot cabling and connection points

Introduction
Connect the robot and controller to each other after securing them to the foundation. The lists
below specify which cables to use for each respective application.

Main cable categories

All cables between the robot and controller are divided into the following categories:
Cable category Description
Robot cables Handles power supply to and control of the robot's motors as
well as feedback from the serial measurement board.
Specified in the table Robot cables on page 133.
Position switch and fan cables Handles supply to and feedback from any position switches
(option) and cooling fans on the robot.
Specified in the table Position switch and fan cables, robot
base to controller (option) on page 134.
Customer cables (option)
司
Handles communication with equipment fitted on the robot

公
by the customer, including databus communication, low

ground.
有 限
voltage signals and high voltage power supply + protective

科技
See the product manual for the controller 1).
External axes cables (option)
育Handles power supply to and control of the external axes'

帮 教 motors as well as feedback from the servo system.

See the Application manual - Additional axes and stand

工 控 alone controller (M2004)orApplication manual - External

axes (M2000) 1).

长 沙
1)
Art. no. is specified in section References on page 10.

The cable categories are divided into sub-categories, specified below.

© Copyright 2004-2011 ABB. All rights reserved.

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 XS2 R1.SMB
and power supply to the serial
measurement board.

Continues on next page

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2 Installation and commissioning
2.7.1. Robot cabling and connection points

Continued

Robot cable, power

Cable Art. no.

Robot cable, power: 7 m 3HAC11818-1
Robot cable, power: 15 m 3HAC11818-2
Robot cable, power: 22 m 3HAC11818-3
Robot cable, power: 30 m 3HAC11818-4

Robot cable, signals

Cable Art. no.

Robot cable signal, shielded: 7 m 3HAC7998-1
Robot cable signal, shielded: 15 m 3HAC7998-2
Robot cable signal, shielded: 22 m 3HAC7998-3
Robot cable signal, shielded: 30 m 3HAC7998-4

Position switch and fan cables, robot base to controller (option)

These cables are not included in the standard delivery, but are included in the delivery if the
position switch option is ordered. The position switches and fans can also be ordered without

公 司
cables. The cables are completely pre-manufactured and ready to plug in.

限
Cabling to be installed on the robot is specified in sections Installation of cooling fan for
有 of position switches (option) on page
122. 科 技
motors, axes 1-3 (option) on page 104andInstallation

育
Cabling between robot base and controller 教
In a M2000 and M2000A帮
switches and cooling控
robot system, the cables specified below are used for both position

沙 工 fans.
长
In a M2004 robot system, however, the cables below are only used for position switches.
Cabling for the cooling fans is specified in the table Cabling between robot base and
controller, cooling fans, M2004 on page 135.

© Copyright 2004-2011 ABB. All rights reserved.

Connec- Connection
Cable Art. no. tion point, point,
robot cabinet
Position switch cable, axis 1, 7 m 3HAC13175-1 R1.SW XS8
Position switch cable, axis 1, 15 m 3HAC13175-2 R1.SW XS8
Position switch cable, axis 1, 22 m 3HAC13175-3 R1.SW XS8
Position switch cable, axis 1, 30 m 3HAC13175-4 R1.SW XS8
Position switch cable, axes 2 and 3, 7 m 3HAC13176-1 R1.SW2/3 XS58
Position switch cable, axes 2 and 3, 15 m 3HAC13176-2 R1.SW2/3 XS58
Position switch cable, axes 2 and 3, 22 m 3HAC13176-3 R1.SW2/3 XS58
Position switch cable, axes 2 and 3, 30 m 3HAC13176-4 R1.SW2/3 XS58

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2.7.1. Robot cabling and connection points

Continued

Cabling between robot base and controller, cooling fans, M2004

The cables specified below are specific for the IRC5 controller and used when the robot is
equipped with cooling fans. The cabling for the cooling fans runs all the way from the robot
base to the inside of the cabinet.
If equipping the robot with only cooling fans, use the cabling specified below. In case both
cooling fans and position switches are used, the cabling for position switches listed in the
previous table and the cabling for cooling fans listed below are used together with a
distributing cable, also specified below.

Cable Art. no. Connection point

Distributing cable 3HAC022708-001 Robot base: R1.SW2/3
Harness - cooling, 7 m 3HAC022723-001 Distributing cable: R1.FAN.SW2/3
Inside cabinet: A43.X10 and A43.X11
Harness - cooling, 15 m 3HAC022723-004 Distributing cable: R1.FAN.SW2/3
Inside cabinet: A43.X10 and A43.X11
Harness - cooling, 22 m 3HAC022723-005 Distributing cable: R1.FAN.SW2/3
Inside cabinet: A43.X10 and A43.X11
Harness - cooling, 30 m 3HAC022723-006 Distributing cable: R1.FAN.SW2/3

公 司Inside cabinet: A43.X10 and A43.X11

Cabling inside control cabinet

有 限
Additional cabling must be connected inside the control cabinet when installing position

科技
switchesor when installing fans for robot systems M2000 and M2000A (fan cabling for
M2004 runs all the way from the robot base to the inside of the cabinet and the additional
育
cabling specified below is therefor not needed).

帮教 Connection Connection

工控
Cable Art. no. point 1 inside point 2 inside

长沙
cabinet cabinet
Bracket in the cabinet wall (M2000 3HAB7286-5 - -
and M2000A)
Bracket in the cabinet wall (M2004) 3HAC020813-082 - -
Harness position switch (M2000) 3HAC15899-1 XS58 XP57
© Copyright 2004-2011 ABB. All rights reserved.

Harness position switch (M2000A) 3HAC14617-1 XS58 XP57

Harness position switch axis 1 3HAC021117-001 XS8 XT8.1 and
(M2004) XT8.2
Harness position switch axes 2 and 3HAC021116-001 XS58 XT58.1 and
3 (M2004) XT58.2
Cable harness fans (M2000) 3HAC15666-1 XS57 XT31
Cable harness fans (M2000A) 3HAC17832-1 XS57 XT31:10
XT31:12

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 工控帮助教小舒QQ2823408167
2 Installation and commissioning
2.8.1. Additional installation procedure

2.8 Making robot ready for operation (Foundry Prime)

2.8.1. Additional installation procedure

General
Robots delivered with the Foundry Prime protection are specially designed to work in water
jet cleaning cells with 100% humidity and alkaline detergent. To ensure that the protection
offers the best reliability, some measures are needed during installation of the robot according
to the procedures below.
NOTE!
For best reliability, it is of highest importance that the special maintenance instructions for
the Foundry Prime robot are followed and documented.

Commissioning
• Never switch off the overpressure in motors and serial measurement compartment
during cooling down of robot after it has been switched off.
• When turning off a cleaning cell we recommend that the humid air inside a cell is

to the raised vacuum when cooled down.

公 司
ventilated out, to avoid that the humid air is sucked into gearboxes for example, due

有 限
科技
Environmental conditions
The table below details the environmental conditions.
育
帮教
Parameter Value

控
Humidity 100%

工
Washing detergent with pH
沙 must contain rust inhibitor
<9.0

and be 长
Washing detergent
approved by ABB
Cleaning bath temperature <60°C, used in a typical waterjet cleaning
application at suitable speed.

Air quality for pressurizing of robot © Copyright 2004-2011 ABB. All rights reserved.

The air must be dry and clean, such as instrument air. The table below details the air
specifications.

Parameter Value
Dew point <+2°C at 6 bar
Solid particle size <5 microns
Oil content <1 ppm (1 mg/m3)

Continues on next page

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2 Installation and commissioning
2.8.1. Additional installation procedure

Continued

Air pressure for pressurizing of robot

Parameter Value
Air pressure supplied to robot Max 0.2 - 0.3 bar ± 0.0 bar

WARNING!
If the air pressure exceeds the specified, it could result in a brake failure in the motors
and cause the robot arms to fall down, leading to personal injury or physical damage.
WARNING!
If the pressurized air contains oil, it could result in a brake failure in the motors and cause the
robot arms to fall down, leading to personal injury or physical damage.
NOTE!
To secure the supply of air pressure, use a pressure sensor.

Pressurize the motors, balancing device and serial measurement board cavity
The robots are prepared with hoses to the motors and the serial measurement board cavity to
enable pressurizing of them.
WARNING!
公 司
限 off, to avoid that the humid
The robot must be pressurized also when it is switch
environmental air is sucked into the motors有
科 技 when cooling down.

Action 育 Note
教
帮 air hose to air
1. Connect a compressed
connector on
工 控 robot base.

长 沙

xx0700000450
© Copyright 2004-2011 ABB. All rights reserved.

• A: Air connection, outside diameter

= 6 mm.
2. Protect the screws on the Harting Do this when the controller cables are
connector on the robot base from corrosion connected.
with Mercasol 3106.
3. Pressurize the robot. See Air quality for pressurizing of robot on
page 136 for correct pressure.
4. Inspect the air system. See Inspection of air hoses (Foundry
Prime) on page 191.

Continues on next page

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 工控帮助教小舒QQ2823408167
2 Installation and commissioning
2.8.1. Additional installation procedure

Continued

Protecting robot from high pressure water

WARNING!
No part of the robot should be exposed to direct high pressure jet of water. The sealings
between the moving parts on the wrist should not be exposed to direct or rebounding high-
pressure jet of water.

Protection points at the wrist joints

The illustration below shows points that are particularly sensitive to water spray.

司
xx0600002792

A Axis 5, bearing support side

限 公
B Axis 5, bearing gear side
有
科技
C Axis 6, mounting flange - gear house

育
控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

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 工控帮助教小舒QQ2823408167
2 Installation and commissioning
2.8.2. Commissioning (Foundry Prime)

2.8.2. Commissioning (Foundry Prime)

General
The following should be taken in consideration when running a robot in a water jet
application cell:
CAUTION!
Never switch off the overpressure in motors and serial measurement compartment during
cooling down of robot after it has been switched off.
NOTE!
To reduce the risk for corrosion due to condensation in gearboxes, it is recommendable that
the robot is running with high speed on each axes at least on one occasion each hour. This is
to lubricate the gearbox cavities.
NOTE!
When turning off a cleaning cell we recommend that the humid air is ventilated out from the
cell, to avoid that the humid air is sucked into gearboxes for example, due to the raised
vacuum when cooled down.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

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2 Installation and commissioning
2.8.2. Commissioning (Foundry Prime)

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

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3 Maintenance
3.1. Introduction

3 Maintenance
3.1. Introduction

Structure of this chapter

This chapter describes all maintenance activities recommended for the manipulator.
It is based on the maintenance schedule located at the beginning of the chapter. The schedule
contains information about required maintenance activities including intervals and refers to
procedures for the activities.
Each procedure contains all the information required to perform the activity, which is
required tools and materials.
The procedures are gathered in different sections and divided according to the maintenance
activity.

Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
司
There are general safety aspects that must be read through, as well as more specific safety
公
有 限
information that describes the danger and safety risks when performing the procedures. Read
the chapter Safety on page 19 before performing any service work.
NOTE!
育 科技
帮教
If the robot is connected to power, always make sure that the robot is connected to earth
before starting any maintenance work!

工 控
For more information see:

长沙
• Product manual - IRC5
© Copyright 2004-2011 ABB. All rights reserved.

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3 Maintenance
3.2.1. Specification of maintenance intervals

3.2 Maintenance schedule and expected life

3.2.1. Specification of maintenance intervals

Introduction
The intervals are specified in different ways depending on the type of maintenance activity to
be carried out and the working conditions of the manipulator:
• Calendar time: specified in months regardless of whether the manipulator system is
running or not
• Operating time: specified in operating hours. More frequent running of the
manipulator means more frequent maintenance activities.
• SIS: specified by the robot's SIS (Service Information System). A typical value is
given for a typical work cycle, but the value will differ depending on how hard each
part is run. The SIS is further detailed in sectionService Information System, M2000
on page 235the Operating manual Service Information System. Document number can
be found in sectionReferences on page 10.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

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3 Maintenance
3.2.2. Maintenance schedule

3.2.2. Maintenance schedule

General
The robot must be maintained regularly to ensure proper function. The maintenance activities
and intervals are specified in the table below.
Non-predictable situations also give rise to inspections of the robot. Any damages must be
attended to immediately!
The inspection intervals do not specify the life of each component.
Values for these are specified in the section Expected component life on page 149

Activities and intervals, standard equipment

The table below specifies the required maintenance activities and intervals:

Maintenance
Equipment Interval Detailed in section
activity
Cleaning Robot - • Cleaning, robot on page
233
Inspection Axis 1 gearbox, Every: • Inspection, oil level

公司
oil level 12 months gearbox axis 2 on page

有限
153
Inspection Axis 2 gearbox, Every: • Inspection, oil level
oil level
科 技 12 months gearbox axis 2 on page
153
育
帮教
Inspection Axis 3 gearbox, Every: • Inspection, oil level
oil level 12 months gearbox axis 3 on page

工 控 156

沙
Inspection Axis 4 gearbox, Every: • Inspection, oil level

长 oil level 12 months gearbox axis 4 on page

158
Inspection Axis 5 gearbox, Every: • Inspection, oil level,
oil level 12 months gearbox axis 5 on page
161
© Copyright 2004-2011 ABB. All rights reserved.

Inspection Axis 6 gearbox, Every: • Inspection, oil level

oil level 12 months gearbox axis 6 on page
164
Inspection Balancing device Every: • Inspection, balancing
• 6 months device on page 168
Inspection Robot harness Every: • Inspection, cable
12 months4) harness on page 174
Inspection Information labels Every: • Inspection, information
• 12 months labels on page 187
Inspection Dampers Every: • Inspection, damper
• 12 months axes 2-5 on page 181
Inspection Mechanical stop, Every: • Inspecting, mechanical
axis 1 • 12 months stop pin, axis 1 on page
177
• Inspection, mechanical
stop, axes 1, 2 and 3 on
page 179

Continues on next page

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3 Maintenance
3.2.2. Maintenance schedule

Continued

Maintenance
Equipment Interval Detailed in section
activity
Changing Axis 1 gearbox oil: Every: • Oil change, gearbox
Optimol Optigear • 12,000 hours axis 1 on page 199
RO 150
Changing Axis 1 gearbox oil: First change when Do not mix with other oils!
Kyodo Yushi TMO DTC 1) reads: • Oil change, gearbox
150 6,000 hours axis 1 on page 199
Second change
when DTC 1) reads:
24,000 hours
Following changes:
Every 24,000 hours
Changing Axis 2 gearbox oil: Every: • Oil change, gearbox
Optimol Optigear • 12,000 hours axis 2 on page 203
RO 150
Changing Axis 2 gearbox oil: First change when Do not mix with other oils!
Kyodo Yushi TMO DTC 1) reads: • Oil change, gearbox
150 6,000 hours axis 2 on page 203
Second change

公 司
when DTC 1) reads:

有 限
24,000 hours
Following changes:

Changing Axis 3 gearbox oil:

科技
Every 24,000 hours

育 Every: • Oil change, gearbox,

帮教
Optomol Optigear • 12,000 hours axis 3 on page 206

Changing
工 控
RO 150
Axis 3 gearbox oil: First change when Do not mix with other oils!

长 沙 Kyodo Yushi TMO

150
DTC 1) reads:
6,000 hours
• Oil change, gearbox,
axis 3 on page 206
Second change
when DTC 1) reads:
24,000 hours

© Copyright 2004-2011 ABB. All rights reserved.

Following changes:
Every 24,000 hours
Changing Axis 4 primary First change when Do not mix with other oils!
gearbox, oil: DTC 1) reads: • Oil change, gearbox,
Kyodo Yushi TMO 6,000 hours axis 4 on page 209
150 Second change
when DTC 1) reads:
24,000 hours
Following changes:
Every 24,000 hours
Changing Axis 4 secondary Every: • Oil change, gearbox,
gearbox, oil: • 12,000 hours axis 4 on page 209
Mobil Gearlube
X320

Continues on next page

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3 Maintenance
3.2.2. Maintenance schedule

Continued

Maintenance
Equipment Interval Detailed in section
activity
Changing Axis 4 secondary First change when Do not mix with other oils!
gearbox, oil: DTC 1) reads: • Oil change, gearbox,
Kyodo Yushi TMO 6,000 hours axis 4 on page 209
150 Second change
when DTC 1) reads:
24,000 hours
Following changes:
Every 24,000 hours
Changing Axis 5 primary First change when Do not mix with other oils!
gearbox, oil: DTC 1) reads: • Oil change, gearbox,
Kyodo Yushi TMO 6,000 hours axis 5 on page 212
150 Second change
when DTC 1) reads:
24,000 hours
Following changes:
Every 24,000 hours
Changing Axis 5 secondary Every: • Oil change, gearbox,
gearbox, oil: • 12,000 hours axis 5 on page 212
Mobil Gearlube
公 司
Changing
X320
Axis 5 secondary 有 限
First change when Do not mix with other oils!

科技
gearbox, oil: DTC 1) reads: • Oil change, gearbox,

育
Kyodo Yushi TMO 6,000 hours axis 5 on page 212

帮教
150 Second change
when DTC 1) reads:

工 控 24,000 hours

长 沙 Following changes:
Every 24,000 hours
Changing Axis 6 gear oil: First change when Do not mix with other oils!
Kyodo Yushi TMO DTC 1) reads: • Oil change, gearbox
150 6,000 hours axis 6 on page 215
© Copyright 2004-2011 ABB. All rights reserved.

Second change
when DTC 1) reads:
24,000 hours
Following changes:
Every 24,000 hours
Overhaul Robot Every: • Expected component
40,000 hours life on page 149
Replacement SMB Battery pack Battery low alert 3) • Replacing SMB battery
on page 218
Lubrication Balancing device Every:
bearings 12,000 hours 5)

1)
• DTC = Duty Time Counter. Shows the operational time of the robot.
3)
• Battery low alert (38213 Battery charge low) is displayed when remaining backup
capacity (robot powered off) is less than 2 months. Typical lifetime of a new battery
is 36 months if the robot is powered off 2 days/week or 18 months if the robot is

Continues on next page

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3 Maintenance
3.2.2. Maintenance schedule

Continued

powered off 16 hours/day. The lifetime can be extended (approx. 3 times) for longer
production breaks by a battery shutdown service routine. See Operating manual -
IRC5 with FlexPendant for instructions.
4)
• Replace when damage or cracks is detected or life limit is approaching as specified
in section Expected component life on page 149.
5)
• Always lubricate the front eye bearing after refitting the shaft of the balancing
device.

Activities and intervals, optional equipment

The table below specifies the required maintenance activities and intervals for common
optional equipment. The maintenance of other external equipment for the robot is detailed in
separate documentation.

Maintenance Detailed in
Equipment Interval Note
activity section
Inspection Signal lamp Every: Inspecting, signal
12 months lamp (option)
Inspection Mechanical stop Every: Mechanical stops in Inspection,

司
axes 1-2-3 12 months addition to the fixed mechanical stop,

Inspection Position Every: 限 公

stops axes 1, 2 and 3
Inspection, position
switches, axes 12 months 有 switch axes 1, 2 and

科技
1-2-3 3
Inspection
育
Motor fans, axes Every 12 Inspect the fans for -

帮 教
1, 2and 3 months contamination that
could hinder the air

工 控 supply. Clean if
necessary.

长 沙
Activities and intervals, Foundry Prime
The table below specifies the required maintenance activities and intervals for Foundry
Prime.
© Copyright 2004-2011 ABB. All rights reserved.
Maintenance
Equipment Interval Detailed in section
activity
Inspection Axis 1 gearbox, oil level Every: Inspection, oil level
• 6 months gearbox axis 1
Inspection Axis 2 gearbox, oil level Every: Inspection, oil level
• 6 months gearbox axis 2
Inspection Axis 3 gearbox, oil level Every: Inspection, oil level
• 6 months gearbox axis 3
Inspection Axis 6 gearbox, oil level Every: Inspection, oil level
• 6 months gearbox axis 6
Inspection Surface treatment Every: Inspection of surface
• 6 months 4) treatment (Foundry Prime)

Continues on next page

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3 Maintenance
3.2.2. Maintenance schedule

Continued

Maintenance
Equipment Interval Detailed in section
activity
Inspection Cable harness Every: Inspection, cable harness
• 6 months on page 174.
Replacement If required 7) Replacement of cable
harness, axes 1-4 on page
251
Replacement of cable
harness, axes 5-6 on page
260
Inspection Air hoses Every: Inspection of air hoses
• 6 months (Foundry Prime) on page
191
Inspection Balancing device Every: • Inspection,
• 6 months balancing device
on page 168
Inspection Information labels Every: • Inspection,
• 12 months information labels
on page 187
Inspection Dampers Every: • Inspection, damper
axes 2-5 on page

公 司
• 12 months
181

有•限12 months
Inspection Mechanical stop, axis 1 Every: • Inspecting,
mechanical stop

科 技 pin, axis 1 on page

177
育
帮教
• Inspection,
mechanical stop,

工 控 axes 1, 2 and 3 on
page 179

长
Analysis沙 Oil gearbox axis 6 Every: Inspection, oil level
• 3,000h or 6 gearbox axis 6
months 2)
Changing Axis 1 gearbox, oil: Every: Oil change, gearbox axis 1
Kyodo Yushi TMO 150
© Copyright 2004-2011 ABB. All rights reserved.

• 6,000 hours
Changing Axis 2 gearbox, oil: Every: Oil change, gearbox axis 2
Kyodo Yushi TMO 150 • 6,000 hours on page 203
Changing Axis 3 gearbox, oil: Every: Oil change, gearbox, axis
Kyodo Yushi TMO 150 • 6,000 hours 3 on page 206
Changing Axis 4 (primary and Every: Oil change, gearbox, axis
secondary) gearbox, oil: • 6,000 hours 4 on page 209
Kyodo Yushi TMO 150
Changing Axis 5 (primary and Every: Oil change, gearbox, axis
secondary) gearbox, oil: • 6,000 hours 5 on page 212
Kyodo Yushi TMO 150
Changing Axis 6 gearbox, oil: Every: Oil change, gearbox axis 6
Kyodo Yushi TMO 150 • 3,000 hours
or 6 months 1)
Replacement SMB Battery pack Battery low alert 3) • Replacing SMB
battery on page
218

Continues on next page

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3 Maintenance
3.2.2. Maintenance schedule

Continued

Maintenance
Equipment Interval Detailed in section
activity
Overhaul Robot 40,000 hours Expected component life
on page 149
Overhaul Axis 6 gearbox Every: Replacement of gearbox,
• 24 months axis 6 on page 397
Lubrication Balancing device, Every:
bearings • 6 months
Rust preventing Wrist bearing Every: Rust preventive
• 6 months measures, support
bearing in wrist (Foundry
Prime) on page 229
Rust preventing Axis 1 sealing Every: Rust preventive
• 6 months measures, bearing axis 1
(Foundry Prime) on page
223
Rust preventive Axis 4 sealing Every: Rust preventive
• 6 months measures, sealing axis 4
(Foundry Prime) on page
226

• 1)
公 司
If the robot is working in cleaning cells that are not emptied when the robot is

有 限
switched off, the oil may be replaced more frequently. See also Analysis of water

科技
content in oil, gearbox axis 6 (Foundry Prime) on page 166.
2)
•
育
Analyse water content in oil in gearbox axis 6 first time after 3,000 hours or 6

帮教
months. If the working conditions changes, analyse again after 3,000 hours or 6
months.
• 3)
工 控
Battery low alert (38213 Battery charge low) is displayed when remaining backup

长 沙
capacity (robot powered off) is less than 2 months. Typical lifetime of a new battery
is 36 months if the robot is powered off 2 days/week or 18 months if the robot is
powered off 16 hours/day. The lifetime can be extended (approx. 3 times) for longer
production breaks by a battery shutdown service routine. See Operating manual -

© Copyright 2004-2011 ABB. All rights reserved.

IRC5 with FlexPendant for instructions.
4)
• Damage to painted surfaces must be repaired as soon as possible to avoid corrosion.
7)
• The warranty does not apply to effects or wear caused by environmental factors.

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3 Maintenance
3.2.3. Expected component life

3.2.3. Expected component life

General
The expected life of a specific component of the robot can vary greatly depending on how
hard it is run.

Expected component life

Component Expected life Note

Cable harness 40,000 hours 3) Not including:
Normal usage 1) • SpotPack harnesses
• Optional upper arm
harnesses
Cable harness 20,000 hours 3) Not including:
Extreme usage 2) • SpotPack harnesses
• Optional upper arm
harnesses
Balancing device 40,000 hours 5)
4)
Gearboxes 40,000 hours

1)
公 司
Examples of "normal usage" in regard to movement: most material handling

有 限
applicationsand limited use of bending backwards mode of axis 3.

科技
2)
Examples of "extreme usage" in regard to movement: presstending, very severe palletizing

育
applications, major use of axis 1 movement and major use of bending backwards of axis 3.

帮教
3)
Severe chemical, thermal or similar environments can result in shortened life expectancy.
4)
控
Depending on application, the lifetime can vary. The Service Information System (SIS),
工
长 沙
integrated in the robot software, can be used as a guidance for planning service of gearbox for
the individual robot. This applies to gearboxes on axes 1, 2, 3 and 6. The lifetime of gearbox
axes 4 and 5 is not calculated by SIS (See the Operating manual - Service Information
System). In some applications, such as Foundry or Washing, the robot can be exposed to
chemicals, high temperature or humidity, which can have an effect on the lifetime of the
© Copyright 2004-2011 ABB. All rights reserved.

gearboxes. Contact the local ABB Robotics Service team for more information.
5)
The given life for the balancing device is based on a test cycle of 4,000,000 cycles that
starts from the initial position and goes to maximum extension, and back. Deviations from
this cycle will result in differences in expected life!
The SIS for an M2004 system is described in the Operating manual - Service Information
System. Document number can be found in section References on page 10.
For an M2000 system, the SIS is described in section Service Information System, M2000 on
page 235.

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3 Maintenance
3.3.1. Inspection, oil level gearbox axis 1

3.3 Inspection activities

3.3.1. Inspection, oil level gearbox axis 1

Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.

公 司
有 限
xx0200000111
育 科技
A
B
Gearbox axis 1

控 帮教
Oil plug, filling
C
沙 工
Motor, axis 1
D 长Oil plug, inspection (not available in all designs)
E Label, specifies type of oil in the axis 1 gearbox

Required equipment
© Copyright 2004-2011 ABB. All rights reserved.
Equipment, etc. Art. no. Note
Lubricating oil 3HAC032140-001 Kyodo Yushi TMO 150
NOTE! Do not mix with other oils!
Standard toolkit - Content is defined in section
Standard toolkit on page 427.
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.

Continues on next page

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3 Maintenance
3.3.1. Inspection, oil level gearbox axis 1

Continued

Inspection through the oil plug, filling

The procedure below details how to inspect the oil level, axis 1 gearbox, when the oil plug
for inspection (shown in figure Location of gearbox on page 150) is not available .

Action Note
1.

WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please read the
safety information in the section WARNING -
Safety risks during work with gearbox
lubricants (oil or grease) on page 51.
2.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not
the air pressure to the gearboxes, motors and
公 司
SMB.
有 限
科技
3. Remove the motor, axis 1. Detailed in section Removal, motor
axis 1 on page 328.

育
4. Measure the oil level through the motor hole.

帮教
Required oil level: 40 mm ± 5 mm to the motor
hole.

工 控
5. If necessary, fill with lubricating oil or drain. Art. no. is specified in Required

长 沙 equipment on page 150!

Filling and draining detailed in Oil
change, gearbox axis 1 on page 199.
6. Refit the motor, axis 1. Detailed in section Refitting, motor
axis 1 on page 329.
© Copyright 2004-2011 ABB. All rights reserved.

7.

WARNING!
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
Type of oil on page 192.

Continues on next page

3HAC022033-001 Revision: K 151
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3 Maintenance
3.3.1. Inspection, oil level gearbox axis 1

Continued

Inspection through the oil plug, inspection

The procedure below details how to inspect the oil level, axis 1 gearbox, when the oil plug
for inspection (shown in the figure Location of gearbox on page 150) is available.

Action Note
1.

WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please read the safety
information in the section WARNING - Safety risks
during work with gearbox lubricants (oil or grease)
on page 51.
2.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!

air pressure to the gearboxes, motors and SMB.

公 司
Turn off all electric power and hydraulic but not the

3. Open the oil plug, inspection.

有 限 Shown in the figure Location of
技
gearbox on page 150!

育科
4. Required oil level: max 10 mm below the oil plug
hole!
5. Add oil if required.
帮 教 Art. no. is specified in Required

工 控 equipment on page 150!

Detailed in section Oil change,

长the沙oil plug, inspection.

gearbox axis 1 on page 199.
6. Refit Tightening torque: 24 Nm.
7.

© Copyright 2004-2011 ABB. All rights reserved.

WARNING!
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section Type
of oil on page 192.

152 3HAC022033-001 Revision: K

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3 Maintenance
3.3.2. Inspection, oil level gearbox axis 2

3.3.2. Inspection, oil level gearbox axis 2

Different designs
The cover of gearbox axis 2 is made in different designs, with different locations of the oil
plug hole for filling. The oil plug hole of the later design is located 33 mm below the original
placement. The measured distance to the oil level varies, depending on the design of the
cover.

Oil plug, early design

The axis 2 gearbox is located in the lower arm rotational center. The figure below shows the
early design of the gearbox cover.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0300000068

A Gearbox, axis 2 (behind motor attachment not shown in figure )

B Oil plug, filling (early design)
C Oil plug, draining
D Label, specifies the type of oil in axis 2 gearbox

Continues on next page

3HAC022033-001 Revision: K 153
 工控帮助教小舒QQ2823408167
3 Maintenance
3.3.2. Inspection, oil level gearbox axis 2

Continued

Oil plug, later design

The axis 2 gearbox is located in the lower arm rotational center. The figure below shows the
later design of the gearbox cover, where the oil plug for filling is located 33 mm below the
original placement.

公 司
有限
xx0200000112
育 科技
A
B 控 帮教
Gearbox, axis 2 (behind motor attachment not shown in figure )
Oil plug, filling (later design)
C
沙 工
Oil plug, draining
D 长Label, specifies the type of oil in axis 2 gearbox
Required equipment

© Copyright 2004-2011 ABB. All rights reserved.

Equipment etc. Art. no. Note
Lubricating oil 3HAC032140-001 Kyodo Yushi TMO 150
NOTE! Do not mix with other oils!
Standard toolkit - Content is defined in section
Standard toolkit on page 427.
Other tools and procedures may These procedures include
be required. See references to references to the tools required.
these procedures in the step-by-
step instructions below.

Continues on next page

154 3HAC022033-001 Revision: K
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3 Maintenance
3.3.2. Inspection, oil level gearbox axis 2

Continued

Inspection, oil level gearbox axis 2

The procedure below details how to inspect the oil level in gearbox axis 2.

Action Note
1.

WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please read the safety
information in the section WARNING - Safety
risks during work with gearbox lubricants (oil or
grease) on page 51.
2.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not
the air pressure to the gearboxes, motors and
SMB.
公 司
有限 Oil
3. Open the oil plug, filling (two different designs). Read more about the differences in
change, gearbox axis 2 on page

科 技 203!
4. Measure the oil level.
Required oil level, to教
育
oil plug (early design): 35
Shown in the figures Oil plug, early
design on page 153 or Oil plug, later
mm ± 5 mm. 帮 design on page 154!
Required oil控
10 mm 工
level, to oil plug (later design): max.

5. 长
沙 below the oil plug hole.
Add oil if required. Art. no. is specified in Required
equipment on page 154!
Detailed in section Filling, oil on
page 205.
© Copyright 2004-2011 ABB. All rights reserved.

6. Refit the oil plug, filling. Tightening torque: 24 Nm.

7.

WARNING!
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
Type of oil on page 192.

3HAC022033-001 Revision: K 155

 工控帮助教小舒QQ2823408167
3 Maintenance
3.3.3. Inspection, oil level gearbox axis 3

3.3.3. Inspection, oil level gearbox axis 3

Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0200000113

© Copyright 2004-2011 ABB. All rights reserved.

A Gearbox, axis 3
B Oil plug, filling
C Oil plug, draining
D Label, specifies the oil type of axis 3 gearbox

Required equipment

Equipment Art. no. Note

Lubricating oil 3HAC032140-001 Kyodo Yushi TMO 150
NOTE! Do not mix with other oils!
Standard toolkit - Content is defined in section
Standard toolkit on page 427.
Other tools and procedures may These procedures include
be required. See references to references to the tools required.
these procedures in the step-by-
step instructions below.

Continues on next page

156 3HAC022033-001 Revision: K
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3 Maintenance
3.3.3. Inspection, oil level gearbox axis 3

Continued

Inspection, oil level gearbox axis 3

The procedure below details how to inspect the oil level in gearbox axis 3.

Action Note
1.

WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please read the safety
information in the section WARNING - Safety
risks during work with gearbox lubricants (oil or
grease) on page 51.
2.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not
the air pressure to the gearboxes, motors and
SMB.
公 司
3. Run the robot to the calibration position.
有 限 Detailed in section Calibration scale
and correct axis position on page

科技
406.
4. Open the oil plug, filling .
育 Shown in the figure Location of

帮 教
5. Required oil level: max. 10 mm below the oil plug
gearbox on page 156!

hole.
工 控
长 沙
6. Add oil if required. Art. no. is specified in Required
equipment on page 156!
Detailed in section Oil change,
gearbox, axis 3 on page 206.
7. Refit the oil plug, filling. Tightening torque: 24 Nm.
© Copyright 2004-2011 ABB. All rights reserved.

8.

WARNING!
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
Type of oil on page 192.

3HAC022033-001 Revision: K 157

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3 Maintenance
3.3.4. Inspection, oil level gearbox axis 4

3.3.4. Inspection, oil level gearbox axis 4

Location of gearbox
The axis 4 gearbox is located at the rear of the upper arm as shown in the figure below.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0200000107

A Upper arm housing

© Copyright 2004-2011 ABB. All rights reserved.

B Cover, axis 4 gearbox
C Oil plug, filling, secondary gear
D Oil plug, draining, secondary gear
E Oil plug, filling, primary gearbox (draining not shown in figure)
F Label, specifies the type of oil in the secondary gear of axis 4
G Label, specifies the type of oil in the primary gear of axis 4

Required equipment

Equipment, etc. Art. no. Note

Lubricating oil 3HAC032140-001 Kyodo Yushi TMO 150
To be used in primary and
secondary gearboxes.
NOTE! Do not mix with other oils!
Standard toolkit - Content is defined in section
Standard toolkit on page 427.

Continues on next page

158 3HAC022033-001 Revision: K
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3 Maintenance
3.3.4. Inspection, oil level gearbox axis 4

Continued

Equipment, etc. Art. no. Note

Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these procedures
in the step-by-step instructions
below.

Inspection, oil level gearbox axis 4

The procedure below details how to inspect the oil level in gearbox axis 4.

Action Note
1.

WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please read the safety
information in the section WARNING - Safety
risks during work with gearbox lubricants (oil or
grease) on page 51.
2.
公 司
有 限
科技
DANGER!
Turn off all electric power, hydraulic and
育
pneumatic pressure supplies to the robot!

帮教
Turn off all electric power and hydraulic but not

工
SMB. 控
the air pressure to the gearboxes, motors and

长沙
3. Run the robot to the calibration position. Shown in section Calibration scale
and correct axis position on page
406.
4. Open the oil plug, filling, in the primary gearbox. Shown in the figure Location of
gearbox on page 158!
© Copyright 2004-2011 ABB. All rights reserved.

5. Measure the oil level.

Required oil level: 35 mm ± 5 mm to the oil plug
hole.
6. Add oil if required. Kyodo Yushi TMO 150
Art. no. is specified in Required
equipment on page 158.
Detailed in section Oil change,
gearbox, axis 4 on page 209.
7. Open the oil plug, filling, in the secondary Shown in the figure Location of
gearbox. gearbox on page 158!
8. Required oil level: max. 10 mm to the oil plug
hole.
9. Add oil if required. Kyodo Yushi TMO 150
Art. no. is specified in Required
equipment on page 158.
Detailed in section Oil change,
gearbox, axis 4 on page 209.
10. Refit both oil plugs. Tightening torque: 24 Nm.

Continues on next page

3HAC022033-001 Revision: K 159
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3 Maintenance
3.3.4. Inspection, oil level gearbox axis 4

Continued

Action Note
11.

WARNING!
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
Type of oil on page 192.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

160 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
3 Maintenance
3.3.5. Inspection, oil level, gearbox axis 5

3.3.5. Inspection, oil level, gearbox axis 5

Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0200000108

A Wrist housing
© Copyright 2004-2011 ABB. All rights reserved.

B Cover, axis 5 gearbox

C Oil plug, filling secondary gear
D Oil plug, draining secondary gear
E Oil plug, filling, primary gearbox (draining on opposite side of wrist housing, not
shown in figure)
F Label, specifies the type of oil in primary gear axis 5
G Label, specifies the type of oil in secondary gear axis 5

Required equipment

Equipment etc. Art. no. Note

Lubricating oil 3HAC032140-001 Kyodo Yushi TMO 150
To be used for primary and
secondary gearboxes.
NOTE! Do not mix with other oils!
Standard toolkit - Content is defined in section
Standard toolkit on page 427.

Continues on next page

3HAC022033-001 Revision: K 161
 工控帮助教小舒QQ2823408167
3 Maintenance
3.3.5. Inspection, oil level, gearbox axis 5

Continued

Equipment etc. Art. no. Note

Other tools and procedures may These procedures include
be required. See references to references to the tools required.
these procedures in the step-by-
step instructions below.

Inspection, oil level gearbox axis 5

The procedure below details how to inspect the oil level in the gearbox axis 5.

Action Note
1.

WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please read the safety
information in the section WARNING - Safety
risks during work with gearbox lubricants (oil or
grease) on page 51.
2.

公 司
DANGER!
有 限
科技
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
育
Turn off all electric power and hydraulic but not

帮教
the air pressure to the gearboxes, motors and
SMB.

工 控
3. Run the robot to the calibration position. Shown in section Calibration scale

长 沙 and correct axis position on page

406.
4. Open the oil plug, filling, in the primary gearbox. Shown in the figure Location of
gearbox on page 161.
5. Measure the oil level.
Required oil level: 80 mm ± 5 mm to the oil plug © Copyright 2004-2011 ABB. All rights reserved.
hole.
6. Add oil if required. Kyodo Yushi TMO 150
Art. no. is specified in Required
equipment on page 161.
Detailed in section Oil change,
gearbox, axis 5 on page 212.
7. Open the oil plug, filling, in the secondary gear . Shown in the figure Location of
gearbox on page 161.
8. Measure the oil level.
Required oil level: max. 10 mm to the oil plug
hole.
9. Add oil if required. Kyodo Yushi TMO 150
Art. no. is specified in Required
equipment on page 161.
Detailed in section Oil change,
gearbox, axis 5 on page 212.
10. Refit both oil plugs. Tightening torque: 24 Nm.
Continues on next page
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3 Maintenance
3.3.5. Inspection, oil level, gearbox axis 5

Continued

Action Note
11.

WARNING!
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
Type of oil on page 192.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 163

 工控帮助教小舒QQ2823408167
3 Maintenance
3.3.6. Inspection, oil level gearbox axis 6

3.3.6. Inspection, oil level gearbox axis 6

Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. The
alternative locations of the oil plugs for filling affects the measured oil level. The different oil
levels are specified in the procedure.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0200000114

© Copyright 2004-2011 ABB. All rights reserved.

A Gearbox, axis 6
B Oil plug, filling (notice the two possible locations B1 or B2)
C Oil plug, draining (can be located on the turning disk instead)
D Label, specifies the type of oil in gearbox axis 6

Required equipment

Equipment Art. no. Note

Lubricating oil 3HAC032140-001 Kyodo Yushi TMO 150
NOTE! Do not mix with other oils!
Standard toolkit - Content is defined in section
Standard toolkit on page 427.
Other tools and procedures may These procedures include
be required. See references to references to the tools required.
these procedures in the step-by-
step instructions below.

Continues on next page

164 3HAC022033-001 Revision: K
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3 Maintenance
3.3.6. Inspection, oil level gearbox axis 6

Continued

Inspection, oil level gearbox axis 6

The procedure below details how to inspect the oil level in the gearbox axis 6.

Action Note
1.

WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please read the safety information
in the section WARNING - Safety risks during work
with gearbox lubricants (oil or grease) on page 51.
2. Move the wrist unit and tilthouse so that the oil plug for Shown in the figure Location of
filling is facing upwards. gearbox on page 164.
3.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!

pressure to the gearboxes, motors and SMB.

公 司
Turn off all electric power and hydraulic but not the air

4. Open the oil plug, filling.

有 限
科技
5. Measure the oil level (measurement a in the figure to
the right).
育
The required oil level depends on where the oil plug is

帮教
located on the tilthouse (shown in the figure to the
right).

工 控
• Location A: required oil level: 40 mm ± 5 mm.

长 沙
• Location B: required oil level: 65 mm ± 5 mm.
xx0500002222
© Copyright 2004-2011 ABB. All rights reserved.

xx0600002737

Continues on next page

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3 Maintenance
3.3.6. Inspection, oil level gearbox axis 6

Continued

Action Note
6. Add oil if required. Art. no. is specified in Required
equipment on page 164.
Detailed in section Oil change,
gearbox axis 6 on page 215.
7. Refit the oil plug, filling. Tightening torque: 24 Nm.
8.

WARNING!
Do not mix oil types! If wrong oil is refilled, the gearbox
must be rinsed as detailed in section Type of oil on
page 192.

Analysis of water content in oil, gearbox axis 6 (Foundry Prime)

When changing oil, check for water content in oil.

If: Then....
1. More than 2% water in oil: Replacement of gearbox axis 6 is required
• With more than 2% water content every two years
there is a risk for corrosion in the 公 司
gearbox and reduced viscosity in
the oil. 有 限

育 科技

控 帮教
沙 工
长
xx0600003155

• A: Water content in oil from gearbox

© Copyright 2004-2011 ABB. All rights reserved.

axis 6
• B: Months or hours in operation
• C: Replacement of gearbox axis 6

Continues on next page

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3 Maintenance
3.3.6. Inspection, oil level gearbox axis 6

Continued

If: Then....
2. Less than 2% water in oil. Normal replacement interval is required for
gearbox axis 6.
See:
• Activities and intervals, Foundry Prime
on page 146

xx0600003156

• A: Water content in oil from gearbox

axis 6
• B: Months or hours in operation

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 167

 工控帮助教小舒QQ2823408167
3 Maintenance
3.3.7. Inspection, balancing device

3.3.7. Inspection, balancing device

General
Several points are to be checked on the balancing device during the inspection. This section
details how to perform the inspection regarding:
• dissonance
• damage
• leakage
• contamination / lack of free space.

Action at detected faults

If any faults are detected during the inspection, a maintenance may be performed according
to specific maintenance kits.
If the balancing device is an older model, it must in some cases be upgraded instead! The
instruction for the current inspection details if a fault requires a maintenance / upgrade and
the table below specifies the different models and which of the two actions they require.
The article number of the balancing device is located on a label at the rear cover, shown in

公 司
the figure Inspection points, balancing device on page 169.

Balancing device, art. no. 有 限

Action at detected faults
3HAC10538-1
科 技Upgrade
3HAC14675-1 育 Maintenance

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

Continues on next page

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3 Maintenance
3.3.7. Inspection, balancing device

Continued

Inspection points, balancing device

The balancing device is located at the top rear of the frame as shown in the figure below. The
figure also shows the inspection points, further detailed in the instructions.

公 司
有限

育科技

控 帮教
沙
xx0300000580工
A 长 Balancing device
B Piston rod (inside)
C Shaft, including securing screw
© Copyright 2004-2011 ABB. All rights reserved.

D Ear, bearing and o-rings

E Label with article number
F Inspect the surroundings
G Bearing, balancing device attachments

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 168 to determine whether to perform
maintenance or upgrade!

Equipment, etc. Spare part no. Art. no. Note

Maintenance kit, 3HAC15834-1 Includes:
complete • complete kit including
the kit with bearings
and seals
• instructions for main-
tenance.

Continues on next page

3HAC022033-001 Revision: K 169
 工控帮助教小舒QQ2823408167
3 Maintenance
3.3.7. Inspection, balancing device

Continued

Equipment, etc. Spare part no. Art. no. Note

Maintenance kit, 3HAC14962-1 Includes:
bearings and seals • kit with bearings, o-
rings and seals only
• instructions for main-
tenance.
Upgrade kit 3HAC14965-1 Includes
• kit with piston rod,
support shaft etc.
• instruction for
conversion,
3HAC15864-2.
Securing screw Securing screw in the shaft.
M16 x 180
Locking liquid must be used
when fitting the screw
(Loctite 243)!
Toolkit for 3HAC15943-1
maintenance
Puller for 4552-2 (Bahco) Used for removing the
separator
公 司 spherical roller bearings.
Separator
限 Used for removing the
4551-C (Bahco)

有 spherical roller bearings.

Standard toolkit
科 技3HAC15571-1 Content is defined in section
Standard toolkit on page 427.
育
帮教
Other tools and These procedures include
procedures may references to the tools
be required. See
references to 工 控 required.

these procedures
长 沙
in the step-by-step
instructions below.

Check for dissonance

The check points are shown in the figure Inspection points, balancing device on page 169. © Copyright 2004-2011 ABB. All rights reserved.

Check for dissonance

If dissonance is detected...
from...
1. • bearing at the link ... perform maintenance or upgrade according to given
ear instructions in Maintenance kit, bearings and seals /
• bearings at the Upgrade kit. The replacement of the bearing at the ear is
balancing devices also detailed in section Replacement of spherical roller
attachments. bearing, balancing device on page 316.
Art. no. for the kit and the documentation are specified in
section Required equipment on page 169.
To decide whether to perform maintenance or upgrade,
see section Action at detected faults on page 168.
2. • balancing device (a ...replace the balancing device or consult ABB Robotics.
tapping sound, How to replace the device is detailed in section
caused by the Replacement of balancing device on page 307. This
springs inside the section also specifies the spare part number!
cylinder).

Continues on next page

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3 Maintenance
3.3.7. Inspection, balancing device

Continued

Check for dissonance

If dissonance is detected...
from...
3. • piston rod ... perform maintenance or upgrade according to given
(squeaking may instructions in Maintenance kit, complete / Upgrade kit.
indicate worn plain Art. no. for the kit and the documentation are specified in
bearings, internal section Required equipment on page 169.
contamination or To decide whether to perform maintenance or upgrade,
insufficient lubrica- see section Action at detected faults on page 168.
tion).

Check for damage

Check for damages, such as scratches, general wear, uneven surfaces or incorrect positions.
The check points are shown in the figure Inspection points, balancing device on page 169.

Check for damage on... If damage is detected...

1. • the piston rod (part of the piston ... perform maintenance or upgrade
rod that is visible at the front of the according to given instructions in
balancing device). Maintenance kit, complete / Upgrade kit.
Art. no. for the kit and the documentation
are specified in section Required

公 司
equipment on page 169.

有 限 To decide whether to perform maintenance

or upgrade, see section Action at detected

科技
faults on page 168.
2. •
育
the securing screw in the front ear ...replace.

帮教
shaft. Dimension is specified in section Required
Also check the tightening torque (50 Nm). equipment on page 169.

工 控
长 沙
© Copyright 2004-2011 ABB. All rights reserved.

Continues on next page

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3 Maintenance
3.3.7. Inspection, balancing device

Continued

Check for leakage

The front ear of the balancing device is lubricated with grease. After filling, excessive grease
may normally be forced out between the shaft and the sealing ring in the sealing spacer. This
is normal behaviour and must not be confused with incorrect leaks from the ear.
Leaks at the o-rings and/or sealings, are not acceptable and must be attended to immediately
in order to avoid any damage to the bearing!
Check the o-rings in the front ear of the balancing device for leaks, as shown and detailed
below.

公 司
有限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0300000284

A Shaft
B O-ring
C Sealing spacer
D Sealing ring in sealing spacer
E Correct way out for excessive grease from inside the front ear
F Incorrect leakage from the front ear

Continues on next page

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3 Maintenance
3.3.7. Inspection, balancing device

Continued

Action Note
1. Clean the area at the front ear from old grease.
2. Run the robot for some minutes, in order to
move the balancing device piston.
3. 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 seals,
Excessive grease from between the shaft and already assembled with sealing
the sealing ring is normal and is not considered spacers and sealing rings.
as a leak! Art. no. for the kit is specified in
Required equipment on page 169.
The replacement of the complete
bearing is also detailed in section
Replacement of spherical roller
bearing, balancing device on page
316.
Incorrect leakage is shown in the
previous figure.

Check for contamination / lack of free space

Action
公 司
限
1.

有
DANGER!
育 科技
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

and SMB.
控 帮教
Turn off all electric power and hydraulic but not the air pressure to the gearboxes, motors

沙 工
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
长
169.
Keep the areas around the balancing device clean and free from objects, such as service
tools.
© Copyright 2004-2011 ABB. All rights reserved.

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3 Maintenance
3.3.8. Inspection, cable harness

3.3.8. Inspection, cable harness

Location of cable harness, axes 1-4

The robot cable harness, axes 1-4, is located as shown in the figure below.

公 司
有 限

育科技

控 帮教
沙 工
长
xx0200000097

A Lower arm
B Cables attached with velcro straps and mounting plate
C Connectors at cable harness division point, R2.M5/6 © Copyright 2004-2011 ABB. All rights reserved.
D Connectors at base

Required equipment

Equipment, etc. Art. no. Note

Standard toolkit - Content is defined in section Standard
toolkit on page 427.
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.
Circuit diagram See chapter Circuit diagram.

Continues on next page

174 3HAC022033-001 Revision: K
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3 Maintenance
3.3.8. Inspection, cable harness

Continued

Inspection, cable harness 1-4

The procedure below details how to inspect the cable harness of axes 1-4.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not
the air pressure to the gearboxes, motors and
SMB.
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 and Shown in the figure Location of cable
at the base. harness, axes 1-4 on page 174.
4.

NOTE!
If the robot is used in a Foundry Prime appli- 公 司
cation, check the cables for cracks in
有 限
科技
insulation.
5. Check that velcro straps and the mounting Location is shown in the figure Location
育
plate are properly attached to the frame. Also of cable harness, axes 1-4 on page 174.

帮教
check the cabling, leading into the lower arm. A certain wear of the hose at the
Make sure it is attached by the straps and not

工
damaged. 控 entrance to the lower arm is natural.

长 沙
6. Replace the cable harness if wear, cracks or
damage is detected.
Detailed in section Replacement of
cable harness, axes 1-6.

Location of cabling axes 5-6

The robot cable harness, axes 5-6, is located as shown in the figure below.
© Copyright 2004-2011 ABB. All rights reserved.

xx0200000155

A Cable attachment, upper arm tube

Continues on next page

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3 Maintenance
3.3.8. Inspection, cable harness

Continued

B Cable attachment, rear of upper arm

C Connectors at cable harness division point, R2.M5/6

Inspection, cable harness, axes 5-6

The procedure below details how to inspect the cable harness of axes 5-6.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but
not the air pressure to the gearboxes, motors
and SMB.
2. Make an overall visual inspection of the cable
harness, in order to detect wear and damage.
3. Check the attachments at the rear of the Shown in the figure Location of cabling
upper arm and in the upper arm tube. axes 5-6 on page 175.
Check the connectors at the cable harness
公 司
division. Make sure the attachment plate is
not bent or in any other way damaged. 限
有 Shown in the figure Location of cable
科技
4.

育
harness, axes 1-4 on page 174.

NOTE!
帮 教
cation, check工 控
If the robot is used
the
in a Foundry Prime appli-
cables for cracks in
沙
insulation.
长 the cable harness if wear, cracks or
5. Replace Detailed in section Replacement of
damage is detected. cable harness, axes 5-6 on page 260

© Copyright 2004-2011 ABB. All rights reserved.

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3 Maintenance
3.3.9. Inspecting, mechanical stop pin, axis 1

3.3.9. Inspecting, mechanical stop pin, axis 1

WARNING!
Mechanical stop pin can not be mounted on robot if option 561-1 Extended work range axis
1 is used.

Location of mechanical stop pin

The mechanical stop axis 1 is located at the base as shown in the figure below.

公 司
xx0200000151
有 限
科技
A Mechanical stop pin

育
帮教
Required equipment

Equipment, etc.
工 控 Art. no. Note

沙
Mechanical stop pin axis 1
长 toolkit
3HAC10499-3 To be replaced when damaged.
Standard - Content is defined in section Standard
toolkit on page 427.

Inspecting, mechanical stop pin

© Copyright 2004-2011 ABB. All rights reserved.

Use this procedure to inspect the mechanical stop pin axis 1.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not
the air pressure to the gearboxes, motors and
SMB.
2. Inspect mechanical stop pin, axis 1. Shown in figure Location of
mechanical stop pin on page 177.
3. Make sure mechanical stop pin can move in both
directions.

Continues on next page

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3 Maintenance
3.3.9. Inspecting, mechanical stop pin, axis 1

Continued

Action Note
4. If the mechanical stop pin is bent or damaged, it Art. no. is specified in Required
must be replaced! equipment on page 177.

NOTE!
The expected life of gearboxes can be reduced
as a result of collisions with the mechanical stop.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

178 3HAC022033-001 Revision: K

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3 Maintenance
3.3.10. Inspection, mechanical stop, axes 1, 2 and 3

3.3.10. Inspection, mechanical stop, axes 1, 2 and 3

Location of the mechanical stops

The figure below shows the location of the additional mechanical stops on axes 1, 2 and 3.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0200000150

A Additional stop
B Fixed stop
© Copyright 2004-2011 ABB. All rights reserved.

Required equipment

Equipment etc. Art. no. Note

Mechanical stop ax 1 3HAC11076-1 Limits the robot working range to
7.5°.
Mechanical stop ax 1 3HAC11076-2 Limits the robot working range to
15°.
Mechanical stop ax 2 3HAC11077-1
Mechanical stop ax 3 3HAC13128-2
Standard toolkit - Content is defined in section
Standard toolkit on page 427.

Continues on next page

3HAC022033-001 Revision: K 179
 工控帮助教小舒QQ2823408167
3 Maintenance
3.3.10. Inspection, mechanical stop, axes 1, 2 and 3

Continued

Inspection, mechanical stops

The procedure below details how to inspect the additional mechanical stops on axes 1, 2 and
3.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the air
pressure to the gearboxes, motors and SMB.
2. Check the additional stops on axes 1, 2 and 3 for Shown in the figure Location of
damage. the mechanical stops on page
179.
3. Make sure the stops are properly attached.
Correct tightening torque: 115 Nm.
4. If any damage is detected, the mechanical stops must Art. no. is specified in Required
be replaced! equipment on page 179!
Correct attachment screws:
公 司
• Axis 1: M16 x 35
• Axis 2: M16 x 50 有 限
• Axis 3: M16 x 80

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

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3 Maintenance
3.3.11. Inspection, damper axes 2-5

3.3.11. Inspection, damper axes 2-5

Location of dampers
The figure below shows the location of all the dampers to be inspected.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0200000099

A Damper, axis 2 (2 pcs)

B Damper, axis 3 (2 pcs)
C Damper, axis 4 (2 pcs)
D Damper, axis 5 (2 pcs)

Required equipment

Equipment Art. no. Note

Damper axis 2 3HAC12990-1 Replace if damaged!
Damper axis 3 3HAC11750-1 Replace if damaged!
Damper axis 4 3HAC13564-1 Replace if damaged!
Damper axis 5 3HAC10503-8 Replace if damaged!
Standard toolkit - Content is defined in section Standard
toolkit on page 427.

Continues on next page

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3 Maintenance
3.3.11. Inspection, damper axes 2-5

Continued

Inspection, damper axis 2-5

The procedure below details how to inspect the dampers, axis 2-5.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the air
pressure to the gearboxes, motors and SMB.
2. Check all dampers for damage, such as cracks or Shown in the figure Location of
existing impressions larger than 1 mm. dampers on page 181.
In order to inspect dampers, axis 4, the two covers on
top of the upper arm must be removed!
3. Check attachment screws for deformation.
4. If any damage is detected, the damper must be Art. no. is specified in Required
replaced with a new one! equipment on page 181.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

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3 Maintenance
3.3.12. Inspection, position switch axes 1, 2 and 3

3.3.12. Inspection, position switch axes 1, 2 and 3

Location of position switches

The position switches, axes 1, 2 and 3, are located as shown in the figures below.

公 司
有 限
xx0100000158

育 科技
A
B Cam帮 教
Position switch, axis 1

C
工 控
Set screw, cam

长沙
D Protection sheet
E Rail
F Rail attachment
© Copyright 2004-2011 ABB. All rights reserved.

Continues on next page

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3 Maintenance
3.3.12. Inspection, position switch axes 1, 2 and 3

Continued

The illustration below shows the position switch for axis 2.

xx0100000159

A Position switch, axis 2

公 司
B
C
Cam
Set screw, cam 有 限
E
F
Rail
Rail attachment 育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

Continues on next page

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3 Maintenance
3.3.12. Inspection, position switch axes 1, 2 and 3

Continued

The illustration below shows the position switch for axis 3.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0100000160

A Position switch, axis 3

B Cam
© Copyright 2004-2011 ABB. All rights reserved.

C Set screw, cam

E Rail
F Rail attachment

Required equipment

Equipment, etc. Spare part no. Note

Position switch, axis 1 3HAC15715-1 To be replaced in case of detected
damage.
Position switch, axis 2 3HAC15715-2 To be replaced in case of detected
damage.
Position switch, axis 3 3HAC15715-2 To be replaced in case of detected
damage.
Standard toolkit - Content is defined in section
Standard toolkit on page 427.

Continues on next page

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3 Maintenance
3.3.12. Inspection, position switch axes 1, 2 and 3

Continued

Equipment, etc. Spare part no. Note

Other tools and procedures may These procedures include
be required. See references to references to the tools required.
these procedures in the step-by-
step instructions below.

Inspection, position switches

The procedure below details how to inspect the position switch, axes 1, 2 and 3.
See the figure Location of position switches on page 183 to locate the different components
to be inspected.

Action
1.

DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not the air pressure to the gearboxes,
motors and SMB.
2. Check the position switch!
公 司
3. Check the rail! 有 限
• Check that the rollers are easy to push in and that they roll freely.

科技
• Check that the rail is firmly attached with the attachment screws.
4. Check the cams!
育
帮教
• Check that the rollers has not caused any impressions on the cams.

工 控
• 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 沙
the protection sheets on axis 1!
长 • Check that the three sheets are in position and not damaged. Deformation can
result in rubbing against the cams!
• Check that the space inside the sheets is clean enough not to disturb the function
of the position switch.
6. If any damage is detected, the position switch must be replaced. © Copyright 2004-2011 ABB. All rights reserved.

186 3HAC022033-001 Revision: K

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3 Maintenance
3.3.13. Inspection, information labels

3.3.13. Inspection, information labels

Location of labels
These figures show the location of the information labels to be inspected.
The symbols are described in section Safety symbols on manipulator labels on page 41.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0200000100
© Copyright 2004-2011 ABB. All rights reserved.

A Warning label concerning high temperature

B Warning sign, symbol of a lightning flash (located on motor cover)
C Instruction label
D Warning label concerning brake release
E Warning label, tools are not allowed around the balancing device during operation
F Warning label concerning shutting off power
G Label, type of oil in gearbox
H Label, type of oil in gearbox
I Label, type of grease in ear
- Information labels at gearboxes and at robot base, if gearboxes are filled with
Kyodo Yushi TMO 150

Continues on next page

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3 Maintenance
3.3.13. Inspection, information labels

Continued

xx0200000101

J Instruction label concerning lifting the robot

K Warning label concerning risk of tipping
公 司
L Foundry logotype
有 限
N
M
技
Warning label concerning stored energy
科in gearboxes of each axis
Information label, types of oil
育
O
教
Label, type of oil in gearbox
帮
Required equipment
工 控
长沙
Equipment Art. no. Note
Labels and plate set See the chapter Includes all labels specified in previous
Spare parts. figures!
Label set, oil labels See the chapter Includes only the oil labels at the
Spare parts. gearboxes and at the robot base. © Copyright 2004-2011 ABB. All rights reserved.
Are fitted to the robot if the gearboxes
include Kyodo Yushi TMO 150.

Inspecting, labels

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.
2. Check the labels, located as shown in the figures.
3. Replace any missing or damaged labels. Art. no. is specified in Required
equipment on page 188.

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3 Maintenance
3.3.14. Inspection, UL-lamp

3.3.14. Inspection, UL-lamp

Location of UL-lamp
The UL-lamp is located as shown in figure below. Notice that the location can vary depending
on how the customer harness for axes 4-6 is mounted.

公 司
有限

育 科技
xx0200000117

控 帮教
工
A UL signal lamp
B
C 长 沙 Warning sign
Warning label
D Position for cable gland
© Copyright 2004-2011 ABB. All rights reserved.

Required equipment

Equipment, etc. Spare part no. Note

Signal lamp 3HAC10830-1 To be replaced in case of detected
damage.
Includes UL signal lamp, 3HAC
13097-1, Warning label, 3HAC 4431-
1, Warning sign, 3HAC 1589-1
Standard toolkit - Content is defined in section Standard
toolkit on page 427.
Other tools and procedures may These procedures include references
be required. See references to to the tools required.
these procedures in the step-by-
step instructions below.

Continues on next page

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3 Maintenance
3.3.14. Inspection, UL-lamp

Continued

Inspection, UL-lamp
The procedure below details how to inspect the function of the UL-lamp.

Action Note
1. Check that the UL-lamp is lit, when the motors are in
operation ("motors ON").
2. If the lamp is not lit, trace the fault! Part no. is specified in
• Check whether the UL-lamp is broken. If so, Required equipment on
replace it. page 189!
• Check the cable connections.
• Measure the voltage in connectors motor axis 3
(=24V).
• Check the cabling. Replace cabling if a fault is
detected.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

190 3HAC022033-001 Revision: K

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3 Maintenance
3.3.15. Inspection of air hoses (Foundry Prime)

3.3.15. Inspection of air hoses (Foundry Prime)

General
The air hoses on Foundry Prime robots must be inspected for leakage every six months.

Required equipment

Equipment, etc. Art. no.

Leak detection spray -
Pressure gauge -
Cut off valve -

Procedure
For this test it is recommended that the air supply to the robot has a pressure gauge and a cut-
off valve connected.

Action Note
1. Apply compressed air to the air Recommended pressure:
connector on robot base, and
raise the pressure with the knob
0.2-0.3 bar
公 司
until the correct value is shown on
the pressure gauge. 有 限

育 科技

控 帮教
沙 工 xx0600002794

• A: Air Connection
长 • B: Cut off valve
• C: Pressure gauge
2. Close the cut off valve. It should take at least 5 seconds for the pressure to
reach 0 bar.
© Copyright 2004-2011 ABB. All rights reserved.

3. The time is < 5 seconds:

• If the answer is YES:
Localize the leakage by
following the procedures
below.
• If the anser is NO: The
system is OK. Remove the
leak testing equipment.
4. Pressurize by opening the cut off
valve.
5. Spray suspected leak areas with
leak detection spray.
Bubbles indicate a leak.
6. When the leak is localized: correct
the leak.

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3 Maintenance
3.4.1. Type of oil

3.4 Changing/replacement activities

3.4.1. Type of oil

Overview
Different types of oil are used in the robot gearboxes depending on the robot serial number.
This section describes:
• Determining oil type on page 193
• Which type of oil does the gearbox contain on page 193
• Robot serial numbers on page 193
• Labels on the robot on page 195
• Article numbers and volumes, Alternative Optimol Optigear RMO 150 on page 196
• Article numbers and volumes, Alternative Kyodo Yushi TMO 150 on page 197
• Mixed types of oil may cause severe damage! on page 197
• Rinsing gearbox on page 198
• Equipment on page 198

Location of gearbox 公 司
有 限
The figure shows the location of the gearboxes on the robot.

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0400000798

A Axis 1 gearbox
B Axis 2 gearbox
C Axis 3 gearbox
D Axis 4 primary gearbox
E Axis 4 secondary gearbox
F Axis 5 primary gearbox
G Axis 5 secondary gearbox
Continues on next page
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3 Maintenance
3.4.1. Type of oil

Continued

H Axis 6 gearbox

Determining oil type

Use this procedure to determine which type of oil is used in the gearboxes.

Action
1. Read the section Which type of oil does the gearbox contain on page 193to find the type
of oil.
2. Use section Article numbers and volumes, Alternative Optimol Optigear RMO 150 on
page 196to get correct oil data.

CAUTION!
When filling gearbox oil, do not mix different types of oil as this may cause severe damage
to the gearbox! Always use the type of oil specified in this section! If oils are mixed the
gearbox must be thoroughly rinsed! see Rinsing gearbox on page 198.

Which type of oil does the gearbox contain

The type of oil filled in the gearbox can be indentified by:
•
• 公 司
Serial number of the robot, see Robot serial numbers on page 193.
Labels attached on the robot, see Labels on the robot on page 195

有 限
科技
Robot serial numbers

育
Serial number Type of oil

帮教
Robot
range Note 1 on page 194

工 控 Axis 1, 2, 3 Axis 4 primary, Axis 4

5 primary, 6 secondary, 5

长 沙 secondary
IRB7600 M2000 76-20000 - 26999 Optimol Shell Tivela S Oil type
Optigear RMO 150 XP320
150
IRB7600 M2000 A 76-30000 - 33999 Optimol Shell Tivela S Oil type
© Copyright 2004-2011 ABB. All rights reserved.

Optigear RMO 150 XP320

150
IRB7600 M2004 76-50000 - 50999 Optimol Shell Tivela S Oil type
Optigear RMO 150 XP320
150

Serial
Type of oil
Robot number
Note 2 on page 194
range
Axis 1 Axis 2, 3 Axis 4 Axis 4
primary, 5 secondary, 5
primary, 6 secondary
IRB7600 76-27000 - Shell Tivela (Shell Tivela S (Shell Tivela S Shell Tivela S
M2000 S 150 150) 150) 150
Kyodo Yushi Kyodo Yushi
TMO 150 TMO 150

Continues on next page

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3 Maintenance
3.4.1. Type of oil

Continued

Serial
Type of oil
Robot number
Note 2 on page 194
range
IRB7600 76-34000 - Shell Tivela (Shell Tivela S (Shell Tivela S Shell Tivela S
M2000 A S 150 150) 150) 150
Kyodo Yushi Kyodo Yushi
TMO 150 TMO 150
IRB7600 76-51000 - Shell Tivela (Shell Tivela S (Shell Tivela S Shell Tivela S
M2004 S 150 150) 150) 150
Kyodo Yushi Kyodo Yushi
TMO 150 TMO 150

Serial number Type of oil

Robot
range Note 3 on page 194
Axis 1, 2 , 3 Axis 4 primary, 4
secondary, 5 primary, 5
secondary, 6
IRB7600 M2000 76-27000 - Kyodo Yushi TMO 150 Kyodo Yushi TMO 150
IRB7600 M2000 A 76-34000 - Kyodo Yushi TMO 150 Kyodo Yushi TMO 150

公司
IRB7600 M2004 76-51000 - Kyodo Yushi TMO 150 Kyodo Yushi TMO 150

Note 1 有限
科 技
Make sure that the original oil has not been changed after delivery
育
Note 2
帮 教
工
axis 2, 3, 4 primary,
控
A Field Service information SI10177, dated Sept. 10, 2008 recommended an oil change in
5 primary, and 6 from Shell Tivela S 150 to Kyodo Yushi TMO 150. A

长沙 schedule was introduced by SI10177.

new maintenance

Note 3
IRB 7600 robots delivered from ABB Robotics since Sept. 1, 2008 has Kyodo Yushi TMO
© Copyright 2004-2011 ABB. All rights reserved.
150 filled in gearboxes axis 1, 2, 3, 4 primary and secondary, 5 primary and secondary, and 6.

Continues on next page

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3 Maintenance
3.4.1. Type of oil

Continued

Labels on the robot

If there are gearboxes filled with Shell Tivela S 150 or TMO 150 there are also labels attached
next to oil plugs on each gearbox and on the base. Following figures show the labels.
NOTE!
Robots delivered with Optimol Optigear RMO150 are not equipped with labels. If the oil is
changed to Tivela S150/TMO 150 after delivery the robot must be completed with these
labels.

Labels next to oil plugs

Labels located next to oil plugs of each gearbox show which type of oil it contains. All
gearboxes must have the correct label clearly visible.

Gearbox 4, 5
公 司
有 限

育 科技

控 帮教
工
xx0900000132

-
长 沙 Labels located next to oil plugs.
© Copyright 2004-2011 ABB. All rights reserved.

Continues on next page

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3 Maintenance
3.4.1. Type of oil

Continued

Label at robot base

Label located at robot base shows the types of oil in all gearboxes.

公 司
有 限
xx0500001397

育 科技
帮教
Article numbers and volumes, Alternative Optimol Optigear RMO 150
Alternative - Optimol Optigear RMO 150. Note 1 on page 196Note 2 on page 197
Gearbox
工 控
Type of oil Art.no. Amount
Axis 1 沙Optimol Optigear RO 150 3HAC031291-001 7,600 ml
Axis 2 长 Optimol Optigear RO 150 3HAC031291-001 4,800 ml
Axis 3 Optimol Optigear RO 150 3HAC031291-001 4,200 ml
Axis 4, Kyodo Yushi TMO 150 3HAC032140-001 900 ml

© Copyright 2004-2011 ABB. All rights reserved.

primary gear
Axis 4, Mobilgear 600 XP320 11712016-604 3,850 ml
secondary
gear
Axis 5, Kyodo Yushi TMO 150 3HAC032140-001 750 ml
primary gear
Axis 5, Mobilgear 600 XP320 11712016-604 3,800 ml
secondary
gear
Axis 6 Kyodo Yushi TMO 150 3HAC032140-001 850 ml
750 ml (with
insulated turning
disk)

Note 1
Optimol Optigear RMO 150 Art. No. 3HAC16843-1 has been replaced by Optimol Optigear
RO 150 Art. No.3HAC031291-001.

Continues on next page

196 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.1. Type of oil

Continued

Note 2
Optigear RO 150 and RMO 150 are mixable but none are mixable with Tivela S 150 or
TMO150.

Article numbers and volumes, Alternative Kyodo Yushi TMO 150

Alternative - Kyodo Yushi TMO 150. Note 1 on page 197 Note 2 on page 197
Gearbox Type of oil Art.no. Amount
Axis 1 Kyodo Yushi TMO 150 3HAC032140-001 7,600 ml
Axis 2 Kyodo Yushi TMO 150 3HAC032140-001 4,800 ml
Axis 3 Kyodo Yushi TMO 150 3HAC032140-001 4,200 ml
Axis 4, primary Kyodo Yushi TMO 150 3HAC032140-001 900 ml
gear
Axis 4, secondary Kyodo Yushi TMO 150 3HAC032140-001 3,850 ml
gear
Axis 5, primary Kyodo Yushi TMO 150 3HAC032140-001 750 ml
gear
Axis 5, secondary Kyodo Yushi TMO 150 3HAC032140-001 3,800 ml
gear

公司
Axis 6 Kyodo Yushi TMO 150 3HAC032140-001 850 ml
750 ml (with insulated

有限
turning disk)

Note 1 科 技
育
帮 教
Shell Tivela S 150 Art No. 3HAC021469-001has been replaced by Kyudo Yushi TMO 150
Art. No. 3HAC032140-001.

工 控
Note 2
长 沙
Kyudo Yushi TMO 150 and Shell Tivela S 150 are mixable but none are mixable with
Optigear RO 150 and RMO 150.

Mixed types of oil may cause severe damage!

© Copyright 2004-2011 ABB. All rights reserved.

When refilling or replacing oil in a gearbox it is important to first check which type of oil is
recommended for use in the gearbox. As Kyodo Yushi TMO 150 (as well as Shell Tivela S
150) is not compatible with mineral oil, contamination with other types of oil in the gearboxes
is not accepted. Equipment used in handling Kyodo Yushi (as well as Shell Tivela S 150) must
be carefully cleaned before use!
If the type of oil needs to be changed, the gearbox must be thoroughly rinsed. See Rinsing
gearbox on page 198.

Continues on next page

3HAC022033-001 Revision: K 197
 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.1. Type of oil

Continued

Rinsing gearbox
Depending on which types of oil are mixed and which type of oil shall be filled in the gearbox
after rinsing, use the appropriate procedure.
The same applies if the type of oil shall be changed in the gearbox.
NOTE!
The explanation given for Kyodo Yushi TMO 150 also applies to Shell Tivela S 150.
The explanation given for Mobilgear 600 XP320 also applies to Mobil Gearlube X320.

Kyodo Yushi TMO 150 mixed with Optimol Optigear RMO 150/Optigear RO 150
Use this procedure to rinse the contaminated gearbox if the oil types Kyodo Yushi TMO 150
and Optimol Optigear RMO 150/Optigear RO 150 are mixed.
• Flush the gearbox properly three times with the correct type of oil. Use a service
program when flushing.
• Refill the gearbox with the correct type of oil.

Kyodo Yushi TMO 150 mixed with Mobilgear 600 XP320

Use this procedure to rinse the contaminated gearbox if the gearbox shall contain Kyodo
Yushi TMO 150 and it is mixed with Mobilgear 600 XP320.
•
公 司
Flush the gearbox properly three times with Kyodo Yushi TMO 150. Use a service
program when flushing.
有 限
科技
• Refill the gearbox with Kyodo Yushi TMO 150.

育
帮教
Equipment

工控
Equipment Art. no. Note

长沙
Label set See Spare Parts. Includes small labels for each gearbox
and the complete label to be fitted at
the robot base.
NOTE! Correct labels must be fitted to
the robot in case of changing oil types.
Oil change equipment 3HAC021745-001 Includes pump with outlet pipe.
© Copyright 2004-2011 ABB. All rights reserved.

198 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.2. Oil change, gearbox axis 1

3.4.2. Oil change, gearbox axis 1

Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
The oil is drained with a hose that may be reached behind the rear cover of the robot base.

公 司
有 限
科技
xx0200000111

A Gearbox, axis 1
育
帮教
B Oil plug, filling
C
D 工 控
Motor, axis 1
Oil plug, inspection (not in all designs)
E
长 沙 Label, specifies the type of oil in the gearbox
© Copyright 2004-2011 ABB. All rights reserved.

Continues on next page

3HAC022033-001 Revision: K 199
 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.2. Oil change, gearbox axis 1

Continued

Oil plug in the base

In some early versions of the robot, the oil plug for draining may be located in the base, as
shown in the figure below.

xx0300000065

A Oil plug in the base

公 司
Required equipment 有 限
Equipment, etc.
育
Art. no. 科技 Amount Note
Lubricating oil
教
3HAC032140-001 7,600 ml Kyodo Yushi TMO 150

控帮
NOTE! Do not mix with other
oils!

沙 工
Oil collecting vessel Capacity: 8,000 ml.
长 equipment
Oil exchange 3HAC17313-1 Content is defined in section
Special tools on page 428.
Standard toolkit - Content is defined in section
Standard toolkit on page 427.
Other tools and These procedures include © Copyright 2004-2011 ABB. All rights reserved.
procedures may be references to the tools
required. See references required.
to these procedures in
the step-by-step instruc-
tions below.

NOTE!
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may differ from the specified amount, depending on how much
oil has previously been drained from the gearbox.

Continues on next page

200 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.2. Oil change, gearbox axis 1

Continued

Draining, oil, gearbox axis 1

The procedure below details how to drain the oil from the 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 200.

Action Note
1.

WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please read the safety
information in the section WARNING - Safety risks
during work with gearbox lubricants (oil or grease)
on page 51.
2.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
公 司
Turn off all electric power and hydraulic but not the

有 限
air pressure to the gearboxes, motors and SMB.

科技
3. Remove the rear cover on the base by unscrewing
its attachment screws.
育
帮教
4. Pull the oil hose out of the rear of the base.
Some early versions of the robot has the oil

工 控
draining plug in the base as shown in the figure Oil
plug in the base on page 200 instead of the hose.

长 沙
5. Place an oil vessel close to the hose end. Vessel capacity specified in
Required equipment on page 200.
6. Remove the oil plug, filling, in order to drain the oil
quicker!
© Copyright 2004-2011 ABB. All rights reserved.

7. Open the hose end and drain the oil into the
vessel.

NOTE!
The draining is time-consuming.
Elapsed time depends on the
temperature of the oil.
8. Close the oil drain hose, and put it back inside the
base.
9. Close the rear cover by securing it with its
attachment screws.

Continues on next page

3HAC022033-001 Revision: K 201
 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.2. Oil change, gearbox axis 1

Continued

Filling, oil, gearbox axis 1

The procedure below details how to fill oil in gearbox, axis 1.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 200.

Action Note
1.

WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please read the safety
information in the section WARNING - Safety risks
during work with gearbox lubricants (oil or grease)
on page 51.
2.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
公 司
Turn off all electric power and hydraulic but not the

有
air pressure to the gearboxes, motors and SMB. 限
科技
3. Open the oil plug, filling. Shown in the figure Location of
gearbox on page 199.
育
帮教
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
控
amount previously being drained. The correct oil
工
level is detailed in section Inspection, oil level
on page 200.

沙
gearbox axis 1 on page 150.
长
5.

WARNING!
Do not mix oil types! If wrong oil is refilled, the © Copyright 2004-2011 ABB. All rights reserved.
gearbox must be rinsed as detailed in section Type
of oil on page 192.
6. Refit the oil plug, filling. Tightening torque: 24 Nm.

202 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.3. Oil change, gearbox axis 2

3.4.3. Oil change, gearbox axis 2

Location of oil plugs

The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor
attachment.

公 司
有 限

育 科技

控 帮教
沙
xx0200000112工
A 长 Gearbox, axis 2
B Oil plug, filling (later design)
C Oil plug, draining
© Copyright 2004-2011 ABB. All rights reserved.

D Label, specifies the type of oil in the gearbox

Required equipment

Equipment, etc. Art. no. Amount Note

Lubricating oil 3HAC032140-001 4,800 ml Kyodo Yushi TMO 150
Note! Do not mix with other oil
types!
Oil collecting vessel - Capacity: 5,000 ml.
Oil exchange 3HAC021745-001 Content is defined in section
equipment Special tools on page 428.
Standard toolkit - Content is defined in section
Standard toolkit on page 427.

Continues on next page

3HAC022033-001 Revision: K 203
 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.3. Oil change, gearbox axis 2

Continued

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 203.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but
not the air pressure to the gearboxes, motors
and SMB.
2.

WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please read the
safety information in the section WARNING - 公 司
Safety risks during work with gearbox
有 限
3.
lubricants (oil or grease) on page 51.
Remove the oil plug, draining, and
技
科drain the Shown in the figure Location of oil plugs
gearbox oil using a hose with 育 nipple and an on page 203.
oil collecting vessel.
帮 教 Vessel capacity is specified in Required

the oil quicker! 控

Remove the oil plug, filling in order to drain equipment on page 203.

沙 工
长 NOTE!
Draining is time-consuming. Elapsed
time varies depending on the

© Copyright 2004-2011 ABB. All rights reserved.

temperature of the oil.
4. Refit the oil plug. Tightening torque: 24 Nm.

Continues on next page

204 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.3. Oil change, gearbox axis 2

Continued

Filling, oil
The procedure below details how to fill oil into the gearbox, axis 2.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 203.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.
2.

WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please read the safety

公 司
information in the section WARNING - Safety risks
during work with gearbox lubricants (oil or grease)
on page 51.
有 限
科技
3. Remove the oil plug, filling and the plug from the Shown in the figure Location of oil
vent hole. plugs on page 203.
育
帮教
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 on
控
amount previously being drained. The correct oil
工
level is detailed in section Inspection, oil level
page 203.

沙
gearbox axis 2 on page 153 .
长
5.

WARNING!
© Copyright 2004-2011 ABB. All rights reserved.

Do not mix oil types! If wrong oil is refilled, the

gearbox must be rinsed as detailed in section Type
of oil on page 192.
6. Refit the oil plug. Tightening torque: 24 Nm.

3HAC022033-001 Revision: K 205

 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.4. Oil change, gearbox, axis 3

3.4.4. Oil change, gearbox, axis 3

Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0200000113

© Copyright 2004-2011 ABB. All rights reserved.

A Gearbox, axis 3
B Oil plug, filling
C Oil plug, draining
D Label, specifies the type of oil in gearbox

Required equipment

Equipment, etc. Art. no. Amount Note

Lubricating oil 3HAC032140-001 4,200 ml Kyodo Yushi TMO 150
Note! Do not mix with other oil
types!
Oil exchange 3HAC021745-001 Content is defined in section
equipment Special tools on page 428.
Oil collecting vessel - Capacity: 5,000 ml.
Standard toolkit - Content is defined in section
Standard toolkit on page 427.

Continues on next page

206 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.4. Oil change, gearbox, axis 3

Continued

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 206.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but
not the air pressure to the gearboxes, motors
and SMB.
2.

WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please read the
safety information in the section WARNING - 公 司
Safety risks during work with gearbox
有 限
3. Remove the oil plug, draining,科
技
lubricants (oil or grease) on page 51.
and drain the Shown in the figure Location of gearbox
gearbox oil using a hose 育with nipple and an on page 206.
oil collecting vessel. 教

控 帮 filling in order to drain

Remove the oil plug,
Vessel capacity is specified in Required
equipment on page 206.
工
the oil quicker!
沙
长
NOTE!
Draining is time-consuming. Elapsed
© Copyright 2004-2011 ABB. All rights reserved.

time varies depending on the

temperature of the oil.
4. Refit the oil plug. Tightening torque: 24 Nm.

Continues on next page

3HAC022033-001 Revision: K 207
 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.4. Oil change, gearbox, axis 3

Continued

Filling, oil
The procedure below details how to fill oil into 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 206.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the air
pressure to the gearboxes, motors and SMB.
2.

WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please read the safety information
in the section WARNING - Safety risks during work
with gearbox lubricants (oil or grease) on page 51. 公 司
3. Remove the oil plug, filling.
有 限 Shown in the figure Location of

科 技 gearbox on page 206.

育
4. Refill the gearbox with lubricating oil. Art. no. and total amount are

帮 教
The amount of oil to be refilled depends on the amount specified in Required
previously drained. The correct oil level is detailed in equipment on page 206.

page 156工 控
the section Inspection, oil level gearbox axis 3 on

5.
长 沙
WARNING!
Do not mix oil types! If wrong oil is refilled, the gearbox
must be rinsed as detailed in section Type of oil on © Copyright 2004-2011 ABB. All rights reserved.
page 192.
6. Detailed in the section Type of
oil on page 192.

NOTE!
Do not mix Kyodo Yushi TMO 150 with other oil types!
7. Refit the oil plug. Tightening torque: 24 Nm.

208 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.5. Oil change, gearbox, axis 4

3.4.5. Oil change, gearbox, axis 4

Different types of oil

The primary and secondary gear may require different types of oil, that must never be mixed!
If they are mixed, the gear must be rinsed according to section Flushing a contaminated
gearbox on page 231.

Location of gearbox
The axis 4 gearbox is located at the rear of the upper arm as shown in the figure below.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0200000107

A Upper arm housing

B Cover, axis 4 gearbox
C Oil plug, filling, secondary gear
D Oil plug, draining, secondary gear
E Oil plug, filling, primary gearbox (draining not shown in figure, located further down
on the motor flange)
F Label, specifies the type of oil in the secondary gear
G Label, specifies the type of oil in the primary gear

Continues on next page

3HAC022033-001 Revision: K 209
 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.5. Oil change, gearbox, axis 4

Continued

Required equipment

Equipment, etc. Art. no. Amount Note

Lubricating oil 3HAC032140-001 900 ml Kyodo Yushi TMO 150
To be used in the primary gearbox.
Lubricating oil 3HAC032140-001 3,850 ml Kyodo Yushi TMO 150
To be used in the secondary
gearbox.
Oil collecting vessel, Capacity: 1,000 ml.
primary gearbox
Oil collecting vessel, Capacity: 4,000 ml.
secondary gearbox
Oil exchange 3HAC17313-1 Content is defined in section Special
equipment tools on page 428.
Standard toolkit - Content is defined in section
Standard toolkit on page 427.

Draining, oil, gearbox axis 4

The procedure below details how to drain the oil from the gearbox, axis 4.

公 司
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.

限
no. for the kit is specified in Required equipment on page 210.
有
科技
Action Note
1. 育
控 帮教
WARNING!
沙 工
Handling gearbox oil involves several safety risks.
长
Before proceeding, please read the safety
information in the section WARNING - Safety risks
during work with gearbox lubricants (oil or grease)
on page 51.

© Copyright 2004-2011 ABB. All rights reserved.

2. Open the oil plug, draining, secondary gear. Shown in the figure Location of
gearbox on page 209.
3. Drain the oil from the secondary gearbox by running Vessel capacity specified in
the upper arm -45° from calibration position. Required equipment on page
210.
4. Run the robot back to its calibration position. Detailed in section Calibration
scale and correct axis position on
page 406.
5.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.
6. Drain the primary gear by opening the oil plug, Vessel capacity specified in
draining, primary gearbox. Required equipment on page
210.

Continues on next page

210 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.5. Oil change, gearbox, axis 4

Continued

Action Note
7. Refit the both oil plugs, draining. Tightening torque: 24 Nm.

Filling, oil, gearbox axis 4

The procedure below details how to fill oil in gearbox, axis 4.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 210.

Action Note
1.

WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please read the safety
information in the section WARNING - Safety risks
during work with gearbox lubricants (oil or grease)
on page 51.
2.

公 司
DANGER!
有 限
科技
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
育
Turn off all electric power and hydraulic but not the

帮教
air pressure to the gearboxes, motors and SMB.

工 控
3. Refill the secondary gear with lubricating oil through Kyodo Yushi TMO 150
the oil plug, filling, secondary gear. Art. no. and amount is specified in

长 沙 Required equipment on page

210.
Shown in the figure Location of
gearbox on page 209.
4. Refill the primary gearbox with oil through the oil Kyodo Yushi TMO 150
© Copyright 2004-2011 ABB. All rights reserved.

plug, filling, primary gear. Make sure the air is Shown in the figure Location of
ventilated through the oil plug during filling, to avoid gearbox on page 209.
overpressure in the gearbox. Art. no. and total amount is
The amount of oil to be refilled depends on the specified in Required equipment
amount previously being drained. The correct oil on page 210.
level is detailed in section Inspection, oil level
gearbox axis 4 on page 158.
5.

WARNING!
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section Type
of oil on page 192.
6. Refit the both oil plugs, filling. Shown in the figure Location of
gearbox on page 209.
Tightening torque: 24 Nm.

3HAC022033-001 Revision: K 211

 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.6. Oil change, gearbox, axis 5

3.4.6. Oil change, gearbox, axis 5

Different types of oil

The primary and secondary gear may require different types of oil, that must never be mixed!
If they are mixed, the gear must be rinsed according to section Flushing a contaminated
gearbox on page 231.

Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0200000108

A Wrist housing
B Cover, axis 5 gearbox
C Oil plug, filling secondary gear
D Oil plug, draining secondary gear
E Oil plug, filling primary gearbox (draining on opposite side of wrist housing, not
shown in figure)
F Label, specifies the type of oil in primary gear
G Label, specifies the type of oil in secondary gear

Continues on next page

212 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.6. Oil change, gearbox, axis 5

Continued

Required equipment

Equipment, etc. Art. no. Amount Note

Lubricating oil 3HAC032140-001 750 ml Kyodo Yushi TMO 150
To be used in the primary gearbox.
Lubricating oil 3HAC032140-001 3,800 ml Kyodo Yushi TMO 150
To be used in the secondary
gearbox.
Oil collecting vessel Capacity: 1,000 ml.
Oil collecting vessel Capacity: 4,000 ml.
Oil exchange 3HAC17313-1 Content is defined in section
equipment Special tools on page 428.
Standard toolkit - Content is defined in section
Standard toolkit on page 427.

NOTE!
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may differ from the specified amount, depending on how much
oil has previously been drained from the gearbox.

公 司
Draining, oil, gearbox axis 5
有 限
The procedure below details how to drain the oil from the gearbox, axis 5.

育 科技
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 213.

帮教
工控
Action Note

长沙
1.

WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please read the safety
© Copyright 2004-2011 ABB. All rights reserved.

information in the section WARNING - Safety risks

during work with gearbox lubricants (oil or grease) on
page 51.
2. Open the oil plug, draining, primary gearbox.
3. Drain the oil from the primary gearbox. Vessel capacity: 1,000 ml.
4. Run axis 4 to a position +90° from the calibration
position.
5. Open the oil plug, draining, secondary gearbox. Shown in the figure Location of
gearbox on page 212.
6. Drain the oil from the secondary gear. Vessel capacity: 4,000 ml.
7. Refit the both oil plugs, draining. Shown in the figure Location of
gearbox on page 212.
Tightening torque: 24 Nm.

Continues on next page

3HAC022033-001 Revision: K 213
 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.6. Oil change, gearbox, axis 5

Continued

Filling, oil, gearbox axis 5

The procedure below details how to fill oil in gearbox, axis 5.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 213.

Action Note
1.

WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please read the safety
information in the section WARNING - Safety risks
during work with gearbox lubricants (oil or grease) on
page 51.
2.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
公 司
Turn off all electric power and hydraulic but not the air
pressure to the gearboxes, motors and SMB.
有 限
科技
3. Refill the primary gearbox with lubricating oil through Kyodo Yushi TMO 150
the oil plug, filling. Make sure the air is ventilated Art. no. and total amount is
育
through the oil plug during filling, to avoid overpres-

帮教
specified in Required equipment
sure in the gearbox. on page 213.

工 控
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil
Shown in the figure Location of
gearbox on page 212.

长 沙
level is detailed in section Inspection, oil level,
gearbox axis 5 on page 161.
4. Refill the secondary gearbox with lubricating Kyodo Yushi TMO 150
oilthrough the oil plug, filling. Art. no. and total amount is
The amount of oil to be refilled depends on the specified in Required equipment

© Copyright 2004-2011 ABB. All rights reserved.

amount previously being drained. The correct oil on page 213.
level is detailed in section Inspection, oil level, Shown in the figure Location of
gearbox axis 5 on page 161. gearbox on page 212.
5.

WARNING!
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section Type of
oil on page 192.
6. Refit the both oil plugs, filling. Shown in the figure Location of
gearbox on page 212.
Tightening torque: 24 Nm.

214 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.7. Oil change, gearbox axis 6

3.4.7. Oil change, gearbox axis 6

Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0200000114

A Gearbox, axis 6
B Oil plug, filling (notice the different locations of the plug, shown as B1 and B2)
© Copyright 2004-2011 ABB. All rights reserved.

C Oil plug, draining (can be located on the turning disk instead)

D Label, specifies the type of oil in gearbox axis 6

Required equipment

Equipment, etc. Art. no. Amount Note

Lubricating oil 3HAC032140-001 850 ml Kyodo Yushi TMO 150
750 ml (with
insulated turning
disk)
Oil collecting vessel Vessel capacity: 1,000 ml.
Oil exchange 3HAC17313-1 Content is defined in section
equipment Special tools on page 428.
Standard toolkit - Content is defined in section
Standard toolkit on page
427.

Continues on next page

3HAC022033-001 Revision: K 215
 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.7. Oil change, gearbox axis 6

Continued

NOTE!
The specified amount of oil is based on the total volume of the gearbox. When changing the
oil, the amount of refilled oil may differ from the specified amount, depending on how much
oil has previously been drained from the gearbox.

Draining, oil, gearbox axis 6

The procedure below details how to drain the 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 215.

Action Note
1.

WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please read the safety
information in the section WARNING - Safety risks
during work with gearbox lubricants (oil or grease)
on page 51.

公
2. Move the wrist so that the oil plug, filling of axis 6司 in the figure Location of
Shown
gearbox faces upwards.
有 限 gearbox on page 215!
If the oil plug, draining is located on the turning

科技
disk, rotate the disk so that the plug faces
downwards.
育
帮教
3.

DANGER! 工 控
长 沙
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.
4. Drain the oil from gearbox 6 by removing the oil Vessel capacity: 1000 ml.
plug. Collect the oil with a suitable vessel. © Copyright 2004-2011 ABB. All rights reserved.

Continues on next page

216 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.7. Oil change, gearbox axis 6

Continued

Filling, oil, gearbox axis 6

The procedure below details how to fill 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 215.

Action Note
1.

WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please read the safety
information in the section WARNING - Safety risks
during work with gearbox lubricants (oil or grease)
on page 51.
2. If the oil plug for draining is located on the turning
disk, rotate the disk so that the oil plug faces
upwards.
3.

DANGER! 公 司
有 限
Turn off all electric power, hydraulic and pneumatic

科技
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
育
air pressure to the gearboxes, motors and SMB.

控 帮教
4. Remove the oil plug, filling. Shown in the figure Location of
gearbox on page 215.

沙 工
5. Refill the wrist with lubricating oil. Art. no. and total amount is

长
Make sure the air is ventilated through the oil plug specified in Required equipment
during filling, to avoid overpressure in the gearbox. on page 215.
If the plug hole for draining is located on the turning
disk, the air is ventilated through the open plug
hole.
© Copyright 2004-2011 ABB. All rights reserved.

The amount of oil to be refilled depends on the

amount previously being drained. The correct oil
level is detailed in section Inspection, oil level
gearbox axis 6 on page 164.
6.

WARNING!
Do not mix oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section Type
of oil on page 192.
7. Refit the both oil plugs. Tightening torque: 24 Nm.

3HAC022033-001 Revision: K 217

 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.8. Replacing SMB battery

3.4.8. Replacing SMB battery

NOTE!
The lifetime of the SMB lithium battery can be extended significantly during a production
break by activating sleep mode with a service routine. See Operating manual - IRC5 with
FlexPendant, section Battery shutdown service routine.

Location of SMB battery

The SMB battery (SMB = serial measurement board) is located on the left hand side of the
frame as shown in the figure below.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0200000238

A SMB battery cover

© Copyright 2004-2011 ABB. All rights reserved.

B SMB battery pack
C Battery cable

Required equipment

Equipment, etc. Spare part no. Note

Battery pack 3HAC16831-1 Battery includes protection circuits. Replace it
only with a given spare part number or an ABB
approved equivalent.
Standard toolkit - Content is defined in section Standard toolkit
on page 427.
Circuit Diagram - See chapter Circuit diagram.

Continues on next page

218 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.8. Replacing SMB battery

Continued

Removing, battery
Use this procedure to remove SMB battery.

Action Note
1. Move robot to its calibration position. This is done in order to facilitate the
updating of the revolution counter.
2.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.
3.

esd

WARNING!

司
The unit is sensitive to ESD. Before handling the
unit please read the safety information in the

限 公
section WARNING - The unit is sensitive to ESD! on
page 49
有
科技
4. Remove SMB battery cover by unscrewing its Shown in figure Location of SMB

育
attachment screws. battery on page 218.

帮教
5. Pull out battery and disconnect battery cable. Shown in figure Location of SMB
battery on page 218.

工 控
6. Remove SMB battery. Shown in figure Location of SMB

长 沙
Battery includes protection circuits. Replace it only battery on page 218.
with the specified spare part or with an ABB
approved equivalent.
© Copyright 2004-2011 ABB. All rights reserved.

Continues on next page

3HAC022033-001 Revision: K 219
 工控帮助教小舒QQ2823408167
3 Maintenance
3.4.8. Replacing SMB battery

Continued

Refitting, battery
Use this procedure to refit the SMB battery.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.
2.

esd

WARNING!
The unit is sensitive to ESD. Before handling the
unit please read the safety information in the
section WARNING - The unit is sensitive to ESD!
on page 49
公 司
fit it to frame.
有 限
3. Reconnect battery cable to SMB battery pack and Art. no. is specified in Required
equipment on page 218.

科技
Shown in figure Location of SMB
battery on page 218.
育
帮教
4. Secure the SMB battery cover with its attachment Shown in figure Location of SMB
screws. battery on page 218.

工 控
5. Update revolution counter. Detailed in chapter Calibration -

长 沙 section Updating revolution

counters on page 408.
6.

DANGER!
Make sure all safety requirements are met when © Copyright 2004-2011 ABB. All rights reserved.
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 47.

220 3HAC022033-001 Revision: K

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3 Maintenance
3.5.1. Lubrication of spherical roller bearing, balancing device

3.5 Lubrication activities

3.5.1. Lubrication of spherical roller bearing, balancing device

Location of bearing
The spherical roller bearing is located at the front ear of the balancing device, as shown in the
figure below.
Note! The balancing device must be mounted on the robot when lubricating the bearing!

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0200000109

A Ear (spherical roller bearing located inside)

B Lubrication nipple or securing screw
C Sealing spacer
D Hole through which the shaft is pressed

Required equipment

Equipment, etc. Art. no. Note

Grease 3HAA1001-294 Optimol PDO, 150 ml
Lubrication nipple M6.
Grease pump -

Continues on next page

3HAC022033-001 Revision: K 221
 工控帮助教小舒QQ2823408167
3 Maintenance
3.5.1. Lubrication of spherical roller bearing, balancing device

Continued

Lubrication, balancing device bearing

The procedure below details how to lubricate the spherical roller bearing.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but
not the air pressure to the gearboxes, motors
and SMB.
2. Lubricate the spherical roller bearing through Art. no. and amount is specified in
the lubrication nipple in the ear with grease. Required equipment on page 221!
Fill until excessive grease is forced out Shown in the figure Location of bearing
between the shaft and the sealing spacer. on page 221!
The balancing device must be
mounted on the robot when lubricating
the bearing!
3. Clean the area from any excessive grease
and check the area once again after
公 司
Read more about the inspection in
section Inspection, balancing device -

有 限
operation of the robot, in order to make sure Check for leakage on page 172.
there is no incorrect leakage from the o-rings.

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

222 3HAC022033-001 Revision: K

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3 Maintenance
3.5.2. Rust preventive measures, bearing axis 1 (Foundry Prime)

3.5.2. Rust preventive measures, bearing axis 1 (Foundry Prime)

Location of bearing axis 1

The bearing axis 1 is located as shown in the illustration. (View from above).

公 司
有 限

育科技
帮教
A
xx0600002866

A
工 控
Plastic ring, (bearing cover)

长 沙
Required equipment

Equipment Art. no. Note

Brush -
© Copyright 2004-2011 ABB. All rights reserved.

Rust preventive 3HAC034903-001 Equivalent:

• Mercasol 3106
Standard toolkit Content is defined in section
Standard toolkit on page 427.
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.

Continues on next page

3HAC022033-001 Revision: K 223
 工控帮助教小舒QQ2823408167
3 Maintenance
3.5.2. Rust preventive measures, bearing axis 1 (Foundry Prime)

Continued

Procedure
The following procedure details how to apply the rust preventive on bearing axis 1.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not
the air pressure to the gearboxes, motors and
SMB.
2. Remove the plastic ring.

公 司
有 限

育 科技

控 帮教
沙 工 A
长 xx0600002866

Parts:
• A: Plastic ring
3. Wipe the surface under the plastic ring.

© Copyright 2004-2011 ABB. All rights reserved.

Continues on next page

224 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
3 Maintenance
3.5.2. Rust preventive measures, bearing axis 1 (Foundry Prime)

Continued

Action Note
4. Apply rust preventive on the bearing with a
brush.

A
xx0600002867

Parts:
• A: Bearing
5. Refit the plastic ring.
公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 225

 工控帮助教小舒QQ2823408167
3 Maintenance
3.5.3. Rust preventive measures, sealing axis 4 (Foundry Prime)

3.5.3. Rust preventive measures, sealing axis 4 (Foundry Prime)

Overview
The sealing axis 4 is located as shown in the illustration.

公 司
限
xx0500002869

A Cover
有
B Cable guide

育 科技
Required equipment
控 帮教
Equipment
沙 工 Art. no. Note
Brush
长
Rust preventive
-
3HAC034903-001 Equivalent:
• Mercasol 3106
Standard toolkit Content is defined in section

© Copyright 2004-2011 ABB. All rights reserved.

Standard toolkit on page 427.
Other tools and procedures These procedures include
may be required. See references to the tools
references to these required.
procedures in the step-by-
step instructions below.

Continues on next page

226 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
3 Maintenance
3.5.3. Rust preventive measures, sealing axis 4 (Foundry Prime)

Continued

Procedure
The procedure describes how to apply rust preventive on sealing axis 1.

Action Note
1. Put the robot in a suitable position.
2.

DANGER!
Turn off all electric power, hydraulic
and pneumatic pressure supplies to
the robot!
Turn off all electric power and
hydraulic but not the air pressure to
the gearboxes, motors and SMB.
3. Remove the cover at the rear end of
the upper arm.

公 司
有 限

育 科技

控 帮教
沙 工 xx0600002872

长 Parts:
• A: Cover
• B: Cable guide
4. Remove the cable guide that covers
© Copyright 2004-2011 ABB. All rights reserved.

the sealing.

xx0600002871

Parts:
• A: Cable guide
5. Wipe the surface under the cable
guide.

Continues on next page

3HAC022033-001 Revision: K 227
 工控帮助教小舒QQ2823408167
3 Maintenance
3.5.3. Rust preventive measures, sealing axis 4 (Foundry Prime)

Continued

Action Note
6. Apply rust preventive on the radial
sealing and the rear part of the tube
with a brush.

xx0600002868

Parts:
• A: Radial sealing and rear part of tube
• B: Cable guide
7. Refit the radial sealing and cable
guide.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

228 3HAC022033-001 Revision: K

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3 Maintenance
3.5.4. Rust preventive measures, support bearing in wrist (Foundry Prime)

3.5.4. Rust preventive measures, support bearing in wrist (Foundry Prime)

Location of bearing
The support bearing in the wrist is located as shown in the illustration.

xx0500002863

A Bearing
B Cable bracket
C Cover
公 司
有 限
科技
Required equipment

Equipment
育
Art. no. Note
Brush
帮 教-
Rust preventive 控 3HAC034903-001 Equivalent:
工
Standard沙
• Mercasol 3106

长 toolkit Content is defined in section

Standard toolkit on page 427.
Other tools and procedures These procedures include
may be required. See references to the tools required.
© Copyright 2004-2011 ABB. All rights reserved.

references to these
procedures in the step-by-
step instructions below.

Greasing bearings
The procedure describes how to apply rust preventive on the support bearing.

Action Note
1. Put the robot and the upper arm in a suitable
position.
2.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.

Continues on next page

3HAC022033-001 Revision: K 229
 工控帮助教小舒QQ2823408167
3 Maintenance
3.5.4. Rust preventive measures, support bearing in wrist (Foundry Prime)

Continued

Action Note
3. Dismantle the air hose from motor axis 6.
4. Tighten the hose clamp on motor axis 6, and
remove the air hose.
5. Remove the cover.

A
xx0600002864

• A: Cover
6. Apply rust preventive on the bearing and cable See Location of bearing on page
bracket with the brush. 229.
7. Refit the cover.
8. Perform a leakdown test. See Inspection of air hoses

司
(Foundry Prime) on page 191.

限 公
有
育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

230 3HAC022033-001 Revision: K

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3 Maintenance
3.6.1. Flushing a contaminated gearbox

3.6 Cleaning activities

3.6.1. Flushing a contaminated gearbox

Different types of oil

As the Shell Tivela S 150 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.
This section details how to flush the primary gears of axis 4 and 5, and the gearbox of axis 6
in case of contamination with other type of oil.

Required equipment

Equipment Art. no. Note

Lubricating oil 3HAC032140-001 Kyodo Yushi TMO 150
Amount: 700 ml for each gearbox and
flush. Three flushes required.
Oil collecting vessel -
Syringe + plastic hose
Standard toolkit
-
3HAC15571-1 公 司
Dinside=4 mm, L= 400 mm.
Content is defined in section Standard

有 限 toolkit on page 427.

Service program
育 科技
帮教
Create a program with motions on axis 3, 4, 5 and 6. There is no need to remove the tool and
equipment installed on the robot if the Service program can be created and is possible to run.

工 控
Recommended motion
• 沙
长axis 3: ± 15 degrees
• axis 4-6: maximum working range with regard to the installation (limitation: axis 4
and 5: ± 90 degrees, axis 6: ± 180 degrees).
© Copyright 2004-2011 ABB. All rights reserved.

Draining the gearbox properly

The contaminated gearbox must be drained properly before and during the flushing
procedure:
• Axis 4 gearbox: open both oil plugs (filling and draining) and run axis 3 in different
directions. Draw out the last volume (approx. 40 –60 ml) by using a syringe with a
prepared hose end.
• Axis 5 gearbox: open both oil plugs (filling and draining) and run axis 4 back and
forward until the oil draining has stopped.
• Axis 6 gearbox: open both oil plugs (filling and draining) and run axis 5 and 6 in
different directions until the oil draining has stopped.

Continues on next page

3HAC022033-001 Revision: K 231
 工控帮助教小舒QQ2823408167
3 Maintenance
3.6.1. Flushing a contaminated gearbox

Continued

Flushing
The procedure below details how to flush a contaminated gearbox. The procedure is the same
for all gearboxes.

Action Note
1. Run the Service program until the castings of the Recommended service program
gearboxes axis 4, 5 and 6 have reached a detailed in section above:
temperature of about 30-35º C. Use the finger tips to Service program.
measure the temperature.
2. Drain the gearbox properly. Described in section above:
Draining the gearbox properly
on page 231.
3. Fill the gearbox with 700 ml of lubricating oil. Kyodo Yushi TMO 150
Art. no . is specified in Required
equipment on page 231.
4. Refit the oil plug. Tightening torque: 24 Nm.
5. Run the Service program at low speed (25%) during
10 minutes.
6. Drain the gearbox properly.
7. Repeat the steps above until the gearbox is flushed
three times. 公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

232 3HAC022033-001 Revision: K

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3 Maintenance
3.6.2. Cleaning, robot

3.6.2. Cleaning, robot

WARNING!
Turn off all electrical power supplies to the manipulator before entering the work space of
manipulator.

General
To secure high uptime it is important that the robot is cleaned regularly. The frequency of
cleaning depends on the environment that the robot is working in.
Depending on the protection of the robot, different methods of cleaning of the robot are
allowed. This section describes how to clean a robot with protection Standard, Foundry Plus
and Foundry Prime.
NOTE!
Always check the serial number sign for verification about the robot protection class.

Cleaning activities
This instruction specifies allowed cleaning methods for each protection class.

Protection
Cleaning method 公 司
classes
限
有Rinse with water
科技
Vacuum Wipe with High pressure water
cleaner cloth or steam
育With light
Standard Yes.
帮 教Yes.
cleaning
Yes. It is highly
recommended that
No.

工控
detergent. water contains a
rust prevention

长沙
solution and that
the robot is dried
afterwards.
Foundry Yes. Yes. With light Yes. It is highly Yes 2). It is highly
Plus cleaning recommended that recommended that water
© Copyright 2004-2011 ABB. All rights reserved.

detergent or water contains a and steam contains rust

spirit. rust prevention preventive, without
solution. cleaning detergents.
Foundry Yes. Yes. With Yes. It is highly Yes 2). It is highly
Prime cleaning recommended that recommended that water
detergent water contains a and steam contains rust
approved by rust prevention preventive. If cleaning
ABB, spirit or solution. detergents are used they
isopropyl must be approved by ABB
alcohol. for Foundry Prime robots.

2)
Perform according to section Cleaning with water and steam on page 234.

Continues on next page

3HAC022033-001 Revision: K 233
 工控帮助教小舒QQ2823408167
3 Maintenance
3.6.2. Cleaning, robot

Continued

Cleaning with water and steam

Cleaning methods that can be used for ABB robots with protection Standard, Foundry Plus,
Wash, Foundry Prime.
Equipment, etc. Note
Vacuum cleaner
Cloth with mild detergent
Water cleaner • Max. water pressure at the nozzel: 700 kN/m 2 (7
bar) (1)
• Fan jet nozzle should be used, min. 45° spread
• Distance from nozzle to encapsulation: min. 0.4
m
• Flow: max. 20 liters/min (1).
Steam cleaner • Water pressure at nozzle: max. 2,500 kN/m 2 (25
bar)
• Type of nozzle: fan jet, min. 45° spread
• Distance from nozzle to encapsulation: min. 0.4
m
• Water temperature: max. 80° C

1) Typical tap water pressure and flow

公 司
Cables
有 限
技
Movable cables need to be able to move freely:
科 sand, dust, and chips, if it prevents cable
• Remove waste material, for example
育
movement.
教
• Clean the cables if帮
工 控 they have a crusty surface for example from dry release agents.

Do's and don'ts!

长 沙
The section below specifies some special considerations when cleaning the robot.
Always!
• Always use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of the robot. © Copyright 2004-2011 ABB. All rights reserved.
• Always check that all protective covers are fitted to the robot before cleaning!
Never!
• Never point the water jet at connectors, joints, sealings or gaskets!
• Never use compressed air to clean the robot!
• Never use solvents that are not approved by ABB to clean the robot!
• Never spray from a distance closer then 0.4m!
• Never remove any covers or other protective devices before cleaning the robot!

234 3HAC022033-001 Revision: K

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3 Maintenance
3.7.1. Using the SIS system

3.7 Service Information System, M2000

3.7.1. Using the SIS system

General
This is a brief description of how to use the Service Information System, SIS for M2000 robot
systems. 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
The section is only valid for M2000 systems. For information regarding M2004 robot
systems, see additional documentation, Operating manual - Service Information System:
Art. no. is specified in section References on page 10.

Basic procedure

Action 公 司
Reference

有 限
1. Determine which of the system functions you These are described in Description of

科技
require. Service Information System (SIS) on
page 236.
育
帮教
2. Define what values are adequate and Recommendations on how to define
suitable for your application in your these are given in SIS system parameters

工 控
production environment. on page 238.

长 沙
3. Enter these parameters in the system. How to do this is detailed in Setting the
SIS parameters on page 240.
4. Run the robot in normal operation.
5. Reset the counter if a repair is made, or if a The TPU displays for resetting any SIS
counter for any other reason is restarted. value are shown in Description of Service
© Copyright 2004-2011 ABB. All rights reserved.

Information System (SIS) on page 236.

6. When a time limit, set in the parameters, is How to access this is detailed in Reading
exceeded, a message may be read on the the SIS output logs on page 242.
Tech Pendant Unit (TPU).
7. If the log containing the message is to be These are described in Exporting the SIS
available from an external PC, or if the SIS data on page 243.
parameters are to be entered from an
external PC, a set of software tools are
available to build such an application.

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3 Maintenance
3.7.2. Description of Service Information System (SIS)

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 240. All system parameters are described in
User´s Guide - 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
公 司
有限
• Gearbox 3 operation time counter, based on percentage of the axis 3 gearbox service
interval
• Gearbox 6 operation time counter, 科 技
based on percentage of the axis 6 gearbox service
interval 育
帮 教
Counters are reset when maintenance has been performed.

工 控
The counter status is displayed after running the service routine for maintenance. Status “OK”
indicates that沙
no service interval limit has been exceeded by that counter.
长
Calendar time
This is a clock within the control system that keeps track of the service interval, based on

© Copyright 2004-2011 ABB. All rights reserved.

calendar time.
When the calendar time limit for maintenance is reached, a message is displayed on the TPU.
How to access this is detailed in section Reading the SIS output logs on page 242.
The following information is available about the calendar time in the service routine.
Prev service Date when the counter was reset last time, i.e. after the last service.
Elapsed time Elapsed time since the counter was reset the last time.
Next service Date when next scheduled service is planned. This date is
calculated using system parameters, as detailed in section Setting
the SIS parameters on page 240.
Remaining time Remaining time to next scheduled service date.

Continues on next page

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3 Maintenance
3.7.2. Description of Service Information System (SIS)

Continued

Operation time
This is a function within the control system that keeps track of the amount of time the
"MOTORS ON" signal is active, i.e. the amount of time the robot is in the operating mode.
When the operation time limit for maintenance is reached, a message is displayed on the TPU.
How to access this is detailed in section Reading the SIS output logs on page 242.
The following information is available about the operation time in the service routine.
Service interval The specified service interval until another service will be required.
This parameter was entered manually as detailed in section Setting
the SIS parameters on page 240.
Elapsed time Operation time since the service interval was set the last time.
Remaining time Remaining operation time until the time set in service interval has
expired.

Gearbox
Based on measurements, torque and RPM, for example, the system calculates an expected
service interval for each gearbox. When service is due, a message will be shown on the TPU.
How to access this is detailed in section Reading the SIS output logs on page 242.
The following information is available about the joint service status in the service routine.
Joint x OK
公 司
Service status for axis x, i.e. the automatically calculated time

Joint x NOK 有 限
parameter has not been exceeded.
The service interval for the axis in question has been reached.
Joint x N/A
科技
No service time parameter calculation available.
育
Applies to axes 4 and 5 (IRB 6600 and IRB 7600).
教
帮 is available for the axis service status in the service routine.
The following information
Consumed time 控 The consumed time as a percentage of the total amount of time.
Elapsed沙 time
工 Operation time for axis x since calculation began.
长 time
Remaining Remaining operation time for axis x until the service time parameter
value has been reached.
© Copyright 2004-2011 ABB. All rights reserved.

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 243!

Service interval exceeded

When the service time has been exceeded for the selection made, an error message (Service
interval exceeded!) is displayed.

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 Maintenance
3.7.3. SIS system parameters

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.

公 司
有 限
en0200000049
育 科技
Operation time limit (service level)
控 帮教
The number of operation hours selected as service interval.
工
长not沙counting the percentage described below.
E.g. by setting the value "20,000", the SIS will save this as the nominal time for activating
the alarm,

Operation time warning

A percentage of the "Operation time limit" specified above.
E.g. by setting the value "90", the SIS will alert the operator 18,000 hours after an operation © Copyright 2004-2011 ABB. All rights reserved.
time "Reset" was made the last time.

Calendar time limit (service level)

The number of calendar years selected as service interval.
E.g. by setting the value "2", the SIS will save this as the nominal time for activating the
alarm, not counting the percentage described below.

Calendar time warning

A percentage of the "Calendar time limit" specified above.
E.g. by setting the value "90", the SIS will alert the operator after 90% of two years, i.e. 657
days after a calendar time "Reset" was made the last time.

Continues on next page

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3 Maintenance
3.7.3. SIS system parameters

Continued

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 (estimated remaining lifetime) 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

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

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3 Maintenance
3.7.4. Setting the SIS parameters

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.

Action Note
1. Open "System parameters" Detailed in the User's Guide.
using the TPU.
2. Go to "System parameters/
Manipulator/types 2".

公 司
有 限

育 科技
帮教
工控
xx0200000045

长沙

© Copyright 2004-2011 ABB. All rights reserved.

en0200000046

Continues on next page

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3 Maintenance
3.7.4. Setting the SIS parameters

Continued

Action Note
3. Select "0 SIS parameters"
and press "Enter".

en0200000047

xx0100000200

4. Select the required system

The parameter list is 公 司
displayed.
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

en0200000048

en0200000049

5. Select the required Available parameters are described in section SIS system
parameters by stepping up parameters on page 238.
and down through the
parameter list.

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3 Maintenance
3.7.5. Reading the SIS output logs

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.

Access to logs
How to open a log and show its contents is detailed in the User's Guide, chapter Service.

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 240.
since last service. Proceed with the required service as detailed in
chapter Repair on page 245 or chapter

公 司
Maintenance on page 141 depending on which
type of service.
Calendar time Service Message
有 限
X number of calendar days remain until the

科技
X calendar days to manually set calendar time limit expires.
next service. How to set the value determining when the
育 message is to be shown, is detailed in section

帮教
Setting the SIS parameters on page 240.

工控
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

长沙
X production hours SIS parameters on page 240.
since last service. Proceed with the required service as detailed in
chapter Repair on page 245 or chapter
Maintenance on page 141 depending on which
type of service.

© Copyright 2004-2011 ABB. All rights reserved.

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 240.
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 245 or chapter
Maintenance on page 141 depending on which
type of service.
Gearbox time Service Message X percent of gearbox hours remain until the auto-
X% of the service matically 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 240.

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3 Maintenance
3.7.6. Exporting the SIS data

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 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.

Signal Unit Counter type Function

sisRestartDate sec Calendar time The date on which the supervision was
started/reset last time.
sisCalendarT sec Calendar time The number of hours since start/last reset.
sisTotRunT sec Operation time Total number of operation hours since the

公 司
system was started. Corresponds to the
operating time counter on the control cabinet.
sisRunT sec Operation time
有The限 number of operation hours since start/

科 技 last reset of the operation time counter.

Corresponds to the operating time counter on
育 the control cabinet.
sisL10h_1
帮 教Gearbox time
hrs Estimated life of gearbox axis 1
sisL10h_Time_1 控sec Gearbox time Operation time of gearbox axis 1
sisL10h_2 工

长 沙
sisL10h_Time_2
hrs
sec
Gearbox time
Gearbox time
Estimated life of gearbox axis 2
Operation time of gearbox axis 2
sisL10h_3 hrs Gearbox time Estimated life of gearbox axis 3
sisL10h_Time_3 sec Gearbox time Operation time of gearbox axis 3
sisL10h_6 hrs Gearbox time Estimated life of gearbox axis 6
© Copyright 2004-2011 ABB. All rights reserved.

sisL10h_Time_6 hrs Gearbox time Operation time of gearbox axis 6

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3 Maintenance
3.7.6. Exporting the SIS data

公 司
有 限

育 科技

控帮教
沙 工
长

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4 Repair
4.1. Introduction

4 Repair
4.1. Introduction

Structure of this chapter

This chapter describes all repair activities recommended for the robot and any external units
of the robot.
It is made up of separate procedures, each describing a specific repair activity. Each
procedure contains all the information required to perform the activity, for example spare
parts numbers, required special tools, and materials.
The procedures are gathered in sections, divided according to the component location on the
robot.

Required equipment
The details of the equipment required to perform a specific repair activity are listed in the
respective procedures.
The details of equipment are also available in different lists in the chapter Reference
information.
公 司
Safety information
有 限
科技
There are general safety information and specific safety information. The specific safety

育
information describes the danger and safety risks while performing specific steps in a

帮教
procedure. Make sure to read through the chapter Safety on page 19 before commencing any

控
service work.
NOTE!
沙 工
长
If the robot is connected to power, always make sure that the robot is connected to earth
before starting any repair work.
For more information see:
• Product manual - IRC5
© Copyright 2004-2011 ABB. All rights reserved.

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4 Repair
4.2.1. Performing a leak-down test

4.2 General procedures

4.2.1. Performing a leak-down test

General
After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox oil must
be tested. This is done in a leak-down test.

Required equipment

Equipment, etc. Art. no. Note

Leakdown tester 3HAC0207-1
Leak detection spray -

Procedure

Action Note
1. Finish the refitting procedure of the motor or gear in
question.

公 司
2. Remove the topmost oil plug on the gear in question Art. no. is specified in Required
and replace it with the leakdown tester.
有 限
Adapters, which are included in the leakdown tester
equipment on page 246.

科技
kit, may be required.

育
3. Apply compressed air and raise the pressure with the Recommended value:

帮教
knob until the correct value is shown on the 0.2 - 0.25 bar (20 - 25 kPa)
manometer.

工 控
4. Disconnect the compressed air supply.
5. Wait for 沙
approx. 8-10 minutes. No pressure loss may If the compressed air is signifi-
长
be detected. cantly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
may occur. This is quite normal.

© Copyright 2004-2011 ABB. All rights reserved.

6. Was any pressure drop evident?
Localize the leak as detailed below.
Remove the leakdown tester and refit the oil plug.
The test is complete.
7. Spray suspected leak areas with leak detection spray.
Bubbles indicate a leak.
8. When the leak has been localized, take the necessary
measures to correct the leak.

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4 Repair
4.2.2. Mounting instructions for bearings

4.2.2. Mounting instructions for bearings

General
This section describes how to mount and grease different types of bearings on the robot.

Equipment

Equipment, etc. Art. no. Note

Grease 3HAB3537-1 Used to grease the bearings, if not
specified otherwise.

Assembly of all bearings

Follow the following instructions while mounting a bearing on the robot.

Action Note
1. To avoid contamination, let a new bearing remain in its wrapping
until it is time for fitting.

公 司
2. Ensure that the parts included in the bearing fitting are free from
burrs, grinding waste, and other contamination. Cast components
must be free of foundry sand.
有 限
科技
3. Bearing rings, inner rings, and roller elements must not be
subjected to direct impact. The roller elements must not be
育
exposed to any stresses during the assembly work.

Assembly of tapered bearings 控 帮教

沙 工
Follow the preceding instructions for the assembly of the bearings when mounting a tapered
长
bearing on the robot.
In addition to those instructions, the following procedure must be carried out to enable the
roller elements to adjust to the correct position against the race flange.
© Copyright 2004-2011 ABB. All rights reserved.

Action Note
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 durability
of the bearing.

Continues on next page

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4 Repair
4.2.2. Mounting instructions for bearings

Continued

Greasing of bearings
The bearings must be greased after assembly according to the following instructions:
• 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 following description:
• 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.

公 司
有 限

育 科技

控 帮教
沙 工
长

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4 Repair
4.2.3. Mounting instructions for seals

4.2.3. Mounting instructions for seals

General
This section describes how to mount different types of seals onto the robot.

Equipment

Equipment, etc. Art. no. Note

Grease 3HAB3537-1 Used to lubricate the seals.

Rotating seals
The procedure below describes 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.
• 司
Use a protective sleeve for the sealing lip during mounting, when sliding over threads,
公
keyways, etc.
有 限
科技
Action Note

育
1. Check the seal to ensure that:

帮教
• The seal is of the correct type (provided with cutting

工 控
edge).
• There is no damage to the sealing edge (feel with a

长 沙
fingernail).
2. Inspect the sealing surface before mounting. If scratches or
damage are found, the seal must be replaced since it may
result in future leakage.
3. Lubricate the seal with grease just before fitting. (Not too Art. no. is specified in
© Copyright 2004-2011 ABB. All rights reserved.

early - there is a risk of dirt and foreign particles adhering to Equipment on page 249.
the seal.)
Fill 2/3 of the space between the dust tongue and sealing lip
with grease. The rubber coated external diameter must also
be greased, unless otherwise specified.
4. Mount the seal correctly with a mounting tool.
Never hammer directly on the seal as this may result in
leakage.

Continues on next page

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4 Repair
4.2.3. Mounting instructions for seals

Continued

Flange seals and static seals

The following procedure describes how to fit flange seals and static seals.

Action
1. Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint (without sealing
compound).
If the flange surfaces are defective, the parts may not be used because leakage could
occur.
2. Clean the surfaces properly in accordance with the recommendations of ABB.
3. Distribute the sealing compound evenly over the surface, preferably with a brush.
4. Tighten the screws evenly when fastening the flange joint.

O-rings
The following procedure describes how to fit o-rings.

Action Note
1. Ensure that the correct o-ring size is used.
2. Check the o-ring for surface defects, burrs,
shape accuracy, and so on. 公 司
Defective o-rings may not be used.

3. Check the o-ring grooves.

有限
Defective o-rings may not be used.

科技
The grooves must be geometrically correct and
should be free of pores and contamination.
育
5.
教
4. Lubricate the o-ring with grease.
帮 while assembling.
Tighten the screws evenly

工 控
长 沙

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4 Repair
4.3.1. Replacement of cable harness, axes 1-4

4.3 Complete robot

4.3.1. Replacement of cable harness, axes 1-4

Location of cable harness

The cable harness for axes 1-4 is run throughout the base, frame and lower arm as shown in
the figure below.
The brake release unit can be located at two alternative places, either at the rear of the base
or at the side of the frame. Depending on the location, the two types of harnesses are
distinguished some from each other! Any differences are pointed out in the procedures!

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0100000140

1 Alternative with brake release at frame

2 Alternative with brake release at base
A Connector at robot base, R1.MP and R1.SMB
B Connectors at motor 1; R2.FB1 and R2.MP1
C Connectors at motor 2; R2.FB2 and R2.MP2
D Connectors at serial measurement board; R1.SMB1-3, R1.SMB4-6, R1.SMB1.7,
R2.FB7 and R2.SMB. Battery connector X3 R1.G and R2.G. If brake release
located at the frame: also connectors X8, X9 and X10!
E Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and
R2.H2
F Connectors at motor 4; R2.FB4 and R2.MP4
G Connectors at cable harness separation; R2.M5/6

Continues on next page

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4 Repair
4.3.1. Replacement of cable harness, axes 1-4

Continued

H Connectors at motor 5; R3.FB5 and R3.MP5

J Connectors at motor 6; R3.FB6 and R3.MP6
K Rear cover plate
L Connector R1.MP
M Connector R1.SMB
N Connection of earth cable

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Cable harness, axes 1-4 3HAC12782-1 Brake release located at
base.
Cable harness, axes 1-4 3HAC14940-1 Brake release located in
frame.
Locking liquid Loctite 638
Used to secure the
attachment screws for the
attachment plate inside the
frame.
Standard toolkit - 司Content is defined in
公 section Standard toolkit on
有限
page 427.

科技
Other tools and These procedures include
procedures may be references to the tools
required. See references 育 required.

帮教
to these procedures in the
step-by-step instructions
below.
工 控
长沙
Circuit Diagram See chapter Circuit
diagram.

Removal, cable harness, axes 1-4

The procedure below details how to remove the cable harness, axes 1-4.
© Copyright 2004-2011 ABB. All rights reserved.
Action Note
1. In order to facilitate refitting of cable harness, run the Axes 2 and 3 may be tilted
robot to the specified position: slightly to improve access.
• Axis 1: 0 °
• Axis 2: 0 °
• Axis 3: 0 °
• Axis 4: 0 °
• Axis 5: +90 °
• Axis 6: no significance
2.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the air
pressure to the gearboxes, motors and SMB.
Continues on next page
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4 Repair
4.3.1. Replacement of cable harness, axes 1-4

Continued

Action Note
3. Remove the rear cover plate from the robot by Shown in the figure Location of
removing its attachment screws. cable harness on page 251.
4. Disconnect the earth cable. Attachment point is shown in the
figure Location of cable harness
on page 251!
5. Disconnect connectors R1.MP and R1.SMB. Attachment points are shown in
the figure Location of cable
harness on page 251.
6. Pull the cable and connectors up through the cable
guide in the center of the frame.
7. Disconnect all connectors at motors 1 and 2. Specified and shown in the figure
Location of cable harness on
page 251!
8. Open the SMB cover carefully.
The cable between the battery and the SMB-unit may
stay connected, in order to avoid an update of the
revolution counter. Be careful not to let the weight of
the cover strain the cable!
In order to remove the cover completely, the

公
a necessary updating of the revolution counter!司
connector R1.G must be disconnected! This causes

有限
9. Disconnect connectors R2.SMB, R1.SMB1-3,

Disconnect X8, X9 and X10 if the 技

R1.SMB4-6 from the SMB unit.

育
board is located in frame. 科 brake release

帮 教
工 控
长 沙

xx0200000118.wmf
© Copyright 2004-2011 ABB. All rights reserved.

Continues on next page

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4 Repair
4.3.1. Replacement of cable harness, axes 1-4

Continued

Action Note
10. Remove
• the cable gland (A), by removing the four
attachment screws from inside the SMB
recess (B)
• the attachment plate (C), by removing the
attachment screws and the velcro strap (D).

NOTE!
Different robot versions are fitted with different
versions of the attachment plate. When replacing the
cable harness, make sure the correct one is used to
avoid cable failure.

公 司
有 限

育 科技

控 帮教
沙 工
长

xx0300000560 © Copyright 2004-2011 ABB. All rights reserved.

• 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.

Continues on next page

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4 Repair
4.3.1. Replacement of cable harness, axes 1-4

Continued

Action Note
12. Remove the cable gland securing the cables to the
arm house.

xx0100000143.wmf

13. Remove the velcro strap from the harness at the Shown in the figure Location of
cable fixing bracket at the arm house.
公 司 cable harness on page 251.
14. Disconnect connector R2.M5/6 at the cable division Shown in the figure Location of
point.
有 限 cable harness on page 251!

科技
15. Disconnect all connectors at motor 3 and motor 4. Specified and shown in the figure
Location of cable harness on
育 page 251!

帮教
16. Gently pull the cable harness out.
控
沙
Refitting, cable harness, axes 1-4工
长
The procedure below details how to refit the cable harness, axes 1-4.

Action Note
1.
© Copyright 2004-2011 ABB. All rights reserved.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.
2. In order to facilitate refitting of cable harness, Axes 2 and 3 may be tilted slightly
move the robot to the specified position: to improve access.
• Axis 1: 0 degrees
• Axis 2: 0 degrees
• Axis 3: 0 degrees
• Axis 4: 0 degrees
• Axis 5: +90 degrees
• Axis 6: no significance

Continues on next page

3HAC022033-001 Revision: K 255
 工控帮助教小舒QQ2823408167
4 Repair
4.3.1. Replacement of cable harness, axes 1-4

Continued

Action Note
3. Pull the cable and connectors down through the Make sure the cables are not
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 the Make a note of the correct positions
rear cover plate. of the connectors!
Attachment point is shown in the
figure Location of cable harness on
page 251.
5. Reconnect the earth cable. Attachment point is shown in the
figure Location of cable harness on
page 251!
6. Refit the rear cover plate to the robot with its Shown in the figure Location of
attachment screws. cable harness on page 251.
7. Reconnect all connectors at motors 1 and 2. Specified and shown in the figure
Location of cable harness on page
251!

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

Continues on next page

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4 Repair
4.3.1. Replacement of cable harness, axes 1-4

Continued

Action Note
8. Secure the cable gland (A) with four attachment Locking liquid is specified in
screws (B) from inside the SMB recess. Required equipment on page 252.
Secure the correct attachment plate (C) to the
cable gland with its two attachment screws, using
locking liquid.
Refit the velcro strap (D).

NOTE!
Different robot versions are fitted with different
versions of the attachment plate. Make sure the
correct one is used to avoid cable failure.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0300000560

• A: Cable gland
• B: Attachment screws, cable
gland
• C: Attachment plate
• D: Velcro strap

Continues on next page

3HAC022033-001 Revision: K 257
 工控帮助教小舒QQ2823408167
4 Repair
4.3.1. Replacement of cable harness, axes 1-4

Continued

Action Note
9. Reconnect connectors R2.SMB, R1.SMB1-3,
R1.SMB4-6 to the SMB unit.
Reconnect X8, X9 and X10 if the brake release
board is located in frame.
Reconnect R1.G if it has been disconnected.

xx0200000118

10. Secure the SMB cover with its attachment screws.

11.

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 48!
公 司
12. Pull the cable harness through the lower arm. 限
有
13.
技
Refit the cable gland securing the cables inside

育科
the lower arm.

帮 教
工 控
长沙 xx0100000142

14. Refit the cable gland securing the cables to the

arm house.

© Copyright 2004-2011 ABB. All rights reserved.

Make sure not to twist the harness!

xx0100000143

15. Reconnect all connectors at motor 3 and motor 4. Specified and shown in the figure
Location of cable harness on page
251!

Continues on next page

258 3HAC022033-001 Revision: K
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4 Repair
4.3.1. Replacement of cable harness, axes 1-4

Continued

Action Note
16. Reconnect the connector R2.M5/6 gently at the Shown in the figure Location of
cable division point. cable harness on page 251!
Be careful not to bend the attachment plate when M6, 2 pcs.
fastening the screws!
17. Secure the cable harness to the upper arm house Shown in the figure Location of
by refitting the velcro strap to the cable bracket at cable harness on page 251!
the upper arm house.
18. Fit a cable protection to the lower arm, if not
already mounted, with two securing screws (A),
M6x16.
Secure the cable harness with two velcro straps
(B), with a distance of approximately 180 mm. Fix
the strap by wrapping it two turns around the
largest cable before wrapping around the
complete harness.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0500002320

19. Refit the cable harness to the guide plate axis 2. Shown in the figure Location of
© Copyright 2004-2011 ABB. All rights reserved.

cable harness on page 251.

20. Refit the velcro strap at the guide plate axis 2. Shown in the figure Location of
cable harness on page 251.
21. If the connection between the SMB battery and Detailed in the Calibration chapter -
the SMB unit has been broken, the revolution section Updating revolution
counters must now be updated! counters on page 408.
22.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 47.

3HAC022033-001 Revision: K 259

 工控帮助教小舒QQ2823408167
4 Repair
4.3.2. Replacement of cable harness, axes 5-6

4.3.2. Replacement of cable harness, axes 5-6

Location of cable harness ax 5-6

The location of the cable harness, axes 5-6, is shown in the figure below.

公 司
有 限

育 科技

控 帮教
xx0100000145
沙 工
A 长Cable attachment, upper arm
B Cable attachment, rear
C Connector at cable harness division; R2.M5/6
D Connectors at motor 5; R3.FB5 and R3.MP5
E Connectors at motor 6; R3.FB6 and R3.MP6 © Copyright 2004-2011 ABB. All rights reserved.

Required equipment

Equipment, etc. Spare part no. Note

Cable harness ax.5-6 3HAC11440-1
Gasket 3HAC033489-001 Recommended to be changed for
Foundry Plus robots.
Standard toolkit - Content is defined in section Standard
toolkit on page 427.
Other tools and procedures may These procedures include references
be required. See references to to the tools required.
these procedures in the step-by-
step instructions below.
Circuit Diagram See chapter Circuit diagram.

Continues on next page

260 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.3.2. Replacement of cable harness, axes 5-6

Continued

Removal, cable harness, axes 5-6

The procedure below details how to remove the upper arm cable harness.

Action Note
1. Position the upper arm as follows:
• Axis 4: 0 degrees
• Axis 5: +90 degrees
• Axis 6: no significance
2.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the air
pressure to the gearboxes, motors and SMB.
3. Remove the left hand side wrist cover by unscrewing its
attachment screws.
4.

公 司
NOTE!
有 限
Axis 5 must be oriented in the correct position (+90º) to

科技
allow the motor 6 cover to open!

育
5. Disconnect all connectors at motor 5 and motor 6. Specified in the figure

帮 教 Location of cable harness ax

5-6 on page 260.
6. Remove the控 plastic cover on the rear of the upper arm,

沙 工
by removing the attachment screws.

长
7. Remove the spiral plate by unscrewing the screw at the
bottom of the spiral cup.
8. Remove eventual cable straps from the harness.
9. Disconnect connector R2.M5/6 at the cable harness Shown in the figure Location
© Copyright 2004-2011 ABB. All rights reserved.

division. of cable harness ax 5-6 on

page 260.
10. Remove the cable attachment inside the upper arm.
11. Gently pull the cable harness out.

Refitting, cable harness, axes 5-6

The procedure below details how to refit the upper cable harness.

Action Note
1. Position the upper arm as follows:
• Axis 4: 0 degrees
• Axis 5: +90 degrees
• Axis 6: no significance
2. Gently insert the cable harness from the rear into the
upper arm.
3. Pull the small spiral plate past motor 5.
4. Route the cables outside the heat protection plate.
Continues on next page
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 工控帮助教小舒QQ2823408167
4 Repair
4.3.2. Replacement of cable harness, axes 5-6

Continued

Action Note
5. Secure the small plate to the large plate. Secure the
spiral cup with its attachment screw in the bottom of
the cup.
6. Secure any excess cable length tightly to the large Excess cable length may be
plate in the wrist housing, using cable straps. present if upper arm length is not
Use the attachment holes in the large plate intended the maximum.
for the cable straps!
7. Reconnect all connectors at motor 5 and motor 6. Specified in the figure Location of
cable harness ax 5-6 on page
260.
8. Secure the cable with the cable attachment inside
the upper arm.
9. Refit the left hand side wrist cover with its
attachment screws.
10. Reconnect connector R2.M5/6 gently at the cable Shown in the figure Location of
harness division with two screws, M6. cable harness ax 5-6 on page
Be careful not to bend the attachment plate when 260.
fastening the screws! M6, 2 pcs.
11. Refit the plastic cover on the rear of the upper arm.
12. Update the revolution counters.
公 司 in section Updating
Detailed

有 限 revolution counters on page 408.

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

262 3HAC022033-001 Revision: K

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4 Repair
4.3.3. Replacement of complete arm system

4.3.3. Replacement of complete arm system

Location of complete arm system

The complete arm system is defined as the complete robot except for the base and gearbox
axis 1, that is the upper and lower arms, balancing device and frame. This is shown in the
figure below.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0100000150

A Gearbox, axis 1
B Motor, axis 1
C Base attachment screws
D Upper arm
E Lower arm
F Frame
G Balancing device
H Block for calibration

Continues on next page

3HAC022033-001 Revision: K 263
 工控帮助教小舒QQ2823408167
4 Repair
4.3.3. Replacement of complete arm system

Continued

Required equipment

Equipment, etc. Art. no. Note

Lifting device, robot 3HAC15607-1 Instruction 3HAC15971-2 enclosed!
Guide pins, M12 x 130 - Used to guide the complete arm
system when refitting.
Standard toolkit - Content is defined in section
Standard toolkit on page 427.
Other tools and procedures These procedures include
may be required. See references to the tools required.
references to these procedures
in the step-by-step instructions
below.

Removal, complete arm system

The procedure below details how to lift and remove the complete arm system.

Action Note
1. Position the robot in its most stable position, as If the brakes need to be released, see
shown in the figure to the right.
司
section Manually releasing the brakes

公
on page 83.

有 限

育科技

控 帮教
沙 工
长
xx0100000103

2.
© Copyright 2004-2011 ABB. All rights reserved.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not
the air pressure to the gearboxes, motors and
SMB.
3. Drain the oil from the gearbox, axis 1. Detailed in section Oil change,
gearbox axis 1 on page 199.
4. Remove the motor, axis 1. Detailed in section Removal, motor
axis 1 on page 328.
5. Run the overhead crane to a position above
the robot.

Continues on next page

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4 Repair
4.3.3. Replacement of complete arm system

Continued

Action Note
6.

CAUTION!
The complete arm system weighs 2000 kg! All
lifting equipment used must be sized accord-
ingly!
7. Fit the lifting device and adjust it as detailed in Art. no. is specified in Required
enclosed instruction. equipment on page 264!
Make sure the lift is done completely
level! How to adjust the lift is described
in the enclosed instruction to the lifting
device! Read the instructions before
lifting!
8. Remove the block for calibration from the Shown in the figure Location of
bottom of the frame. complete arm system on page 263!
9. Remove the arm system from the base by Shown in the figure Location of
unscrewing the 24 base attachment screws. complete arm system on page 263!
10. Lift the arm system and secure it in a safe area. Make sure all hooks and attachments

司
maintain in correct position while lifting

限 公 the robot!
Always move the robot at very low
有 speeds, making sure it does not tip.

Refitting, complete arm system 育 科技

帮教
The procedure below details how to refit the complete arm system to the robot.
控
Action
沙 工 Note
1.
长
DANGER!
Turn off all electric power, hydraulic and
© Copyright 2004-2011 ABB. All rights reserved.

pneumatic pressure supplies to the robot!

Turn off all electric power and hydraulic but
not the air pressure to the gearboxes,
motors and SMB.
2.

CAUTION!
The complete arm system weighs 2000 kg!
All lifting equipment used must be sized
accordingly!
3. Fit and adjust the lifting device as detailed in Art. no. is specified in Required
enclosed instruction. equipment on page 264.
4. Lift the complete arm system and move it at Make sure all the hooks and attachments
very low speed, making sure it does not tip! maintain in correct position while lifting
Make sure the lift is done completely level, the robot!
adjust the length of the chains as detailed in
enclosed instruction!

Continues on next page

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 工控帮助教小舒QQ2823408167
4 Repair
4.3.3. Replacement of complete arm system

Continued

Action Note
5. Fit two guide pins, M12 x 130, in the frame
attachment holes as shown in the figure to
the right.
Fit one guide pin next to the guiding hole (for
the spring pin in the gearbox) and the other
guide pin straight across the frame.

xx0300000070

The figure above shows a view from

below of the frame.
A. Attachment holes for the guide
pins, M12.
B. Guiding hole for the spring pin
located in the gearbox, axis 1.
6. Look through the empty mounting hole of This is a complex task to be performed
motor axis 1, to assist in aligning the with outmost care in order to avoid injury
司
assembly during refitting of the arm system. or damage!
公
The guiding pin in the gearbox must be fitted
to the guiding hole of the frame (B).
有 限
科技
Lower the arm system with guidance from
the guide pins previously fitted to the frame.
育
帮教
7. Refit 22 of the 24 attachment screws before
the arm system is completely lowered.
控
8. Remove the guide pins and secure the arm Shown in the figure Location of complete
工
沙
system to the base with the 24 base arm system on page 263.

长
attachment screws and washers. 24 pcs, M12 x 110; 12.9 quality
UNBRAKO, tightening torque: 110 Nm.
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints on page 423 before fitting.
9. Refit the block for calibration at the bottom Shown in the figure Location of complete © Copyright 2004-2011 ABB. All rights reserved.
of the frame. arm system on page 263.
10. Refit the motor, axis 1. Detailed in section Refitting, motor axis 1
on page 329.
11. Perform a leak-down test. Detailed in section Performing a leak-
down test on page 246.
12. Refill the gearbox axis 1 with lubricating oil. Detailed in section Filling, oil, gearbox
axis 1 on page 202.
13. Recalibrate the robot. Calibration is detailed in a separate
calibration manual enclosed with the
calibration tools.
General calibration information is
included in section Calibration information
on page 403.

Continues on next page

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4 Repair
4.3.3. Replacement of complete arm system

Continued

Action Note
14.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER -
First test run may cause injury or damage!
on page 47.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 267

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4 Repair
4.3.4. Replacement of air nipple and hose (Foundry Prime)

4.3.4. Replacement of air nipple and hose (Foundry Prime)

Location
The illustration below shows the routing of the Foundry Prime air hose.

公 司
有 限

育 科技
xx0500002176
控 帮教
Hose lengths
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0600003157

Pos 1A Hose length 40 mm

Pos 1B Hose length 40 mm
Pos 1C Hose length 1570 mm
Pos 1D Hose length 1140 mm
Pos 1E Hose length 310 mm
Pos 1F Hose length 35 mm
Pos 1G Hose length 260 mm
Continues on next page
268 3HAC022033-001 Revision: K
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4 Repair
4.3.4. Replacement of air nipple and hose (Foundry Prime)

Continued

Pos 1H Hose length 570 mm

Pos 1K Hose length 4040 mm
Pos 1L Hose length 150 mm
Pos 1M Hose length 120 mm
Pos 1N Hose length 35 mm
Pos 1P Hose length 1540 mm
Pos 1Q Hose length 940 mm
Pos 1R Hose length 1500 mm
A Pneumatic hose
B Y-plug connector
C T-plug connector
a Balancing cylinder, rear end
b Motor axis 1
c Battery cover
d Motor axis 2
e Length = 805 mm
f Motor axis 6
g
司
Rubber clamp on washer on gear axis 6
公
限
h Rubber clamp on tilthouse
j
有
Rubber clamp on wrist cover

科技
k Motor axis 5
m
育
Motor axis 3
n
帮 教Motor axis 4

工控
o Bulkhead plug connector

Required equipment 长沙
Equipment Art. no. Pos. in illustration
Velcro strap 3HAC12625-1 9 (only in illustrations below)
© Copyright 2004-2011 ABB. All rights reserved.

Cable straps 21662055-3 8 (only in illustrations below)

Elbow fitting 3HAC026511-001 6 (only in illustrations below)
Rubber clamp 3HAC026523-001 5
T-plug connector 3HAC026515-001 4
Y-plug connector 3HAC026514-001 3
Bulkhead plug connector 3HAC026513-001 2
Hose 3HAC026526-001 1

Continues on next page

3HAC022033-001 Revision: K 269
 工控帮助教小舒QQ2823408167
4 Repair
4.3.4. Replacement of air nipple and hose (Foundry Prime)

Continued

Procedure
The following procedures details how to replace the Foundry Prime air nipples and hose. The
pos. no. in following procedures correspond to the illustration in Hose lengths on page
268and the table in Required equipment on page 269

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot.
2. Locate the damaged hose or air connector,
and continue to replace the damaged hose.
Route the hose according to the illustrations
in the procedure below.
3. Connection at base.

公 司
有 限

育 科技

控 帮教
沙 工 xx0600003042

Items in illustration are detailed in

长 Required equipment on page 269 and
Hose lengths on page 268.
4. Axis 1.

© Copyright 2004-2011 ABB. All rights reserved.

xx0600003043

Continues on next page

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4 Repair
4.3.4. Replacement of air nipple and hose (Foundry Prime)

Continued

Action Note
5. Balancing device.

xx0600003397

Item in illustration is detailed in Hose

lengths on page 268.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

Continues on next page

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4 Repair
4.3.4. Replacement of air nipple and hose (Foundry Prime)

Continued

Action Note
6. Axis 1-2.

xx0600003418

公 司
有限

育 科技

控 帮教
沙 工
长
xx0600003420

© Copyright 2004-2011 ABB. All rights reserved.

xx0600003045

Continues on next page

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4 Repair
4.3.4. Replacement of air nipple and hose (Foundry Prime)

Continued

Action Note
7. Upper arm housing.

xx0600003046

公 司
有 限

育 科技

控 帮教
沙 工
长
8. Tube shaft.
xx0600003047
© Copyright 2004-2011 ABB. All rights reserved.

xx0600003163

• 1P: Lay the hose in a spiral in the

tube shaft.

Continues on next page

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4 Repair
4.3.4. Replacement of air nipple and hose (Foundry Prime)

Continued

Action Note
9. Wrist.

NOTE!
Make sure the cable length from 5a to the
nipple of axis 6 = S, see Hose lengths on
page 268.

xx0600003097

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

274 3HAC022033-001 Revision: K

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4 Repair
4.4.1. Replacing turning disk

4.4 Upper and lower arm

4.4.1. Replacing turning disk

Location of turning disk

The turning disk is located in the center of the wrist unit as shown in the figure below.

公 司
有 限

育 科技
xx0100000129

控 帮教
A
沙 工 Turning disk
B
C
长 Oil plug, filling (oil plug for draining is located on the opposite side of the tilthouse)
Turning disk attachment screws, 33 pcs

Required equipment
© Copyright 2004-2011 ABB. All rights reserved.

Equipment, etc. Spare part no. Art. no. Note

Turning disk, dia. 250 3HAC13193-1 Does not include o-ring!
Turning disk, insulated 3HAC023124-002
O-ring 21522012-433 Must be replaced when
replacing the turning disk!
Grease 3HAB3537-1 Used to lubricate the o-ring.
Standard toolkit - Content is defined in section
Standard toolkit on page 427.
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.

Continues on next page

3HAC022033-001 Revision: K 275
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4 Repair
4.4.1. Replacing turning disk

Continued

Removing turning disk

Use the procedure to remove the turning disk.

Action Info
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but
not the air pressure to the gearboxes,
motors and SMB.
2. Drain the oil from gearbox 6. Detailed in section Oil change, gearbox
axis 6 on page 215.
3. Remove the attachment screws (33 pcs) Shown in the figure Location of turning
securing the turning disk. disk on page 275.
4. Remove the turning disk.

公 司
有 限

育 科技

控 帮教
沙 工 xx1000001135

© Copyright 2004-2011 ABB. All rights reserved.

Continues on next page

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4 Repair
4.4.1. Replacing turning disk

Continued

Refitting turning disk

Use this procedure to refit the turning disk.

Action Info
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but
not the air pressure to the gearboxes,
motors and SMB.
2. Lubricate the o-ring with grease and fit it to Art. no. is specified in Required
the rear of the turning disk. equipment on page 275.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0100000130

A. O-ring, turning disk

3. Secure the turning disk with its attachment Attachment screws:
screws. • M10 x 25, 12.9 quality UNBRAKO
• Tightening torque: 50 Nm.
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints on page 423 before fitting.
4. Refill the gearbox, axis 6, with oil. Detailed in section Filling, oil, gearbox
axis 6 on page 217.

Continues on next page

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4 Repair
4.4.1. Replacing turning disk

Continued

Action Info
5.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These
are further detailed in the section DANGER
- First test run may cause injury or damage!
on page 47.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

278 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
4 Repair
4.4.2. Replacement of complete wrist unit

4.4.2. Replacement of complete wrist unit

Location of wrist unit

The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.

公 司
有 限

育 科技

控 帮教
xx0100000147
沙 工
A 长 Wrist unit
B Wrist unit attachment screws and washers
C Attachment, cable harness axis 5-6
© Copyright 2004-2011 ABB. All rights reserved.

D Connectors at cable harness division; R2.M5/6

E Turning disk
F Cover, axis 5
G Rear cover
H View with cable harness mounted on robot

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Wrist, type 3 3HAC16628-4
Wrist, insulated 3HAC16628-3
Wrist, Foundry Prime 3HAC027295-001
Friction washer 3HAC11755-1 A new friction washer must
always be used when
refitting the wrist unit.
Lifting tool, wrist unit 3HAC12734-1

Continues on next page

3HAC022033-001 Revision: K 279
 工控帮助教小舒QQ2823408167
4 Repair
4.4.2. Replacement of complete wrist unit

Continued

Equipment, etc. Spare part no. Art. no. Note

Standard toolkit - Content is defined in
section Standard toolkit on
page 427.
Calibration Pendulum 3HAC15716-1 Complete kit that also
toolkit includes operating
manual.
Other tools and These procedures include
procedures may be references to the tools
required. See references required.
to these procedures in
the step-by-step instruc-
tions below.
Circuit diagram - See chapter Circuit
diagram.

Removal, wrist unit

The procedure below details how to remove the complete wrist unit.

Action Note
1.
公 司
有 限
科技
DANGER!

育
Turn off all electric power, hydraulic and pneumatic

帮教
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the air
控
pressure to the gearboxes, motors and SMB.
工
长 沙
2. Remove all equipment fitted to the turning disk.
3. Turn axis 4 to a position where the cover, axis 5 faces Shown in the figure Location of
upwards. wrist unit on page 279.
4. Remove the cover, axis 5, by unscrewing its
attachment screws.

© Copyright 2004-2011 ABB. All rights reserved.

5.

CAUTION!
The complete wrist unit weighs 200 kg! All lifting
equipment used must be sized accordingly!
6. Fit the lifting tool, wrist unit to the two holes on the Art. no. is specified in Required
sealing surface against the cover, axis 5. equipment on page 279.
If required, cut any cable ties
securing the cables in order to fit
the tool.
7. Remove the rear cover by unscrewing its attach- Shown in the figure Location of
ments. wrist unit on page 279.
8. Disconnect connector R2.M5/6 at the rear cable Shown in the figure Location of
division point. wrist unit on page 279.
9. Remove all cable attachment inside the upper arm Do not remove the attachments
and at the rear of the robot. from the cabling!
10. Slightly raise the wrist unit to unload the screw joint,
facilitating removal of the attachment screws.
Continues on next page
280 3HAC022033-001 Revision: K
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4 Repair
4.4.2. Replacement of complete wrist unit

Continued

Action Note
11. Remove the wrist unit attachment screws and
washers.
12. Pull the cabling forwards through the upper arm tube. Make sure the attachments do
not get stuck inside the tube!
13. Remove the friction washer between the wrist unit A new washer must always be
and the upper arm tube. used on reassembly.
14. Lift the wrist unit down and place it on a secure
surface.

Refitting, wrist unit

The procedure below details how to refit the complete wrist unit.

Action Note
1.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
公 司
detailed in the section DANGER - First test run may
cause injury or damage! on page 47.
有 限
科技
2.

育
帮教
CAUTION!

工 控
The complete wrist unit weighs 200 kg! All lifting
equipment used must be sized accordingly!

沙
3. Remove the cover, axis 5 from the wrist unit to be
长 the lifting tool, wrist unit to the wrist unit.
fitted. Fit
Art. no. is specified in Required
equipment on page 279.
4. Lift the wrist unit and move it to its mounting
position.
5. Fit a new friction washer between the upper arm Art. no. is specified in Required
© Copyright 2004-2011 ABB. All rights reserved.

tube and the wrist unit. equipment on page 279.

6. Gently pull the wrist unit cable harness through the
upper arm and out the rear.
7. Secure the wrist unit with its attachment screws and Screws: M12 x 50, UNBRAKO
washers. quality 12.9, tightening torque:
115 Nm.
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints on
page 423 before fitting.
8. Secure the cable harness with the cable attachment Make sure the cabling is not
inside the upper arm as well as at the rear of the twisted!
upper arm.
9. Remove the lifting tool and refit the cover, axis 5 Shown in the figure Location of
with its attachment screws. wrist unit on page 279.
10. Refit any cable ties that were previously cut during
disassembly.

Continues on next page

3HAC022033-001 Revision: K 281
 工控帮助教小舒QQ2823408167
4 Repair
4.4.2. Replacement of complete wrist unit

Continued

Action Note
11. Reconnect connector R2.M5/6 at the rear cable Shown in the figure Location of
division point. wrist unit on page 279.
12. Refit the rear cover with its attachment screws. Shown in the figure Location of
wrist unit on page 279.
13. Check the oil levels at gearboxes axis 5 and 6. Detailed in sections:
• Inspection, oil level,
gearbox axis 5 on page
161
• Inspection, oil level
gearbox axis 6 on page
164
14. Recalibrate the robot. Calibration is detailed in a
separate calibration manual
enclosed with the calibration
tools.
General calibration information is
included in section Calibration
information on page 403.
15. Refit any equipment previously removed from the

16.
turning disk.

公 司
有 限
科技
DANGER!

育
Make sure all safety requirements are met when

帮教
performing the first test run. These are further
detailed in the section DANGER - First test run may
控
cause injury or damage! on page 47.
工
长 沙

© Copyright 2004-2011 ABB. All rights reserved.

282 3HAC022033-001 Revision: K

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4 Repair
4.4.3. Replacement of complete upper arm

4.4.3. Replacement of complete upper arm

Location of upper arm

The upper arm is located on top of the robot as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0100000148

A Upper arm
B Attachment screws, upper arm
C Connectors at cable harness division; R2.M5/6
D Rear cable attachment
E Oil plug, draining
F Oil plug, filling
G Attachment hole, M12
H Sealing between lower arm and gearbox 3
J Attachment holes for lifting device, upper arm
K Attachment holes for lifting eye

Continues on next page

3HAC022033-001 Revision: K 283
 工控帮助教小舒QQ2823408167
4 Repair
4.4.3. Replacement of complete upper arm

Continued

Required equipment

Equipment, etc. Art. no. Note

Sealing, axis 2/3 3HAC11054-1 Always use a new sealing
when reassembling!
Washer 3HAC11828-1 Replace if damaged!
Standard toolkit - Content is defined in section
Standard toolkit on page 427.
Lifting eye, M12 3HAC14457-3
Lifting device, upper arm 3HAC15536-1
Lifting tool (chain) 3HAC15556-1
Hoisting block - Standard hoisting block,
capacity 200 kg.
Guide pins, sealing axis 2/3 3HAC14627-2 80 mm.
For guiding "Sealing, axis 2/3".
Guide pins, sealing axis 2/3 3HAC14627-3 100 mm.
For guiding "Sealing, axis 2/3".
Other tools and procedures may be These procedures include
required. See references to these references to the tools
procedures in the step-by-step
instructions below. 公 司 required.

有 限
科技
Removal, upper arm

育
The procedure below details how to remove the complete upper arm.

Action
控 帮教 Note
1. 工
Run the upper arm to a horizontal position.
2.
长沙
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot! © Copyright 2004-2011 ABB. All rights reserved.
Turn off all electric power and hydraulic but not the air
pressure to the gearboxes, motors and SMB.
3.

CAUTION!
The complete upper arm weighs 450 kg without any
additional equipment fitted! Use a suitable lifting
device to avoid injury to personnel!
4. Fit the lifting eye to the attachment hole in the wrist Shown in the figure Location of
unit. upper arm on page 283.
Art. no. is specified in Required
equipment on page 284.
5. Fit one of the pieces included in the lifting device, Shown in the figure Location of
upper arm to the attachment holes for lifting device, upper arm on page 283.
upper arm using the included attachment screws. Art. no. is specified in Required
equipment on page 284.

Continues on next page

284 3HAC022033-001 Revision: K
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4 Repair
4.4.3. Replacement of complete upper arm

Continued

Action Note
6. Run the lifting chain from the rear lifting point through Art. no. is specified in Required
the overhead crane hook, through the hoisting block to equipment on page 284.
the lifting eye in the front.
7. Use the hoisting block to adjust the tension in the
chain in order to lift the upper arm completely level.
8. Drain the oil from gearbox 3. Detailed in section Oil change,
gearbox, axis 3 on page 206.
9. Disconnect connector R2.M5/6 at the rear cable
division point as well as all remaining connections to
the upper arm.
10. Disconnect all connectors inside motors 3 and 4.
11. Remove all brackets securing cabling to the upper arm
by unscrewing their attachment screws respectively.
12. Raise the lifting equipment to take the weight of the
upper arm.
13. Carefully remove the upper arm attachment screws . Shown in the figure Location of
Make sure that the upper arm is lifted in a completely upper arm on page 283.
level position in all planes in order not to damage the 30 pcs.
upper arm!

公 司
14. Lift the upper arm and place it on a secure surface.
15. Remove the sealing from the lower arm.
有 限
Refitting, upper arm
育 科技
帮教
The procedure below details how to refit the upper arm to the robot.

Action
工 控 Note/Illustration
1.
长 沙
DANGER!
Turn off all electric power, hydraulic and pneumatic
© Copyright 2004-2011 ABB. All rights reserved.

pressure supplies to the robot!

Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.

Continues on next page

3HAC022033-001 Revision: K 285
 工控帮助教小舒QQ2823408167
4 Repair
4.4.3. Replacement of complete upper arm

Continued

Action Note/Illustration
2. Fit the two guide pins, sealing axis 2/3 in two of the Always use a new sealing when
attachment screw holes on gearbox 3, see figure to reassembling!
the right. Art. no. is specified in Required
Guide the new sealing, axis 2/3 into position with equipment on page 284.
the guide pins, on gearbox 3.

xx0200000125

A. Holes for guide pins in the

gearbox.
3.
公 司
CAUTION! 有 限
科技
The complete upper arm weighs 450 kg without any

育
additional equipment fitted! Use a suitable lifting

4. Fit the lifting eye to the

教
device to avoid injury to personnel!
帮attachment hole in the wrist Shown in the figure Location of
unit.
工 控 upper arm on page 283.

长 沙 Art. no. is specified in Required

equipment on page 284.
5. Fit one of the pieces included in the lifting device, Shown in the figure Location of
upper arm to the attachment holes for lifting device, upper arm on page 283.
upper arm using the included attachment screws. Art. no. is specified in Required

© Copyright 2004-2011 ABB. All rights reserved.

equipment on page 284.
6. Run the lifting chain from the rear lifting point Art. no. is specified in Required
through the overhead crane hook, through the equipment on page 284.
hoisting block to the lifting eye in the front.
7. Use the hoisting block to adjust the tension in the
chain in order to lift the upper arm completely level.
8. Lift the upper arm and move it to its mounting
position.
9. Fit the three washers to be placed beneath the Make sure the washers are not
attachment screws. scarred or pitted in the surface
facing the screw heads. If both
washer sides are damaged,
replace the washer. Art. no. is
specified in Required equipment
on page 284.

Continues on next page

286 3HAC022033-001 Revision: K
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4 Repair
4.4.3. Replacement of complete upper arm

Continued

Action Note/Illustration
10. Insert the attachment screws. In some cases, removing the
Do not remove the guide pins until the attachment plastic mechanical stops may be
screws are tightened as detailed below! required before fitting the upper
arm.
If guide pins are removed before
the screws are tightened, the
sealing can be involuntarily
moved into wrong position.
11. Secure the lower arm to gearbox axis 3 with the 30 pcs: M16 x 50. Tightening
upper arm attachment screws . torque: 300 Nm.
Shown in the figure Location of
upper arm on page 283.
12. Remove the guide pins and fit the two remaining
attachment screws. Tighten them as detailed above!
13. Refit any cabling removed during the removal
process.
14. Reconnect all connectors inside motors 3 and 4.
15. Reconnect connector R2.M5/6 gently at the rear
cable division point.
Be careful not to bend the attachment plate when
fastening the screws! 公 司
16. Refill the gearbox with oil.
有 限 Detailed in section Filling, oil on

17. Recalibrate the robot. 科 技 page 208.

Calibration is detailed in a
育 separate calibration manual

帮 教 enclosed with the calibration

工 控 tools.
General calibration information is

长 沙 included in section Calibration

information on page 403.
18.
© Copyright 2004-2011 ABB. All rights reserved.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run may
cause injury or damage! on page 47.

3HAC022033-001 Revision: K 287

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4 Repair
4.4.4. Replacement of complete lower arm

4.4.4. Replacement of complete lower arm

Location of lower arm

The lower arm is located as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0100000149

A Lower arm
B Pivot point, axis 2
C Front shaft, balancing device, including securing screw
D Attachment for lifting eye, M12, balancing device

Attachment points, lower arm

The lower arm attachment points are located as shown in the figure below:
• The figure (1) shows gearbox 3, but the location of sealing axis 2/3 in relation to the
gearbox is identical for axis 3.
• The figure (2) shows a cut view through the lower arm pivot point in axis 2 (item B in
the figure above!).

Continues on next page

288 3HAC022033-001 Revision: K
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4 Repair
4.4.4. Replacement of complete lower arm

Continued

公 司
有限
xx0200000031
育 科技
帮教
A Gearbox
B
C 工 控Lower arm
Balancing device piston rod ear
D
长 沙 Frame
E Shaft hole
201 Sealing, axis 2/3
202 Attachment screw
© Copyright 2004-2011 ABB. All rights reserved.

204 Washer
401 Bearing
402 Thrust washer
403 Bushing
404 Retaining ring
405 Shaft
406 Protection plug
409 Protection washer

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Bearing 3HAC4310-1 Always use a new bearing!
Sealing, axis 2/3 3HAC11054-1 Always use a new sealing!
VK cover 3HAA2166-23

Continues on next page

3HAC022033-001 Revision: K 289
 工控帮助教小舒QQ2823408167
4 Repair
4.4.4. Replacement of complete lower arm

Continued

Equipment, etc. Spare part no. Art. no. Note

Lifting tool, lower 3HAC14691-1 Tool that may be rent from
arm ABB.
Includes
• Guidances,
3HAC14445-1
The guidings are used for
guiding the sealing, axis 2/3.
Rotation tool 3HAC17105-1
Lifting eye M12 3HAC14457-3 Used to lift the balancing
device.
Puller tool, balancing 3HAC12475-1 Used to pull out the shaft from
device shaft the balancing device front ear.
Hydraulic pump, 80 3HAC13086-1 To be used together with the
MPa press device, axis 2 shaft and
the puller tool.
Hydraulic pump, 150 3HAC021563-012 To be used together with the
MPa (Glycerin) press tool, axis 2 shaft and the
puller tool.
Press device, axis 2 3HAC021600-001
shaft
公 司
Press tool, axis 2
bearing
限
3HAC13453-1
有
科技
Power supply - 24 VDC, 1.5 A.

育 For releasing the brakes.

帮教
Retaining ring pliers -

工控
Standard toolkit - Content is defined in section
Standard toolkit on page 427.

长沙
Calibration 3HAC15716-1 Complete kit that also includes
Pendulum toolkit operating manual.
Other tools and These procedures include
procedures may be references to the tools
required. See required.
© Copyright 2004-2011 ABB. All rights reserved.
references to these
procedures in the
step-by-step instruc-
tions below.

Removal, lower arm

The procedure below details how to remove the complete lower arm.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not
the air pressure to the gearboxes, motors and
SMB.

Continues on next page

290 3HAC022033-001 Revision: K
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4 Repair
4.4.4. Replacement of complete lower arm

Continued

Action Note
2. Remove the upper arm. Detailed in section Replacement of
complete upper arm on page 283.
3. Disconnect and remove the cables from inside Detailed in section Replacement of
the lower arm. cable harness, axes 1-4 on page 251.
Release any cable attachments.
4. Apply the lifting eye to the balancing device Art. no. is specified in Required
and raise to unload the device. equipment on page 289.
Attachment is shown in the figure
Location of lower arm on page 288.
5. Unload the balancing device in order to make Detailed in section Unloading the
the piston rod and front ear adjustable when balancing device using hydraulic press
pulling the front shaft out. tool. on page 320.
6. Remove the securing screw from the Shown in the figure Location of lower
balancing device front shaft. arm on page 288.

7. Apply the shaft puller tool to the shaft through Art. no. is specified in Required
the hole in the frame. equipment on page 289.
The shaft has a M20 thread diameter and a 40
mm depth of thread, as shown in the figure to
the right.
公 司
限
Pull the shaft out using the puller tool and the
hydraulic pump.
有
科技
xx0300000060

育
帮教 NOTE!

沙 工控 The dimension of the shaft puller tool is

M20. Do not mix up with the shaft press
长
8. Lower the balancing device until it rests safely
tool used when mounting the shaft.

against the bottom of the frame, out of reach

from the lower arm.
© Copyright 2004-2011 ABB. All rights reserved.

9. Move the lower arm backwards to the lowest

position possible.

xx0300000015

10.

CAUTION!
The lower arm weighs 225 kg! All lifting
equipment used must be sized accordingly!

Continues on next page

3HAC022033-001 Revision: K 291
 工控帮助教小舒QQ2823408167
4 Repair
4.4.4. Replacement of complete lower arm

Continued

Action Note
11. Apply the lifting tool to the lower arm. Art. no. is specified in Required
equipment on page 289!
12. Drain the oil from gearbox 2. Detailed in section Oil change, gearbox
axis 2 on page 203.
13. Raise the tool to unload the lower arm.
14. Remove the protection plug. Shown in the figure Attachment points,
lower arm on page 288!
15. Remove the protection washer and the Shown in the figure Attachment points,
retaining ring. lower arm on page 288!
Use a pliers for the retaining ring.
16. Fit the press (/puller) tool as shown in the Art. no. is specified in Required
figure to the right and mount both the hydraulic equipment on page 289!
pump and the glycerin pump to it.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0300000010

17. Increase the pressure of the glycerin pump Do not exceed the limit of maximum
and, at the same time, pull out the shaft with pressure classified for the pumps!
the puller tool by increasing the pressure of the
hydraulic pump.
18. Remove the lower arm attachment screws and Shown in the figure Attachment points,
washers that attaches the lower arm to the lower arm on page 288.
gearbox 2.
19. Lift the lower arm down and place it on a
secure surface.
20. Remove the bearing and thrust washer from Shown in the figure Attachment points,
the shaft hole in the lower arm. lower arm on page 288.
On reassembly a new bearing must be
used!

Continues on next page

292 3HAC022033-001 Revision: K
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4 Repair
4.4.4. Replacement of complete lower arm

Continued

Action Note
21. Remove the sealing from the lower arm. Shown in the figure Attachment points,
lower arm on page 288.
On reassembly a new sealing must be
used!

Refitting, lower arm

The procedure below details how to refit the lower arm to the robot.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not
the air pressure to the gearboxes, motors and
SMB.

existing if damaged.
公 司
2. Fit a new VK-cover on new lower arm or replace Spare part no. is specified in Required
equipment on page 289.

the lower arm.

限
3. Fit the two guidings in the attachment holes
有 art.
of Included in the lifting tool, lower arm,
no. is specified in Required
技 equipment on page 289.

育科
帮 教
工 控
长沙
© Copyright 2004-2011 ABB. All rights reserved.

xx0200000262

A. Attachment holes for the two

guidings.
4. Fit the new sealing, axis 2/3 on the guidings. Always use a new sealing when reas-
sembling!
Art. no. is specified in Required
equipment on page 289.
5.

CAUTION!
The lower arm weighs 225 kg! All lifting
equipment used must be sized accordingly!
6. Apply the lifting tool to the lower arm. Art. no. is specified in Required
equipment on page 289.
7. Lift the lower arm and move it to its mounting
position.

Continues on next page

3HAC022033-001 Revision: K 293
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4 Repair
4.4.4. Replacement of complete lower arm

Continued

Action Note
8. In case the holes of the lower arm and the ones Connect power supply to connector
of the gearbox axis 2 doesn´t match, use power R2.MP2:
supply to release the motor axis 2 brakes and • + : pin 2
rotate the pinion and gear with the rotation tool. • - : pin 5

xx0200000165

The rotation tool (A) is used beneath

the motor cover, directly on the motor
shaft as shown in the figure above!
Art. no. is specified in Required
equipment on page 289.
9. Secure the lower arm with 28 of the 30
attachment screws and washers in gearbox 2. 公 司
30 pcs: M16 x 50; tightening torque:
300 Nm.

有 限 Shown in the figure Attachment

科技
points, lower arm on page 288.
10. Remove the guidings and secure the two
育
remaining attachment screws as detailed above!

控 帮教
11. Apply grease to the shaft hole. Art. no. is specified in Required
equipment on page 289.
工
12. Push the shaft in by hand.
沙
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0300000014

A. Retaining ring
B. Protection washer
C. Bearing
D. Thrust washer
E. Shaft
F. Protection washer
13. Apply the press tool, axis 2 shaft. Art. no. is specified in Required
equipment on page 289.
14. Tighten the M16 nut. Tightening torque: 20 Nm.
15. Fit both the hydraulic pump and the glycerin
pump to the press tool.
Continues on next page
294 3HAC022033-001 Revision: K
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4 Repair
4.4.4. Replacement of complete lower arm

Continued

Action Note
16. Set the indicator on the press tool to zero.
17. Press in the shaft with the hydraulic cylinder by
setting the pressure of the hydraulic pump to
approximately 35-55 MPa and the pressure of
the glycerin pump to 55 MPa.
18. Increase the pressure of the both pumps Correct value: 2.45 mm ± 0.15 mm
alternately until the correct value is reached with
the indicator on the press tool.

NOTE!
Do not exceed the limit of maximum
pressure classified for the pumps!
19. Remove the press tool, axis 2 shaft. Release the pressure from the
glycerin pump first, then from the
hydraulic cylinder (approximately 1/2
minute after), in order to avoid
movement of the shaft.
20. Refit the thrust washer to the shaft. Shown in the figure Attachment
points, lower arm on page 288.
21. Apply grease to the location of the shaft where
the bearing is to be mounted.
公 司
有限 sembling!
22. Press the bearing in with the press tool, axis 2 Always use a new bearing when reas-
bearing.

科 技 Art. no. is specified in Required

育 equipment on page 289.

帮 教
23. Refit the protection washer and the retaining Shown in the figure Attachment
ring.
24. Refit the工
控
protection plug.
points, lower arm on page 288.
Shown in the figure Attachment

长 沙 points, lower arm on page 288.

25. Refit and restore the balancing device. Detailed in section Refitting,
balancing device on page 312.
26. Refit the upper arm. Detailed in section Refitting, upper
arm on page 285.
© Copyright 2004-2011 ABB. All rights reserved.

27. Perform a leak-down test. Detailed in section Performing a leak-

down test on page 246.
28. Refill the axis 2 gearbox with oil. Detailed in section Filling, oil on page
205.
29. Refit and reconnect all cables inside the lower Detailed in section Refitting, cable
arm. harness, axes 1-4 on page 255.
Refit removed cable attachments.
30. Recalibrate the robot. Calibration is detailed in a separate
calibration manual enclosed with the
calibration tools.
General calibration information is
included in section Calibration
information on page 403.

Continues on next page

3HAC022033-001 Revision: K 295
 工控帮助教小舒QQ2823408167
4 Repair
4.4.4. Replacement of complete lower arm

Continued

Action Note
31.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 47.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

296 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
4 Repair
4.5.1. Replacement of SMB unit

4.5 Frame and base

4.5.1. Replacement of SMB unit

Location of SMB unit

The SMB unit (SMB = serial measurement board) is located on the left hand side of the frame
as shown in the figure below.

公 司
有限

育 科技
xx0200000203
控 帮教
A
沙 工 SMB cover
B
C
长 SMB unit
Pins
D Battery cable
© Copyright 2004-2011 ABB. All rights reserved.

Required equipment

Equipment, etc. Spare part no. Art. no. Note

SMB unit
Brush - Option: Foundry prime
Rust preventive 3HAC026621-001 Option: Foundry prime
Equivalent:
• Mercasol 3106
Standard toolkit - Content is defined in section
Standard toolkit on page 427.
Circuit Diagram - See chapter Circuit diagram.

Continues on next page

3HAC022033-001 Revision: K 297
 工控帮助教小舒QQ2823408167
4 Repair
4.5.1. Replacement of SMB unit

Continued

Removal, SMB unit

Use this procedure to remove the SMB unit.

Action Note
1. Move the robot to the calibration position.
2.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the air
pressure to the gearboxes, motors and SMB.
3.

esd

WARNING!
The unit is sensitive to ESD. Before handling the unit

司
please read the safety information in the section
WARNING - The unit is sensitive to ESD! on page 49
4. Remove the SMB cover by unscrewing its
公
限 Shown in the figure Location of
attachment screws. 有 SMB unit on page 297.
5. Remove the connectors X8, X9 and X10 技
科space.from the
育
brake release board, if need of more
6. 教 from the pins securing
Remove the nuts and washers
帮
Shown in the figure Location of

控
the board. SMB unit on page 297.
7.
沙
when pulling
工
Gently disconnect the connectors from the SMB unit
the board out.
Connectors R1.SMB1-3,
R1.SMB4-6 and R2.SMB
长
8. Disconnect the battery cable from the SMB unit. Shown in the figure Location of
SMB unit on page 297.

Refitting, SMB unit

Use this procedure to refit the SMB unit. © Copyright 2004-2011 ABB. All rights reserved.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not
the air pressure to the gearboxes, motors and
SMB.

Continues on next page

298 3HAC022033-001 Revision: K
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4 Repair
4.5.1. Replacement of SMB unit

Continued

Action Note
2.

esd

WARNING!
The unit is sensitive to ESD. Before handling the
unit please read the safety information in the
section WARNING - The unit is sensitive to ESD!
on page 49
3. Connect the battery cable to the SMB unit. Shown in the figure Location of SMB
unit on page 297.
4. Connect all connectors to the SMB board and fit Art. no. is specified in Required
the SMB unit onto the pins. equipment on page 297.
Shown in the figure Location of SMB
unit on page 297.
R1.SMB1-3, R1.SMB4-6 and R2.SMB
5. Secure the SMB unit to the pins with the nuts and
washers.
6. If disconnected, reconnect the connectors X8, X9
and X10 to the brake release board.
公 司
7. Secure the SMB cover with its attachment
screws.
限 Shown in the figure Location of SMB
有 unit on page 297.
8. Update the revolution counter!
科 技 See Updating revolution counters on

育 page 408.
9.
帮 教
工 控
长 沙
DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 47.
© Copyright 2004-2011 ABB. All rights reserved.

Replacement of SMB unit (Foundry Prime)

Robots working with Foundry Prime and that have the special tightness for this application
require special repair routines to maintain the tightness level.
The repair must be done according to the previous repair procedure with the following
additions.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.

Continues on next page

3HAC022033-001 Revision: K 299
 工控帮助教小舒QQ2823408167
4 Repair
4.5.1. Replacement of SMB unit

Continued

Action Note
2.

esd

WARNING!
The unit is sensitive to ESD. Before handling the
unit please read the safety information in the section
WARNING - The unit is sensitive to ESD! on page
49
3. Remove the SMB unit as detailed in Removal, SMB
unit on page 298
4. Refit the new SMB unit according to step 3 - 6 in
Refitting, SMB unit on page 298
5.

NOTE!
Make sure that the gasket under the SMB cover is
not damaged!
Secure the SMB cover with its attachment screws.
公 司
6. Apply rust preventive on the surface around the
有
SMB cover and under/on top of the screw heads. 限
科技
7. Perform a leakdown test according to Inspection of

育
air hoses (Foundry Prime) on page 191.

帮教
8. Update the revolution counter! See Updating revolution counters
on page 408.
9.
工 控
长 沙
DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run may
cause injury or damage! on page 47. © Copyright 2004-2011 ABB. All rights reserved.

300 3HAC022033-001 Revision: K

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4 Repair
4.5.2. Replacement of brake release unit

4.5.2. Replacement of brake release unit

Different designs
Depending on the robot version, the brake release unit may be located either at the base or at
the frame. The following two figures show the different locations.
The early design includes a brake release unit with or without push buttons, located at the
base. The later design instead includes a brake release unit with push buttons, placed together
with the SMB unit on the left hand side of the frame.
The different designs are not compatible.

Location of brake release unit, base

The early design includes a brake release unit with or without push buttons, located at the base
as shown in the figure below.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0200000127

A Brake release circuit (brake release unit inside)

B Attachment screws, brake release circuit, 4 pcs

Continues on next page

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4 Repair
4.5.2. Replacement of brake release unit

Continued

Location of brake release unit, frame

The later design includes a brake release unit with push buttons, placed together with the
SMB unit on the left hand side of the frame as shown in the figure below.

公 司
有 限

育 科技
xx0200000226

控 帮教
A
B
工
Brake release unit
沙 screws, brake release unit (4 pcs)
Attachment
C 长Buttons
D SMB cover
E Push button guard

© Copyright 2004-2011 ABB. All rights reserved.

Required equipment

Equipment, etc. Spare part no. Note

Brake release circuit 3HAC14219-1 Brake release at the base, according to
without buttons, at base figure Location of brake release unit, base
on page 301.
Includes brake release unit 3HAC14228-1.
Brake release circuit with 3HAC12989-1 Brake release at the base, according to
buttons, at base figure Location of brake release unit, base
on page 301.
Includes brake release unit 3HAC16036-1.
Brake release unit with 3HAC16036-1 Brake release unit at the frame, according
buttons, at frame to figure Location of brake release unit,
frame on page 302.
Push button guard 3HAC2744-1
Standard toolkit - Content is defined in section Standard
toolkit on page 427.

Continues on next page

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4 Repair
4.5.2. Replacement of brake release unit

Continued

Equipment, etc. Spare part no. Note

Other tools and These procedures include references to the
procedures may be tools required.
required. See references
to these procedures in the
step-by-step instructions
below.

Removal of brake release unit, located at base

The procedure below details how to remove the brake release unit, located at the rear of the
base. See the figure Location of brake release unit, base on page 301.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the air
pressure to the gearboxes, motors and SMB.
公 司
2.
有 限
esd
育 科技
帮教
WARNING!

工 控
The unit is sensitive to ESD. Before handling the unit
please read the safety information in the section

长 沙
WARNING - The unit is sensitive to ESD! on page 49
3. Remove the cover at the rear of the base.
4. Unscrew the four attachment screws, brake release Shown in the figure Location of
circuit on the outside of the base. brake release unit, base on page
301.
© Copyright 2004-2011 ABB. All rights reserved.

5. Disconnect the cable from the brake release circuit

and remove the circuit from the base.

Removal of brake release unit, located on frame

The procedure below details how to remove the brake release unit, located on the side of the
frame. See the figure Location of brake release unit, frame on page 302.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but
not the air pressure to the gearboxes,
motors and SMB.

Continues on next page

3HAC022033-001 Revision: K 303
 工控帮助教小舒QQ2823408167
4 Repair
4.5.2. Replacement of brake release unit

Continued

Action Note
2.

esd

WARNING!
The unit is sensitive to ESD. Before
handling the unit please read the safety
information in the section WARNING - The
unit is sensitive to ESD! on page 49
3. Remove the push button guard from the Shown in the figure Location of brake
SMB cover. release unit, frame on page 302.
The guard must be removed to ensure a
correct refitting of the brake release unit.
4. Remove the SMB cover by unscrewing the Shown in the figure Location of brake
attachment screws. release unit, frame on page 302.
Let the battery stay connected, to avoid the
need of synchronization of the robot!
5. Disconnect the connectors X8, X9 and X10
from the brake release unit.

公 司
有 限

育 科技

控 帮教
沙 工
长 xx0200000129

• A: Connector X8
• B: Connector X9
• C: Connector X10
• D: Push buttons for each axis © Copyright 2004-2011 ABB. All rights reserved.
6. Remove the brake release unit from the Shown in the figure Location of brake
plate by unscrewing the four attachment release unit, frame on page 302!
screws, brake release unit.

Continues on next page

304 3HAC022033-001 Revision: K
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4 Repair
4.5.2. Replacement of brake release unit

Continued

Refitting of brake release circuit, located at base

The procedure below details how to refit the brake release circuit, located at the rear of the
base. See the figure Location of brake release unit, base on page 301.

Action Note
1.

esd

WARNING!
The unit is sensitive to ESD. Before handling the
unit please read the safety information in the section
WARNING - The unit is sensitive to ESD! on page
49
2. Place the brake release circuit in the base of the Spare part no. is specified in
robot. Required equipment on page 302.
Shown in the figure Location of
brake release unit, base on page
301.

司Shown in the figure Location of

3. Reconnect the cable to the brake release circuit.

on the outside of the rear of the base.

公
4. Fasten the attachment screws, brake release circuit
限 brake release unit, base on page
有 301.
技
育科
5. Refit the cover of the rear of the base.

帮
Refitting of brake release unit, located on frame 教
The procedure below控details how to refit the brake release unit, located on the side of the
frame. See the工
长 沙 figure Location of brake release unit, frame on page 302.

Action Note
1.
© Copyright 2004-2011 ABB. All rights reserved.

esd

WARNING!
The unit is sensitive to ESD. Before handling
the unit please read the safety information in
the section WARNING - The unit is sensitive to
ESD! on page 49
2. Fit the brake release unit on the plate with the Shown in the figure Location of brake
attachment screws. release unit, frame on page 302.
Make sure the unit is positioned as straight as Spare part no. is specified in Required
possible on the plate! The push buttons can equipment on page 302.
otherwise get jammed when the SMB-cover is
refitted.

Continues on next page

3HAC022033-001 Revision: K 305
 工控帮助教小舒QQ2823408167
4 Repair
4.5.2. Replacement of brake release unit

Continued

Action Note
3. Connect the connectors X8, X9 and X10 to the
brake release unit.

xx0200000129

A. Connector X8
B. Connector X9
C. Connector X10
D. Push buttons
4. Refit the SMB cover with its attachment screws. Shown in the figure Location of brake
release unit, frame on page 302.
5.
公 司
WARNING! 有 限

育 科技
Before continuing any service work, please
observe the safety information in section

帮教
WARNING - The brake release buttons may be
jammed after service work on page 48!

工 控
6. Refit the push button guard on the SMB cover. Shown in the figure Location of brake

长 沙
7. If the battery has been disconnected the
release unit, frame on page 302.
Detailed in section Updating revolution
revolution counters must be updated. counters on page 408.
8.

DANGER! © Copyright 2004-2011 ABB. All rights reserved.

Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on page
47.

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4 Repair
4.5.3. Replacement of balancing device

4.5.3. Replacement of balancing device

Location of balancing device

The balancing device is located on rear top of the frame as shown in the figure below.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0100000139

A Balancing device
B Rear cover
© Copyright 2004-2011 ABB. All rights reserved.

C Support shaft inside (included in balancing device 3HAC14675-1)

D Attachment screws, rear cover
E Balancing device shaft, including screw and washer
F Bearing attachment
G Parallel pin (inside bearing attachment)
H Attachment screws, bearing attachment

Continues on next page

3HAC022033-001 Revision: K 307
 工控帮助教小舒QQ2823408167
4 Repair
4.5.3. Replacement of balancing device

Continued

Attachment points, balancing device

The attachment points for the lifting tools etc. are located as shown in the figure below.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0600002653

A Attachment hole for lifting eye, M12

B Attachment hole for securing screw that secures the bearing attachment to the
balancing device (protection plug fitted normally)
C Hole in frame to access the balancing device front eye shaft with the puller/press tool
D Attachment hole for locking screw that secures the lower arm to the frame

Continues on next page

308 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.5.3. Replacement of balancing device

Continued

Required equipment

Equipment Spare part no. Art. no. Note

Balancing device 3HAC14214-1 Includes:
• balancing device
3HAC14675-1 or
3HAC023018-001
• o-ring 3HAB3772-
44 (2 pcs)
O-ring 3HAB3772-44 2 pcs , to be replaced if
damaged! (included with
the new balancing device)
Locking screw 3HAB3409-90 M16 x 90
For securing the lower arm.
Securing screw 9ADA183-66 M12 x 35, 2 pcs required
For securing the bearing
attachments to the
balancing device when
lifting.
Bearing grease 3HAB3537-1 For lubricating the o-rings

Grease 公 司
3HAA1001-294
and the shaft.
150 ml, Optimol PDO

有 限 For lubrication of spherical

科技
roller bearing in ear, in case
of new balancing device.
Brush 育 -
Rust preventive
控 帮教 3HAC026621-001 Equivalent:
• Mercasol 3106

沙 工
Locking liquid - Loctite 243

长 To apply to the securing

screw in the shaft.
Grease pump - To lubricate spherical roller
bearing.
© Copyright 2004-2011 ABB. All rights reserved.

Guide pins M16 x 300 3HAC13120-5 Always use guide pins in

pairs!
Lifting eye M12 3HAC14457-3
Lifting tool (chain) 3HAC15556-1
Press tool, balancing 3HAC020902-001
device
Puller tool, balancing 3HAC12475-1
device shaft
Press tool, balancing 3HAC17129-1
device shaft
Hydraulic cylinder 3HAC11731-1 To be used with the press
and puller tools.
Hydraulic pump, 80 3HAC13086-1 To be used with the
MPa hydraulic cylinder.
Standard toolkit - Content is defined in
section Standard toolkit on
page 427.

Continues on next page

3HAC022033-001 Revision: K 309
 工控帮助教小舒QQ2823408167
4 Repair
4.5.3. Replacement of balancing device

Continued

Equipment Spare part no. Art. no. Note

Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the
step-by-step instruc-
tions below.

Removal, balancing device

The procedure below details how to remove the balancing device.

Action Note
1. Move the lower arm to a position close to the
calibration position.
2.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
公 司
有
the air pressure to the gearboxes, motors and 限
Turn off all electric power and hydraulic but not

SMB.
技
育科 hole in
3. Secure the lower arm to the frame by inserting Attachment hole for the locking screw

教
the locking screw into the attachment is shown in the figure Attachment
the frame.

控 帮 points, balancing device on page 308.

Art. no. is specified in Required
工 equipment on page 309!

长沙
4.

CAUTION!
The balancing device weighs 300 kg! All lifting
© Copyright 2004-2011 ABB. All rights reserved.
equipment used must be sized accordingly!
5. Fit the lifting eye, M12 to the balancing device Art. no. is specified in Required
and raise to unload the weight. equipment on page 309!
Attachments are shown in the figure
Attachment points, balancing device
on page 308.
6. Unload the balancing device with the press tool Art. no. is specified in Required
in order to make the piston rod and front ear equipment on page 309!
adjustable when pulling the shaft out. Detailed in section Unloading the
balancing device using hydraulic
press tool. on page 320.
7. Remove the securing screw and washer from Shown in the figure Location of
the balancing device shaft. balancing device on page 307!

Continues on next page

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4 Repair
4.5.3. Replacement of balancing device

Continued

Action Note
8. Apply the puller tool, balancing device shaft to Art. no. is specified in Required
the shaft through the hole in the frame. equipment on page 309!
The shaft has a M20 thread diameter, as shown The hole in the frame is shown in the
in the figure to the right. figure Attachment points, balancing
Pull the shaft out using the puller tool and the device on page 308!
hydraulic pump.

xx0300000060

NOTE!
The dimension of the shaft puller tool
is M20. Do not mix up with the shaft
press tool used when mounting the
shaft.
9. Restore the balancing device. Detailed in section Restoring the

公 司 balancing device using a hydraulic

press tool. on page 324.

有
10. Secure the two bearing attachments to the 限 Shown in the figure Attachment points,

科 技
balancing device by replacing the protection
plug on the outside of each attachment, with
balancing device on page 308!
Dimensions for the securing screws
securing screws. 育 are specified in Required equipment

帮 教
The protection plugs must be refitted after on page 309.

工
them! 控
refitting the balancing device, do not loose

长 沙
11. Remove the two bearing attachments from the Shown in the figure Location of
frame by unscrewing their four attachment balancing device on page 307!
screws. Make sure the parallel pins inside are
not lost!
12. Fit two guide pins through the upper holes of Art. no. is specified in Required
© Copyright 2004-2011 ABB. All rights reserved.

the bearing attachments, to the frame. equipment on page 309!

13. Lift the balancing device gently backwards to a
secure area, allowing the bearing attachments
to slide on the guide pins.
NOTE!
Make sure not to burden the guide
pins with the weight of the balancing
device!

Continues on next page

3HAC022033-001 Revision: K 311
 工控帮助教小舒QQ2823408167
4 Repair
4.5.3. Replacement of balancing device

Continued

Refitting, balancing device

The procedure below details how to refit the balancing device.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not
the air pressure to the gearboxes, motors and
SMB.
2. Secure the lower arm to the frame by inserting Art. no. is specified in Required
the locking screw into the attachment hole in equipment on page 309!
the frame. Attachment hole is shown in the
figure Attachment points, balancing
device on page 308.
3. Secure the bearing attachments to the Shown in the figure Attachment
balancing device with securing screws. points, balancing device on page

公 司308!
Dimension of the securing screws is

有 限 specified in Required equipment on

page 309.

育 科技
4. Refit the two parallel pins in the frame. Shown in the figure Location of
balancing device on page 307!

帮教
5. Fit two guide pins to the upper holes in the

控
frame, where the bearing attachments are to be

6.
attached.

沙
Fit the
工
lifting eye to the balancing device. Art. no. is specified in Required
长 equipment on page 309!
Attachments are shown in the figure-
Attachment points, balancing device
on page 308.

© Copyright 2004-2011 ABB. All rights reserved.

7.

CAUTION!
The balancing device weighs 210 kg! All lifting
equipment used must be sized accordingly!
8.

CAUTION!
The balancing device weighs 300 kg! All lifting
equipment used must be sized accordingly!
9. Lift the balancing device and bring it forward,
gliding the bearing attachments on to the guide
pins.
NOTE!
Make sure not to burden the guide
pins with the weight of the balancing
device!

Continues on next page

312 3HAC022033-001 Revision: K
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4 Repair
4.5.3. Replacement of balancing device

Continued

Action Note
10. Remove the guide pins.
11. Secure the rear of the balancing device by Shown in the figure Location of
fastening the two bearing attachments to the balancing device on page 307!
frame with their four attachment screws. 4 pcs, M16x90, 12.9 quality
UNBRAKO, tightening torque: 300
Nm.
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints on
page 423 before fitting.
12. Remove the screws from outside of the bearing
attachments and refit the protection plugs.
13. Raise the balancing device to a position where
the balancing device shaft may be inserted
through the piston shaft front eye.
14. Unload the balancing device with the press Detailed in section Unloading the
tool. balancing device using hydraulic
press tool. on page 320.
Art. no. is specified in Required

公 司 equipment on page 309!

For an easier reassembling of the

有 限 shaft, the piston rod may be pressed

out more than necessary and then

科技
pressed in when fitting the shaft.

育
15. Lubricate the shaft with grease. Art. no. is specified in Required

帮 教
16. Apply the shaft press tool to the lubricated
equipment on page 309!
The hole in the frame is shown in the
shaft .
工 控 figure Attachment points, balancing

长 沙Fit the shaft to the piston shaft front eye through

the hole in the frame, using the shaft press tool
device on page 308!
Art. no. is specified in Required
and the hydraulic pump . equipment on page 309!
© Copyright 2004-2011 ABB. All rights reserved.

NOTE!
Make sure the shaft is pressed all the
way to the bottom.
17. Refit the securing screw and washer into the M16 x 180, tightening torque: 50 Nm.
shaft using locking liquid. Locking liquid is specified in
Required equipment on page 309!
18. Lubricate the bearing in the ear with grease Art. no. and amount are specified in
through the lubricating nipple, with a grease Required equipment on page 309!
pump. Lubrication is further detailed in
Fill until excessive grease pierces between the section Lubrication of spherical roller
shaft and the sealing spacer. bearing, balancing device on page
221.
19. Restore the balancing device. Detailed in section Restoring the
balancing device using a hydraulic
press tool. on page 324.

Continues on next page

3HAC022033-001 Revision: K 313
 工控帮助教小舒QQ2823408167
4 Repair
4.5.3. Replacement of balancing device

Continued

Action Note
20.

DANGER!
The rear cover of the balancing device is a
safety device for the piston rod during
operation! Make sure the cover is properly
secured before commissioning of the robot!
21. Remove the locking screw that secures the
lower arm to the frame.

xx0200000454

1. Attachment hole for the

公 司 securing screw.
22.
有 限
DANGER!
育 科技
帮教
Make sure all safety requirements are met
when performing the first test run. These are

工 控
further detailed in the section DANGER - First
test run may cause injury or damage! on page
47.
长 沙
Replacement of balancing device (Foundry Prime)
Robots working with Foundry Prime and that have the special tightness for this application

© Copyright 2004-2011 ABB. All rights reserved.

require special repair routines to maintain the tightness level.
The repair must be done according to the repair chapter in the Product Manual with the
following additions.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not
the air pressure to the gearboxes, motors and
SMB.

Continues on next page

314 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.5.3. Replacement of balancing device

Continued

Action Note
2. Pull out the sealing spacers, but let them still
remain on the ear.
• Apply rust preventive abundantly in the
gap
• press the sealing back in place
• wipe off surplus material.

xx0600003131

• A: Sealing spacers
3. Apply Mercasol 3106 to the shaft and hole in
frame.

公 司
有 限

育 科技
帮教
工控
xx0600003130

• A: Mercasol on shaft and in

长沙
hole
• B: Mercasol between piston
rod and ear
4.
© Copyright 2004-2011 ABB. All rights reserved.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 47.

3HAC022033-001 Revision: K 315

 工控帮助教小舒QQ2823408167
4 Repair
4.5.4. Replacement of spherical roller bearing, balancing device

4.5.4. Replacement of spherical roller bearing, balancing device

Location of bearing
The bearing is located at the front ear of the balancing device, as shown in the figure below.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0500002249

A Spherical roller bearing

B Sealing ring
C O-ring
D Sealing spacer © Copyright 2004-2011 ABB. All rights reserved.
E Front ear of balancing device

Required equipment

Equipment Spare part no. Art. no. Note

Spherical roller 3HAA2167-17
bearing
Sealing spacer 3HAC12988-1 2 pcs required.
O-ring 3HAB3772-76 2 pcs required.
Sealing ring 3HAC11581-6 2 pcs required.
Grease 3HAB3537-1 For lubrication of the
components.
Toolkit 3HAC15943-1 The tools in the set are
shown in the section Tool
set.

Continues on next page

316 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.5.4. Replacement of spherical roller bearing, balancing device

Continued

Equipment Spare part no. Art. no. Note

Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the
step-by-step instruc-
tions below.

Tool set
The parts of the tool set for replacing the spherical roller bearing are shown in the figure.

xx0500002259

A Threaded bar
公 司
B Dolly
有 限
C
D
技
Press tool for removal of bearing

科 of bearing
Press tool for refitting
Hexagon nut育
E
F 帮
Plain
教 M12 (2pcs)
washer 13x24x2,5 (2pcs)

工控
长沙
Removal, spherical roller bearing
Use this procedure to remove the spherical roller bearing from the balancing device front ear.

Action Note
© Copyright 2004-2011 ABB. All rights reserved.

1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but
not the air pressure to the gearboxes,
motors and SMB.
2. Remove the balancing device from the Detailed in section Replacement of
robot. balancing device on page 307.
3. Remove the both sealing spacers with a Shown in the figure Location of bearing
screwdriver or any equal tool. on page 316.
4. Insert the threaded bar through the bearing.

Continues on next page

3HAC022033-001 Revision: K 317
 工控帮助教小舒QQ2823408167
4 Repair
4.5.4. Replacement of spherical roller bearing, balancing device

Continued

Action Note
5. Fit the press tool and dolly to the threaded
bar.
Secure with the nut and washer at each
end.

xx0500002255

A. Threaded bar 3HAC15945-1

B. Dolly 3HAC15948-1
C. Press tool 3HAC15941-1
6. Press out the bearing from the front ear.

Refitting, spherical roller bearing

公 司
Use this procedure to refit the spherical roller bearing to the balancing device front ear.

Action 有Note限
1.
育 科技
DANGER!
控 帮教
沙 工
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
长
Turn off all electric power and hydraulic but
not the air pressure to the gearboxes,
motors and SMB.
2. Grease the inside walls of the front ear.
3. Insert the threaded bar through the new Spare part no. is specified in Required © Copyright 2004-2011 ABB. All rights reserved.
bearing and place it at the front ear. Fit also equipment on page 316.
the press tool and the dolly to the bar as
shown in the figure to the right.
Secure with the nut and washer at each
end.

xx0500002257

A. Threaded bar 3HAC15945-1

B. Dolly 3HAC15948-1
C. Press tool 3HAC15846-1
4. Press in the bearing properly inside the ear.

Continues on next page

318 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.5.4. Replacement of spherical roller bearing, balancing device

Continued

Action Note
5. Apply grease to the new sealing rings and o- Spare part no:s are specified in Required
rings and fit one of each to the new sealing equipment on page 316.
spacers. Also, grease the sealing spacers.
6. Press in the sealing spacers with the press
tools, as shown in the figure to the right.
Secure the press tool and dolly with nuts
and washers.

NOTE!
Fit the sealing spacers one at a time!

xx0500002258

A. Threaded bar 3HAC15945-1

B. Dolly 3HAC15948-1
C. Press tool 3HAC15846-1
7. Refit the balancing device to the robot.
公 司Detailed in section Refitting, balancing

有 限 device on page 312.

科技
8. Lubricate the spherical roller bearing in the Detailed in section Lubrication of
ear. spherical roller bearing, balancing device

育 on page 221

NOTE! 控 帮教
沙 工
The balancing device must be mounted on
长
the robot when lubrication is performed!
9. Make sure no incorrect leakage occurs. It Further information is available in section
could indicate damaged o-rings. Check for leakage on page 172.
10.
© Copyright 2004-2011 ABB. All rights reserved.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER -
First test run may cause injury or damage!
on page 47.

3HAC022033-001 Revision: K 319

 工控帮助教小舒QQ2823408167
4 Repair
4.5.5. Unloading the balancing device using hydraulic press tool.

4.5.5. Unloading the balancing device using hydraulic press tool.

Prerequisite
This section details how to unload the balancing device using the hydraulic press tool.
The lower arm must be secured before unloading the balancing device! How to secure the
lower arm is detailed in the current repair activity, for example removal of the balancing
device.
DANGER!
There is a high tensioned spring inside the balancing device, incorrect handling may cause
injuries and damage property.

Press tool and hydraulic cylinder

The figure below shows the hydraulic cylinder mounted on the press tool.
The press tool includes two press devices that are used to different models of the balancing
device.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

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

Continues on next page

320 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.5.5. Unloading the balancing device using hydraulic press tool.

Continued

Required equipment

Equipment, etc. Art. no. Note

Press tool, balancing device 3HAC020902-001 Includes
• press device 3HAC15767-2
• press device 3HAC18100-1
Choose the correct device, depending
on model of balancing device.
Hydraulic cylinder 3HAC11731-1 To be used with the press tool.
Hydraulic pump, 80 MPa 3HAC13086-1 To be used with the hydraulic cylinder.
Standard toolkit - Content is defined in section Standard
toolkit on page 427.

Using the correct press device

The different designs of the balancing device require different versions of the press device,
included in the complete press tool. The table below specifies which press device to use to
which balancing device.
The article number of the balancing device may be found on a label at the rear of the balancing
device.
公 司
Balancing device
有 限 Press device

育 科技

控 帮教
沙 工
长
xx0300000600

xx0300000605 Art. no: 3HAC15767-2 (for balancing

Art. no: 3HAC14675-2 device 3HAC14675-1)
© Copyright 2004-2011 ABB. All rights reserved.

xx0300000599

xx0700000423 Art. no: 3HAC18100-1 (for balancing

device 3HAC023018-001)
Art. no: 3HAC023018-001

Continues on next page

3HAC022033-001 Revision: K 321
 工控帮助教小舒QQ2823408167
4 Repair
4.5.5. Unloading the balancing device using hydraulic press tool.

Continued

Unloading the balancing device

The procedure below details how to use the press tool in order to unload the balancing device.
How to remove the press tool, is detailed in section Restoring the balancing device using a
hydraulic press tool. on page 324.

Action Note
1. Fit the moving pin to the current press device. Choose the correct press device,
according to the table Using the correct
press device on page 321.
The moving pin is shown in the figure
Press tool and hydraulic cylinder on
page 320.
2. Fit the correct press device and moving pin to Shown in the figure Press tool and
the press tool. Secure with the bolt, press hydraulic cylinder on page 320.
device.

NOTE!
Make sure the bolt is secured properly!
3. Remove the rear cover of the balancing
device, by unscrewing the attachment screws. 公 司
有 限
DANGER! 育 科技
帮教
DO NOT! remove any other screws then the

控
rear cover attachment screws.

工
长 沙 xx0200000175

• E: Rear cover attachment

screws, 4 pcs
4. Remove the o-ring from the balancing device
end.

© Copyright 2004-2011 ABB. All rights reserved.

5. Remove the support shaft.
6. Fit the press tool to the rear of the balancing Art. no. is specified in Required
device with enclosed bolts. Tighten them equipment on page 321.
properly! See the figure Press tool and hydraulic
cylinder on page 320.
7. Fit the hydraulic cylinder to the press tool. Art. no. is specified in Required
equipment on page 321.
See the figure Press tool and hydraulic
cylinder on page 320.
8. Connect the hydraulic pump to the cylinder. Art. no. is specified in Required
equipment on page 321.
9. Increase the pressure and press until the See the figure Press tool and hydraulic
marking on the moving pin indicates the cylinder on page 320.
correct position (in level with the pressure Do not apply more pressure than
block). necessary, it could damage bearings
and sealings at the shaft.
10. Turn the fix plate to position "Closed" in order See the figure Press tool and hydraulic
to lock the tool in loaded condition. cylinder on page 320.

Continues on next page

322 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.5.5. Unloading the balancing device using hydraulic press tool.

Continued

Action Note
11. Unload the hydraulic cylinder.
12. The hydraulic cylinder may now be removed
from the tool, when necessary.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 323

 工控帮助教小舒QQ2823408167
4 Repair
4.5.6. Restoring the balancing device using a hydraulic press tool.

4.5.6. Restoring the balancing device using a hydraulic press tool.

Overview
This section details how to restore the balancing device and how to remove the press tool
from the device.
DANGER!
There is a high tensioned spring inside the balancing device, incorrect handling may cause
injuries and damage property.

Press tool and hydraulic cylinder

The figure below shows the hydraulic cylinder mounted on the press tool.
The press tool includes two press devices that are used to different models of the balancing
device.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

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

Continues on next page

324 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.5.6. Restoring the balancing device using a hydraulic press tool.

Continued

Required equipment

Equipment, etc. Art. no. Note

Hydraulic cylinder 3HAC11731-1 To be used with press tool.
Hydraulic pump, 80 MPa 3HAC13086-1 To be used with hydraulic cylinder.
Brush -
Rust preventive 3HAC026621-001 Equivalent:
• Mercasol 3106
Locking liquid - Loctite 577
Used to secure the attachment screws
of the rear cover at the end of the
balancing device.
Standard toolkit 3HAC15571-1 Content is defined in section Standard
toolkit on page 427.
Sikaflex 521FC

Restoring the balancing device

The procedure below details how to restore the balancing device, that is removing the press

司
tool.

Action
公
限 Note
有
科技
1. Refit the hydraulic cylinder to the press tool, in Shown in the figure Press tool and
case it has been removed. hydraulic cylinder on page 324.
育
2. Press with the cylinder and the hydraulic pump Shown in the figure Press tool and

控 帮教
until the fix plate is movable again. Turn the pin hydraulic cylinder on page 324!
on the fix plate to position "Open". Do not apply more pressure than

沙 工 necessary, it could damage bearings

and sealings at the shaft.
长
3. Unload the cylinder and make sure the moving Shown in the figure Press tool and
pin indicates that the tool has returned to its hydraulic cylinder on page 324!
starting position.
4. Remove the hydraulic cylinder.
© Copyright 2004-2011 ABB. All rights reserved.

5. Remove the press tool by unscrewing the bolts. Shown in the figure Press tool and
hydraulic cylinder on page 324!
6. Lubricate and refit the o-ring at the end of the Make sure the o-ring is seated
balancing device. properly! Replace if damaged.
7. Refit the support shaft to the balancing device.
8. Lubricate and refit the o-ring on the support Make sure the o-ring is seated
shaft. properly! Replace if damaged.

Continues on next page

3HAC022033-001 Revision: K 325
 工控帮助教小舒QQ2823408167
4 Repair
4.5.6. Restoring the balancing device using a hydraulic press tool.

Continued

Action Note
9. Refit the rear cover to the balancing device with
its attachment screws, using locking liquid.
Apply sikaflex 521FX on the cover.

xx0200000175

• E: 4 pcs: M10x30, tightening

torque: 50 Nm.
Locking liquid is specified in Required
equipment on page 325.
10.

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
公 司
commissioning of the robot!

有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

326 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
4 Repair
4.6.1. Replacement of motor, axis 1

4.6 Motors

4.6.1. Replacement of motor, axis 1

NOTE!
This procedure requires calibration of the robot.
Use the Calibration Pendulum tool 3HAC15716-1.

Location of motor
The motor axis 1 is located on the left hand side of the robotas shown in the figure below.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0100000123

A Motor, axis 1
B Cable gland cover, motor axis
C Cover for connector access
D Motor attachment screws

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Motor, axis 1 3HAC14207-1 Includes:
• motor
• pinion
• o-ring 21522012-
430.
O-ring 21522012-430 Must be replaced when
reassemling the motor.

Continues on next page

3HAC022033-001 Revision: K 327
 工控帮助教小舒QQ2823408167
4 Repair
4.6.1. Replacement of motor, axis 1

Continued

Equipment, etc. Spare part no. Art. no. Note

Sikaflex 521FC 3HAC026759-001 Option Foundry Prime
Brush - Option Foundry Prime
Mercasol 3106 3HAC026621-001 Option Foundry Prime
Loctite 574
Gasket 3HAC3438-1 Option Foundry Prime
Must be replaced if the
cabling is dismantled from
the motor.
Grease 3HAB3537-1 Used to lubricate the o-
ring.
Removal tool, motor 3HAC14973-1 Always use the removal
M12x tools in pairs!
Lifting tool, motor ax 1, 3HAC14459-1
4, 5
Extension 300mm for 3HAC12342-1
bits 1/2"
Power supply - 24 VDC, max. 1,5 A
For releasing the brakes.
Standard toolkit -
公 司 Content is defined in

有 限 section Standard toolkit

on page 427.
Calibration Pendulum
科 技3HAC15716-1 Complete kit that also

育
toolkit includes operating

帮教
manual.
Other tools and These procedures include

工控
procedures may be references to the tools
required. See required.

长沙
references to these
procedures in the
step-by-step instruc-
tions below.
Circuit Diagram See chapter Circuit
© Copyright 2004-2011 ABB. All rights reserved.
diagram.

Removal, motor axis 1

The procedure below details how to remove motor, axis 1.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.
2. Remove the cover for connector access on top of
the motor by unscrewing its four attachment screws.

Continues on next page

328 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.6.1. Replacement of motor, axis 1

Continued

Action Note
3. Remove the cable gland cover at the cable exit by
unscrewing its two attachment screws.

NOTE!
Make sure the gasket is not damaged!

xx0200000199

• A: Cable gland cover

4. Disconnect all connectors beneath the motor cover.
5. Apply lifting tool, motor axis 1, 4, 5 to the motor. Art. no. is specified in Required
equipment on page 327.
6. In order to release the brakes, connect the 24 VDC Connect to connector R2.MP1
power supply. • +: pin 2
• -: pin 5
7. Remove the motor by unscrewing its four
attachment screws and plain washers.
司Shown in the figure Location of
公 motor on page 327.
有限
If required, use the extension 300mm for bits 1/2". Art. no. is specified in Required

8. 科 技 equipment on page 327.

育
帮 教
CAUTION!
工 控
The motor weighs 32 kg! All lifting equipment used

9. 长
沙
must be sized accordingly!
Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.
10. Remove the motor by gently lifting it straight up.
© Copyright 2004-2011 ABB. All rights reserved.

Refitting, motor axis 1

The procedure below details how to refit motor, axis 1.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.
2. Make sure the o-ring on the circumference of the Art no. is specified in Required
motor is seated properly. Lightly lubricate the o-ring equipment on page 327.
with grease.

Continues on next page

3HAC022033-001 Revision: K 329
 工控帮助教小舒QQ2823408167
4 Repair
4.6.1. Replacement of motor, axis 1

Continued

Action Note
3.

CAUTION!
The motor weighs 32 kg! All lifting equipment used
must be sized accordingly!
4. Apply the lifting tool, motor axis 1, 4, 5 to the motor. Art no. is specified in Required
equipment on page 327.
5. In order to release the brake, connect the 24 VDC Connect to connector R2.MP1
power supply. • +: pin 2
• -: pin 5
6. Fit the motor, making sure the motor pinion is Make sure the motor is turned the
properly mated to gearbox of axis 1. correct way, that is connection of
motorcable forwards..
Make sure the motor pinion does
not get damaged!
7. Fit the clutch on the pinion on the motor.
8. Secure the motor with its four attachment screws M10 x 40, tightening torque: 50
and plain washers. Nm.
9. Disconnect the brake release voltage.
公 司
有with限its Make sure the cover is tightly
10. Reconnect all connectors beneath the motor cover.
11.
two attachment screws.
科 技
Refit the cable gland cover at the cable exit
sealed!
12. Refit the motor cover with its育
four attachment Make sure the cover is tightly
screws.
帮 教 sealed!
13.
工 控
Recalibrate the robot! Calibration is detailed in a
separate calibration manual

长 沙 enclosed with the calibration tools.

General calibration information is
included in section Calibration
information on page 403.
14.
© Copyright 2004-2011 ABB. All rights reserved.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run may
cause injury or damage! on page 47.

Continues on next page

330 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.6.1. Replacement of motor, axis 1

Continued

Replacement of the motor axis 1 (Foundry Prime)

Robots working with Foundry Prime and that have the special tightness for this application
require special repair routines to maintain the tightness level.
The repair must be done according to the previous repair procedures with the following
additions.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.
2. Remove the cover for connector access on top of
the motor by unscrewing its four attachment B
screws.

A
公司
有限
C

科 技
育
帮 教 D

工 控
长 沙 xx0600002874

• A: Attachment screw
• B: Air hose
• C: Top cover
© Copyright 2004-2011 ABB. All rights reserved.

• D: Motor unit
3.

NOTE!
Keep the old top cover, with the air nipple
mounted.
4. Remove the motor unit, according to step 5 and
forwards in section Removal, motor axis 1 on
page 328.

Continues on next page

3HAC022033-001 Revision: K 331
 工控帮助教小舒QQ2823408167
4 Repair
4.6.1. Replacement of motor, axis 1

Continued

Action Note
5. Fill the four screw recesses on the new motor with
Sikaflex. (After hardening, Sikaflex can be formed
with a knife)

xx0600002875

• A: Motor unit
• B: Sikaflex in screw
recesses
6. Continue to refit the new motor according to
section, Refitting, motor axis 1 on page 329.
7. After mounting the motor on the robot, the surface
between the motor and the base frame must be

司
protected with Mercasol 3106.

限 公
有
育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0600002877

• A: Base frame
• B: Motor unit
8. Perform a leak test according to Inspection of air
hoses (Foundry Prime) on page 191

332 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
4 Repair
4.6.2. Replacement of motor axis 2

4.6.2. Replacement of motor axis 2

Location of motor
The motor, axis 2, is located on the left-hand side of the robot as shown in the figure below.

公 司
有 限
科技
xx0100000124

A Motor, axis 2
育
B
C
教
Cable gland cover, motor axis 2
帮screw
Hole for lock

工 控
Required equipment
长 沙
Equipment, etc. Spare part no. Art. no. Note
Motor axis 2 3HAC14209-2 Includes:
(IRB 7600 - 500/2.3, • motor
© Copyright 2004-2011 ABB. All rights reserved.

IRB 7600 - 400/2.55, • pinion

IRB 7600 - 340/2.8, • o-ring 2152 2012-
IRB 7600 - 150/3.5) 430
Motor axis 2 3HAC025819-001 Includes:
(IRB7600 - 500/2.55, • motor
IRB7600 - 325/3.1) • pinion
• o-ring 2152 2012-
430
O-ring 21522012-430 21522012-430 Must be replaced when
reassembling motor!
Sikaflex 521FC 3HAC026759-001 Option Foundry Prime.
Gasket 3HAC3438-1 Option Foundry Prime
Must be replaced if the
cablling is dismantled from
the motor.
Mercasol 3106 3HAC026621-001 Option Foundry Prime
Loctite 574 Option Foundry Prime

Continues on next page

3HAC022033-001 Revision: K 333
 工控帮助教小舒QQ2823408167
4 Repair
4.6.2. Replacement of motor axis 2

Continued

Equipment, etc. Spare part no. Art. no. Note

Grease 3HAB3537-1 For lubricating the o-ring.
Locking screw 3HAA1001-266 M16 x 60
For securing the lower arm.
Removal tool, motor 3HAC14973-1 Always use the removal
M12x tools in pairs!
Guide pins M10 x 3HAC15521-1 For guiding the motor.
100 Guides are to be used in
pairs!
Guide pins M10 x 3HAC15521-2 For guiding the motor.
150 Guides are to be used in
pairs!
Lifting tool, motor ax 3HAC15534-1
2, 3, 4
Extension 300mm for 3HAC12342-1
bits 1/2"
Extension bar, 300 3HAC12342-1
mm for bits 1/2"
Power supply - 24 VDC, 1.5 A

Rotation tool 公
3HAC17105-1
司 Used to rotate the motor
For releasing the brakes.

有 限 pinion when mating it to the

科技
gear when brakes are
released with 24VDC
育 power supply.

帮教
Standard toolkit - Content is defined in
section Standard toolkit on

工 控 page 427.
Calibration 沙 3HAC15716-1 Complete kit that also
长toolkit
Pendulum includes operating manual.
Other tools and These procedures include
procedures may be references to the tools
required. See required.

© Copyright 2004-2011 ABB. All rights reserved.

references to these
procedures in the
step-by-step instruc-
tions below.
Circuit diagram See chapter Circuit
diagram.

Continues on next page

334 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.6.2. Replacement of motor axis 2

Continued

Removal, motor
The procedure below details how to remove the motor, axis 2.

Action Note
1. Move the robot to a position close Shown in the figure Location of motor on page
enough to its calibration position, to 333.
allow the lock screw to be inserted
into thehole for lock screw .
2.

DANGER!
Turn off all electric power, hydraulic
and pneumatic pressure supplies to
the robot!
Turn off all electric power and
hydraulic but not the air pressure to
the gearboxes, motors and SMB.
3. Lock the lower arm by inserting the Art. no. and dimension is specified in Required
lock screw into the hole. equipment on page 333.
4. Drain the oil from gearbox, axis 2.
司
Detailed in the section Oil change, gearbox axis 2
公
on page 203.
5. Remove the cover on top of the
有 限
科技
motor by unscrewing its four
attachment screws.
育
6. Remove the cable gland cover at Shown in the figure Location of motor on page

帮教
the cable exit by unscrewing its two 333.

控
attachment screws. Make sure the gasket is not damaged!

沙 工
7. Disconnect all connectors beneath
the motor cover.
8. 长 Use the lock screw to lock the lower arm, as
detailed above!

DANGER!
© Copyright 2004-2011 ABB. All rights reserved.

Secure the weight of the lower arm

properly before releasing the brakes
of motor, axis 2!
When releasing the holding brakes
of the motor, the lower arm will be
movable and may fall down!
9. In order to release the brake, Connect to connector R2.MP2
connect the 24 VDC power supply. • +: pin 2
• -: pin 5
10. Remove the motor by unscrewing its
four attachment screws and plain
washers.
11. Fit the two guide pins in two of the Art. no. is specified in Required equipment on
motor attachment holes. page 333.
Shown in the figure Location of motor on page
333.

Continues on next page

3HAC022033-001 Revision: K 335
 工控帮助教小舒QQ2823408167
4 Repair
4.6.2. Replacement of motor axis 2

Continued

Action Note
12. If required, press the motor out of Art. no. is specified in Required equipment on
position by fitting the removal tool, page 333.
motor to the remaining motor Shown in the figure Location of motor on page
attachment holes. 333.
Always use the removal tools in pairs!
13. Remove the removal tools and fit Art. no. is specified in Required equipment on
the lifting tool, motor axis 2, 3, 4 to page 333.
the motor.
14.

CAUTION!
The motor weighs 32 kg! All lifting
equipment used must be sized
accordingly!
15. Lift the motor to get the pinion away Make sure the motor pinion does not get
from the gear. damaged!
16. Remove the motor by gently lifting it
straight out and place it on a secure
surface. Disconnect the brake
release voltage.
公 司
有 限
Refitting, motor
技
育科
The procedure below details how to refit the motor axis 2.

Action
帮 教 Note
1.
工 控
长沙
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!

© Copyright 2004-2011 ABB. All rights reserved.

Turn off all electric power and hydraulic but
not the air pressure to the gearboxes, motors
and SMB.
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 333.
the o-ring with grease.
3. In order to release the brake, remove the Connect to connector R2.MP2
cover on top of the motor and connect the 24 • +: pin 2
VDC power supply. • -: pin5
4. Fit the lifting tool, motor axis 2, 3, 4 to the Art. no. is specified in Required
motor. equipment on page 333.
5. Fit the two guide pins in the two lower motor Art. no. is specified in Required
attachment holes. equipment on page 333.
Shown in the figure Location of motor on
page 333.

Continues on next page

336 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.6.2. Replacement of motor axis 2

Continued

Action Note
6.

CAUTION!
The motor weighs 32 kg! All lifting equipment
used must be sized accordingly!
7. Lift the motor and guide it onto the guide pins,
as close to the correct position as possible
without pushing the motor pinion into the
gear.
Make sure that the motor is turned the right
direction, that is the cables facing
downwards.
8. Remove the lifting tool and allow the motor to
rest on the guide pins.
9. Use the rotation tool in order to rotate the Art. no. is specified in Required
motor pinion when mating it to the gear (see equipment on page 333.
the figure to the right). Fit the motor, making
sure the motor pinion is properly mated to the
gear of gearbox axis 2 and that it does not get
damaged.
公 司
有 限

育 科技
帮教
工控
xx0200000165

The rotation tool is used beneath the

长沙
motor cover, directly on the motor shaft
as shown in the figure above.
• A: Rotation tool
10. Remove the guide pins.
11. Secure the motor with four attachment screws M10 x 40, tightening torque: 50 Nm.
© Copyright 2004-2011 ABB. All rights reserved.

and plain washers. Reused screws may be used, providing

If required, use the extension 300mm for bits they are lubricated as detailed in section
1/2". Screw joints on page 423 before fitting.
12. Disconnect the brake release voltage.
13. Reconnect all connectors beneath the motor Connect in accordance with markings
cover. on connectors.
14. Refit the cable gland cover at the cable exit Shown in the figure Location of motor on
with its two attachment screws. page 333.
15. Refit the cover on top of the motor with its four Make sure the cover is tightly sealed!
attachment screws.
16. Remove the lock screw from the hole for lock Shown in the figure Location of motor on
screw. page 333.
17. Perform a leak down test. Detailed in Performing a leak-down test
on page 246.
18. Refill the gearbox with oil. Detailed in the section Oil change,
gearbox axis 2 on page 203.

Continues on next page

3HAC022033-001 Revision: K 337
 工控帮助教小舒QQ2823408167
4 Repair
4.6.2. Replacement of motor axis 2

Continued

Action Note
19. Recalibrate the robot. Calibration is detailed in a separate
calibration manual enclosed with the
calibration tools.
General calibration information is
included in section Calibration
information on page 403.
20.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on page
47.

Replacement of the motor axis 2 (Foundry Prime)

Robots working with Foundry Prime and that have the special tightness for this application
require special repair routines to maintain the tightness level.
司
The repair must be done according to the previous repair procedures with the following
公
additions.
有 限
科技
Action Note

育
1. Move the robot to a position close enough to its Shown in the figure Location of

帮教
calibration position, to allow the lock screw to be motor on page 333.
inserted into the hole for lock screw.
2.
工 控
长 沙
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!

© Copyright 2004-2011 ABB. All rights reserved.

3. Lock the lower arm by inserting the lock screw into Art. no. and dimension is specified
the hole. in Required equipment on page
333.
4. Drain the oil from gearbox, axis 2. Detailed in section Oil change,
gearbox axis 2 on page 203.

Continues on next page

338 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.6.2. Replacement of motor axis 2

Continued

Action Note
5. Remove the cover for connector access on top of
the motor by unscrewing its four attachment B
screws.

xx0600002874

• A: Attachment screw
• B: Air hose
• C: Top cover
• D: Motor unit
6. Disconnect all connectors beneath the motor
公 司
7.
cover.

有 限

育 科技
NOTE!
帮 教
Keep the old top cover with the air nipple
mounted. 控
8.
沙 工
长
DANGER!
Secure the weight of the lower arm properly
before releasing the brakes of motor, axis 2!
© Copyright 2004-2011 ABB. All rights reserved.

When releasing the holding brakes of the motor,

the lower arm will be movable and may fall down!
9. After the weight of the lower arm is properly
secured, continue removal of the motor unit, as
detailed in section Removal, motor on page 335.

Continues on next page

3HAC022033-001 Revision: K 339
 工控帮助教小舒QQ2823408167
4 Repair
4.6.2. Replacement of motor axis 2

Continued

Action Note
10. Fill the four screw recesses on the new motor with
Sikaflex. (After hardening, Sikaflex can be formed
with a knife)

xx0600002875

• A: Motor unit
• B: Sikaflex in screw
recesses
11. Continue to refit the new motor according to
section, Refitting, motor on page 336.
12. Perform a leak test according to Inspection of air
hoses (Foundry Prime) on page 191.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

340 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
4 Repair
4.6.3. Replacement of motor, axis 3

4.6.3. Replacement of motor, axis 3

Location of motor
The motor axis 3 is located on the left hand side of the robot as shown in the figure below.

公 司
有限
科技
xx0200000186

A Motor axis 3
育
帮教
B Cable gland cover, motor axis 3
C
工 控Motor attachment holes (4 pcs)

Required equipment
长 沙
Equipment, etc. Spare part no. Art. no. Note
Motor, axis 3 3HAC14209-1 Includes:
© Copyright 2004-2011 ABB. All rights reserved.

• motor
• pinion
• o-ring 21522012-430.
O-ring 21522012-430 Must be replaced when reas-
sembling motor!
Sikaflex 521FC 3HAC026759-001 Option: Foundry Prime
Gasket 3HAC3438-1 Option: Foundry Prime
Mercasol 3106 3HAC0266621- Option: Foundry Prime
001
Loctite 574 Option: Foundry Prime
Mechanical stop 3HAC12708-2 May be used to fix axis 3.
axis 3 Use attachment screws 3HAB
3409-86 (M16 x 60).
Grease 3HAB3537-1 For lubricating the o-ring.
Removal tool, 3HAC14973-1 Always use the removal tools
motor M12x in pairs!

Continues on next page

3HAC022033-001 Revision: K 341
 工控帮助教小舒QQ2823408167
4 Repair
4.6.3. Replacement of motor, axis 3

Continued

Equipment, etc. Spare part no. Art. no. Note

Lifting tool, motor 3HAC15534-1
ax 2, 3, 4
Bolts M16x60 3HAB3409-86
(for mechanical
stop axis 3)
Washers (for 3HAA1001-186
mechanical stop
axis 3)
Guide pins M10 x 3HAC15521-1 For guiding the motor.
100
Guide pins M10 x 3HAC15521-2 For guiding the motor.
150
Extension 300mm 3HAC12342-1
for bits 1/2"
Rotation tool 3HAC17105-1 Used to rotate the motor
pinion when mating it to the
gear when brakes are
released with 24 VDC power
supply.
Power supply -
公 司 24 VDC, max. 1.5 A

Standard toolkit - 有 限 For releasing the brakes.

Content is defined in section

科技
Standard toolkit on page 427.
Calibration
育 3HAC15716-1 Complete kit that also
Pendulum toolkit
Other tools and 帮 教 includes operating manual.
These procedures include

工
procedures may be 控 references to the tools

长 沙
required. See
references to these
required.

procedures in the
step-by-step
instructions below.
Circuit Diagram See chapter Circuit diagram.
© Copyright 2004-2011 ABB. All rights reserved.

Continues on next page

342 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.6.3. Replacement of motor, axis 3

Continued

Removal, motor
The procedure below details how to remove motor, axis 3.

Action Note
1. Unload the upper arm of the robot
by either:
• Move the robot to a position
where the turning disk rests
against the foundation (rec-
ommended).
• Use a fork lift to rest the
upper arm onto.
• Use lifting slings and an
overhead crane to rest the
upper arm.
• Use a mechanical stop to
rest the upper arm. Fit the xx0300000051
mechanical stop in the
Fit the mechanical stop to the third and final
attachment hole (A) with
attachment hole (A), below the fixed stop (B) in the
tightening torque: 115 Nm.
upper arm. See the figure above!
2.
公 司
DANGER! 有 限

育 科技
Turn off all electric power, hydraulic
and pneumatic pressure supplies to

帮教
the robot!
Turn off all electric power and
控
hydraulic but not the air pressure to
工
沙
the gearboxes, motors and SMB.

长
3. Drain the oil from gearbox axis 3. Detailed in section Oil change, gearbox, axis 3 on
page 206.
4. Remove any equipment hindering
access to motor axis 3.
© Copyright 2004-2011 ABB. All rights reserved.

5. Remove the cover on top of the

motor by unscrewing its four
attachment screws.
6. Remove the cable gland cover at Shown in the figure Location of motor on page 341.
the cable exit by unscrewing its two Make sure the gasket is not damaged!
securing screws.
7. Disconnect all connectors beneath
the motor cover.
8. Unscrew the motors four Shown in the figure Location of motor on page 341.
attachment screws and plain
washers .
9. Fit the two guide pins in two of the Art. no. is specified in Required equipment on
motor attachment screw holes. page 341.
10. Press the motor out of position by Art. no. is specified in Required equipment on
fitting removal tool, motor to the page 341.
remaining motor attachment screw Always use the removal tools in pairs!
holes.
11. Apply the lifting tool, motor axis 2 ,3, Art. no. is specified in Required equipment on
4 to the motor. page 341.
Continues on next page
3HAC022033-001 Revision: K 343
 工控帮助教小舒QQ2823408167
4 Repair
4.6.3. Replacement of motor, axis 3

Continued

Action Note
12.

CAUTION!
The motor weighs 32 kg! All lifting
equipment used must be sized
accordingly!
13. Lift the motor to get the pinion away
from the gear.
14. Remove the motor by gently lifting it Make sure the motor pinion is not damaged!
straight out and disconnect the
brake release voltage.

Refitting, motor
The procedure below details how to refit motor, axis 3.

Action Note
1.

公 司
DANGER!
Turn off all electric power, hydraulic and 有 限
科技
pneumatic pressure supplies to the robot!

育
Turn off all electric power and hydraulic but not the

2.
教
air pressure to the gearboxes, motors and SMB.
Make sure the o-ring帮 on the circumference of the Art no. is specified in Required
motor is seated控 properly. Lightly lubricate it with equipment on page 341.
grease.
沙 工
3.
长
Fit the lifting tool, motor axis 2, 3, 4 to the motor. Art no. is specified in Required
equipment on page 341.
4. Fit the two guide pins in the two lower motor Art no. is specified in Required
attachment holes. equipment on page 341.

© Copyright 2004-2011 ABB. All rights reserved.

Shown in the figure Location of
motor on page 341
5.

CAUTION!
The motor weighs 32 kg! All lifting equipment
used must be sized accordingly!
6. Lift the motor and guide it onto the guide pins, as
close to the correct position as possible without
pushing the motor pinion into the gear.
7. Remove the lifting tool and allow the motor to stay
on the guide pins.
8. In order to release the brake, connect the 24 VDC Connect to connector R2.MP3
power supply. • +: pin 2
• -: pin 5

Continues on next page

344 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.6.3. Replacement of motor, axis 3

Continued

Action Note
9. Use the rotation tool in order to rotate the motor Art no. is specified in Required
pinion when mating it to the gear! equipment on page 341.
Fit the motor, making sure the motor pinion is Make sure the motor pinion does not
properly mated to the gear of gearbox, axis 3. get damaged!
Make sure the motor is turned the
right direction, that is the cables
facing forwards.

xx0200000165

The rotation tool is used beneath the

motor cover, directly on the motor
shaft as shown in figure above.
• A: Rotation tool.
10. Remove the guide pins.
公 司
11. Secure the motor with four attachment screws
and plain washers.
有 限 4 pcs: M10 x 40, tightening torque:
50 Nm.

科技
If required, use the extension 300mm for bits 1/2". Art. no. is specified in Required
equipment on page 341.
育
教
12. Disconnect the brake release voltage.
帮 beneath the motor
13. Reconnect all connectors Connect in accordance with
cover. 控 markings on connectors.
14. Refit the工
长 沙 cable gland cover at the cable exit with
its two attachment screws.
Make sure the cover is tightly
sealed!
Shown in the figure Location of
motor on page 341.
15. Refit the cover on top of the motor with its four Make sure the cover is tightly
© Copyright 2004-2011 ABB. All rights reserved.

attachment screws. sealed!

16. Remove the equipment used to unload the upper
arm.
17. Perform a leak-down test. Detailed in the section Performing a
leak-down test on page 246.
18. Refill the gearbox with oil. Detailed in the section Oil change,
gearbox, axis 3 on page 206.
19. Recalibrate the robot! Calibration is detailed in a separate
calibration manual enclosed with the
calibration tools.
General calibration information is
included in section Calibration
information on page 403.

Continues on next page

3HAC022033-001 Revision: K 345
 工控帮助教小舒QQ2823408167
4 Repair
4.6.3. Replacement of motor, axis 3

Continued

Action Note
20.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 47.

Replacement of the motor axis 3 (Foundry Prime)

Robots working with Foundry Prime and that have the special tightness for this application
require special repair routines to maintain the tightness level.
The repair must be done according to the previous repair procedures with the following
additions.

Action Note
1.

DANGER! 公 司
Turn off all electric power, hydraulic and
有 限
科技
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
育
air pressure to the gearboxes, motors and SMB.

控 帮教
2. Remove the motor according to step 2 - 4 in
Removal, motor on page 343.

沙 工
3. Remove the cover for connector access on top of
the motor by unscrewing its four attachment B
长
screws.

© Copyright 2004-2011 ABB. All rights reserved.

C

xx0600002874

• A: Attachment screw
• B: Air hose
• C: Top cover
• D: Motor unit

Continues on next page

346 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.6.3. Replacement of motor, axis 3

Continued

Action Note
4.

NOTE!
Keep the old top cover with the air nipple
mounted.
5. Continue removal of the motor unit, according to
step 6 and forwards in section Removal, motor on
page 343.
6. Fill the four screw recesses on the new motor with
Sikaflex. (After hardening, Sikaflex can be formed
with a knife)

公 司 xx0600002875

有 限 •
•
A: Motor unit
B: Sikaflex in screw

科技
recesses

育
7. Continue to refitt the new motor according to
教
section, Refitting, motor on page 344.
帮according to Inspection of air
8. Perform a leak test

工 控
hoses (Foundry Prime) on page 191.

长沙
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 347

 工控帮助教小舒QQ2823408167
4 Repair
4.6.4. Replacement of motor, axis 4

4.6.4. Replacement of motor, axis 4

Location of motor
The motor axis 4 is located on the left-hand side of the upper arm as shown in the figure
below.

公 司
有 限
科技
xx0200000202

A Motor, axis 4
育
帮教
B Cable gland cover, motor axis 4
C
控
Motor attachment holes (4 pcs)

工
Required equipment
长 沙
Equipment, etc. Spare part no. Art. no. Note
Motor, axis 4 3HAC14210-1 Includes:

© Copyright 2004-2011 ABB. All rights reserved.

• motor
• pinion
• o-ring 21522012-430
O-ring 21522012-430 Must be replaced when reas-
sembling motor!
Sikaflex 521FC 3HAC026759-001 Option Foundry Prime
Mercasol 3106 3HAC026621-001 Option Foundry Prime
Loctite 574 Option Foundry Prime
Gasket 3HAC3438-1 Option Foundry Prime
Lifting tool, motor ax 3HAC14459-1
1, 4, 5
Lifting tool, motor ax 3HAC14459-1
2, 3, 4
Lifting tool, motor ax 3HAC14459-1
2, 3, 4
Grease 3HAC3537-1 Used to lubricate the o-ring.

Continues on next page

348 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.6.4. Replacement of motor, axis 4

Continued

Equipment, etc. Spare part no. Art. no. Note

Lifting tool, motor ax 3HAC14459-1 To be used if the upper arm is
1, 4, 5 positioned vertically.
Lifting tool, motor ax 3HAC15534-1 To be used if the upper arm is
2, 3, 4 positioned horizontally.
Removal tool, motor 3HAC14973-1 Always use the removal tools
M12x in pairs!
Guide pins M10 x 3HAC15521-1 For guiding the motor.
100
Guide pins M10 x 3HAC15521-2 For guiding the motor.
150
Extension 300mm 3HAC12342-1
for bits 1/2"
Rotation tool 3HAC17105-1 Used to rotate the motor
pinion when mating it to the
gear when brakes are
released with 24 VDC power
supply.
Power supply - 24 VDC, max. 1,5 A
For releasing the brakes.
Standard toolkit -
公 司 Content is defined in section

Calibration 有限
3HAC15716-1
Standard toolkit on page 427.
Complete kit that also

科技
Pendulum toolkit includes operating manual.
Other tools and
育 These procedures include

帮教
procedures may be references to the tools
required. See required.
控
references to these
工
沙
procedures in the

长
step-by-step
instructions below.
Circuit Diagram See chapter Circuit diagram.
© Copyright 2004-2011 ABB. All rights reserved.

Removal, motor axis 4

The procedure below details how to remove the motor, axis 4.

Action Note
1. Move the upper arm to one of the basic
positions:
• upper arm is pointed straight up. This
position enables the motor to be
replaced without draining the gear
oil, which in turn saves time.
• upper arm is close to horizontal. This
position is recommended if the
gearbox is also to be replaced, i.e.
when the gearbox oil has to be
drained anyway.

Continues on next page

3HAC022033-001 Revision: K 349
 工控帮助教小舒QQ2823408167
4 Repair
4.6.4. Replacement of motor, axis 4

Continued

Action Note
2.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but
not the air pressure to the gearboxes,
motors and SMB.
3. In horizontal position: unload the upper arm
to avoid movement of the axis, with one of
the given methods:
• move the upper arm to a position
where the turning disk rests against
the foundation (recommended)
• use a fork lift or an overhead crane
and lifting slings to rest the weight of
the upper arm.
4. In horizontal position: drain the gearbox, Detailed in section Draining, oil, gearbox
axis 4. axis 4 on page 210.
5. Remove the cable gland cover at the cable
公 司
Shown in the figure Location of motor on
exit of the motor by unscrewing its two
attachment screws.
有 限
page 348.
Make sure the gasket is not damaged!

育 科技
6. Remove the cover on top of the motor by
教
unscrewing its four attachment screws.
帮 beneath the
motor cover. 控
7. Disconnect all connectors

8. In order沙
工
to release the brake, connect the 24 Connect to connector R2.MP4
VDC长power supply. • +: pin 2
• -: pin 5
9.

© Copyright 2004-2011 ABB. All rights reserved.

CAUTION!
The motor weighs 22 kg! All lifting
equipment used must be sized accordingly!
10. Unscrew the motors four attachment screws Shown in the figure Location of motor on
and plain washers. page 348.
11. Fit the two guide pins in two of the motor
attachment screw holes.
12. If required, press the motor out of position by Art. no. is specified in Required
fitting removal tool, motor to the motor equipment on page 348.
attachment screw holes. Always use the removal tools in pairs!

Continues on next page

350 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.6.4. Replacement of motor, axis 4

Continued

Action Note
13. Fit the lifting tool to the motor. Choose the correct lifting tool:
• lifting tool, motor axis 1, 4 and 5, if
the upper arm is positioned
vertically.
• lifting tool, motor axis 2, 3 and 4, if
the upper arm is positioned hori-
zontally.
Art. no. is specified in Required
equipment on page 348.
14. Lift the motor to get the pinion away from the
gear and disconnect the brake release
voltage.
15. Remove the motor by gently lifting it straight Make sure the motor pinion is not
out. damaged!

Refitting, motor axis 4

The procedure below details how to refit motor, axis 4.

Action Note
1.
公 司
有 限
科技
DANGER!

育
Turn off all electric power, hydraulic and

帮教
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but

工 控
not the air pressure to the gearboxes,
motors and SMB.

长 沙
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 348.
lubricate the o-ring with grease.
3.
© Copyright 2004-2011 ABB. All rights reserved.

CAUTION!
The motor weighs 22 kg! All lifting
equipment used must be sized accordingly!
4. Fit the lifting tool to the motor. Choose the correct lifting tool:
• lifting tool, motor axis 1, 4 and 5, if
the upper arm is positioned
vertically
• lifting tool, motor axis 2, 3 and 4, if
the upper arm is positioned hori-
zontally.
Art. no. is specified in Required
equipment on page 348.
5. In order to release the brakes, connect the Connect to connector R2.MP4:
24 VDC power supply. • +: pin 2
• -: pin 5

Continues on next page

3HAC022033-001 Revision: K 351
 工控帮助教小舒QQ2823408167
4 Repair
4.6.4. Replacement of motor, axis 4

Continued

Action Note
6. Fit the two guide pins in two of the motor Art. no. is specified in Required
attachment holes. equipment on page 348.
Shown in the figure Location of motor on
page 348.
7. Fit the motor with guidance of the pins, Make sure the motor pinion does not get
making sure the motor pinion is properly damaged!
mated to the gear of gearbox 4.
8. Use the rotation tool in order to rotate the Art. no. is specified in Required
motor pinion when mating it to the gear! equipment on page 348.
Fit the motor, making sure the motor pinion Make sure the motor pinion does not get
is properly mated to the gear, axis 4. damaged!
Make sure the motor is turned the right
direction, that is the cables facing
forwards.

公 司
有 限

育 科技 xx0200000165

The rotation tool is used beneath the

帮教
motor cover, directly on the motor shaft as
shown in figure above.

工 控 • A: Rotation tool.

长沙
9. Remove the guide pins.
10. Secure the motor with four attachment 4 pcs: M10 x 80, tightening torque: 50 Nm.
screws and plain washers. Art. no. is specified in Required
If required, use the extension 300mm for bits equipment on page 348.
1/2".
11. Disconnect the brake release voltage. © Copyright 2004-2011 ABB. All rights reserved.
12. Reconnect all connectors beneath the motor
cover.
13. Refit the cover on top of the motor with its Make sure the cover is tightly sealed!
four attachment screws.
14. Refit the cable gland cover at the cable exit Shown in the figure Location of motor on
with its two attachment screws. page 348.
15. Perform a leak-down test if the gearbox has Detailed in the section Performing a leak-
been drained. down test on page 246.
16. Refill the gearbox with oil if drained. Detailed in the section Filling, oil, gearbox
axis 4 on page 211.
17. Recalibrate the robot! Calibration is detailed in a separate
calibration manual enclosed with the
calibration tools.
General calibration information is
included in section Calibration information
on page 403.

Continues on next page

352 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.6.4. Replacement of motor, axis 4

Continued

Action Note
18.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER -
First test run may cause injury or damage!
on page 47.

Replacement of the motor axis 4 (Foundry Prime)

Robots working with Foundry Prime and that have the special tightness for this application
require special repair routines to maintain the tightness level.
The repair must be done according to the previous repair procedures with the following
additions.

Action Note
1.

公 司
DANGER!
有 限
科技
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
育
Turn off all electric power and hydraulic but not the

帮教
air pressure to the gearboxes, motors and SMB.

工 控
2. Remove the cover for connector access on top of
the motor by unscrewing its four attachment B
沙
screws.
长 A

C
© Copyright 2004-2011 ABB. All rights reserved.

xx0600002874

• A: Attachment screw
• B: Air hose
• C: Top cover
• D: Motor unit
3.

NOTE!
Keep the old top cover with the air nipple
mounted.

Continues on next page

3HAC022033-001 Revision: K 353
 工控帮助教小舒QQ2823408167
4 Repair
4.6.4. Replacement of motor, axis 4

Continued

Action Note
4. Remove the motor unit, according to step 4 to 12
in section Removal, motor axis 4 on page 349.
5. Fill the four screw recesses on the new motor with
Sikaflex. (After hardening, Sikaflex can be formed
with a knife)

xx0600002875

• A: Motor unit
• B: Sikaflex in screw
recesses
6. Continue to refit the new motor according to
section, Refitting, motor axis 4 on page 351.
7. Perform a leak test according to Inspection of air
hoses (Foundry Prime) on page 191.
公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

354 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
4 Repair
4.6.5. Replacement of motor, axis 5

4.6.5. Replacement of motor, axis 5

Location of motor
The motor axis 5 is located in the rear of the wrist unit as shown in the figure below.
Notice that the left hand side cover already is removed in the figure!

公 司
限
xx0100000127

A Motor, axis 5 有
B
C 育
Heat protection plate
科技
Cable gland cover, motor axis 5

Required equipment 控 帮教
Equipment,
工
沙 etc. Spare part no. Art. no. Note
长
Motor, axis 5 3HAC14725-1 Includes:
• motor
• pinion
© Copyright 2004-2011 ABB. All rights reserved.

• o-ring 21522012-430
O-ring 21522012-430 Must be replaced when
replacing motor!
Grease 3HAB3537-1 For lubricating the o-ring.
Standard toolkit - Content is defined in section
Standard toolkit on page 427.
Guide pins M10 x 100 3HAC15521-1 For guiding the motor.
Guide pins M10 x 150 3HAC15521-2 For guiding the motor.
Lifting tool, motor ax 1, 4, 3HAC14459-1 For lifting the motor in a
5 vertical position
Power supply 24 VDC, 1.5 A.
For releasing the brakes.
Extension 300mm for 3HAC12342-1
bits 1/2"
Removal tool, motor 3HAC14973-1 Always use the removal tools
M12x in pairs!

Continues on next page

3HAC022033-001 Revision: K 355
 工控帮助教小舒QQ2823408167
4 Repair
4.6.5. Replacement of motor, axis 5

Continued

Equipment, etc. Spare part no. Art. no. Note

Calibration Pendulum 3HAC15716-1 Complete kit that also
toolkit includes operating manual.
Other tools and These procedures include
procedures may be references to the tools
required. See references required.
to these procedures in
the step-by-step instruc-
tions below.
Circuit Diagram See chapter Circuit diagram.

Removal, motor axis 5

The procedure below details how to remove the motor, axis 5.

Action Note
1. Move the robot to a position where the motor in axis
5 is pointed straight up. This position enables the
motor to be replaced without draining the gear oil,
which in turn saves time.
2.

公 司
DANGER! 有 限
科技
Turn off all electric power, hydraulic and pneumatic

育
pressure supplies to the robot!

帮教
Turn off all electric power and hydraulic but not the air
pressure to the gearboxes, motors and SMB.

工 控
3. Remove the left hand side cover of the wrist unit by The motor is accessible behind

长 沙
unscrewing its six attachment screws.
4. Remove the heat protection plate by unscrewing its
the rear part of the cover.
Shown in the figure Location of
two attachment screws. motor on page 355.
5. Remove the cover on top of the motor by unscrewing
its four attachment screws.

© Copyright 2004-2011 ABB. All rights reserved.

6. Remove the cable gland cover at the cable exit by Shown in the figure Location of
unscrewing its two attachment screws. motor on page 355.
7. Disconnect all connectors beneath the motor cover.
8. In order to release the brake, connect the 24 VDC Connect to connector R3.MP5
power supply. • +: pin 2
• -: pin 5
9.

CAUTION!
The motor weighs 22 kg! All lifting equipment used
must be sized accordingly!
10. Remove the motor by unscrewing its four attachment Art. no. is specified in Required
screws and plain washers. equipment on page 355.
If required, use the extension 300 mm for bits 1/2.
11. Fit the lifting tool, motor axis 1, 4, 5 to the motor. Art. no. is specified in Required
equipment on page 355.

Continues on next page

356 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.6.5. Replacement of motor, axis 5

Continued

Action Note
12. Fit the two guide pins in two of the motor attachment Art. no. is specified in Required
screw holes. equipment on page 355.
13. If required, press the motor out of position by fitting Art. no. is specified in Required
removal tool, motor to the motor attachment screw equipment on page 355.
holes. Always use the removal tools in
pairs and diagonally!
14. Lift the motor to get the pinion away from the gear and
disconnect the brake release voltage.
15. Remove the motor by gently lifting it straight out. Make sure the motor pinion is
not damaged!

Refitting, motor axis 5

The procedure below details how to refit the motor, axis 5.

Action Note
1.

DANGER!
公 司
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
有 限
科技
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.
育
2. Make sure the o-ring on the circumference of the Art. no. is specified in Required

帮教
motor is seated properly. Lightly lubricate the o-ring equipment on page 355.

3. 工 控
with grease.

长 沙
CAUTION!
The motor weighs 22 kg! All lifting equipment used
must be sized accordingly!
© Copyright 2004-2011 ABB. All rights reserved.

4. Fit the lifting tool, motor axis 1, 4, 5 to the motor.

5. In order to release the brakes, connect the 24 VDC Connect to connector R3.MP5
power supply to the motor. • +: pin 2
• -: pin 5
6. Fit the two guide pins in two of the motor Art. no. is specified in Required
attachment holes. equipment on page 355.
7. Fit the motor, with guidance from the pins, making Make sure the motor pinion does
sure the motor pinion is properly mated to the gear not get damaged!
of gearbox, axis 5. Make sure the motor is turned the
right direction, that is the cables
facing forward.

Continues on next page

3HAC022033-001 Revision: K 357
 工控帮助教小舒QQ2823408167
4 Repair
4.6.5. Replacement of motor, axis 5

Continued

Action Note
8. If necessary, use the rotation tool in order to rotate Art. no. is specified in Required
the motor pinion when mating it to the gear! equipment on page 355.

xx0200000165

The rotation tool (A) is used

beneath the motor cover, directly
on the motor shaft as shown in
figure above.
9. Secure the motor with four attachment screws and M10 x 40, 12.9 quality.
plain washers. Tightening torque: 50 Nm.
If required, use the extension 300 mm for bits 1/2". Art. no. is specified in Required
equipment on page 355.
10. Disconnect the brake release voltage.
11. Reconnect all connectors beneath the motor cover.
公 司
12.
two attachment screws.
限
Refit the cable gland cover at the cable exit with its Shown in the figure Location of
有 motor on page 355.
13.
科 技
Refit the cover on top of the motor with its four Make sure the cover is tightly

14.
attachment screws.
Refit the heat protection教
育
plate with its two
sealed!
Shown in the figure Location of
attachment screws. 帮
15.
控
工loose, place them correctly and tie
If cables are
motor on page 355.

them up 沙 with cable ties.

长the left hand side cover of the wrist unit with its
16. Refit
six attachment screws.
17. Recalibrate the robot. Calibration is detailed in a
separate calibration manual
© Copyright 2004-2011 ABB. All rights reserved.
enclosed with the calibration
tools.
General calibration information is
included in section Calibration
information on page 403.
18.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run may
cause injury or damage! on page 47.

358 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
4 Repair
4.6.6. Replacement of motor, axis 6

4.6.6. Replacement of motor, axis 6

Location of motor
The motor axis 6 is located in the center of the wrist unit as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views on page 463 .

公 司
有 限

育 科技
xx0100000128
控 帮教
A
沙 工 Motor, axis 6

长
Required equipment

Equipment, etc. Spare part no. Art. no. Note

© Copyright 2004-2011 ABB. All rights reserved.

Motor, axis 6 3HAC14211-1 Includes:

• motor
• pinion
• o-ring 21522012-430
O-ring 21522012-430 Must be replaced when reas-
sembling motor!
Brush - Option Foundry Prime
Mercasol 3106 3HAC026621- Option Foundry Prime
001
Sikaflex 521FC 3HAC026759- Option Foundry Prime
001
Loctite 574 Option Foundry Prime
Loctite 480
Gasket 3HAC12877-1 Protection Standard.
Must be replaced when
replacing motor

Continues on next page

3HAC022033-001 Revision: K 359
 工控帮助教小舒QQ2823408167
4 Repair
4.6.6. Replacement of motor, axis 6

Continued

Equipment, etc. Spare part no. Art. no. Note

Gasket 3HAC033206-001 Protection Foundry Plus,
Foundry Prime
Must be replaced when
replacing motor
Gasket, cover 3HAC033489-001 Must be replaced when
opening cover.
Removal tool, motor 3HAC14972-1 Always use the removal tools
M10x in pairs!
Extension 300mm for 3HAC12342-1
bits 1/2"
Power supply - 24 VDC, 1.5 A
For releasing the brakes.
Grease 3HAB3537-1 For lubricating the o-ring.
Standard toolkit - Content is defined in section
Standard toolkit on page
427.
Calibration Pendulum 3HAC15716-1 Complete kit that also
toolkit includes operating manual.
Other tools and
procedures may be 司These procedures include
公 references to the tools
有限
required. See required.
references to these
procedures in the step-
by-step instructions 科 技
育
below.
Circuit Diagram
帮 教 - See chapter Circuit diagram.

工 控
Removal, motor
长 沙
The procedure below details how to remove the motor, axis 6.

Action Note

© Copyright 2004-2011 ABB. All rights reserved.

1. Move the robot to one of the recommended
positions:
• 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.
• to a position where the motor in axis 6 is
close to horizontal. This position may be
selected when the gearbox is to be replaced,
i.e. when the gearbox oil has to be drained
anyway.
2.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.

Continues on next page

360 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.6.6. Replacement of motor, axis 6

Continued

Action Note
3. In horizontal position: drain the oil from the axis 6 Detailed in section Draining, oil,
gearbox. gearbox axis 6 on page 216.
4. Remove the rear motor cover by unscrewing the five
attachment screws.
5. Disconnect all connectors beneath the cover.
6. In order to release the brake, connect the 24 VDC Connect to connector R3.MP6
power supply. • +: pin 2
• -: pin 5
7. Remove the motor by unscrewing its four Art. no. is specified in Required
attachment screws and plain washers. equipment on page 359.
If required, use the extension 300mm for bits 1/2".
8. If required, press the motor out of position by fitting Art. no. is specified in Required
removal tool, motor to the motor attachment screw equipment on page 359.
holes. Always use the removal tools in
pairs!
9. Lift the motor carefully to get the pinion away from Make sure the motor pinion is not
the gear and disconnect the brake release voltage. damaged!
10. Remove the motor by gently lifting it straight out.

公 司
Refitting, motor
有 限
The procedure below details how to refit motor, axis 6.

Action
育 科技 Note

帮 教
1. Make sure the o-ring on the circumference of the Art. no. is specified in Required

工 控
motor is seated properly. Lightly lubricate the o- equipment on page 359.
ring with grease.

长 沙
2. In order to release the brake, connect the 24
VDC power supply.
Connect to connector R3.MP6
• +: pin 2
• -: pin 5
3. Fit the two guide pins in two of the motor Art. no. is specified in Required
attachment holes. equipment on page 359.
© Copyright 2004-2011 ABB. All rights reserved.

4. Fit the motor, with guidance from the pins, Make sure the pinion on the motor
making sure the motor pinion is properly mated shaft is not damaged!
to the gear of gearbox, axis 6.
5. Remove the guide pins.
6. Secure the motor with its four attachment screws 4 pcs: M8 x 25, tightening torque: 24
and plain washers. Nm.
If required, use extension 300mm for bits 1/2". Art. no. is specified in Required
equipment on page 359.
7. Disconnect the brake release voltage.
8. Reconnect all connectors beneath the motor
cover.
9. Refit the cover on top of the motor with its five Make sure the cover is tightly sealed!
attachment screws.
10. Perform a leak-down test (if the gearbox has Detailed in section Performing a
been drained). leak-down test on page 246.
11. Refill the gearbox with oil, if it has been drained. Detailed in section Filling, oil,
gearbox axis 6 on page 217.

Continues on next page

3HAC022033-001 Revision: K 361
 工控帮助教小舒QQ2823408167
4 Repair
4.6.6. Replacement of motor, axis 6

Continued

Action Note
12. Recalibrate the robot. Calibration is detailed in a separate
calibration manual enclosed with the
calibration tools.
General calibration information is
included in section Calibration
information on page 403.
13.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 47.

Replacement of the motor axis 6 (Foundry Plus and Foundry Prime)

Robots working with Foundry Plus or Foundry Prime and that have the special tightness for
this application require special repair routines to maintain the tightness level.
The repair must be done according to the previous repair procedure with the following
additions.
公 司
Action 有 限 Note
1.
科 技
Move the robot to one of the recommended
positions: 育
帮
• to a position where 教the motor in axis 6
enables 控
is pointed straight up. This position

沙 工draining the gear oil, which in

without
the motor to be replaced

长•
turn saves time.
to a position where the motor in axis 6
is close to horizontal. This position may
be selected when the gearbox is to be
replaced, that is when the gearbox oil
has to be drained anyway. © Copyright 2004-2011 ABB. All rights reserved.
2.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not
the air pressure to the gearboxes, motors and
SMB.
3. In horizontal position: drain the oil from the axis Detailed in section: Draining, oil, axis 6.
6 gearbox.

Continues on next page

362 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.6.6. Replacement of motor, axis 6

Continued

Action Note
4. Remove the rear motor cover by unscrewing
the five attachment screws.

xx0600002885

• A: Motor unit
• B: Attachment screw (5 pcs)
• C: Air nipple
• D: Rear motor cover
• E: Gasket

公 司
• G: Air nipple

有
to step 6 and forwards in Removal, motor
限
5. Continue to remove the motor unit, according
on
page 360.
科 技
6.
育
帮 教
NOTE! 控
工old rear motor cover with the air
长 沙
Keep the
nipple.
For Foundry Prime robots: Replace the gasket
on the cover.
© Copyright 2004-2011 ABB. All rights reserved.

Continues on next page

3HAC022033-001 Revision: K 363
 工控帮助教小舒QQ2823408167
4 Repair
4.6.6. Replacement of motor, axis 6

Continued

Action Note
7. For Foundry Prime robots: Fill the four screw
recesses on the new motor with Sikaflex. (After
hardening, Sikaflex can be formed with a
knife).
Remove the protection strip on the gasket and
mount it on the motor.

公 司
有 限xx0600002884

科技
• A: Mercasol 3106
• B: Motor unit
育
帮教
• C: Attachment screw (4pcs)
• D: Sikaflex in screw recesses

工 控 •
•
E: Loctite 570
F: Tilt house

长 沙 • G: Grease
• J: Sealing
• K: Sealing
8. Apply Mercasol 3106 on the motor end cover,

© Copyright 2004-2011 ABB. All rights reserved.

and Loctite 570 on the tilt house (on the
surface facing the motor end cover).
9. Apply grease on the o-ring on the motor.
10. Continue to refit the new motor according to
section, Refitting, motor on page 361.
11. Perform a leak test according to Inspection of
air hoses (Foundry Prime) on page 191

364 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
4 Repair
4.7.1. Replacement of gearbox, axis 1

4.7 Gearboxes

4.7.1. Replacement of gearbox, axis 1

Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views on page 463 .

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0100000133
© Copyright 2004-2011 ABB. All rights reserved.

A Gearbox, axis 1
B Oil plug, filling
C Attachment screws, gearbox to frame
D Frame
E Base
- Attachment screws, base to gearbox (not shown in figure)

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Gearbox 3HAC10828-1 Includes:
• gearbox
• all o-rings and
sealing rings
O-ring 3HAB3772-54 Replace only when
damaged!

Continues on next page

3HAC022033-001 Revision: K 365
 工控帮助教小舒QQ2823408167
4 Repair
4.7.1. Replacement of gearbox, axis 1

Continued

Equipment, etc. Spare part no. Art. no. Note

O-ring 3HAB3772-55 Replace only when
damaged!
Sealing ring 3HAC11581-4 Replace only when
damaged!
Grease 3HAC3537-1 For lubricating the o-rings.
Brush - Option Foundry Prime
Rust preventive 3HAC026621-001 Mercasol 3106 (Option
Foundry Prime)
Support, base 3HAC15535-1
Lifting device, base 3HAC15560-1
Lifting tool (chain) 3HAC15556-1
Standard toolkit - Content is defined in
section Standard toolkit on
page 427.
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the
step-by-step instruc-
公 司
tions below.
有 限
Removal, gearbox axis 1
育 科技
帮教
The procedure below details how to remove gearbox, axis 1.

Action
工 控 Note

长沙
1. Move the robot to its most stable position,
shown in the figure to the right.

© Copyright 2004-2011 ABB. All rights reserved.

xx0300000022

2.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but
not the air pressure to the gearboxes,
motors and SMB.

Continues on next page

366 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.7.1. Replacement of gearbox, axis 1

Continued

Action Note
3. Drain the oil from gearbox 1. Detailed in section Oil change, gearbox
axis 1 on page 199.
4. Disconnect all cabling in the rear of the
robot base and remove the cable support
plate inside of the base.
5. Pull the disconnected cabling up through
the center of gearbox 1.
6. Remove the complete arm system. Detailed in section Removal, complete
arm system on page 264.
7. Remove the robot's attachment screws to
unfasten the base from the foundation.
8. Attach the lifting device, base and gear 1 Art. no. is specified in Required
and the lifting tool (chain), to the gearbox. equipment on page 365.
9.

CAUTION!
The base and gearbox weighs 510 kg
together! All lifting equipment must be used
accordingly!
公 司
10. Lift the robot base to allow fitting the

有 限
Art. no. is specified in Required
support, base and gear 1 on each sides of equipment on page 365.

科技
the base.
11. Fit the support, base.
育
帮教
Make sure the base remains in a stable
position before performing any work

工 控
underneath the base!
12. Remove the bottom plate from underneath

长 沙
the base in order to get access to the
attachment screws. It may be necessary to
also remove the rear connector plate.
© Copyright 2004-2011 ABB. All rights reserved.

xx0300000612

• A: Bottom plate
• B: Rear connector plate
• C: Attachment screw
• D: Groove

Continues on next page

3HAC022033-001 Revision: K 367
 工控帮助教小舒QQ2823408167
4 Repair
4.7.1. Replacement of gearbox, axis 1

Continued

Action Note
13. Unscrew the 18 attachment screws and
remove the 3 washers, shown in the figure
to the right.

xx0200000227

A view from below:

• A: Oil drain hose
• B: Attachment screws, gearbox
axis 1, 18 pcs
• C: Washers, 3 pcs
14. Remove the cable guide in the center of
gearbox 1 by unscrewing its attachment
screws.

公 司
有 限

育 科技
帮教
xx0200000256

工控
• A: Location for attachment screws,
cable guide (cable guide removed

长沙
in the figure)
15.

CAUTION!

© Copyright 2004-2011 ABB. All rights reserved.

The gearbox weighs 200 kg! All lifting
equipment used must be sized accordingly!
16. Lift the gearbox away with the already
mounted lifting tools.

Continues on next page

368 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.7.1. Replacement of gearbox, axis 1

Continued

Refitting, gearbox axis 1

The procedure below details how to refit gearbox, axis 1.

Action Note
1. If the base is not supported with support, base Mounting of the support, base and gear
and gear 1, this should be done first. 1 is detailed in section Removal,
gearbox axis 1 on page 366.
2. Make sure the two o-rings (C, D) on the cir- Art no. is specified in Required
cumference of the gearbox are seated equipment on page 365.
properly in their grooves respectively.
Lubricate them with grease .
Make sure the small o-ring around the oil hole
is fitted properly!

公 司
有 限

育 科技 xx0200000055

帮教
• A: Guide pin
• C: O-ring 3HAB 3772-54

工 控 • D: O-ring 3HAB 3772-55

长 沙
3. Refit the cable guide in the center of gearbox
• E: Sealing ring 3HAC 11581-4

1 with its attachment screws.

© Copyright 2004-2011 ABB. All rights reserved.

xx0200000256

• A: Location for attachment

screws, cable guide (cable
guide removed in figure)
4. Fit the lifting device, base and the lifting tool Art no. is specified in Required
(chain) to the gearbox. equipment on page 365.
5.

CAUTION!
The gearbox weighs 200 kg! All lifting
equipment used must be sized accordingly!
6. Lift the gearbox to its mounting position in the
center of the base.

Continues on next page

3HAC022033-001 Revision: K 369
 工控帮助教小舒QQ2823408167
4 Repair
4.7.1. Replacement of gearbox, axis 1

Continued

Action Note
7. Make sure the guide pin in the bottom face of Shown in the figure xx0200000055
the gearbox is properly aligned with the base. above!
8. Secure the gearbox and the three washers 18 pcs, M16 x 90, 12.9 quality
with the 18 attachment screws, gearbox axis UNBRAKO, tightening torque: 300 Nm.
1. Reused screws may be used, providing
they are lubricated as detailed in
section Screw joints on page 423
before fitting.

xx0200000227

A view from below:

公 司 • A: Oil drain hose

• B: Attachment screws, gearbox

有 限 axis 1, 18 pcs

9. Refit the bottom plate underneath

技
科the robot
• C: Washers, 3 pcs
1 screw: M6 x 8.

the attachment screw. 教

育
base by pushing it into the groove and fitting

If removed, also refit帮

工 控 the rear connector plate.

长 沙
NOTE!
Direct the bends on the bottom plate
downwards!

© Copyright 2004-2011 ABB. All rights reserved.

xx0300000612

• A: Bottom plate
• B: Rear connector plate
• C: Attachment screw
• D: Groove
10.

CAUTION!
The base and gearbox weighs 510 kg
together! All lifting equipment must be used
accordingly!
11. Lift the robot base and gearbox 1 to allow
removing the support, base and gear.
12. Secure the base to the mounting site. Detailed in section Orienting and
securing the robot on page 94.

Continues on next page

370 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.7.1. Replacement of gearbox, axis 1

Continued

Action Note
13. Refit the complete arm system. Detailed in section Refitting of complete
arm system.
This is a complex task to be performed
with utmost care in order to avoid injury
or damage!
14. Refit the cable support plate inside of the base
and reconnect the cabling in the rear of the
robot base.
15. Perform a leak-down test. Detailed in section Performing a leak-
down test on page 246.
16. Refill the gearbox with oil. Detailed in section Filling, oil, gearbox
axis 1 on page 202.
17. Recalibrate the robot. Calibration is detailed in a separate
calibration manual enclosed with the
calibration tools.
General calibration information is
included in section Calibration
information on page 403.
18.

公 司
DANGER!
有
Make sure all safety requirements are met
限

育 科技
when performing the first test run. These are
further detailed in the section DANGER - First

帮教
test run may cause injury or damage! on page
47.

工 控
沙 with Foundry Prime and that have the special tightness for this application
Refitting, gearbox axis 1 (Foundry Prime)
长working
Robots
require special repair routines to maintain the tightness level.
The repair must be done according to the repair chapter in the Product Manual with the
© Copyright 2004-2011 ABB. All rights reserved.

following additions.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but
not the air pressure to the gearboxes, motors
and SMB.

Continues on next page

3HAC022033-001 Revision: K 371
 工控帮助教小舒QQ2823408167
4 Repair
4.7.1. Replacement of gearbox, axis 1

Continued

Action Note
2. Apply Mercasol 3106 on unpainted areas.

A B
xx0600003132

• A: Surface on the underside of

the frame
• B: Radial sealing gear axis 1,
against base
3.

DANGER! 公 司
Make sure all safety requirements are met
有 限
科技
when performing the first test run. These are
further detailed in the section DANGER - First
育
test run may cause injury or damage! on page

帮教
47.

工 控
长 沙

© Copyright 2004-2011 ABB. All rights reserved.

372 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
4 Repair
4.7.2. Replacement of gearbox, axis 2

4.7.2. Replacement of gearbox, axis 2

Location of gearbox
The axis 2 gearbox is located in the lower arm rotational center as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0100000135

A Gearbox, axis 2 (behind motor attachment not shown in figure )

© Copyright 2004-2011 ABB. All rights reserved.

B Motor, axis 2
C Oil plug, filling
D Oil plug, draining
E Front gearbox attachment screws
F Attachment holes, fixture lower arm
G Motor attachment
H Sealing (between gearbox and lower arm, not shown in figure )
I Hole for locking screw, lower arm, M16 x 60

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Gearbox, axis 2 3HAC12641-1 Includes gearbox and o-
ring
O-ring 3HAB3772-51
Sealing, axis 2/3 3HAC17213-1 A new sealing must be
used on each assembly!
Continues on next page
3HAC022033-001 Revision: K 373
 工控帮助教小舒QQ2823408167
4 Repair
4.7.2. Replacement of gearbox, axis 2

Continued

Equipment, etc. Spare part no. Art. no. Note

Grease 3HAB3537-1 For lubricating the o-ring.
Standard toolkit - Content is defined in
section Standard toolkit on
page 427.
Lifting tool, gearbox axis 2 3HAC12731-1
Fixture lower arm 3HAC13660-1
Locking screw, lower arm M16 x 60 8.8.
Included in the fixture,
lower arm.
Guide pins M16 x 150 3HAC13120-2 To be used in pairs!
Guide pins M16 x 200 3HAC13120-3 To be used in pairs!
Guide pins M16 x 300 3HAC13120-5 For guiding the gearbox.
Always use the guide pins
in pairs.
Guide pins, sealing ax 2/3, 3HAC14627-2 For guiding the sealing
80mm axis 2/3. Guides are to be
used in pairs!
Guide pins, sealing ax 2/3, 3HAC14627-3 For guiding the sealing
100mm 司 axis 2/3. Guides are to be
公 used in pairs!
Calibration Pendulum
有 限
3HAC15716-1 Complete kit that also
toolkit
科 技 includes operating manual.

育
Other tools and procedures These procedures include
may be required. See
references to these
帮 教 references to the tools
required.

工 控
procedures in the step-by-
step instructions below.

长 沙
Removal, gearbox
The procedure below details how to remove gearbox, axis 2.

© Copyright 2004-2011 ABB. All rights reserved.

Action Note
1. Remove any equipment fitted to the turning disk.
2. Run the robot to the calibration position. The
upper arm may be directed in three different ways,
shown in figure to the right.
The lowered position, as in figure A, is
recommended as it gives the least load on the
tool.

xx0200000260

Continues on next page

374 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.7.2. Replacement of gearbox, axis 2

Continued

Action Note
3.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.
4. If the robot is fitted with moveable mechanical
stops on axis 2 (not stock equipment), these must
be removed at this point.
The attachment holes of the mechanical stops are
used to attach the fixture, lower arm.
5. Secure the lower arm to the frame by inserting the Art. no. is specified in Required
locking screw into the hole. equipment on page 373!
Shown in the figure Location of
gearbox on page 373!
6. Fit the fixture, lower arm to prevent the lower arm Art. no. is specified in Required
from falling. equipment on page 373!
• Make sure that both adjusters (B) on the
fixture are screwed back.
公 司 Attachment holes for the fixture are
shown in the figure Location of

arm. 有 限
• Align the fixture with the frame and lower gearbox on page 373!
Make sure the fixture is pressed

科技
• Tighten the four M16 bolts (C) on the tightly against the lower arm before
securing with screws!
育
inside of the frame, in attachment holes,

帮教
with tightening torque: 220 Nm.
• Screw in the two adjusters (B) until they

工 控
rest against the flats on the lower arm.
Tighten by hand.

长 沙
• Lock, using the two ring nuts (D).
• Tighten the two M12 bolts (E) in the
attachment holes, fixture lower arm with
tightening torque: 91 Nm.
© Copyright 2004-2011 ABB. All rights reserved.

xx0200000261

• A: Locking screw, lower arm

7. Unload the balancing device shaft by using a Detailed in section Unloading the
specific press tool. balancing device using hydraulic
press tool. on page 320.
8. Drain the gearbox, axis 2. Detailed in section Draining, oil on
page 204.
9. Remove the motor, axis 2. Detailed in section Removal, motor
on page 335.

Continues on next page

3HAC022033-001 Revision: K 375
 工控帮助教小舒QQ2823408167
4 Repair
4.7.2. Replacement of gearbox, axis 2

Continued

Action Note
10. Remove the 30 rear gearbox attachment screws
(A) from inside the lower section of the lower arm.

xx0300000064

11. Remove the motor attachment by unscrewing the Shown in the figure Location of
front gearbox attachment screws. gearbox on page 373!
12. Fit the lifting tool, gearbox axis 2, to the motor Art. no. is specified in Required
attachment and secure it with the hook on the tool. equipment on page 373.
Remove the motor attachment.
13.

公 司
CAUTION!
有 限
The gearbox weighs 125 kg! All lifting equipment

科技
used must be sized accordingly!

育
14. Fit the lifting tool, gearbox axis 2, to the gearbox. Art. no. is specified in Required

帮 教
15. Fit two guide pins in 180° relation to each other
equipment on page 373.
Art. no. is specified in Required

工 控
instead of the removed front attachment screws. equipment on page 373.

长 沙
16. If required, apply an M16 screw to the hole shown Art. no. is specified in Required
in the figure to press it free. equipment on page 373.

© Copyright 2004-2011 ABB. All rights reserved.

xx0200000033

• A: M16 holes for pressing

the gearbox out
17. Remove the gearbox using an overhead crane or
similar.

Continues on next page

376 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.7.2. Replacement of gearbox, axis 2

Continued

Action Note
18. Remove the sealing from the lower arm. On reassembly a new sealing must
be used!
Art. no. is specified in the refitting
instructions Required equipment on
page 373!

Refitting, gearbox axis 2

The procedure below details how to refit the gearbox, axis 2.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.
2. Fit the guide pins, sealing axis 2/3 on gearbox,
axis 2.
公 司
Only the holes showed in figure beside are
allowed to be used to the guide pins! 有 限

育 科技

控 帮教
沙 工
长 xx0200000125

A. Holes for guide pins, sealing

axis 2/3 on gearbox 2.
Always use a new sealing when
© Copyright 2004-2011 ABB. All rights reserved.

reassembling!
Art. no. is specified in Required
equipment on page 373.
3. Fit the new sealing, axis 2/3 on gearbox, axis 2,
with guidance from the guide pins.
4. Fit two guide pins, M16 180° in relation to each Art. no. is specified in Required
other in the attachment holes in the frame. equipment on page 373.
5. Fit the lifting tool, gearbox axis 2, to the gearbox. Art. no. is specified in Required
equipment on page 373.

Continues on next page

3HAC022033-001 Revision: K 377
 工控帮助教小舒QQ2823408167
4 Repair
4.7.2. Replacement of gearbox, axis 2

Continued

Action Note
6. Make sure the o-ring is fitted to the rear of the Art. no. is specified in Required
gearbox. Lightly grease the o-ring. equipment on page 373.

xx0100000136

公司
A. O-ring, gearbox, axis 2
7. Lift the gearbox to its mounting position.

有限
8. Fit the gearbox onto the guide pins and slide it into Make sure the gearbox is seated
position.
9. Remove the lifting tool. 科 技 properly!

育
帮 教
10. In a similar way, fit the lifting tool to the motor
flange. Lock the tool with the hook.

工 控
Lift it and slide it onto the guide pins.
Remove the lifting tool.

长 沙
11. Insert and secure 18 of the 20 attachment screws Tightening torque: 300 Nm.
on the front of the motor attachment. Reused screws may be used,
Remove the guide pins and tighten the remaining providing they are lubricated as
two screws. detailed in section Screw joints on
page 423 before fitting.
12. Remove the guide pins and tighten the remaining © Copyright 2004-2011 ABB. All rights reserved.
two screws as above.

Continues on next page

378 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.7.2. Replacement of gearbox, axis 2

Continued

Action Note
13. Insert and secure 28 of the 30 attachment screws
on the inside of the lower arm.

xx0300000064

Tightening torque: 300 Nm.

Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints on
page 423 before fitting.
14. Remove the guide pins, sealing axis 2/3 and
tighten the remaining two screws as above.
15. Refit the motor. 司Detailed in section Refitting, motor
公 on page 336.
16. Perform a leak-down test.
有限 Detailed in section Performing a

科 技 leak-down test on page 246.

育
17. Refill the gearbox with oil. Detailed in section Filling, oil on

帮 教
18. Restore the balancing device by removing the
page 205.
Detailed in section Restoring the

工 控
balancing device tools. balancing device on page 325.

20. 长
沙
19. Remove the fixture, lower arm.
Remove the locking screw, lower arm.
21. Refit any mechanical stops if such were removed
during disassembly.
22. Refit any equipment to the turning disc if such was
© Copyright 2004-2011 ABB. All rights reserved.

removed during assembly.

23. Recalibrate the robot. Calibration is detailed in a separate
calibration manual enclosed with
the calibration tools.
General calibration information is
included in section Calibration
information on page 403.
24.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run
may cause injury or damage! on page 47.

3HAC022033-001 Revision: K 379

 工控帮助教小舒QQ2823408167
4 Repair
4.7.3. Replacement of gearbox, axis 3

4.7.3. Replacement of gearbox, axis 3

Location of gearbox
The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.

公 司
有 限

育 科技

控 帮教
沙 工
长

xx0100000137 © Copyright 2004-2011 ABB. All rights reserved.

A Gearbox, axis 3
B Attachment screws, gearbox
C Oil plug, filling
D Oil plug, draining
E Motor, axis 3
F Attachment screws, upper arm
G Attachment screws, motor
H Sealing, axis 2/3 (between lower arm and gearbox 3)

Continues on next page

380 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.7.3. Replacement of gearbox, axis 3

Continued

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Gearbox 3HAC12641-1 Includes gearbox and all
o-rings. Does not include
the sealing, axis 2/3.
O-ring 3HAB3772-68 1 pc on the gearbox.
3HAB3772-51 Replace if damaged.
Grease 3HAB3537-1 For lubricating the o-rings.
Brush - Option Foundry Prime
Rust preventive 3HAC026621-001 Option Foundry Prime
Equivalent:
• Mercasol 3106
Sealing, axis 2/3 3HAC17212-1 A new sealing must be
3HAC17213-1 used on each assembly!
Mechanical stop axis 3HAC12708-2 Used to secure the upper
3 arm. Use attachment
screws 3HAB3409-86
(M16 x 60).
Washers (for
mechanical stop axis
司
3HAA1001-186
公
3)
有 限
Bolt, M16x60 (for
mechanical stop axis
科 技 3HAB3409-86

3)
育
帮教
3HAC025333-005

工控
Lifting eye M16 3HAC14457-4
Guide pins M16 x 250 3HAC13120-4 For guiding the gearbox.

长沙
Guide pins M16 x 300 3HAC13120-5
Use guides in pairs!
For guiding the gearbox.
Use guides in pairs!
Guide pins, sealing ax 3HAC14627-2 For guiding the sealing,
© Copyright 2004-2011 ABB. All rights reserved.

2/3, 80mm axis 2/3.

Use guides in pairs!
Guide pins, sealing ax 3HAC14627-3 For guiding the sealing,
2/3, 100mm axis 2/3.
Use guides in pairs!
Standard toolkit - Content is defined in
section Standard toolkit on
page 427.
Calibration Pendulum 3HAC15716-1 Complete kit that also
toolkit includes operating
manual.
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the
step-by-step instruc-
tions below.

Continues on next page

3HAC022033-001 Revision: K 381
 工控帮助教小舒QQ2823408167
4 Repair
4.7.3. Replacement of gearbox, axis 3

Continued

Removal, gearbox axis 3

The procedure below details how to remove gearbox, axis 3.

Action Note
1.

DANGER!
Turn off all electric power,
hydraulic and pneumatic pressure
supplies to the robot!
Turn off all electric power and
hydraulic but not the air pressure
to the gearboxes, motors and
SMB.
2. Secure the upper arm in a Art. no. is specified in Required equipment on page
horizontal position using round 381.
slings.
3. Remove the motor, axis 3. Detailed in section Removal, motor on page 343.

公 司
NOTE!
有 限
When removing the motor axis 3, the brake on axis

科技
3 is released. Make sure the upper arm is secured

育 and disabled to move!

帮教
4. Remove the upper arm. Detailed in section Removal, upper arm on page
284.

工 控
5. Remove the sealing, axis 2/3 On reassembly a new sealing must be used! Art.

arm.
长 沙
between the gearbox and lower no. is specified in Required equipment on page
381.
6. Place the upper arm safely on a
workbench, in a fixture or similar.
7. Remove the attachment screws, Shown in the figure Location of gearbox on page

© Copyright 2004-2011 ABB. All rights reserved.

gearbox. 380.
8. Fit the two guide pins in 180° Art. no. is specified in Required equipment on page
relation to each other in the 381.
gearbox attachment screw holes.

Continues on next page

382 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.7.3. Replacement of gearbox, axis 3

Continued

Action Note
9. Fit the lifting eye to the gearbox, in Art. no. is specified in Required equipment on page
one of the attachment screw holes 381.
that attaches the gearbox to the
lower arm .
If required, use screws in the holes
(A) shown in the figure to the right
to press the gearbox free.

xx0200000033

• A: M16 holed for pressing the gearbox out

10.

CAUTION!
The gearbox weighs 125 kg! All 公 司
lifting equipment used must be
有 限
科技
sized accordingly!
11. Remove the gearbox, with
育
guidance from the guide pins,

帮教
using an overhead crane or
similar.

工 控
Refitting, gearbox axis 3
长 沙
The procedure below details how to refit gearbox, axis 3.

Action Note
© Copyright 2004-2011 ABB. All rights reserved.

1.

DANGER!
Turn off all electric power,
hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and
hydraulic but not the air
pressure to the gearboxes,
motors and SMB.
2. Turn the upper arm in such a
position that the gear mating
surface faces upwards.
3. Fit two guide pins in 180° Art. no. is specified in Required equipment on page
relation to each other in the 381.
holes in the upper arm, used for
the gearbox attachment screws.

Continues on next page

3HAC022033-001 Revision: K 383
 工控帮助教小舒QQ2823408167
4 Repair
4.7.3. Replacement of gearbox, axis 3

Continued

Action Note
4.

CAUTION!
The gearbox weighs 125 kg! All
lifting equipment used must be
sized accordingly!
5. Fit the lifting eye to the gearbox. Art. no. is specified in Required equipment on page
381.
6. Make sure the o-ring is fitted to Art. no. is specified in Required equipment on page
the rear of the gearbox. Apply 381.
grease to it to make sure it sticks
in its groove during assembly!
Replace if damaged!

公 司
有 限

育 科技
帮教
工控
xx0100000136

• A: O-ring, gearbox axis 3

Lift the沙
7.
长 gearbox to its mounting
position.
8. Turn the gearbox to align the
attachment screw holes with
those in the upper arm.
9. Fit the gearbox onto the guide Make sure the o-rings are seated properly and the © Copyright 2004-2011 ABB. All rights reserved.
pins and slide it into position. gearbox correctly oriented!
10. Remove the lifting tool.
11. Secure the gearbox with 18 of 20 pcs: M16 x 90; 12.9 quality UNBRAKO, tightening
the 20 gearbox attachment torque: 300 Nm.
screws. Reused screws may be used, providing they are
Remove the guide pins and lubricated as detailed in section Screw joints on page
tighten the remaining two 423 before fitting.
screws.
12. Refit the upper arm with a new Art. no. is specified in Required equipment on page
sealing, axis 2/3 . 381.
Detailed in section Refitting, upper arm on page 285.
13. Refit the motor. Detailed in section Refitting, motor on page 344.
14. Recalibrate the robot! Calibration is detailed in a separate calibration
manual enclosed with the calibration tools.
General calibration information is included in section
Calibration information on page 403.

Continues on next page

384 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.7.3. Replacement of gearbox, axis 3

Continued

Action Note
15.

DANGER!
Make sure all safety require-
ments are met when performing
the first test run. These are
further detailed in the section
DANGER - First test run may
cause injury or damage! on
page 47.

Refitting, gearbox axis 3 (Foundry Prime)

Robots working with Foundry Prime and that have the special tightness for this application
require special repair routines to maintain the tightness level.
The repair must be done according to the repair chapter in the Product Manual with the
following additions.

Action Note
1. 公 司
有 限
DANGER!
育 科技
Turn off all electric power, hydraulic and

帮教
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
控
air pressure to motors and SMB.
工
长 沙
2. Apply Mercasol on surfaces on lower arm and
gear before assembly.
Area where Mercasol shall be applied:
• gaps around screw heads and
washers.
© Copyright 2004-2011 ABB. All rights reserved.

xx0600003138

• A: Apply Mercasol 3106 on

surfaces
3.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First test
run may cause injury or damage! on page 47.

3HAC022033-001 Revision: K 385

 工控帮助教小舒QQ2823408167
4 Repair
4.7.4. Replacement of gearbox, axis 4

4.7.4. Replacement of gearbox, axis 4

Location of gearbox
The axis 4 gearbox is located at the rear of the upper arm as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0100000144

A Upper arm housing

B Gearbox, axis 4
C Cover, axis 4 gearbox
D Attachment screws, cover axis 4
E Oil plug, filling, secondary gearbox
F Oil plug, draining, secondary gearbox
G Gear, Z3
H Gear attachment screws
I Motor, axis 4
J Motor flange
K Oil plug, filling, primary gearbox (draining not shown in figure)

Continues on next page

386 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.7.4. Replacement of gearbox, axis 4

Continued

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Gear axis 4 3HAC17810-1 Includes all o-rings!
O-ring 3HAB3772-49 Replace if damaged!
O-ring 3HAB3772-50 Replace if damaged!
Friction washer 3HAC10122-27 2 pcs. Must be replaced at
assembly!
Gasket, cover axis 4 3HAC11423-3
Grease 3HAB3537-1 For lubrication of gearbox,
motor and motor attachment
mating surfaces.
Guide pins M10 x 100 3HAC15521-1 Always use the guide pins in
pairs!
Guide pins M10 x 150 3HAC15521-2 Always use the guide pins in
pairs!
Standard toolkit - Content is defined in section
Standard toolkit on page
427.
Calibration Pendulum
toolkit
公 司
3HAC15716-1 Complete kit that also
includes operating manual.
Other tools and procedures
有 限 These procedures include
may be required. See
references to these
科 技 references to the tools
required.
procedures in the step-by-
育
step instructions below.
帮 教
Removal, gearbox axis 4
工 控
长 沙
The procedure below details how to remove gearbox, axis 4.

Action Note
1.
© Copyright 2004-2011 ABB. All rights reserved.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the air
pressure to the gearboxes, motors and SMB.
2. Drain the oil from the primary gearbox through the oil Detailed further in section Oil
plug, draining. change, gearbox, axis 4 on page
209.
3. Drain the oil from the secondary gearbox through the Shown in the figure Location of
oil plug, draining. gearbox on page 386.
Draining is further detailed in
section Oil change, gearbox,
axis 4 on page 209.
4. Remove the plastic housing from the cover, axis 4
gearbox.
5. Remove the cover, axis 4 gearbox by unscrewing its Shown in the figure Location of
attachment screws. gearbox on page 386.

Continues on next page

3HAC022033-001 Revision: K 387
 工控帮助教小舒QQ2823408167
4 Repair
4.7.4. Replacement of gearbox, axis 4

Continued

Action Note
6. Loosen the gear attachment screws but do not Shown in the figure Location of
remove the gear Z3. gearbox on page 386.
7. Remove the motor, axis 4. Detailed in section Removal,
motor axis 4 on page 349.
8. Remove gear Z3 from the gearbox by unscrewing the Shown in the figure Location of
15 gear attachment screws. gearbox on page 386.
If required, insert screws into three holes in gear Z3
to press it out.
9. Remove the motor flange attachment screws and Shown in the figure Location of
plain washers. gearbox on page 386.
10. Pull the motor flange and gearbox, axis 4 out along M10.
with the friction washers.
If required, insert screws into two holes in the gearbox
to press it out.

Refitting, gearbox axis 4

The procedure below details how to refit the gearbox of axis 4.

Action
公 司Note
1.

有 限
DANGER!
育 科技
Turn off all electric power, hydraulic and

帮教
pneumatic pressure supplies to the robot!

工 控
Turn off all electric power and hydraulic but not
the air pressure to the gearboxes, motors and
SMB.
长 沙
2. Make sure the two o-rings on the circumference Art. no. is specified in Required
of the gearbox are seated properly in their equipment on page 387.
grooves respectively. Lightly lubricate the o-
rings with grease.

© Copyright 2004-2011 ABB. All rights reserved.

3. Lubricate the gearbox, motor and motor Art. no. is specified in Required
attachment mating surfaces with grease. equipment on page 387.
4. Fit four guide pins symmetrically in the
attachment holes in the upper arm housing.

xx0200000067

A. Attachment holes for guide

pins, M10
Art. no. is specified in Required
equipment on page 387.

Continues on next page

388 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.7.4. Replacement of gearbox, axis 4

Continued

Action Note
5. Fit two new friction washers onto the guide pins. Spare part no. is specified in Required
equipment on page 387.

NOTE!
Make sure the surface beneath the
friction washers is clean and dry!
6. Push in the gearbox, axis 4, and the motor Shown in the figure Location of
flange. gearbox on page 386.
If necessary, use screws in the attachment
holes to press in the motor flange.

NOTE!
Make sure the motor flange is oriented
correctly by observing the oil plugs as
shown in the figure Location of
gearbox on page 386.
7. Secure the motor flange to the upper arm 18 pcs: M10 x 40; tightening torque:
housing with 16 of the 18 washers and 65 Nm.
attachment screws.
公 司
Secure with locking liquid.
8. Remove the guide pins and secure the 有 限
科技
remaining two attachment screws as specified
in previous step.
育
帮教
9. Refit the motor, axis 4. Detailed in section Refitting, motor
axis 4 on page 351.

工 控
10. Refit gear Z3 to the gearbox with its gear Shown in the figure Location of

长 沙
attachment screws. gearbox on page 386.
9 pcs: M12 x 50; tightening torque:
115 Nm.
6 pcs: M16 x 60: tightening torque:
300 Nm.
© Copyright 2004-2011 ABB. All rights reserved.

11. Replace the gasket, cover axis 4. Art. no. is specified in Required
equipment on page 387.
12. Refit the cover, axis 4 gearbox with its Tightening torque: 10 Nm.
attachment screws and secure with locking Shown in the figure Location of
liquid. gearbox on page 386.
13. Perform a leak-down test. Detailed in section Performing a leak-
down test on page 246.
14. Refill the primary gearbox with oil. Further detailed in section Filling, oil,
gearbox axis 4 on page 211.
15. Refill the secondary gearbox with oil. Further detailed in section Filling, oil,
gearbox axis 4 on page 211.
16. Recalibrate the robot. Calibration is detailed in a separate
calibration manual enclosed with the
calibration tools.
General calibration information is
included in section Calibration
information on page 403.

Continues on next page

3HAC022033-001 Revision: K 389
 工控帮助教小舒QQ2823408167
4 Repair
4.7.4. Replacement of gearbox, axis 4

Continued

Action Note
17.

DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in the section DANGER - First
test run may cause injury or damage! on page
47.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

390 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
4 Repair
4.7.5. Replacement of gearbox, axis 5

4.7.5. Replacement of gearbox, axis 5

Location of gearbox
The axis 5 gearbox is located in the wrist unit as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0100000146

A Wrist housing
B Cover, axis 5 gearbox
C Attachment screws, cover axis 5
D Oil plug, secondary, filling
E Oil plug, secondary, draining
F Gear, Z3
G Wheel unit
H Attachment screws, gear Z3
K Gearbox, axis 5
L Oil plug, primary, filling (draining plug on the opposite side of the wrist housing, not
shown in figure)
N VK-cover
O Attachment screws, bearing washer, M6 x 16
Continues on next page
3HAC022033-001 Revision: K 391
 工控帮助教小舒QQ2823408167
4 Repair
4.7.5. Replacement of gearbox, axis 5

Continued

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Gear axis 5 3HAC17810-1 Includes all o-rings!
O-ring 3HAB3772-49 Replace if damaged!
O-ring 3HAB3772-50 Replace if damaged!
Friction washer 3HAC10122-27 2 pcs. Must be replaced at
assembly!
VK-cover 3HAA2166-24 Must be replaced!
Gasket, cover 3HAC 11409-5
Grease 3HAB3537-1 For lubricating the o-rings
and the packing box.
Locking liquid 3HAB7116-1 Loctite 243
Isopropanol 11771012-208 To clean surface beneath VK-
cover.
Standard toolkit - Content is defined in section
Standard toolkit on page 427.
Lifting eye M12 3HAC14457-3 2 pcs required!
For lifting the gearbox.
Removal tool, wheel unit
公 司For removing and lifting the
3HAC15814-1

有 限 wheel unit.
科技
Guide pins M10 x 100 3HAC15521-1 Always use guide pins in
pairs!
Guide pins M10 x 150 育 3HAC15521-2 Always use guide pins in

帮教
pairs!

工控
Calibration Pendulum 3HAC15716-1 Complete kit that also
toolkit includes operating manual.

长沙
Other tools and These procedures include
procedures may be references to the tools
required. See references required.
to these procedures in
the step-by-step instruc-

© Copyright 2004-2011 ABB. All rights reserved.

tions below.

Removal, gearbox
The procedure below details how to remove the gearbox, axis 5.

Action Note
1.

DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
Turn off all electric power and hydraulic but not the air
pressure to the gearboxes, motors and SMB.
2. Drain the oil from the primary gearbox. Detailed in section Oil change,
gearbox, axis 5 on page 212.
3. Drain the oil from the secondary gearbox. Detailed in section Oil change,
gearbox, axis 5 on page 212.

Continues on next page

392 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.7.5. Replacement of gearbox, axis 5

Continued

Action Note
4. Remove the motor, axis 5. Detailed in section Replacement
of motor, axis 5 on page 355.
5. Remove the cover, axis 5 gearbox by unscrewing its Shown in the figure Location of
attachment screws. gearbox on page 391!
6. Remove gear Z3 from the gearbox by unscrewing its Shown in the figure Location of
attachment screws (let axis 6 turn to the stop). gearbox on page 391!
If necessary, insert screws into the three holes in gear 6 pcs: M16 x 60.
Z3 to remove it. 9 pcs: M12 x 50.
7. Remove the wheel unit. Detailed in following section
(Removal, wheel unit on page
393).
8. Remove the gearbox, axis 5 by unscrewing its Shown in the figure Location of
attachment screws and removing the washers. gearbox on page 391!
18 pcs: M10 x 40.
9. Apply two lifting eyes to the gearbox, axis 5, in Art. no. is specified in Required
opposite positions. equipment on page 392!
10. Remove the gearbox by gently lifting it straight out.
11. Remove the friction washers, located beneath the
gearbox, from the wrist housing.

公 司
Removal, wheel unit
有 限
科技
The procedure below details how to remove the wheel unit.

育
帮教
Action Note

工控
1. Drain the oil from the secondary gearbox. Detailed in section Oil change,
gearbox, axis 5 on page 212.

长沙
2. Remove the cover, axis 5 gearbox by unscrewing Shown in the figure Location of
its attachment screws. gearbox on page 391!
3. Make a short cut in the center of the VK-cover and Shown in the figure Location of
remove it from the wheel unit by bending it off. gearbox on page 391!
© Copyright 2004-2011 ABB. All rights reserved.

NOTE!
Avoid damaging screws or surfaces
beneath, when removing the cover!
4. Unscrew the attachment screws, bearing washer Shown in the figure Location of
located beneath gear Z4. gearbox on page 391 and in the
Turn the gear Z4 in order to reach all the srews. figure below!
7 pcs: M6 x 16.

Continues on next page

3HAC022033-001 Revision: K 393
 工控帮助教小舒QQ2823408167
4 Repair
4.7.5. Replacement of gearbox, axis 5

Continued

Action Note
5. Remove the attachment screws, gear Z4.

xx0200000068

A. Gear Z4
B. Surface beneath VK-cover
C. VK-cover
D. Attachment screws, gear Z4,
21 pcs: M16
E. Attachment screws, bearing
washer, 7 pcs: M6

公 司
6. Apply the removal tool to the center hole of gear Art. no. is specified in Required
Z4 to press the wheel unit free.
有 限 equipment on page 392!
7. Remove the wheel unit by gently lifting it straight

科技
out.

育
帮教
Refitting, gearbox axis 5

Action
工 控 Note
1.
长 沙
DANGER!
Turn off all electric power, hydraulic and pneumatic

© Copyright 2004-2011 ABB. All rights reserved.

pressure supplies to the robot!
Turn off all electric power and hydraulic but not the
air pressure to the gearboxes, motors and SMB.
2. Make sure the two o-rings on the circumference of Art. no. is specified in Required
the gearbox are seated properly in their grooves equipment on page 392.
respectively. Lightly lubricate the o-rings with
grease.
3. Fit two guide pins in the housing. Art. no. is specified in Required
equipment on page 392.
4. Refit the two new friction washers (2 pcs) in the wrist Art. no. is specified in Required
housing. equipment on page 392.
5. Apply two lifting eyes to the gearbox, axis 5 , in Art. no. is specified in Required
opposite positions. equipment on page 392.
6. Refit the gearbox, axis 5 to the wrist housing, by Shown in the figure Location of
gently lowering it straight down, using the guide gearbox on page 391.
pins.

Continues on next page

394 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.7.5. Replacement of gearbox, axis 5

Continued

Action Note
7. Secure the gearbox with 16 of the 18 attachment 18 pcs: M10 x 40: tightening
screws and washers. torque: 65 Nm.
Shown in the figure Location of
gearbox on page 391.
8. Remove the guide pins and fit the remaining two
attachment screws as specified in the previous step.
9. Refit the gear Z3 to the gearbox, axis 5 with its 9 pcs: M12 x 50; 12.9 quality
attachment screws. UNBRAKO, tightening torque: 115
Nm.
6 pcs: M16 x 60: tightening
torque: 300 Nm.
Shown in the figure Location of
gearbox on page 391.
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints on
page 423 before fitting.
10. Refit the wheel unit. Detailed in the following
procedures (Refitting, wheel unit
on page 396).
11. Replace the gasket.
公 司Art. no. is specified in Required
有 限 equipment on page 392.
科技
12. Refit the cover, axis 5 gearbox with its attachment 14 pcs, tightening torque: 10 Nm.
screws and secure with locking liquid. Shown in the figure Location of
育 gearbox on page 391.

帮教
13. Refit the motor, axis 5. Detailed in section Refitting,

工 控
14. Perform a leak-down test.
motor axis 5 on page 357.
Detailed in section Performing a

长 沙 leak-down test on page 246.

15. Refill the primary gearbox with oil. Detailed further in section Filling,
oil, gearbox axis 5 on page 214.
16. Refill the secondary gearbox with oil. Detailed further in section Filling,
oil, gearbox axis 5 on page 214.
© Copyright 2004-2011 ABB. All rights reserved.

17. Recalibrate the robot. Calibration is detailed in a

separate calibration manual
enclosed with the calibration
tools.
General calibration information is
included in section Calibration
information on page 403.
18.

DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in the section DANGER - First test run may
cause injury or damage! on page 47.

Continues on next page

3HAC022033-001 Revision: K 395
 工控帮助教小舒QQ2823408167
4 Repair
4.7.5. Replacement of gearbox, axis 5

Continued

Refitting, wheel unit

The procedure below details how to refit the wheel unit.

Action Note
1. Clean the wheel unit and the tube mating surfaces.
2. Lubricate packing box with grease. Art. no. is specified in Required
equipment on page 392.
3. Apply removal tool to the center hole of the gear Z4. Art. no. is specified in Required
equipment on page 392.
4. Refit wheel unit by gently lowering it straight down.
5. Gently knock on the wheel unit with a plastic mallet,
to press it all the way down.

NOTE!
Make sure the bearing reaches
the bottom, before continuing the
mounting!
6. Fasten the bearing washer with its attachment
screws and secure with locking liquid .
Turn the gear Z4 in order to reach all the screws.

公 司
有 限

育 科技

控 帮教
沙 工
长
xx0200000068

A. Gear Z4
B. Surface beneath VK-cover
C. VK-cover
D. Attachment screws, gear
© Copyright 2004-2011 ABB. All rights reserved.
Z4, 21 pcs: M16
E. Attachment screws,
bearing washer, 7 pcs: M6
7. Clean the surface beneath the VK-cover with iso-
propanol.
8. Secure the wheel unit with attachment screws, gear 21 pcs: M16 x 90; 12.9 quality
Z4. UNBRAKO, tightening torque:
300 Nm.
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints on
page 423 before fitting.
9. Refit the VK-cover. Art. no. is specified in Required
equipment on page 392.
Shown in the figure Location of
gearbox on page 391.
10. Proceed with step 11 in the refitting detailed in the
previous procedure (procedure Refitting, gearbox
axis 5 on page 394).

396 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
4 Repair
4.7.6. Replacement of gearbox, axis 6

4.7.6. Replacement of gearbox, axis 6

Location of gearbox
The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.

公 司
有 限

育 科技

控 帮教
沙
xx0100000131
工
A 长 Gearbox, axis 6
B Attachment screws, gearbox
C Washers
© Copyright 2004-2011 ABB. All rights reserved.

D Oil plug, filling

E Oil plug, draining (can be located on the turning disk instead)
- O-ring (not shown in the figure)

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Gear axis 6 3HAC17811-1 Includes o-ring 3HAB3772-
49.
Washers 3HAC10122-13 Not included in the
gearbox. Replace if
damaged!
O-ring 3HAB3772-49 Must be replaced when
3HAB3772-64 reassembling gearbox!
3HAB3772-61
O-ring (type 2) 3HAB3772-57 Must be replaced when
164.7x3.53 reassembling gearbox.

Continues on next page

3HAC022033-001 Revision: K 397
 工控帮助教小舒QQ2823408167
4 Repair
4.7.6. Replacement of gearbox, axis 6

Continued

Equipment, etc. Spare part no. Art. no. Note

O-ring (type 2) 3HAB3772-64 Must be replaced when
150.0x2.0 reassembling gearbox.
O-ring (type 2) 12 pcs 3HAB3772-61 Must be replaced when
13.1x1.6 reassembling gearbox.
Grease 3HAB3537-1 For lubricating the o-ring.
Brush - Option Foundry Prime
Rust preventive 3HAC026621-001 Option Foundry Prime
Equivalent:
• Mercasol 3106
Removal tool, motor 3HAC14972-1 Use the removal tool in
M10x pairs.
Standard toolkit - Content is defined in
section Standard toolkit on
page 427.
Calibration Pendulum 3HAC15716-1 Complete kit that also
toolkit includes operating manual.
Other tools and These procedures include
procedures may be references to the tools
required. See
references to these 公 司 required.

procedures in the
有 限
科技
step-by-step instruc-
tions below.
育
Removal, gearbox
控 帮教
The procedure below details how to remove gearbox, axis 6.

沙 工
长
Action Note
1.

© Copyright 2004-2011 ABB. All rights reserved.

DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but not
the air pressure to the gearboxes, motors and
SMB.
2. Drain the oil from gearbox, axis 6. Detailed in the section Draining, oil,
gearbox axis 6 on page 216.
3. Remove the turning disk. Detailed in the section Removing
turning disk on page 276.
4. Remove the gearbox by unscrewing its 18 Shown in the figure Location of gearbox
attachment screws and two washers. on page 397.

Continues on next page

398 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.7.6. Replacement of gearbox, axis 6

Continued

Action Note
5. If required, fit the removal tool, motor M10 to
the holes shown in the figure to the right, to
press it free.

xx0200000220

• A: M10 holes for pressing out

the gearbox
6. Remove the gearbox axis 6 by lifting it out Be careful not to damage the motor
carefully. pinion!

公 司
Refitting, gearbox
有 限
科技
The procedure below details how to refit gearbox, axis 6.

Action 育 Note
1.
控 帮教
沙
DANGER!
工
长
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
Turn off all electric power and hydraulic but
not the air pressure to the gearboxes,
© Copyright 2004-2011 ABB. All rights reserved.

motors and SMB.

Continues on next page

3HAC022033-001 Revision: K 399
 工控帮助教小舒QQ2823408167
4 Repair
4.7.6. Replacement of gearbox, axis 6

Continued

Action Note
2. Make sure the o-ring is fitted to the rear of Art. no. is specified in Required equipment
the gearbox. Lubricate the o-ring with on page 397.
grease.

xx0100000132

• A: O-ring, gearbox axis 6

公 司
3. Release the holding brake of motor axis 6. Detailed in the section Manually releasing
限
the brakes on page 83.
有
科技
4. Insert the gearbox, axis 6 into the wrist unit. Art. no. is specified in Required equipment
on page 397.

育 Shown in the figure Location of gearbox on

帮教
page 397.
Make sure the gears of the gearbox mate

工 控 with the gears of the motor!

长沙
5. Fit the both washers and secure the Shown in the figure Location of gearbox on
gearbox with the attachment screws. page 397.
18 pcs: M10 x 50; 12.9 quality Gleitmo,
Tightening torque: 65 Nm.
Reused screws may be used, providing

© Copyright 2004-2011 ABB. All rights reserved.

they are lubricated as detailed in section
Screw joints on page 423 before fitting.
6. Refit the turning disk. Detailed in the section Refitting turning disk
on page 277.

Continues on next page

400 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
4 Repair
4.7.6. Replacement of gearbox, axis 6

Continued

Action Note
7. If the robot is going to work in a water jet
application cell:
• apply Mercasol 3106 on unpainted
surfaces between gearbox and
turning disk
• apply Mercasol 3106 on the screw
heads in the front of the turning
disk.

xx0600003143

• A: Unpainted surface between

gearbox and turning disk
• B: Screw heads
8. Perform a leak-down test.
司
Detailed in the section Performing a leak-

公
down test on page 246.
9. Refill the gearbox with oil.
有 限
Detailed in the section Filling, oil, gearbox
axis 6 on page 217.
10. Recalibrate the robot.
育 科技 Calibration is detailed in a separate
calibration manual enclosed with the

帮教
calibration tools.
General calibration information is included

工 控 in section Calibration information on page

11.
长 沙 403.

DANGER!
© Copyright 2004-2011 ABB. All rights reserved.

Make sure all safety requirements are met

when performing the first test run. These
are further detailed in the section DANGER
- First test run may cause injury or damage!
on page 47.

3HAC022033-001 Revision: K 401

 工控帮助教小舒QQ2823408167
4 Repair
4.7.6. Replacement of gearbox, axis 6

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

402 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
5 Calibration information
5.1. Introduction

5 Calibration information
5.1. Introduction

General
This chapter includes general information about the different calibration methods and also the
detailed procedures that do not require specific calibration equipment.
When the robot system must be recalibrated, it is done according to the documentation
enclosed with the calibration tools.

When to calibrate
The system must be calibrated if any of the following situations occur.

The resolver values are changed

If resolver values are changed, the robot must be recalibrated using the calibration methods
supplied by ABB. Calibrate the robot carefully with standard calibration. The different
methods are briefly described in the section Calibration methods on page 404, and further
detailed in separate calibration manuals.
司
If the robot has absolute accuracy calibration, it is also recommended, but not always
公
necessary to calibrate for new absolute accuracy.
有 限
科技
The resolver values will change when parts affecting the calibration position are replaced on
the robot, for example motors or parts of the transmission.
育
The revolution counter memory is lost
教
帮memory is lost, the counters must be updated. See Updating
If the revolution counter

工 控
revolution counters on page 408. This will occur when:

长
• The 沙 battery is discharged
• A resolver error occurs
• The signal between a resolver and measurement board is interrupted
• A robot axis is moved with the control system disconnected
© Copyright 2004-2011 ABB. All rights reserved.

The revolution counters must also be updated after the robot and controller are connected at
the first installation.

The robot is rebuilt

If the robot is rebuilt, for example, after a crash or when the reach ability of a robot is changed,
it needs to be recalibrated for new resolver values.
If the robot has absolute accuracy calibration, it needs to be calibrated for new absolute
accuracy.

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5 Calibration information
5.2. Calibration methods

5.2. Calibration methods

Overview
This section specifies the different types of calibration and the calibration methods that are
supplied by ABB.

Types of calibration

Type of
Description Calibration method
calibration
Standard The calibrated robot is positioned at home Calibration Pendulum
calibration position, that is when the positions of the axes (standard method)
(angles) are set to 0º. or
Standard calibration data is found on the SMB Levelmeter calibration
(serial measurement board) in the robot. (alternative method)
For robots with RobotWare 5.04 or older, the
calibration data is delivered in a file, calib.cfg,
supplied with the robot at delivery. The file
identifies the correct resolver/motor position
corresponding to the robot home position.
Absolute accuracy
calibration 公 司
Based on standard calibration, and besides
positioning the robot at home position, the
CalibWare

(optional) 限
Absolute accuracy calibration also
compensates for: 有
育
structure科技
• Mechanical tolerances in the robot

帮教
• Deflection due to load

控
Absolute accuracy calibration focuses on

沙 工 positioning accuracy in the Cartesian

coordinate system for the robot.

长 Absolute accuracy calibration data is found on

the SMB (serial measurement board) in the
robot.
For robots with RobotWare 5.05 or older, the
absolute accuracy calibration data is delivered
in a file, absacc.cfg, supplied with the robot at © Copyright 2004-2011 ABB. All rights reserved.
delivery. The file replaces the calib.cfg file and
identifies motor positions as well as absolute
accuracy compensation parameters.
A robot calibrated with absolute accuracy has
a sticker next to the identification plate of the
robot.
To regain 100% absolute accuracy perfor-
mance, the robot must be recalibrated for
absolute accuracy!

xx0400001197

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5 Calibration information
5.2. Calibration methods

Continued

Calibration methods
Each calibration method is detailed in a separate manual. Following is a brief description of
the methods available.

Calibration Pendulum - standard method

Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB
6400R, IRB 640, IRB 1400H, and IRB 4400S) and is also the most accurate method for the
standard type of calibration. It is the recommended method in order to achieve proper
performance.
Two different routines are available for the Calibration Pendulum method:
• Calibration Pendulum II
• Reference calibration
The calibration equipment for Calibration Pendulum is delivered as a complete toolkit,
including the operating manual for Calibration Pendulum, which describes the method and
the different routines further.

Levelmeter calibration - alternative method

Levelmeter calibration is referred to as the alternative method for calibration of ABB robots

公 司
because of the less accurate values obtained during calibration. The method uses the same
principles as Calibration Pendulum, but does not have as good of mechanical tolerances to

有 限
the toolkit parts as the standard method with Calibration Pendulum.

科技
This method may, after calibration, require modifications in the robot program and is
therefore not recommended.
育
控 帮教
The calibration equipment for Levelmeter Calibration is ordered as separate parts for each
robot and the operating manual for Levelmeter calibration is enclosed with the Levelmeter
2000.
沙 工
长
CalibWare - absolute accuracy calibration
To achieve a good positioning in the Cartesian coordinate system, absolute accuracy
calibration is used as a TCP calibration. The CalibWare tool guides through the calibration
process and calculates new compensation parameters. This is further detailed in the
© Copyright 2004-2011 ABB. All rights reserved.

application manual Absolute accuracy calibware field 5.0.

If a service operation is done to a robot with absolute accuracy, a new absolute accuracy
calibration is required in order to establish full performance. For most cases after motor and
transmission replacements that do not include taking apart the robot structure, standard
calibration is sufficient. Standard calibration also supports wrist exchange.

References
Article numbers for the calibration tools are listed in the section Special tools on page 428.
The calibration equipment for Calibration Pendulum is delivered as a complete toolkit,
including Operating manual - Calibration Pendulum, which describes the method and the
routines further.

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5 Calibration information
5.3. Calibration scale and correct axis position

5.3. Calibration scale and correct axis position

Introduction
This section specifies the calibration scale positions and/or correct axis position for all robot
models.

Calibration scales/marks, IRB 7600

The illustration below shows the location of the calibration scales on specific plates and the
calibration marks directly in the casting at axes 2 and 3.
The figure shows IRB 6600, but the scales and their positions are the same.

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xx0200000176

A1 Calibration scale, axis 1 (early design)

A2 Calibration scale, axis 1 (later design)
B1 Calibration scale, axis 2 (early design) © Copyright 2004-2011 ABB. All rights reserved.
B2 Calibration mark, axis 2 (later design)
C1 Calibration scale, axis 3 (early design)
C2 Calibration mark, axis 3 (later design)
D Calibration scale, axis 4
E Calibration scale, axis 5
F Calibration scale, axis 6

Calibration marks at axes 2 and 3

The calibration marks at axes 2, 3 and 6, shown in the figure above, consist of two single
marks that should be positioned opposite to one another when the robot is standing in its
calibration position. One of the marks is more narrow than the other and should be positioned
within the limits of the wider mark.

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5 Calibration information
5.4. Calibration movement directions for all axes

5.4. Calibration movement directions for all axes

Overview
When calibrating, the axis must consistently be run towards the calibration position in the
same direction in order to avoid position errors caused by backlash in gears and so on.
Positive directions are shown in the graphic below.
This is normally handled by the robot calibration software.

Calibration movement directions, 6 axes

Note! The graphic shows an IRB 7600. The positive direction is the same for all 6-axis robots,
except the positive direction of axis 3 for IRB 6400R, which is in the opposite direction!

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© Copyright 2004-2011 ABB. All rights reserved.

xx0200000089

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5 Calibration information
5.5. Updating revolution counters

5.5. Updating revolution counters

Introduction
This section describes how to do a rough calibration of each robot axis, which is updating the
revolution counter value for each axis using the FlexPendant.

Step 1 - Manually running the robot to the calibration position

Use this procedure to manually run the robot to the calibration position.

Action Note
1. Select axis-by-axis motion mode.
2. Jog the robot to place the calibration marks Shown in the section Calibration scale and
within the tolerance zones. correct axis position on page 406.
3. When all axes are positioned, store the Step 2 - Storing the revolution counter
revolution counter settings. setting with the TPU on page 409
(BaseWare 4.0).
Step 2 - Storing the revolution counter
setting with the FlexPendant on page 410.

Correct calibration position of axis 4 and 6

公 司
When running the robot to calibration position, it is限 extremely important to make sure that
axes 4 and 6 of the following mentioned robots有
calibrated at the wrong turn, resulting 科
技 are positioned correctly. The axes can be
in an incorrectly calibrated robot.
Make sure the axes are positioned育
according to the calibration
教 according to the correct calibration values, not only
帮 The correct values are found on a label, located either on
marks.

工 控
the lower arm or underneath the flange plate on the base.
沙
At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before
长 counters are updated.
the revolution
If one of the following mentioned axes are rotated one or more turns from its calibration
position before updating the revolution counter, the correct calibration position will be lost

© Copyright 2004-2011 ABB. All rights reserved.

due to uneven gear ratio. This affects the following robots:

Robot variant Axis 4 Axis 6

IRB 7600 Yes Yes

If the calibration marks seem to be wrong (even if the motor calibration data is correct), try
to rotate the axis one turn, update the revolution counter and check the calibration marks
again (try both directions, if needed).

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5 Calibration information
5.5. Updating revolution counters

Continued

Step 2 - Storing the revolution counter setting with the TPU

Use this procedure to store the revolution counter setting with the TPU (BaseWare 4.0).

Action Note
1. Press the button Miscellaneous then ENTER to select the service
window.

xx0100000194

2. Select Calibration from the View menu.

The Calibration window appears.
If there is more than one unit connected to the robot, they will be listed
in the window.

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有 限

育 科技
xx0100000201

3. Select the desired帮

教
unit and choose Rev Counter Update from the Calib
menu. 控
工 Counter Update window appears.
沙
The Revolution

长
© Copyright 2004-2011 ABB. All rights reserved.

xx0100000202

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.
6. Press OK again to confirm and start the update.
CANCEL returns to the Revolution Counter Update window.
7. At this point, it is recommended that the revolution counter values are Not required.
saved to a diskette.

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5 Calibration information
5.5. Updating revolution counters

Continued

Action Note
8.

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 412.

Step 2 - Storing the revolution counter setting with the FlexPendant

Use this procedure to store the revolution counter setting with the FlexPendant (IRC5).

Action
1. On the ABB menu, tap Calibration.
All mechanical units connected to the system are shown with their calibration status.
2. Tap the mechanical unit in question.
A screen is displayed, tap Rev. Counters.

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© Copyright 2004-2011 ABB. All rights reserved.

en0400000771

3. Tap Update Revolution Counters....

A dialog box is displayed warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to update the revolution counters.
• Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
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.

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5 Calibration information
5.5. Updating revolution counters

Continued

Action
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 the section Checking the calibration position on page 412.

公 司
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5 Calibration information
5.6. Checking the calibration position

5.6. Checking the calibration position

Introduction
Check the calibration position before beginning any programming of the robot system. This
may be done:
• Using a MoveAbsJ instruction with argument zero on all axes.
• Using the Jogging window on the FlexPendant.

Using a MoveAbsJ instruction on the TPU, S4Cplus

Use this procedure to create a program that runs all the robot axes to their zero position

Action Note
1. Create the following program:
MoveAbsJ [[0,0,0,0,0,0], [9E9,
9E9,9E9,9E9,9E9,9E9]]
\NoEOffs, v1000, z50, Tool0
2. Run the program in manual mode.
3. Check that the calibration marks for the axes align See Calibration scale and correct
correctly. If they do not, update the revolution
counters. 公 司
axis position on page 406, and
Updating revolution counters on

有 限 page 408.

Using a MoveAbsJ instruction

育 科技
帮教
Use this procedure to create a program that runs all the robot axes to their zero position.

Action
工 控 Note
1. On ABB 沙
menu tap Program editor.
长 a new program.
2. Create
3. Use MoveAbsJ in the Motion&Proc menu.
4. Create the following program:

© Copyright 2004-2011 ABB. All rights reserved.

MoveAbsJ [[0,0,0,0,0,0],
[9E9,9E9,9E9,9E9,9E9,9E9]]\
NoEOffs, v1000, z50, Tool0
5. Run the program in manual mode.
6. Check that the calibration marks for the axes align See Calibration scale and correct
correctly. If they do not, update the revolution axis position on page 406, and
counters. Updating revolution counters on
page 408.

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5 Calibration information
5.6. Checking the calibration position

Continued

Using the jogging window on the TPU, S4Cplus

Use this procedure to jog the robot to zero position of all axes.

Action Illustration/Note
1. Open the Jogging window.

xx0100000195

2. Select running axes-by-axes.

xx0100000196

3. Manually run the robot axes to a position

where the axis position value read on the
TPU, is equal to zero.
4. Check that the calibration marks for the axes See Calibration scale and correct axis
align correctly. If they do not, update the position on page 406, and Updating
revolution counters. revolution counters on page 408.

Using the jogging window

公 司
有 限
Use this procedure to jog the robot to the zero position of all axes.

Action
科 技 Note
育
2. Tap Motion mode
教
1. On the ABB menu, tap Jogging.

帮to select group of axes

to jog. 控
工 the axis to jog, axis 1, 2, or 3.
4. 长
沙
3. Tap to select
Manually run the robots axes to a position
where the axis position value read on the
FlexPendant, is equal to zero.
5. Check that the calibration marks for the See Calibration scale and correct axis
© Copyright 2004-2011 ABB. All rights reserved.

axes align correctly. If they do not, update position on page 406, and Updating
the revolution counters! revolution counters on page 408.

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5 Calibration information
5.6. Checking the calibration position

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6 Decommissioning
6.1. Environmental information

6 Decommissioning
6.1. Environmental information

Hazardous material
The table specifies some of the materials in the robot and their respective use throughout the
product.
Dispose components properly to prevent health or environmental hazards.

Material Example application

Batteries, NiCad or Lithium Serial measurement board
Copper Cables, motors
Cast iron/nodular iron Base, lower arm, upper arm
Steel Gears, screws, base frame, and so on.
Neodymium Brakes, motors
Plastic/rubber Cables, connectors, drive belts, and so on.
Oil, grease Gearboxes
Aluminium 司
Covers, sync. brackets
公
Oil and grease 有 限

育 科技
Where possible, arrange for oil and grease to be recycled. Dispose of via an authorized
person/contractor in accordance with local regulations. Do not dispose of oil and grease near

控 帮教
lakes, ponds, ditches, down drains, or onto soil. Incineration must be carried out under
controlled conditions in accordance with local regulations.

沙 工
Also note that:
• 长Spills can form a film on water surfaces causing damage to organisms. Oxygen
transfer could also be impaired.
• Spillage can penetrate the soil causing ground water contamination.
© Copyright 2004-2011 ABB. All rights reserved.

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6 Decommissioning
6.2. Decommissioning of balancing device

6.2. Decommissioning of balancing device

General
There is much energy stored in the balancing device. Therefore a special procedure is
required to dismantle it. The coil springs inside the balancing device exert a potentially lethal
force unless dismantled properly.
The device must be dismantled by a decommissioning company.

Required equipment

Equipment Art. no. Note

Standard toolkit - Content is defined in section Standard
toolkit on page 427.
Cutting torch For opening housing and cutting coils
Other tools and procedures may be These procedures include references
required. See references to these to the tools required.
procedures in the step-by-step
instructions below.

DANGER!
公 司
有 限
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

科技
is potentially lethal!

育
帮教
Action on field, decommissioning

工 控
The procedure below details the actions to perform on field, when the balancing device is to
be decommissioned.

长 沙
Action Note
1. Remove the balancing device from the robot. Detailed in section Removal of balancing
device.

© Copyright 2004-2011 ABB. All rights reserved.

2. Send the device to a decommissioning Make sure the decommissioning
company. company is well informed about the
stored energy built up by high tensioned
compression springs and that the device
contains some grease.
The following procedure contains useful
information about decommissioning.

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6 Decommissioning
6.2. Decommissioning of balancing device

Continued

Decommissioning at decommissioning company, balancing device

The instruction below details how to decommission the balancing device. Contact ABB
Robotics for further consultation.

Action Note
1.

DANGER!
There is stored energy built up by high
tensioned compression springs inside the
balancing device! The device also contains
some grease!
2. Place the device on a workbench or
similar. Make sure it is clamped in position
with a vice or similar.
3. Open a hole in the side of the housing as Use a cutting torch. The measurements
shown in the figure. shown below are maximum values!

公 司
有 限

育 科技

控 帮教
沙 工
长 xx0200000082

4. Cut the coils of the three springs inside the Use a cutting torch.
housing as specified below:
• Outer spring: cut at least five coils!
© Copyright 2004-2011 ABB. All rights reserved.

• Middle spring: cut at least four coils!

• Inner spring: cut at least four coils!
5. Double-check the number of coils cut and
make sure all the tension in the springs is
removed.

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6 Decommissioning
6.2. Decommissioning of balancing device

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7 Reference information
7.1. Introduction

7 Reference information
7.1. Introduction

General
This chapter includes general information, complementing the more specific information in
the different procedures in the manual.

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7 Reference information
7.2. Applicable safety standards

7.2. Applicable safety standards

Standards, EN ISO
The manipulator system is designed in accordance with the requirements of:

Standard Description
EN ISO 12100 -1 Safety of machinery - Basic concepts, general principles for
design - Part 1: Basic terminology, methodology
EN ISO 12100 -2 Safety of machinery - Basic concepts, general principles for
design - Part 2: Technical principles
EN ISO 13849-1 Safety of machinery, safety related parts of control systems -
Part 1: General principles for design
EN ISO 13850 Safety of machinery - Emergency stop - Principles for design
EN ISO 10218-11 Robots for industrial environments - Safety requirements -Part 1
Robot
EN ISO 9787 Manipulating industrial robots, coordinate systems, and motion
nomenclatures
EN ISO 9283 Manipulating industrial robots, performance criteria, and related
test methods
EN ISO 14644-12
公 司
Classification of air cleanliness

有限
EN ISO 13732-1 Ergonomics of the thermal environment - Part 1

技
EN IEC 61000-6-4 EMC, Generic emission
(option 129-1)
EN IEC 61000-6-2 EMC,育
科
Generic immunity
EN IEC 60974-13
帮 教
Arc welding equipment - Part 1: Welding power sources
EN IEC 60974-103
工 控 Arc welding equipment - Part 10: EMC requirements
长 沙
EN IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part 1
General requirements
IEC 60529 Degrees of protection provided by enclosures (IP code)

1. There is a deviation from paragraph 6.2 in that only worst case stop distances and stop

© Copyright 2004-2011 ABB. All rights reserved.

times are documented.
2. Only robots with protection clean room.
3. Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standards

Standard Description
EN 614-1 Safety of machinery - Ergonomic design principles - Part 1:
Terminology and general principles
EN 574 Safety of machinery - Two-hand control devices - Functional
aspects - Principles for design
EN 953 Safety of machinery - General requirements for the design and
construction of fixed and movable guards

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7 Reference information
7.2. Applicable safety standards

Continued

Other standards

Standard Description
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
(option 429-1)
CAN/CSA Z 434-03 Industrial robots and robot Systems - General safety require-
(option 429-1) ments

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7 Reference information
7.3. Unit conversion

7.3. Unit conversion

Converter table
Use the following table to convert units used in this manual.

Quantity Units
Length 1m 3.28 ft 39.37 in
Weight 1 kg 2.21 lb
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.738 lbf
Moment 1 Nm 0.738 lbf-tn
Volume 1L 0.264 US gal

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7 Reference information
7.4. Screw joints

7.4. Screw joints

General
This section describes how to tighten the various types of screw joints on the robot.
The instructions and torque values are valid for screw joints comprised of metallic materials
and do not apply to soft or brittle materials.

UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It
features special surface treatment (gleitmo as described below) and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other type of
replacement screw is allowed. Using other types of screws will void any warranty and may
potentially cause serious damage or injury.

Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with gleitmo may be reused 3-4 times before the coating disappears. After this

公 司
the screw must be discarded and replaced with a new one.

有限
When handling screws treated with gleitmo, protective gloves of nitrile rubber type should
be used.
科 技
育
Screws lubricated in other ways
Screws lubricated with帮
教
Molycote 1000 should only be used when specified in the repair,

工 控
maintenance or installation procedure descriptions.

长沙
In such cases, proceed as follows:
1. Apply lubricant to the screw thread.
2. Apply lubricant between the plain washer and screw head.
3. Screw dimensions of M8 or larger must be tightened with a torque wrench. Screw
© Copyright 2004-2011 ABB. All rights reserved.

dimensions of M6 or smaller may be tightened without a torque wrenchif this is done

by trained and qualified personnel..

Lubricant Art. no.

Molycote 1000 (molybdenum disulphide grease) 11712016-618

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7 Reference information
7.4. Screw joints

Continued

Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be applied.
The standard torques are specified in the following tables. Any special torques are
specified in the repair, maintenance or installation procedure descriptions. Any
special torque specified overrides the standard torque!
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.
• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, which is do not jerk. Tighten the screw in a slow,
flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
The following table specifies the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.

Tightening torque (Nm)

Dimension
Class 4.8, oil-lubricated
M2.5 0.25
公 司
M3 0.5
有 限
科技
M4 1.2
M5 2.5
育
帮教
M6 5.0

工 控
The following table specifies the recommended standard tightening torque for oil-lubricated
screws with allen head screws.

长 沙
Tightening torque Tightening torque Tightening torque
(Nm) (Nm) (Nm)
Dimension
Class 8.8, oil-lubri- Class 10.9, oil-lubri- Class 12.9, oil-lubri-
cated cated cated
© Copyright 2004-2011 ABB. All rights reserved.
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
M20 550
M24 725 960 1150

Continues on next page

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7 Reference information
7.4. Screw joints

Continued

The following table specifies the recommended standard tightening torque for Molycote-
lubricated screws with allen head screws.

Tightening torque (Nm) Tightening torque (Nm)

Dimension
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8 28 35
M10 55 70
M12 96 120
M16 235 280
M20 550
M24 790 950

The following table specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of brass.

Tightening torque Tightening torque Tightening torque

Dimension
Nm - Nominal Nm - Min. Nm - Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15
公司 25

有限
1/2 40 30 50
3/4 70

科 技55 90

育
控 帮教
沙 工
长
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7 Reference information
7.5. Weight specifications

7.5. Weight specifications

Definition
In installation, repair, and maintenance procedures, weights of the components handled are
sometimes specified. All components exceeding 22 kg (50 lbs) are highlighted in this way.
To avoid injury, ABB recommends the use of a lifting accessory when handling components
with a weight exceeding 22 kg. A wide range of lifting accessories and devices are available
for each manipulator model.

Example
Following is an example of a weight specification in a procedure:

Action Note

CAUTION!
The motor weighs 32 kg! All lifting accessories used
must be sized accordingly!

公 司
有 限

育 科技

控 帮教
沙 工
长

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7 Reference information
7.6. Standard toolkit

7.6. Standard toolkit

General
All service (repairs, maintenance, and installation) procedures contains lists of tools required
to perform the specified activity.
All special tools required are listed directly in the procedures while all the tools that are
considered standard are gathered in the standard toolkit and defined in the following table.
This way, the tools required are the sum of the standard toolkit and any tools listed in the
instruction.

Contents, standard toolkit

Qty Tool Rem.

1 Ring-open-end spanner 8-19 mm
1 Socket head cap 5-17 mm
1 Torx socket no: 20-60
1 Box spanner set
1 Torque wrench 10-100 Nm
1 Torque wrench 75-400 Nm
公 司
1 Ratchet head for torque wrench 1/2
有 限
2
1
技
Hexagon-headed screw M10x100
科14 socket 40 mm L100 mm
Bit for: Socket head cap no.
育
1
1 Bit for: Socket帮
教
Bit for: Socket head cap no. 14 socket 40 mm L 20 mm To be shortened to 12 mm
head cap no. 6 socket 40 mm L 145 mm
1
工 控 head cap no. 6 socket 40mm bit L220 mm
Bit for: Socket

长沙
© Copyright 2004-2011 ABB. All rights reserved.

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7 Reference information
7.7. Special tools

7.7. Special tools

General
All service instructions contain lists of tools required to perform the specified activity. The
required tools are a sum of standard tools, defined in the section Standard toolkit on page 427,
and of special tools, listed directly in the instructions and also gathered in this section.

Basic tools
The following table specifies the toolsin the basic toolkit (3HAC15571-3) that are used for
the current robot model. This toolkit is necessary primary when removing and refitting the
motors.
The tools are also listed directly in the instructions.

Description Qty Art. no.

Extension 300mm for bits 1/2" 1 3HAC12342-1
Guide pins M8 x 100 2 3HAC15520-1
Guide pins M8 x 150 2 3HAC15520-2
Guide pins M10 x 100 2 3HAC15521-1
Guide pins M10 x 150 2
公 司
3HAC15521-2
Lifting tool, wrist unit
有
1 限 3HAC12734-1
Lifting tool, motor ax 1, 4, 5
Lifting tool, motor ax 2, 3, 4 科 技1 1 3HAC14459-1
3HAC15534-1
育
Removal tool, motor M10x
帮 教 2 3HAC14972-1

控
Removal tool, motor M12x 1 3HAC14973-1

工 Fits motors, axes 1, 2, 3, 4 and 5.

长沙
Rotation tool 1 3HAC17105-1
Mechanical stop axis 3 2 3HAC12708-2
Bolts M16 x 80 (for mechanical stop axis 3) 2 3HAB3409-89
Washers (for mechanical stop axis 3) 2 3HAA1001-186

© Copyright 2004-2011 ABB. All rights reserved.

Standard toolkit (content described in section 1 3HAC15571-1
Standard toolkit on page 427)

Special tools
The following table specifies the special tools required during several of the service
procedures. The tools may be ordered separately and are also specified directly in concerned
instructions in the Product manual, procedures.

Description Qty Art. no.

Allen key No. 6 special 1 For more information see section
Replacement of motor axis 5:
• Removal tools, motor
attachment screws
Fixture lower arm 1 3HAC13660-1
Guide pins M12 x 130 2 3HAC022637-001
Guide pins M16 x 150 2 3HAC13120-2
Guide pins M16 x 200 2 3HAC13120-3
Continues on next page
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7 Reference information
7.7. Special tools

Continued

Description Qty Art. no.

Guide pins M16 x 250 1 3HAC13120-4
Guide pins M16 x 300 2 3HAC13120-5
Guide pins, sealing ax 2/3, 100mm 1 3HAC14627-3
Guide pins, sealing ax 2/3, 80mm 1 3HAC14627-2
Holder for bits (Stahlwille 736/40 S 5/16") 1 3HAC029090-001
Hydraulic cylinder 1 3HAC11731-1
Hydraulic pump, 80 MPa 1 3HAC13086-1
Hydraulic pump, 150 MPa (Glycerin) 1 3HAC021563-012
Lifting device, base 1 3HAC15560-1
Lifting device, robot 1 3HAC15607-1
Lifting device, upper arm 1 3HAC15536-1
Lifting eye VLBG M12 1 3HAC16131-1
Lifting eye M12 2 3HAC14457-3
Lifting eye M16 2 3HAC14457-4
Lifting tool (chain) 1 3HAC15556-1
Lifting tool, gearbox axis 2 1 3HAC12731-1
Measuring tool 1
公 司 6896134-GN
Motor press pinion
有1 限
1 3HAC021883-001

科技
Oil injector / max 500 MPa 3HAC021590-001
Press tool, axis 2 bearing 1 3HAC13453-1
育
帮 教
Puller device, axis 2 shaft
Press device, axis 2 shaft
1
1
3HAC021563-001
3HAC021600-001

工 控
Press tool, balancing device 1 3HAC020902-001

长 沙
Press tool, balancing device shaft 1 3HAC17129-1
Puller tool, balancing device shaft 1 3HAC12475-1
Removal tool, wheel unit 1 3HAC15814-1
Support, base 1 3HAC15535-1
© Copyright 2004-2011 ABB. All rights reserved.

Tool set balancing device 1 3HAC15943-1

Tools that may be rented

The following table specifies the tools that may be rented from ABB in order to perform
certain service procedures as described in the Product manual.
The special tools are also listed directly in the instructions.

Description Art. no. Note

Lifting tool, lower arm 3HAC14691-1 Includes
• Guidances, 3HAC14445-1

Continues on next page

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7 Reference information
7.7. Special tools

Continued

Calibration equipment, Levelmeter (alternative method)

The following table specifies the calibration equipment required when calibrating the robot
with the alternative method, Levelmeter Calibration.

Description Art. no. Note

Angel bracket 68080011-LP
Calibration bracket 3HAC13908-9
Calibration tool ax1 3HAC13908-4
Levelmeter 2000 kit 6369901-347 Includes one sensor.
Measuring pin 3HAC13908-5
Sensor fixture 68080011-GM
Sensor plate 3HAC0392-1
Sync. adapter 3HAC13908-1
Turn disk fixture 3HAC68080011-GU

Calibration equipment, Calibration Pendulum

The following table specifies the calibration equipment needed when calibrating the robot
with the Calibration Pendulum method.
公 司
Description Art. no.
有 限
Note
Calibration Pendulum toolkit 3HAC15716-1
科 技 Complete
manual.
kit that also includes operating

育
Oil exchange equipment 帮 教
工 控
The following table specifies the recommended equipment for oil exchange.

长沙
Description Art. no. Note
Oil exchange equipment 3HAC021745-001 Includes:
• Vacuum pump with
regulator, hose and coupling
• Couplings and adapters © Copyright 2004-2011 ABB. All rights reserved.
• Pump (manual) with hose
and coupling
• Graduated measuring glass
• Oil gun
• User instructions.

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7 Reference information
7.8. Lifting accessories and lifting instructions

7.8. Lifting accessories and lifting instructions

General
Many repair and maintenance activities require different pieces of lifting accessories, which
are specified in each procedure.
The use of each piece of lifting accessories is not detailed in the activity procedure, but in the
instruction delivered with each piece of lifting accessories.
This implies that the instructions delivered with the lifting accessories should be stored for
later reference.

公 司
有 限

育 科技

控 帮教
沙 工
长
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7 Reference information
7.8. Lifting accessories and lifting instructions

公 司
有 限

育科技

控 帮教
沙 工
长

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8 Spare part / part list
8.1. Introduction

8 Spare part / part list

8.1. Introduction

Definitions
This chapter specifies all spare parts and replacement articles of the robot.

公 司
有 限

育 科技

控 帮教
沙 工
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8 Spare part / part list
8.2.1. Introduction

8.2 Spare parts

8.2.1. Introduction

Overview
This section specifies all articles considered spare parts of the robot. The spare parts are also
specified as required equipment directly in the repair instruction of the current spare part.

公 司
有 限

育 科技

控 帮教
沙 工
长

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8 Spare part / part list
8.2.2. Spare part list

8.2.2. Spare part list

Spare part list

The list below specifies all the recommended spare parts for the robot.
The item numbers given within parenthesis in the column Note refer to the exploded views
in the chapter Exploded views on page 463. The spare parts are also shown in the figure
Location, spare parts on page 436.

Item Description Spare part no. Note

A Motor axis 1 3HAC14207-2 With pinion. (109.306)
3HAC027315-001 Foundry Prime
B Gear axis 1 3HAC10828-1 (101.2.2)
C Motor axis 2 3HAC14209-2 With pinion. (109.307)
3HAC027316-001 Foundry Prime
C Motor axis 2 -500/2.55 3HAC025819-001 With pinion. (109.307)
D Gear axis 2 3HAC12641-1 (109.301)
E Motor axis 3 3HAC14209-2 With pinion. (102.3.5)
3HAC027317-001 Foundry Prime
F Gear axis 3
公 司 (102.3.2.1)
3HAC12641-1
G Motor axis 4 限
3HAC14210-2
有
With pinion. (102.1.2)

H Gear axis 4 科 技
3HAC027318-001
3HAC17810-1
Foundry Prime
(102.1.8.1)
育
I
J SMB Unit帮
教
Friction washer 3HAC10122-27
3HAC022286-001
(102.1.33)
(109.326)
K
工 控pack
Battery 3HAC16831-1 (109.328)
-
长 沙Harness manipulator 1-4 3HAC12782-1 Brake release at base (106)
- Harness manipulator 1-4 3HAC14940-1 Brake release in frame (106)
- Cable harness ax.5-6 3HAC11440-1 (103.40)
- Gasket motor axis 6 3HAC033489-001
© Copyright 2004-2011 ABB. All rights reserved.

- Foundry Plus, Cable 3HAC035933-001 Option no. 908-1

guard
L Wrist, type 3 3HAC16628-4 Standard and Foundry, (103)
3HAC027295-001 Foundry Prime
L Wrist, insulated 3HAC16628-3 (103)
M Friction washer 3HAC11755-1 (108.205)
- Motor axis 5 3HAC14725-2 With pinion (103.16)
3HAC027319-001 Foundry Prime
- Gear axis 5 3HAC17810-1 (103.6.1)
- Friction washer 3HAC10122-27 2 pcs. (103.13)
N Motor axis 6 3HAC14211-2 With pinion. (103.28.13)
3HAC027320-001 Foundry Prime
- Gasket 3HAC12877-1 Protection Standard
- Gasket 3HAC033206-001 Protection Foundry Plus
- Gasket 3HAC033489-001 Protection Foundry Plus
O Gear axis 6 3HAC17811-1 (103.28.2)

Continues on next page

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8 Spare part / part list
8.2.2. Spare part list

Continued

Item Description Spare part no. Note

P Turning disk, dia. 250 3HAC13193-1 (103.28.5)
P Turning disk, insulated 3HAC023124-002 (103.28.3)
R Balancing device 3HAC14214-1 (104)
- Maintenance kit 3HAC15834-1 For balancing device.
- Maintenance kit 3HAC14962-1 For balancing device. Only
bearings.

Location, spare parts

The items are specified in the previous table.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0600002679

Repair instructions
Each spare part is replaced as described in corresponding repair instruction in the chapter
Repair on page 245.

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8 Spare part / part list
8.3.1. Introduction

8.3 Part list

8.3.1. Introduction

Overview
This section specifies all the replacement articles of the robot. The parts are shown in
exploded views or in foldouts, either in this or in a separate chapter.
Specific spare parts are listed separately in a Spare part list.

公 司
有 限

育 科技

控 帮教
沙 工
长
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8 Spare part / part list
8.3.2. Rebuilding parts

8.3.2. Rebuilding parts

Overview
The robot has some rebuilding parts that differ from eachother, depending on the version of
the robot. The table below is a general overview of which parts belongs to which versions.

Rebuilding parts

500/ 500 400/ 340/ 325/ 150/ Item no.

Art. no. Part
2.55 /2.3 2.55 2.8 3.1 3.5 and type
3HAC13063-1 Axis 3-4 400kg X X X X X 102
Standard
3HAC13063-4 Axis 3-4 400kg X X X X X 102
Foundry
3HAC13063-2 Axis 3-4 500kg X 102
Standard
3HAC13063-5 Axis 3-4 500kg X 102
Foundry

公司
3HAC10509-1 Tube shaft 2.55 X X X X X 102.2
Standard

有限
3HAC15932-1 Tube shaft 2.55 X X X X X 102.2

3HAC10509-5 Tube shaft 2.3 科 技X Foundry

102.2
育 Standard
3HAC15932-2
帮 教
Tube shaft 2.3 X 102.2
控
工Arm extender
Foundry

沙
3HAC9760-1
长 250mm
X 2X 111.501
Standard
3HAC15932-3 Arm extender X 2X 111.501
250mm Foundry
3HAC9760-5 Arm extender X 111.501
© Copyright 2004-2011 ABB. All rights reserved.
956mm Standard
3HAC15932-4 Arm extender X 111.501
956mm Foundry
3HAC11755-1 Friction washer X 2X X 111.502
3HAB7700-69 Screw M12x50 20X 40X 20X 111.503
3HAA1001-134 Washer 13x19x1,5 20X 40X 20X 111.504
9ABA107-56 Parallel pin 10x20 X 2X X 111.505
3HAC14207-2 Motor axis 1 X X X X X X 109.306
3HAC14209-2 Motor axis 2 X X X X 109.307
3HAC025819- Motor axis 2 X X 109.307
001
3HAC14209-2 Motor axis 3 X X X X X X 102.3.5
3HAC14210-2 Motor axis 4 X X X X X X 102.1.2
3HAC16628-4 Wrist, type 3 X X X X X X 103
3HAC16628-3 Wrist, insulated X X X X X X 103

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8 Spare part / part list
8.3.3. Part list, overview

8.3.3. Part list, overview

Overview
The table below contains an overview of the parts of the robot. They are further specified in
the referred sections and shown in the exploded views according to the item numbers.

Item Qty Art. number Description Note / Dimension

5 1 3HAC12812-2 Mech. stop ax. 1 assembly See section Mechanical stop
axis 1, 3HAC12812-2 on
page 441.
6 1 3HAC10499-7 Cover sheet
7 1 3HAB7700-89 Hex socket head cap M16 x 90
screw
8 1 3HAC14222-1 Plate T=4
9 4 9ADA618-57 Torx pan head screw Steel 8.8-A2F, M6 x 20
10 2 3HAC10509-11 Cover
101 1 3HAC12304-1 Base incl frame ax 1 See section Base incl frame
axis 1, 3HAC12304-1 on
page 442.
102 1 3HAC13063-1 Axis 3-4
公 司 Standard protection.

有 限 IRB 7600 -150/3.5, - 325/3.1,

-340/2.8, -400/2.55, -500/

科技
2.55

育 See section Axis 3-4,

帮教
3HAC13063-1 (IRB 7600 -
150/3.5, - 325/3.1, -340/2.8, -

工 控 400/2.55, -500/2.55) on page

443.

长 沙 3HAC13063-2 Axis 3-4 Standard protection.

IRB 7600 - 500/2.3
See section Axis 3-4,
3HAC13063-2 (IRB 7600 -
500/2.3) on page 446.
© Copyright 2004-2011 ABB. All rights reserved.

3HAC13063-4 Axis 3-4 Foundry

IRB 7600 -150/3.5, - 325/3.1,
-340/2.8, -400/2.55, -500/
2.55
See section Axis 3-4,
Foundry, 3HAC13063-4 (IRB
7600 -150/3.5, - 325/3.1, -
340/2.8, - 400/2.55, - 500/
2.55) on page 447.
3HAC13063-5 Axis 3-4 Foundry
IRB 7600 - 500/2.3
See section Axis 3-4
Foundry, 3HAC13063-5 (IRB
7600 - 500/2.3) on page 448.

Continues on next page

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8 Spare part / part list
8.3.3. Part list, overview

Continued

Item Qty Art. number Description Note / Dimension

103 1 3HAC16628-4 Wrist See section Wrist,
(spare part no.) 3HAC16628-4 /
3HAC16628-3 on page 449.
3HAC16628-3 Wrist Insulated tool flange.
(spare part no.) See section Wrist,
3HAC027295-001 3HAC16628-4 /
Foundry Prime) 3HAC16628-3 on page 449.
104 1 3HAC14675-1 Balancing Device E
105 1 3HAC10523-1 Lower arm
106 1 3HAC14940-1 Cable harness, man. ax1-4 Brake release in frame.
3HAC12782-1 Cable harness, man. ax1-4 Brake release in base.
108 1 3HAC13079-1 Material set manipulator See section Material set
robot, 3HAC13079-1 on
page 455.
109 1 3HAC13077-1 Material set ax 1-2 See section Material set axis
1-2, 3HAC13077-1 on page
456.
110 1 3HAC13082-1 Mtrl.set balancing device See section Material set

公 司 balancing device,
3HAC13082-1 on page 459.

有限
111 1 3HAC12311-1 Arm extension set 956mm IRB 7600 - 150/3.5

科 技 See section Arm extension

set, 956 mm, 3HAC12311-1
育 (IRB 7600 - 150/3.5) on page

帮教
460.

工控
1 3HAC12311-2 Arm extension set 250mm IRB 7600 - 340/2.8
See section Arm extension

长沙
set, 250 mm, 3HAC12311-2
(IRB 7600 - 340/2,8) on page
461.
1 3HAC12311-3 Arm extension set 500 mm IRB 7600 - 325/3.1
See section XREF.

© Copyright 2004-2011 ABB. All rights reserved.

112 1 3HAC17637-1 Cover plate
113 4 or 9ADA618-56 Torx pan head screw Steel 8.8-A2F, M6x16
8
114 1 3HAC13416-1 Protection cover
115 1 3HAC18281-1 Cover

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8 Spare part / part list
8.3.4. Mechanical stop axis 1, 3HAC12812-2

8.3.4. Mechanical stop axis 1, 3HAC12812-2

Part list

Item Qty Art. number Description Dimension

5.1 1 3HAC12812-1 Mechanical stop
5.2 1 9ABA142-92 Spring pin, slotted 10 x 30

公 司
有 限

育 科技

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长
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8 Spare part / part list
8.3.5. Base incl frame axis 1, 3HAC12304-1

8.3.5. Base incl frame axis 1, 3HAC12304-1

Part list

Item Qty Art. number Description Note

101.1 1 3HAC10044-1 Base, machining See section below.
101.2 1 3HAC12303-1 Frame incl ax 1 gearbox See section below.
101.3 3 3HAC11732-2 Washer T=3
101.4 18 3HAB7700-89 Hex socket head cap screw UNBRAKO 12.9
Gleitmo 610, M16x90
101.5 1 3HAC11529-1 Rubber lined clip D=28
101.6 1 3HAC14453-1 Hose with flange
101.7 1 3HAC14453-2 Plug
101.8 1 3HAC4428-2 Hose Clip
101.9 1 9ADA618-56 Torx pan head screw Steel 8.8-A2F, M6x16

Base machining, 3HAC10044-1

Item Qty Art. number Description Note

101.1.1 1 3HAC10044-2
公 司
Base, casting
101.1.2 5 3HAC4836-7 限
Protection plug
有 Cover compl.
101.1.3
101.1.4
1
1
3HAC1383-2
3HAC14024-1
技Protection
科 Protection screw
育
Frame incl axis 1 gearbox, 3HAC12303-1
控number 帮教
Item
沙 工
QtyArt. Description Note
101.2.1
101.2.2
长1
1
3HAC15865-1
3HAC10828-1
Frame machining
RV 500C-219,95 assembly
101.2.3 24 3HAB7700-77 Hex socket head cap screw UNBRAKO 12.9
Gleitmo 610, M12x110

© Copyright 2004-2011 ABB. All rights reserved.

101.2.4 24 3HAA1001-134 Washer 13x19x1,5

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8 Spare part / part list
8.3.6. Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/2.55)

8.3.6. Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/
2.55)

Part list

Item Qty Art. no. Description Note

102.1 1 3HAC022181-001 Material set ax 4 See table Material set axis
4, 3HAC022181-001 on
page 443.
102.2 1 3HAC10509-1 Tube shaft 2,55 See table Tube shaft 2,55,
3HAC10509-1 on page
445.
102.3 1 3HAC13062-1 Axis 3 See table Axis 3,
3HAC13062-1 on page
445.

Material set axis 4, 3HAC022181-001

Item Qty Art. number Description Note / Dimension

102.1.1 1 3HAC020489-001 Gear Z4 / 4
102.1.2 1 3HAC024853-001
公 司
Rot. AC motor incl. pinion See table Rot ac

有 限 motor incl pinion,

3HAC024853-001 on

科技
page 444.
102.1.3 4 3HAB3409-50
育 Hex socket head cap screw Steel 12.9 Gleitmo

102.1.4 4 帮 教
3HAB4233-1 Washer
610, M10x40

102.1.5 1 控
工 3HAB3409-60
3HAC11499-1 Motor flange, machining
102.1.6 沙18 Hex socket head cap screw Steel 12.9 Gleitmo
长 610, M10x80
102.1.7 2 3HAC10122-12 Washer, RV 125 F, axis4,5 T=3
102.1.8 1 3HAC17810-1 RV 125F-97,909 assembly See table RV 125F-
97,909 assembly,
© Copyright 2004-2011 ABB. All rights reserved.

3HAC17810-1 on
page 444.
102.1.9 1 3HAC12640-1 Cover ax 4 incl. sealing See table Cover ax 4
incl. sealing,
3HAC12640-1 on
page 444.
102.1.10 10 3HAC11409-6 Shoulder Screw M6x8x8
102.1.12 2 3HAC13564-1 Damper axis 4
102.1.13 2 3HAA1001-17 Stop, Axis 4, Casting
102.1.14 2 3HAC11925-1 Mechanical stop head
102.1.15 4 3HAB3409-81 Hex socket head cap screw Steel 12.9 Gleitmo
610, M16x35
102.1.16 2 3HAA1001-98 Gasket
102.1.17 8 9ADA183-37 Hex socket head cap screw Steel 8.8-A2F, M8x25
102.1.18 8 9ADA312-7 Plain washer M8 8,4x16x1,6
102.1.19 2 3HAA2103-21 Taper roller bearing

Continues on next page

3HAC022033-001 Revision: K 443
 工控帮助教小舒QQ2823408167
8 Spare part / part list
8.3.6. Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/2.55)

Continued

Item Qty Art. number Description Note / Dimension

102.1.20 1 2216261-18 Sealing 170x200x15
102.1.21 1 21522012-535 O-ring 169,3x5,7
102.1.22 1 3HAC022620-001 Spacer ring
102.1.23 1 3HAC11461-1 Sealing
102.1.24 1 3HAC17219-1 Thrust washer
102.1.25 1 9ABA135-45 Retaining ring, shaft
102.1.26 1 3HAC11928-1 Protective ring housing
102.1.27 1 3HAC17218-1 Set of shims
102.1.28 2 2522122-1 Magnetic plug G1/4"
102.1.29 2 3HAC16721-1 Magnetic plug
102.1.30 900 3HAC032140-001 Lubricating oil:
ml Kyodo Yushi TMO 150
102.1.31 3,850 3HAC032140-001 Lubricating oil:
ml Kyodo Yushi TMO 150
102.1.32 1 9ABA107-56 Parallel pin 10x20
102.1.33 2 3HAC10122-27 Friction washer
102.1.34 1 3HAB7116-1 Locking liquid
公 司
102.1.35 30
102.1.36 1
3HAB3537-1
3HAC020486-001
Bearing grease

有
Pinion Z3 / 4,5
限
102.1.37 1
102.1.38 9
3HAC020619-001
3HAB7700-69
科技
Set of shims Z3 / 4,5

育 Hex socket head cap screw UNBRAKO 12.9

帮教
Gleitmo 610, M12x50

工控
102.1.39 6 3HAB3409-86 Hex socket head cap screw Steel 12.9 Gleitmo
610, M16x60

长沙
102.1.40 2 21520441-1 Washer 13,5x18x1,5

Rot ac motor incl pinion, 3HAC024853-001

Item Qty Art. number Description Note

© Copyright 2004-2011 ABB. All rights reserved.

102.1.2.1 1 3HAC17484-2 Rotational ac motor M2
102.1.2.2 1 3HAC10122-17 Pinion RV 125F-97,909
102.1.2.3 1 21522012-430 O-ring

RV 125F-97,909 assembly, 3HAC17810-1

Item Qty Art. number Description Dimension

102.1.8.1 1 3HAC11384-1 RV 125F, i=97,909
102.1.8.2 1 3HAB3772-50 O-ring 196,52X2,62
102.1.8.3 1 3HAB3772-49 O-ring 189,3X3,1

Cover ax 4 incl. sealing, 3HAC12640-1

Item Qty Art. number Description Note

102.1.9.1 1 3HAC11423-4 Cover axis 4 See following table.
102.1.9.2 1 3HAA1001-628 Sealing

Continues on next page

444 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
8 Spare part / part list
8.3.6. Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/2.55)

Continued

Cover axis 4, 3HAC11423-4

Item Qty Art. number Description Note

102.1.9.1.1 1 3HAC11423-1 Cover axis 4, machined
102.1.9.1.2 1 3HAC11423-3 Gasket cover axis 4

Tube shaft 2,55, 3HAC10509-1

Item Qty Art. number Description Note

102.2.1 1 3HAC10509-2 Tube shaft 2,55, cast
102.2.2 1 3HAC1383-2 Protection Cover compl.

Axis 3, 3HAC13062-1

Item Qty Art. number Description Note / Dimension

102.3.1 1 3HAC10502-3 Axis 4 housing, mach.
102.3.2 1 3HAC12641-1 RV 700F incl. gear See following table.
102.3.3 20 3HAB7700-89 Hex socket head cap UNBRAKO 12.9
screw Gleitmo 610, M16x90
102.3.4 20 3HAC10264-1 Washer
公 司 17x30x3
102.3.5
102.3.6
1
4
3HAC14724-1
3HAB3409-50 有 限
Rot ac motor incl pinion
Hex socket head cap
See following table.
Steel 12.9 Gleitmo

102.3.7 4
育 科技 screw
3HAB4233-1 Washer
610, M10x40

102.3.8 1
帮 教
3HAC16721-1 Magnetic plug
102.3.9
工 控
4,200 ml 3HAC032140-001 Lubricating oil:
Kyodo Yushi TMO150

长
102.3.10 沙 1 9ABA142-92 Spring pin, slotted 10x30

RV 700F incl. gear, 3HAC12641-1

Item Qty Art. number Description Note

© Copyright 2004-2011 ABB. All rights reserved.

102.3.2.1 1 3HAC17272-1 RV 700F-269,21 assembly

102.3.2.2 1 3HAC11636-1 Gear Z2 /2.3

Rot ac motor incl pinion, 3HAC14724-1

Item Qty Art. number Description Note

102.3.5.1 1 3HAC17484-1 Rotational ac motor M1
102.3.5.2 1 3HAC11632-1 Pinion Z1 /2.3
102.3.5.3 1 21522012-430 O-ring

3HAC022033-001 Revision: K 445

 工控帮助教小舒QQ2823408167
8 Spare part / part list
8.3.7. Axis 3-4, 3HAC13063-2 (IRB 7600 - 500/2.3)

8.3.7. Axis 3-4, 3HAC13063-2 (IRB 7600 - 500/2.3)

Part list

Item Qty Art. number Description Note

102.1 1 3HAC022181-001 Material set ax 4 See table Material
set axis 4,
3HAC022181-001 on
page 443.
102.2 1 3HAC10509-5 Tube shaft 2,3 See table below.
102.3 1 3HAC13062-1 Axis 3 See table Axis 3,
3HAC13062-1 on
page 445.

Tube shaft 2,3, 3HAC10509-5

Item Qty Art. number Description Note

102.2.1 1 3HAC10509-6 Tube shaft 2,55, cast
102.2.2 1 3HAC1383-2 Protection Cover compl.

公 司
有 限

育科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

446 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
8 Spare part / part list
8.3.8. Axis 3-4, Foundry, 3HAC13063-4 (IRB 7600 -150/3.5, - 325/3.1, - 340/2.8, - 400/2.55, - 500/2.55)

8.3.8. Axis 3-4, Foundry, 3HAC13063-4 (IRB 7600 -150/3.5, - 325/3.1, - 340/2.8, - 400/
2.55, - 500/2.55)

Part list

Item Qty Art. no. Description Note

102.1 1 3HAC022181-001 Material set ax 4 See table Material set axis
4, 3HAC022181-001 on
page 443.
102.2 1 3HAC15932-1 Tube shaft 2,55 See table below.
Foundry
102.3 1 3HAC13062-1 Axis 3 See table Axis 3,
3HAC13062-1 on page
445.

Tube shaft 2,55 Foundry, 3HAC15932-1

Item Qty Art. number Description Note

102.2.1 1 3HAC10509-2 Tube shaft 2,55, cast
102.2.2 1 3HAC1383-2
公 司
Protection Cover compl.

有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 447

 工控帮助教小舒QQ2823408167
8 Spare part / part list
8.3.9. Axis 3-4 Foundry, 3HAC13063-5 (IRB 7600 - 500/2.3)

8.3.9. Axis 3-4 Foundry, 3HAC13063-5 (IRB 7600 - 500/2.3)

Part list

Item Qty Art. no. Description Note

102.1 1 3HAC022181-001 Material set ax 4 See table Material set axis
4, 3HAC022181-001 on
page 443.
102.2 1 3HAC15932-2 Tube shaft 2,55 See table below.
102.3 1 3HAC13062-1 Axis 3 See table Axis 3,
3HAC13062-1 on page
445.

Tube shaft 2,55 Foundry, 3HAC15932-2

Item Qty Art. number Description Note

102.2.1 1 3HAC10509-6 Tube shaft 2,55, cast
102.2.2 1 3HAC1383-2 Protection Cover compl.

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

448 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
8 Spare part / part list
8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3

8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3

Part list

Item Qty Art. number Description Note / Dimension

103.1 1 3HAC11409-7 Cover, right See table Cover, right,
3HAC11409-7 on page
451.
Spare part number
3HAC11409-9.
103.2 14 3HAC11409-6 Shoulder Screw M6x8x8
103.5 2 3HAC16721-1 Magnetic plug R1/2"
103.6 1 3HAC037194-001 RV 125F-97,909 See table RV 125F-
assembly 97,909 assembly,
3HAC037194-001 on
page 451.
103.7 18 3HAB3409-50 Hex socket head cap M10x40
screw
103.8 2 3HAC10122-12 Washer, RV 125 F, axis4,5 T=3

司
103.9 1 3HAC10503-3 Wrist housing, machining
103.10 2 2522122-1
公
Magnetic plug R1/4"

有限
103.11 4 9ADA183-35 Hex socket head cap

103.12 2 3HAC10503-8科 技Damper ax 5

screw

育 Friction washer
103.13
103.14
2
4
教
3HAC10122-27

帮
3HAB3409-50 Hex socket head cap M10x40
控 screw
4工
103.15
长 1
103.16
沙 3HAB4233-1 Washer
3HAC024853-001 Rot ac motor incl pinion See table Rot ac motor
incl pinion,
3HAC024853-001 on
page 451.
© Copyright 2004-2011 ABB. All rights reserved.

103.17 2 3HAC029646-001 Washer

103.18 1 3HAC11409-3 Cover, left machining
103.19 4 9ADA618-56 Torx pan head screw M6x16
103.21 7 3HAB3409-50 Hex socket head cap M10x40
screw
103.22 7 3HAB4233-1 Washer
103.24 1 3HAC10503-14 Support shaft inc bearing See table Support
shaft inc bearing,
3HAC10503-14 on
page 451.
103.25 1 3HAC9953-1 Syncplate with nonie
103.26 9 9ADA618-56 Torx pan head screw M6x16

Continues on next page

3HAC022033-001 Revision: K 449
 工控帮助教小舒QQ2823408167
8 Spare part / part list
8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3

Continued

Item Qty Art. number Description Note / Dimension

103.28 1 3HAC024852-002 Axis 6 complete Foundry See table Axis 6
3HAC024852-001 Axis 6 complete standard complete Foundry and
standard,
3HAC024852-002 /
3HAC024852-001 on
page 452.

3HAC024594-001 Axis 6 insulated See table Axis 6

insulated,
3HAC024594-001 on
page 453.
103.31 1 3HAA2166-24 VK-Cover
103.32 21 3HAB3409-90 Hex socket head cap M16x90
screw
103.33 1 3HAC022184-001 Wheel unit, tightened See table Wheel unit,
tightened,
3HAC022184-001 on
page 452.
103.34 1 3HAA1001-628 Sealing
103.35 7 9ADA624-56
司
Torx counters. head screw M6x16
公
限
103.37 1 3HAB7116-1 Locking liquid
103.38 1 3HAC11440-5
有
Heat protection plate

科技
103.39 3 21662055-3 Cable straps, outdoors
103.40 1 3HAC11440-1
育 Cable harness,manip

帮教
ax5-6

工控
103.41 3,800 ml 3HAC032140-001 Lubricating oil: NOTE! Do not mix with
TMO 150 other oils!

长沙
The different types of
oils are further
specified in section Oil
in gearboxes.
103.42 750 ml 3HAC032140-001 Lubricating oil:

© Copyright 2004-2011 ABB. All rights reserved.

Kyodo Yushi TMO 150
103.43 1 3HAC024760-001 Wrist label Foundry
3HAC022183-002/
3HAC16628-4
3HAC024758-001 Wrist label standard
3HAC022183-001/
3HAC16628-4
3HAC024761-001 Wrist label insulated
3HAC024630-001/
3HAC16628-3
103.44 1 3HAC020486-001 Pinion Z3 / 4,5
103.45 1 3HAC020619-001 Set of shims Z3 / 4,5
103.46 9 3HAB3409-71 Hex socket head cap M12x60
screw
103.47 6 3HAB3409-86 Hex socket head cap M16x60
screw

Continues on next page

450 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
8 Spare part / part list
8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3

Continued

Item Qty Art. number Description Note / Dimension

103.51 1 3HAC024924-001 Axis 6 insulated Only for the insulated
wrist!
See table Axis 6,
insulated,
3HAC024924-001 on
page 454.
103.100 2 3HAC021480-001 Label
103.101 2 3HAC17765-1 ABB-logotype

Cover, right, 3HAC11409-7

Spare part number 3HAC11409-9

Item Qty Art. number Description Note

103.1.1 1 3HAC11409-1 Cover, right machining
103.1.2 1 3HAC11409-5 Gasket

RV 125F-97,909 assembly, 3HAC037194-001

Item Qty Art. number

公 司 Description Note
103.6.1 1 3HAC037194-002
有 限125F, i=97,909
RV
103.6.2
103.6.3
1
1
3HAB3772-50
科
3HAB3772-49
技 O-ring
O-ring
育
帮
Rot ac motor incl pinion, 3HAC024853-001
教
工 控
Item
长 1
103.16.1
沙 Qty Art. number
3HAC17484-2
Description
Rotational ac motor M2
Note

103.16.2 1 3HAC10122-17 Pinion RV 125F-97,909

103.16.3 1 21522012-430 O-ring
© Copyright 2004-2011 ABB. All rights reserved.

Support shaft inc bearing, 3HAC10503-14

Item Qty Art. number Description Dimension

103.24.1 1 3HAC11470-1 Shaft
103.24.2 1 3HAA2325-12 Ball bearing incl. two seal. 130x200x33
103.24.3 3 9ADA618-56 Torx pan head screw M6x16
103.24.4 1 ml 3HAB7116-1 Locking liquid

Continues on next page

3HAC022033-001 Revision: K 451
 工控帮助教小舒QQ2823408167
8 Spare part / part list
8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3

Continued

Wheel unit, tightened, 3HAC022184-001

Item Qty Art. number Description Dimension

103.33.1 1 3HAC020487-001 Gear Z4 / 5
103.33.2 1 3HAC10503-12 Bearing Washer
103.33.3 1 3HAB3710-19 Groove ball bearing 160x220x28
103.33.4 1 3HAC10503-15 Support Ring
103.33.5 1 3HAB7116-2 Locking liquid

Axis 6 complete Foundry and standard, 3HAC024852-002 / 3HAC024852-001

Item Qty Art. number Description Note / Dimension

103.28.1 1 3HAC16010-1 Tilthouse RV125F, foundry
3HAC10436-1 Tilthouse RV125F, standard
103.28.2 1 3HAC037474- RV 125F-178,41 assembly See following table.
001
103.28.3 2 3HAC10122-13 Washer, RV 125 F T=3
103.28.4 18 3HAB3409-55 Hex socket head cap screw M10x50
103.28.5 1 3HAC13193-1 Turning disc
公 司
103.28.6
103.28.7
33
2
3HAB3409-53
2522122-1 有 限
Hex socket head cap screw M10x25
Magnetic plug R1/4"
103.28.8 1 3HAC11471-1
科 技
Sync. Plate
103.28.9 1 育 O-ring
3HAB3772-83 104,5x3
103.28.10 2
帮 教
9ADA618-32 Torx pan head screw M4x8

工控
103.28.11 6 3HAB7116-1 Locking liquid

长沙
103.28.12 850 ml 3HAC032140- Lubricating oil:
001 Kyodo Yushi TMO 150
103.28.13 1 3HAC024842- Motor incl. pinion
001
103.28.14 4 9ADA312-7 Plain washer M8 8.4x16x1.6
103.28.15 4 9ADA183-37 Hex socket head cap screw M8x25 © Copyright 2004-2011 ABB. All rights reserved.
103.28.16 1 3HAC14263-1 Protection Cover
103.28.17 1 9ADA624-69 Torx counters. head screw
103.28.18 4 3HAC029646- Washer
001

RV 125F-178,41 assembly, 3HAC037474-001

Item Qty Art. number Description Dimension

103.28.2.1 1 3HAC037474-002 RV 125F, i=178,41
103.28.2.2 1 3HAB3772-49 O-ring 189.3x3.1

Continues on next page

452 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
8 Spare part / part list
8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3

Continued

Rot AC motor incl pinion, 3HAC024842-001

Item Qty Art. number Description Note

103.28.13.1 1 3HAC17484-3 Rotational AC motor M3
103.28.13.2 1 3HAC10122-19 Pinion RV 125F-178.4
103.28.13.3 1 21522012-430 O-ring

Axis 6 insulated, 3HAC024594-001

Item Qty Art. number Description Note

103.28.3 1 3HAC023124-002 Turning disk, insulated
103.28.5 33 3HAC022910-002 Sleeve, plastic
103.28.6 33 3HAC022843-001 Washer, insulating
103.28.7 33 3HAC022910-003 Cover, plastic
103.28.8 33 3HAB3409-53 Hex socket head cap screw M10x25
103.28.9 33 ml 3HAC16151-1 UV hardening glue
103.28.10 1 3HAC024953-001 Axis 6 complete, insulated See following table.

Axis 6 complete, insulated, 3HAC024953-001

公 司
Item Qty Art. number 限
有Description Note
103.28.10.1 1
科 技
3HAC10436-1 Tilthouse RV125F
103.28.10.2 1
育
3HAC037474- RV 125F-178,41 See table RV 125F-

帮 教
001 assembly 178,41 assembly,
3HAC037474-001

工 控 on page 452.

长 沙
103.28.10.13
103.28.10.14
2
18
3HAC10122-13
3HAB3409-55
Washer, RV 125 F
Hex socket head cap M10x50
screw
103.28.10.16 6 ml 3HAB7116-1 Locking liquid
103.28.10.18 1 3HAC11471-1 Sync. Plate
© Copyright 2004-2011 ABB. All rights reserved.

103.28.10.19 2 9ADA618-32 Torx pan head screw Steel 8.8-A2F, M4x8

103.28.10.20 2 2522122-1 Magnetic plug
103.28.10.21 3 3HAA2166-27 VK-cover
103.28.10.22 2 3HAC029646- Washer
001

Continues on next page

3HAC022033-001 Revision: K 453
 工控帮助教小舒QQ2823408167
8 Spare part / part list
8.3.10. Wrist, 3HAC16628-4 / 3HAC16628-3

Continued

Axis 6, insulated, 3HAC024924-001

Item Qty Art. number Description Note

103.51.4 750 ml 3HAC032140-001 Lubricating oil:
Kyodo Yushi TMO 150
103.51.10 1 3HAC14263-1 Protection Cover
103.51.11 1 9ADA624-69 Torx counters. head screw M8x20
103.51.12 1 3HAC024842-001 Rot. AC motor incl. pinion
103.51.15 4 9ADA312-7 Plain washer M8
103.51.16 6 ml 3HAB7116-1 Locking liquid
103.51.17 4 9ADA183-37 Hex socket head cap Steel 8.8-A2F,
screw M8x25

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

454 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
8 Spare part / part list
8.3.11. Material set robot, 3HAC13079-1

8.3.11. Material set robot, 3HAC13079-1

Part list

Item Qty Art. number Description Note

108.201 2 3HAC17213-1 Sealing axis 2/3
108.202 60 3HAB3409-84 Hex socket head cap screw M16x50
108.203 3 3HAC11828-1 Washer axis 3
108.204 30 3HAA1001-186 Washer 17x25x3
108.205 1 3HAC11755-1 Friction Washer
108.206 20 3HAB7700-69 Hex socket head cap screw M12x50
108.207 20 3HAA1001-134 Washer 13x19x1.5
108.210 1 3HAC14300-1 Cable protector
108.211 1 3HAC020679-001 Lower arm cable protection
108.212 1 3HAC11771-1 Cable guide, end part
108.213 1 3HAC13960-1 Connection plate, ax3
108.214 2 3HAC11750-1 Damper axis 3

司
108.215 2 3HAC12990-1 Damper axis 2
108.216 2 9ADA624-65
公
Torx counters. head screw
限washer,conical
M6x60

有
108.217 2 9ADA334-7 Spring 8.4x18x2
108.218 2
技
9ADA618-57
科
Torx pan head screw M6x20
108.220 2
育
3HAC9953-1 Syncplate with nonie

帮教
108.222 1 3HAC14658-1 Syncplate with nonie ax 3
108.223
108.225
2

工
17
控 9ADA183-48
9ADA618-56
Hex socket head cap screw M10x16
Torx pan head screw M6x16

长沙 1
108.228
108.229 1
3HAC3261-1
3HAC15431-1
Cover
Cable protection
108.230 1 3HAC14880-1 Cable fixing bracket
108.231 1 21662055-3 Cable straps, outdoors
© Copyright 2004-2011 ABB. All rights reserved.

108.232 5 3HAC16721-1 Magnetic plug R1/2"

108.233 1 2522122-1 Magnetic plug R1/4"
108.234 1 21520441-1 Washer
108.235 1 3HAC021071-001 Cable protection lower arm,
type-b

3HAC022033-001 Revision: K 455

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8 Spare part / part list
8.3.12. Material set axis 1-2, 3HAC13077-1

8.3.12. Material set axis 1-2, 3HAC13077-1

Part list

Item Qty Art. number Description Note / Dimension

109.301 1 3HAC12641-1 RV 700F incl. gear See table RV 700F incl.
gear, 3HAC12641-1 on
page 457.
109.302 1 3HAC11198-1 Cover, machining
109.303 1 3HAC14698-1 Friction washer 381x438x1
109.304 20 3HAB3409-92 Hex socket head cap M16x110
screw
109.305 20 3HAA1001-186 Washer 17x25x3
109.306 1 3HAC14723-1 Rot ac motor incl pinion See table Rot ac motor
incl pinion,
3HAC14723-1 on page
458.
109.307 1 3HAC025752-001 Rot. AC motor incl. IRB 7600 - 500/2.55
pinion See table Rot. AC

司
motor incl. pinion,

限 公 3HAC025752-001 on
page 458.
109.307 1 3HAC14724-1 有
Rot ac motor incl pinion IRB 7600 -500/2.3, -

科技
400/2.55, -340/2.8, -
325/3.1, -150/3.5
育
帮教
See table Rot ac motor
incl pinion,

工 控 3HAC14724-1 on page
458.

长
109.308 8 沙 3HAB3409-50 Hex socket head cap M10x40
screw
109.309 8 3HAB4233-1 Washer
109.310 1 3HAC12252-1 Bottom plate

© Copyright 2004-2011 ABB. All rights reserved.

109.311 1 3HAC14131-1 Connection plate, base
109.312 1 3HAC11774-3 Adapter, complete
109.313 1 3HAC11769-1 Cable guide, ax.1
109.320 1 3HAC021287-001 Sync plate
109.321 1 3HAC12671-6 Block for calibration
109.322 1 3HAC14024-1 Protection screw and o-
ring
109.324 24 9ADA618-56 Torx pan head screw M6x16
109.325 3 9ADA618-57 Torx pan head screw M6x20
109.326 1 3HAC022286-001 Serial measurement unit
DSQC 633
109.327 1 3HAC14788-3 Cover SMB and BRU See table Cover SMB
and BRU, 3HAC14788-
3 on page 458.
109.328 1 3HAC16831-1 Battery pack
109.329 1 3HAC13151-1 Cable battery/SMB
109.330 2 3HAC11526-1 Stud screw M6x150
Continues on next page
456 3HAC022033-001 Revision: K
 工控帮助教小舒QQ2823408167
8 Spare part / part list
8.3.12. Material set axis 1-2, 3HAC13077-1

Continued

Item Qty Art. number Description Note / Dimension

109.331 1 3HAC13152-1 Bracket SMB
109.332 1 3HAC14791-3 Cover battery box See table Cover battery
box, 3HAC14791-3 on
page 458.
109.334 6 9ADA618-53 Torx pan head screw M6x8
109.335 1 3HAA2166-23 VK-Cover
109.336 1 3HAC020122-001 Attachment plate
109.337 2 3HAC12625-1 Strap, Velcro
109.338 1 3HAC14793-1 Bracket
109.339 1 3HAC15619-1 Cable, FB7-SMB 1.7
109.340 1 ml 12690014-413 Locking liquid
109.341 7,600 ml 3HAC032140-001 Lubricating oil: NOTE! Do not mix with
Kyodo Yushi TMO 150 other oils!
109.342 4,800 ml 3HAC032140-001 Lubricating oil:
Kyodo Yushi TMO 150
109.344 1 ml 3HAB7116-1 Locking liquid
109.345 2 9ADA267-6 Hexagon nut M6
BU w. buttons司
109.346 1 3HAC16036-1
公 DSQC

有at限
561
3HAC14219-1 BU the base Read more about the

科
3HAC12989-1 技BU at the base difference in section

育 Replacement of brake

帮 教 release unit on page

301.
109.347 1
工 控 3HAC2744-1 Push button guard

长
109.349
沙
109.348 4
2
9ADA629-56
9ADA618-58
Torx pan head roll. screw M6x16
Torx pan head screw M6x25
109.350 1 3HAC4813-1 Cover, push button
guard
109.351 10 9ADA618-44 Torx pan head screw M5x12
© Copyright 2004-2011 ABB. All rights reserved.

109.352 1 3HAC14024-1 Protection screw and o-

ring
109.353 1 3HAC17423-1 Washer
109.354 1 9ADA269-4 Hexagon nut M8
109.360 4 3HAB3558-14 Lock washer

RV 700F incl. gear, 3HAC12641-1

Item Qty Art. number Description Note

109.301.1 1 3HAC17272-1 RV 700F-269,21 See following table.
assembly
109.301.2 1 3HAC11636-1 Gear Z2 /2.3

Continues on next page

3HAC022033-001 Revision: K 457
 工控帮助教小舒QQ2823408167
8 Spare part / part list
8.3.12. Material set axis 1-2, 3HAC13077-1

Continued

RV 700F-269,21 assembly, 3HAC17272-1

Item Qty Art. number Description Note

109.301.1.1 1 3HAC10122-21 RV 700F, i=269,21
109.301.1.2 1 3HAB3772-51 O-ring

Rot ac motor incl pinion, 3HAC14723-1

Item Qty Art. number Description Note

109.306.1 1 3HAC17484-1 Rotational ac motor M1
109.306.2 1 3HAC11350-1 Pinion RV 500C & RV 320C
109.306.3 1 21522012-430 O-ring D=89.5x3

Rot. AC motor incl. pinion, 3HAC025752-001

Item Qty Art. number Description Note

109.307.1 1 3HAC025724-001 Rotational AC motor, M13
109.307.2 1 3HAC11632-1 Pinion Z1 /2.3
109.307.3 1 21502012-430 O-ring D=89.5x3

Rot ac motor incl pinion, 3HAC14724-1 限 公司

有
Item Qty 技
Art. number
科
Description Note
109.307.1 1 育
3HAC17484-1 Rotational ac motor M1
109.307.2 1
帮 教
3HAC11632-1 Pinion Z1 /2.3
109.307.3 1 控 21522012-430 O-ring D=89.5x3

长
Cover SMB and BRU, 3HAC14788-3
沙工
Item Qty Art. number Description Note
109.327.1 1 3HAC023546-003 Cover SMB
109.327.2 1 3HAC14788-2 Gasket © Copyright 2004-2011 ABB. All rights reserved.
109.327.3 1 3HAC023764-001 Rubber cloth

Cover battery box, 3HAC14791-3

Item Qty Art. number Description Note

109.332.1 1 3HAC14791-1 Cover
109.332.2 1 3HAC14791-2 Gasket
109.332.3 1 3HAC16977-1 Warning label battery

458 3HAC022033-001 Revision: K

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8 Spare part / part list
8.3.13. Material set balancing device, 3HAC13082-1

8.3.13. Material set balancing device, 3HAC13082-1

Part list

Item Qty Art. number Description Note

110.401 1 3HAC4310-1 Sealed spherical bearing
110.402 1 3HAC13124-1 Thrust washer
110.403 1 3HAC13122-1 Bushing
110.404 1 9ABA135-32 Retaining ring, shaft
110.405 1 3HAC13123-1 Shaft
110.406 1 3HAC4836-7 Protection plug 16x12.3x9x7
110.407 4 3HAB7700-89 Hex socket head cap M16x90
screw
110.408 2 9ABA107-56 Parallel pin 10x20
110.409 1 3HAC12548-2 Protection washer
110.410 1 3HAC11427-1 Shaft, Balancing device
110.411 4 3HAA1001-186 Washer 17x25x3
110.412 120 ml 3HAA1001-294 Grease
110.413 2 3HAC4836-1
公 司
Protection plug 20x14.6x7.5x5.5
110.414 1 9ADA183-490
有 限
Hex socket head cap
screw
M16x80

科 技
育
帮 教
工 控
长 沙
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 459

 工控帮助教小舒QQ2823408167
8 Spare part / part list
8.3.14. Arm extension set, 956 mm, 3HAC12311-1 (IRB 7600 - 150/3.5)

8.3.14. Arm extension set, 956 mm, 3HAC12311-1 (IRB 7600 - 150/3.5)

Part list

Item Qty Art. number Description Dimension

111.501 1 3HAC9760-5 Arm extender 956 mm
111.501 1 3HAC15932-4 Arm extender 956 mm, Foundry
111.502 1 3HAC11755-1 Friction washer
111.503 20 3HAB7700-69 Hex socket head cap screw M12x50
111.504 20 3HAA1001-134 Washer 13x19x1.5
111.505 1 9ABA107-56 Parallel pin 10x20

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

460 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
8 Spare part / part list
8.3.15. Arm extension set, 250 mm, 3HAC12311-2 (IRB 7600 - 340/2,8)

8.3.15. Arm extension set, 250 mm, 3HAC12311-2 (IRB 7600 - 340/2,8)

Part list

Item Qty Art. number Description Dimension

111.501 1 3HAC9760-1 Arm extender 250 mm
111.501 1 3HAC15932-3 Arm extender 250 mm Foundry
111.502 1 3HAC11755-1 Friction washer
111.503 20 3HAB7700-69 Hex socket head cap screw M12x50
111.504 20 3HAA1001-134 Washer 13x19x1.5
111.505 1 9ABA107-56 Parallel pin 10x20

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 461

 工控帮助教小舒QQ2823408167
8 Spare part / part list
8.3.15. Arm extension set, 250 mm, 3HAC12311-2 (IRB 7600 - 340/2,8)

公 司
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

462 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
9 Exploded views
9.1. Introduction

9 Exploded views
9.1. Introduction

Definitions
This chapter contains detailed views of the components on the manipulator.
The numbered details are specified with item numbers in the Part List.
The exploded views are divided into:
• Base, incl. frame
• Frame-Lower arm 1
• Frame-Lower arm 2
• Upper arm
• Wrist complete

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 463

 工控帮助教小舒QQ2823408167
9 Exploded views
9.2. Base incl. Frame

9.2. Base incl. Frame

Exploded view

公 司
有 限

育 科技

控帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0200000329

464 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
9 Exploded views
9.3. Frame-Lower arm 1

9.3. Frame-Lower arm 1

Exploded view

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0200000330

3HAC022033-001 Revision: K 465

 工控帮助教小舒QQ2823408167
9 Exploded views
9.4. Frame-Lower arm 2

9.4. Frame-Lower arm 2

Exploded view

公 司
有 限

育 科技

控帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0200000331

466 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
9 Exploded views
9.5. Upper arm

9.5. Upper arm

Exploded view

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

xx0200000333

3HAC022033-001 Revision: K 467

 工控帮助教小舒QQ2823408167
9 Exploded views
9.6. Wrist complete

9.6. Wrist complete

Exploded view

公 司
有 限

育 科技

控帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

xx0200000332

468 3HAC022033-001 Revision: K

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10 Circuit Diagram
10.1. About circuit diagrams

10 Circuit Diagram
10.1. About circuit diagrams

Overview
The circuit diagrams are not included in this manual, but delivered as separate documents on
the documentation DVD. See following for correct article numbers.

Controllers

Product Article numbers for circuit diagrams

IRC5 3HAC024480-005
IRC 5 Compact 3HAC031403-003
IRC5 Panel Mounted Controller 3HAC026871-006
Euromap 3HAC024120-004

Robots

Product
司
Article numbers for circuit diagrams
公
IRB 120
IRB 140 type C 有
3HAC6816-3
限
3HAC031408-003

IRB 260
IRB 360 育 科技3HAC025611-001
3HAC028647-009
IRB 460
IRB 660 控 帮教 3HAC036446-005
3HAC025691-001
IRB 760
沙 工 3HAC025691-001
IRB长1410 3HAC2800-3
IRB 1600 type A 3HAC021351-003
IRB 2400 3HAC6670-3
© Copyright 2004-2011 ABB. All rights reserved.

IRB 2600 3HAC029570-007

IRB 4400/4450S 3HAC9821-1
IRB 4600 3HAC029038-003
IRB 4600 Foundry Prime 3HAC029038-003
IRB 6400RF 3HAC8935-1
IRB 6600 type A 3HAC13347-1
3HAC025744-001
IRB 6600 type B 3HAC13347-1
3HAC025744-001
IRB 6620 3HAC025090-001
IRB 6620LX 3HAC025090-001
IRB 6640 3HAC025744-001
IRB 6650S 3HAC13347-1
3HAC025744-001
IRB 6660 3HAC029940-001
3HAC025744-001

Continues on next page

3HAC022033-001 Revision: K 469
 工控帮助教小舒QQ2823408167
10 Circuit Diagram
10.1. About circuit diagrams

Continued

Product Article numbers for circuit diagrams

IRB 7600 3HAC13347-1
3HAC025744-001

公 司
有 限

育 科技

控帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

470 3HAC022033-001 Revision: K

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10 Circuit Diagram
10.2.1. Validity of circuit diagram 3HAC 025744-1

10.2 Circuit diagram 3HAC 025744-001

10.2.1. Validity of circuit diagram 3HAC 025744-1

Is this circuit diagram valid for your robot?

The validity of the circuit diagram depends on which cable harness is fitted to the robot.
Check the article number of the cable harness fitted to the robot and see page 3 of the circuit
diagram in order to determine if the diagram is valid for the harness or not.
Where to find the article number Action
Label on the cable harness The label is located at the connectors in the base.
Remove the rear cover plate to see the label.
WebConfig

公 司
有 限

育 科技

控 帮教
沙 工
长
© Copyright 2004-2011 ABB. All rights reserved.

3HAC022033-001 Revision: K 471

 工控帮助教小舒QQ2823408167
10 Circuit Diagram
10.3.1. Validity of circuit diagram 3HAC 13347-1

10.3 Circuit diagram 3HAC 13347-1

10.3.1. Validity of circuit diagram 3HAC 13347-1

Is this circuit diagram valid for your robot?

The validity of the circuit diagram depends on which cable harness is fitted to the robot.
Check the article number of the cable harness fitted to the robot.
Where to find the article number Action
Label on the cable harness The label is located at the connectors in the base.
Remove the rear cover plate to see the label.
WebConfig -

This circuit diagram is valid for the following cable harness assemblies:
Robot Cable harness Revision
IRB 6600 3HAC 14940-1 all
IRB 6650, IRB 6650S 3HAC 16331-1 all
IRB 7600 3HAC 14940-1 revision 0-2

公 司
For remaining cable harness assemblies, see section Circuit diagram 3HAC 025744-001 on
page 471.
有 限

育 科技

控 帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

472 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
Index

A D
Absolute Accuracy, calibration 405 damage to mechanical stop 177
aluminum 415 danger levels 39
dimensions
B
frame 99
balancing device bearing, replacement 316 lower arm 97
balancing device, replacement 307 turning disk 100
base plate upper arm 98
securing 90 direction of axes 407
batteries 415
battery shutdown service routine 218 E
brake release 83 emergency stop
brakes definition 37
testing function 32 devices 38
buttons for brake release 83 enabling device 34
environmental information 415
C
equipment on robot 97
cable harness axes 1-4, replacement 251 ESD
cabling damage elimination 49
position switches 122 sensitive equipment 49
cabling between robot and controller 133 wrist strap connection point 49
cabling, robot 133 expected life 149
cabling, robot axes 1-4 252 extended lifetime of SMB battery 218
cabling, robot axes 5-6 260
司
extra equipment
calibrating
roughly 408
限
frame 99 公
fastener quality 101

calibration
有
lower arm 97

科技
Absolute Accuracy type 404 robot 97
alternative method 405 turning disk 100
Levelmeter calibration 405
育 upper arm 98

帮教
rough 408
standard type 404 F
when to calibrate 403
calibration manuals 405 工 控 fastener quality for extra equipment 101
fire extinguishing 30
calibration marks 406
长 沙 fitting equipment on robot 97
calibration position 408 FlexPendant
checking 412 jogging to calibration position 413
jogging to 413 MoveAbsJ instruction 412
jogging to, TPU 413 updating revolution counters 410
© Copyright 2004-2011 ABB. All rights reserved.

scales 406 forces and torques, robot 64

calibration scales 406 fork lift 71
calibration, Absolute Accuracy 405 foundation 64
CalibWare 404 levelness 64
carbon dioxide extinguisher 30 loads 64
cleaning requirements 64
robot 233 resonance frequency 64
conditions frame
operating robot 64 dimensions 99
storing robot 64
G
connecting the robot and controller, cabling 133
connection gearbox axis 1, replacement 365
external safety devices 20 gearbox axis 3, replacement 380
copper 415 gearbox axis 6, replacement 397
grease
disposal 415
H
hazardous material 415
hold-to-run 34

3HAC022033-001 Revision: K 473

 工控帮助教小舒QQ2823408167
Index

I O
information labels location 187 oil
inspecting disposal 415
information lables 187 oil change
mechanical stop 177 safety risks 51
installation oil in gearboxes 192
mechanical stop axis 1 115 operating conditions, robot 64
mechanical stop axis 2 117
P
mechanical stop axis 3 119
installing plastic 415
position switches 122 position switches
installing equipment on robot 97 cabling on robot 122
insulated wrist unit 279, 435 installing 122
intervals for maintenance 143 positive directions, axes 407
IP classification 65 protection class 65
protection standards 420
L
R
labels
manipulator 41 replacement
Levelmeter calibration 405 balancing device 307
levelness on foundation 64 bearing, balancing device 316
lifetime extension of SMB lithium battery 218 cable harness axes 1-4 251
lifting accessory 426 gearbox axis 1 365
gearbox axis 3 380
司
lifting robot
gearbox axis 6 397
with fork lift 71
with lifting slings 79
限 公
motor axis 1 327
with roundslings 81
有
motor axis 2 333

科技
lifting slings, robot 79 motor axis 3 341
Litium 415 motor axis 4 348
loads on foundation 64 育 motor axis 6 359

帮教
lower arm replacing
dimensions 97 SMB battery 218

M 工 控 requirement
foundation 64
maintenance schedule 143
长 沙 resonance frequency on foundation, min. value 64
manipulator responsibility and validity 20
symbols 41 restricting
manually releasing brakes 83 working range axis 1 115
mechanical stop working range axis 2 117

© Copyright 2004-2011 ABB. All rights reserved.

axis 1 115 working range axis 3 119
axis 2 117 revolution counters
axis 3 119 storing on FlexPendant 410
mechanical stop location 177 storing on TPU 409
motor axis 1, replacement 327 updating 408
motor axis 2, replacement 333 risk of tipping 70
motor axis 3, replacement 341 robot
motor axis 4, replacement 348 cleaning 233
motor axis 6, replacement 359 symbols 41
MoveAbsJ instruction 412 weight 63
TPU 412 roundslings attached to robot 81
rubber 415
N
negative directions, axes 407
neodymium 415
NiCad 415

474 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167
Index

S standards
safety ANSI 421
brake testing 32 CAN 421
emergency stop 37 EN 420
ESD 49 EN IEC 420
fence dimensions 29 EN ISO 420
fire extinguishing 30 protection 420
FlexPendant 34 safety 420
introduction 19 storage conditions, robot 64
manipulator system 20 symbols
moving manipulators 46 safety 39
reduced speed function 33 sync marks 406
release manipulator arm 31 T
service 20
temperatures allowed
signal lamp 36
operating robot 64
signals 39
stored robot 64
signals in manual 39
testing
symbols 39
brakes 32
symbols on manipulator 41
tightening torque
test run 47
mechanical stop axis 1 116
working range 35
mechanical stop axis 2 118
wrist strap 49
tilt, max value on foundation 64
safety equipment
tools
mechanical stop 115
mechanical stop axis 2 117
公 司
calibration equipment, Levelmeter 430
Calibration Pendulum equipment 430
mechanical stop axis 3 119
position switches 122
有 限
for service 428

科技
oil exchange equipment 430
safety risk
torques and forces, robot 64
electric parts 27
hot parts 23 育 TPU

帮教
jogging to calibration position 413
hydraulic system 25
MoveAbsJ instruction 412
installation 21
oil change 51
工 控 updating revolution counters 409
turning disk dimensions 100
operational disturbance 26
pneumatic system 25
长 沙 type of oil 192
tools 24 U
voltage 27 updating revolution counters 408
safety risks upper arm
service work 21 dimensions 98
© Copyright 2004-2011 ABB. All rights reserved.

work pieces 24
safety signals V
in manual 39 validity and responsibility 20
safety standards 420
scales on robot 406 W
schedule for maintenance 143 weight
securing balancing device 310, 312
base plate 90 base plate 89, 93
securing the robot to foundation, attachment screws 94 complete arm system 265
securing, robot 94 gearbox 368, 369, 376, 383, 384
securing, upper arm 343 lower arm 291, 293
serial measurement board unit, replacement 297 motor 350, 351, 356, 357
signal lamp 36 robot 78, 80, 82
signals upper arm 284, 286
safety 39 wrist unit 280, 281
SMB battery weight, robot 63
extension of lifetime 218
replacement 218
special tools 428
stability 70

3HAC022033-001 Revision: K 475

 工控帮助教小舒QQ2823408167
Index

working range
IRB 7600 - 150/3.5 66
IRB 7600 - 340/2.8 67
IRB 7600 - 400/2.55 68
IRB 7600 - 500/2.3 69
IRB 7600 - 500/2.55 68
restricting axis 1 115
restricting axis 2 117
restricting axis 3 119
wrist unit, insulated 279, 435

公 司
有 限

育 科技

控帮教
沙 工
长

© Copyright 2004-2011 ABB. All rights reserved.

476 3HAC022033-001 Revision: K

 工控帮助教小舒QQ2823408167

公 司
有 限

育 科技

控帮教
沙 工
长
 工控帮助教小舒QQ2823408167
Contact us

3HAC022033-001 Rev K, en
ABB AB
Discrete Automation and Motion
Robotics
S-721 68 VÄSTERÅS
SWEDEN
Telephone +46 (0) 21 344 400

公 司
有 限

育 科技

控帮教
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长

www.abb.com