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The information in this manual is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABBs written
permission, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Safety
11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
39
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Table of Contents
72
75
80
88
2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.3 Mechanically restricting the working range of axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.4 Mechanically restricting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4.5 Position switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
89
90
92
94
96
103
109
112
115
118
121
124
126
132
135
137
139
141
145
148
150
154
158
161
164
168
172
Table of Contents
193
Table of Contents
365
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.6 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Decommissioning
350
354
360
362
365
366
368
369
370
374
377
Overview
Overview
About this manual
This manual contains instructions for
Usage
This manual should be used during
installation, from lifting the manipulator to its work site and securing it to the
foundation to making it ready for operation
maintenance work
repair work.
installation personnel
maintenance personnel
repair personnel.
Prerequisites
The reader should...
Overview
Organization of chapters
The manual is organized in the following chapters:
Chapter
Contents
Safety, service
Safety information
Installation and
commissioning
Maintenance
Repair
Calibration information
Decommissioning
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.
Safety information
Part list
Circuit diagrams
Software manuals
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.
Controller hardware option manual
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
Safety information
Part list
Circuit diagrams
RobotWare manuals
The following manuals describe the robot software in general and contain relevant reference
information:
10
RAPID reference manual part 2: Description of all RAPID functions and data types.
Application manuals
Specific applications (e.g. software or hardware options) are described in Application
manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
Operators manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
include:
Miscellaneous
A number of manuals provide generic descriptions of the robot and robot system. These
include:
11
Step Action
Note/Illustration
8.
Step Action
Note/Illustration
3.
Safety information
The manual includes a separate safety chapter that must be read through before proceeding
with any service or installation procedures. All procedures also include specific safety
information when dangerous steps are to be performed. Read more in chapter Safety on page
13.
12
1 Safety
1.1. Introduction
1 Safety
1.1. Introduction
Overview
The safety information in this manual is divided in two categories:
general safety aspects, important to attend to before performing any service work on
the robot. These are applicable for all service work and are found in section General
safety information on page 14.
specific safety information, pointed out in the procedure at the moment of the danger.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in section Safety related instructions on
page 33.
13
1 Safety
1.2.1. Introduction
Safety, service
Limitation of liability
Referenced documents
2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split
into different categories:
3. Safety actions details actions which may be taken to remedy or avoid dangers.
14
Fire extinguishing
Brake testing
1 Safety
1.2.2.1. Safety, service
15
1 Safety
1.2.2.2. Limitation of Liability
16
1 Safety
1.2.2.3. Related information
Detailed in document
Section
Users Guide
Start-up
17
1 Safety
1.2.3.1. Safety risks during service work on robot
Description
Hot components!
Caution!
Warning!
Cabling
Safety risk
Description
Caution!
18
1 Safety
1.2.3.1. Safety risks during service work on robot
Description
Caution!
Balancing device
Safety risk
Description
Warning!
19
1 Safety
1.2.3.2. Safety risks related to gripper
20
1 Safety
1.2.3.3. Safety risks related to tools/workpieces
21
1 Safety
1.2.3.4. Safety risks related to pneumatic/hydraulic systems
Residual energy may be present in these systems so, after shutdown, particular care
must be taken.
The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.
Gravity may cause any parts or objects held by these systems to drop.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
Safe design
22
1 Safety
1.2.3.5. Safety risks during operational disturbances
The industrial robot is a flexible tool which can be used in many different industrial
applications.
All work must be carried out professionally and in accordance with the applicable
safety regulations.
Remedial action must only be carried out by qualified personnel who are familiar with
the entire installation as well as the special risks associated with its different parts.
Qualified personnel
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.
23
1 Safety
1.2.3.6. Safety risks during installation and service
The instructions in the Product Manual - Installation and Commissioning must always
be followed.
Emergency stop buttons must be positioned in easily accessible places so that the robot
can be stopped quickly.
Those in charge of operations must make sure that safety instructions are available for
the installation in question.
Those who install the robot must have the appropriate training for the robot system in
question and in any safety matters associated with it.
Safety zones, which have to be crossed before admittance, must be set up in front of
the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
parallel arm.
Energy, stored in the robot for the purpose of counterbalancing certain axes, may be
released if the robot, or parts thereof, is dismantled.
Never use the robot as a ladder, i.e. do not climb on the robot motors or other part
during service work. There is a serious risk of slipping because of the high temperature
of the motors or oil spills that can occur on the robot.
24
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.
1 Safety
1.2.3.7. Risks associated with live electric parts
Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
The mains supply to the robot must be connected in such a way that it can be turned
off outside the robot's working space.
Units inside the controller, e.g. I/O modules, can be supplied with power from an
external source.
The power supply unit for the computer system (230 VAC)
The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
The power supply unit for tools, or special power supply units for the machining
process
The external voltage connected to the control cabinet remains live even when the robot
is disconnected from the mains.
Additional connections
The user connections for tools or other parts of the installation (max. 230 VAC, see
Installation and Commissioning Manual)
25
1 Safety
1.2.4.1. Safety fence dimensions
26
1 Safety
1.2.4.2. Fire extinguishing
27
1 Safety
1.2.4.3. Emergency release of the robots arm
The robot arm may be moved manually on smaller robot models, but larger models may
require using an overhead crane or similar.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, further increasing any injury!
28
1 Safety
1.2.4.4. Brake testing
29
1 Safety
1.2.4.5. Risk of disabling function "Reduced speed 250 mm/s"
30
1 Safety
1.2.4.6. Safe use of the Teach Pendant Unit
During programming and testing, the enabling device must be released as soon as
there is no need for the robot to move.
The programmer must always bring the Teach Pendant Unit with him/her, when
entering the robot's working space. This is to prevent anyone else taking control over
the robot without the programmer knowing.
31
1 Safety
1.2.4.7. Work inside the manipulators working range
32
The operating mode selector on the controller must be in the manual mode position to
render the enabling device operative and to block operation from a computer link or
remote control panel.
The robot's speed is limited to max. 250 mm/s when the operating mode selector is in
position < 250 mm/s. This should be the normal position when entering the working
space. The position 100% "full speed" may only be used by trained personnel who are
aware of the risks that this entails.
Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in
order not to get entangled with hair or clothing. Also be aware of any danger that may
be caused by rotating tools or other devices mounted on the manipulator or inside the
cell.
Test the motor brake on each axis, according to section Brake testing on page 29.
1 Safety
1.3.1. Safety signals, general
A caption specifying the danger level (DANGER, WARNING or CAUTION) and the
type of danger.
A brief description of what will happen if the operator/service personnel does not
eliminate the danger.
Danger levels
The table below defines the captions specifying the danger levels used throughout this
manual.
Symbol
Designation
Signification
DANGER
WARNING
ELECTRICAL
SHOCK
CAUTION
danger
warning
Electrical shock
caution
33
1 Safety
1.3.1. Safety signals, general
Symbol
Designation
Signification
Electrostatic discharge
(ESD)
NOTE
TIP
Note
Tip
34
1 Safety
1.3.2. DANGER - Moving manipulators are potentially lethal!
Action
Info/Illustration
1.
2.
3.
35
1 Safety
1.3.3. WARNING - The brake release buttons may be jammed after service work
1.3.3. WARNING - The brake release buttons may be jammed after service work
Description
The brake release unit has push buttons for brake release of each axis motor. When service
work is performed inside the SMB recess that includes removal and refitting of the brake
release unit, the brake release buttons may be jammed after refitting!
In case the power is turned on while a brake release button is jammed in depressed position,
the affected motor brake is released! This may cause serious personal injuries and damage to
the robot!
Elimination
To eliminate the danger after service work has been performed inside the SMB recess, follow
the procedure below:
Step
36
Action
1.
2.
3.
Check the push buttons of the brake release unit by pressing them down, one by
one.
Make sure none of the buttons are jammed in the tube.
4.
If a button gets jammed in the depressed position, the alignment of the brake release
unit must be adjusted so that the buttons can move freely in their tubes!
1 Safety
1.3.4. WARNING - The unit is sensitive to ESD!
Action
Note/Illustration
1.
2.
3.
37
1 Safety
1.3.5. WARNING - Safety risks during work with gearbox oil
Description
Elimination / Action
Hot oil!
When opening the oil plug,
Open oil plug carefully and keep
there may be pressure present away from the opening. Do not
in the gearbox, causing oil to overfill the gearbox when filling.
spray from the opening!
-
Do not overfill!
38
1 Safety
1.3.5. WARNING - Safety risks during work with gearbox oil
Warning
Specified amount
depends on drained
volume!
Description
Elimination / Action
The specified amount of oil is After refilling, check the oil level.
based on the total volume of
the gearbox. When changing
the oil, the amount of refilled oil
may differ from the specified
amount, depending on how
much oil has previously been
drained from the gearbox.
39
1 Safety
1.3.6. WARNING - Mixed oils may cause severe damage to gearbox!
Action
Note
1.
Flush the gearbox properly three times with the correct type
of oil. Use a service program when flushing.
2.
40
Action
Note
41
2.2 Unpacking
2.2.1. Pre-installation procedure
General
This instruction is primarily intended for use when unpacking and installing the manipulator
(mechanical robot) for the first time. It also contains information useful during later reinstallation of the manipulator.
Checking the pre-requisites for installation
The checklist below details what must be observed before proceeding with the actual
installation of the manipulator:
Step
42
Action
Info/Illustration
1.
2.
3.
4.
5.
Specified in Operating
conditions, manipulator on
page 44.
6.
Specified in Loads on
foundation, manipulator on
page 43, Requirements on
foundation, manipulator on
page 43 and Protection
classes, manipulator on
page 44Protection classes,
manipulator on page 44
respectively.
7.
8.
Specified in Weight,
manipulator on page 43.
Weight, manipulator
The table below shows the weights of the different models (without DressPack):
Manipulator model
Weight
2400 kg
2400 kg
2450 kg
2450 kg
Force
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
Requirement
Value
Min. levelness
0.5 mm
Max. tilt
Min. resonance
frequency
22 Hz
Note
The limit for the maximum payload on the
manipulator is reduced if the manipulator is
tilted from 0.
Contact ABB for further information about
acceptable payload.
43
Parameter
Value
-25 C
+55 C
+70 C
Parameter
Value
+5 C
+50 C
44
Equipment
Protection class
IP 67
xx0100000101
45
xx0300000296
46
xx0100000100
47
en0100000099
48
xx0100000103
WARNING!
The robot is likely to be mechanically unstable while not secured to the foundation!
49
xx0200000386
50
Frame version without an oil plug, use the fork lift set: 3HAC 0604-2
Frame version with an oil plug (C), use the fork lift set: 3HAC 0604-1
Oil plug
Attachment points
The attachment points for the fork lift equipment are shown in the figure below.
xx0400000707
Required equipment
To determine which fork lift set to use, see the section Different designs on page 50.
Equipment, etc.
Art. no.
Note
51
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 1557-1
xx0100000102
52
Spacer (2 pcs)
xx0200000379
Spacer (2 pcs)
53
Action
Info/Illustration
1.
2.
Position the robot as shown in the figure to Release the brakes if required as
the right!
detailed in section Manually releasing
Note! No load is permitted on the robot if the brakes on page 63.
the fork lift set 3HAC 0604-2 is used!
xx0200000079
xx0200000387
3.
54
Step
Action
Info/Illustration
4.
Caution!
Caution!
The fork lift pocket weighs 60 kg!
5.
xx0400001068
6.
A: horizontal attachment
screws, 4 pcs, M16 x 60.
Tightening torque: 60 Nm.
B: spacers, 2 pcs.
xx0400000977
A: securing screw
55
Step
7.
Action
Info/Illustration
xx0300000464
Caution!
Caution!
The fork lift pocket weighs 22 kg!
9.
xx0200000380
56
Step
Action
Info/Illustration
11.
Caution!
Caution!
The robot weighs 2550 kg! All lifting
equipment used must be dimensioned
accordingly!
12. Carefully lift the robot and move it to its
installation site.
13.
Warning!
WARNING!
Personnel must not, under any
circumstances, be present under the
suspended load!
57
xx0200000153
58
Load hook
Shortening hook
Chain
Hook
3HAC 022033-001 Revision: B
Required equipment
Equipment
Art. no.
Note
3HAC 15607-1
Includes
user instructions (3HAC 15971-2).
Action
Note
1.
2.
3.
Fit the lifting device, manipulator to the Art. no. is specified in Required
robot as described in the enclosed
equipment on page 59!
instruction!
xx0100000103
4.
Caution!
Caution!
The robot weighs 2550 kg! All lifting
equipment used must be dimensioned
accordingly!
59
Step
Action
Note
5.
Warning!
WARNING!
Personnel must not, under any
circumstances, be present under the
suspended load!
6.
60
xx0200000315
Chain sling with shortener, 4250 kg, 3 pcs (0.5 m, 0.5 m, 0.265 m)
Required equipment
Equipment
Note
Lengths: 4 m (3 pcs).
61
Safety information
Read the safety information before lifting the manipulator!
CAUTION!
The manipulator weighs 2550 kg! All lifting equipment used must be dimensioned
accordingly!
Slings attached directly on to manipulator
The section below details how to attach roundslings to the manipulator in order to lift the
complete robot.
Step
Action
1.
Note
Recommended manipulator
position is described in section
Risk of tipping / stability on page
49.
Caution!
62
2.
3.
Attach the three chain slings with shorteners to Shown in the figure Roundslings
the overhead crane hook.
attached to the manipulator on
page 61!
Lengths are specified in Required
equipment on page 61!
4.
Fit the three roundslings, 2000 kg to the robot. Shown in the figure Roundslings
Attach the roundslings to the chain slings
attached to the manipulator on
hanging from the overhead crane.
page 61!
Lengths are specified in Required
equipment on page 61!
5.
6.
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 section Supplying power to connector R1.MP on page 65.
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 section Manually releasing the brakes, external brake release unit on page 66
xx0200000375
Internal brake release unit with push buttons, located on the robot base
63
xx0200000376
Internal brake release unit with push buttons, located on the robot frame
Action
Info/Illustration
2.
Danger!
When releasing the holding brakes, the robot axes may
move very quickly and sometimes in unexpected ways!
Make sure no personnel is near the robot arm!
3.
64
Action
Note/Illustration
1.
Danger!
Incorrect connections, such as
supplying power to the wrong pin, may
cause all brakes to be released
simultaneously!
2.
xx0300000565
65
Art. no.
3HAC 12987-1
Connections, manipulator
The illustration below shows where to connect the external brake release unit in order to
release the holding brakes of the manipulator.
xx0100000104
66
Connector R1.BU
xx0200000081
Connector R1.MP
Connector R1.BU
Connect to R1.BU
Action
Note/Illustration
1.
2.
67
Step
68
Action
Note/Illustration
3.
4.
5.
6.
Equipment
Art. no.
Note
3HAC 14457-4
3 pcs
Lifting slings
3 pcs
Length: approx. 2 m
Hole configuration
xx0200000096
Action
Info/Illustration
1.
Caution!
The base plate weighs 353 kg! All lifting equipment
used must be dimensioned accordingly!
2.
3.
69
xx0100000105
70
xx0400000715
Note1
3HAC 022033-001 Revision: B
xx0300000045
Required equipment
Equipment
Art. no.
Note
Base plate
3HAC 12937-7
Includes
guide sleeves, 3HAC 12937-3
levelling screws, 9ADA 120-79
attachment screws and
washers for securing the
manipulator to the base plate.
A drawing of the base plate itself may
be ordered from ABB Robotics!
Standard toolkit
3HAC 15571-1
Recommendations, quality
The table specifies any recommendations made by ABB:
Variable
Recommendation
Base plate
This section details how to secure the base plate to the foundation.
CAUTION!
The base plate weighs 353 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Info/illustration
1.
2.
3.
4.
Use the base plate as a template and drill 16 If possible, observe the
attachment holes as required by the selected recommendations specified in
bolt dimension.
section Recommendations, quality
on page 73. ABB does not assume
any responsibility for other
foundation qualities, due to great
variations in the foundation
properties.
5.
Fit the base plate and use the levelling bolts Shown in the figure Base plate,
to level the base plate.
grooves and holes on page 72.
6.
7.
8.
73
xx0100000107
Levelling 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.
74
M24 x 140
Quality:
Quality 8.8
Suitable washer:
Thickness: 4 mm
Outer diameter: 44 mm
Inner diameter: 25 mm
Tightening torque:
725 Nm
Action
Info/Illustration
1.
2.
3.
4.
5.
6.
xx0300000046
75
xx0100000109
76
xx0100000115
77
xx0100000120
xx0100000116
78
xx0300000299
xx0100000117
79
xx0100000118
80
xx0100000119
Fastener quality
When fitting tools on the mounting flange (see the figures above), use only screws with
quality 12.9. When fitting other equipment, standard screws with quality 8.8 can be used.
81
xx0400001071
82
Stop
Shield (4 pcs)
Sliding cover
Required equipment
Equipment
Art. no.
Note
3HAC 020529-004
Locking liquid
Loctite 577
Used to secure the attachment
screws of the rear cover at the
end of the balancing device.
Standard toolkit
3HAC 15571-1
Installation
The procedure below details how to install the chip and dust protection to the robot.
Step
1.
Action
Illustration
xx0400001077
A: Bearing unit
B: Lower arm shaft
C: Washer and nut
Also shown in the figure Illustration, equipment
mounted on robot on page 82
83
Step
Action
2.
3.
Illustration
xx0400001096
xx0400001095
xx0400001079
84
Step
4.
Action
Illustration
xx0400001098
5.
xx0400001081
6.
xx0400001099
85
Step
7.
Action
Illustration
xx0400001083
8.
xx0400001086
86
Step
9.
Action
Illustration
xx0400001085
xx0400001087
J: Bushing
K: Hub
87
Step
11.
Action
Illustration
xx0400001100
12.
L: Rubber cloth
M: Upper shield
N: Rear bracket
xx0400001088
Removing parts
In case the chip and dust protection must be removed, for example in order to perform certain
repair activities, read and follow the information below. If removing the complete protection,
follow the removal order below. If only removing some parts, follow the actions detailed for
the specific part.
Part to be removed
Action
Sliding cover
88
1.
2.
3.
4.
Shields
Stop
Part to be removed
Action
89
2.3.11. Loads
General
Any loads mounted on the robot must be defined correctly and carefully (with regard to the
position of center of gravity and inertia factor) in order to avoid jolting movements and
overloading the motors. If this is not done correctly operational stops may result.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified in the
Product Specification. The loads must also be defined in the software as detailed in Users
Guide (RobotWare 4.0), or Operators manual (RobotWare 5.0).
Stop time and braking distances
Robot motor brake performance depends on any loads attached. For further information about
brake performance, please contact ABB.
90
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 180. The working range may however
be increased to 220 with option 561-1 "Extended working range axis 1". Notice that this
option also requires installation of a position switch on axis 1.
This section describes how to install hardware that restricts the working range.
Notice that adjustments must be made also in the software, references to software manuals
are given in following installation procedures.
91
xx0300000049
Required equipment
92
Equipment, etc.
Art. no.
Note
3HAC 11076-1
3HAC 11076-2
Standard toolkit
3HAC 15571-1
Action
Note
1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
3.
4.
Warning!
If the mechanical stop has been deformed
after a hard collision, it must be replaced!
93
xx0300000047
Required equipment
Equipment, etc.
Art. no.
Standard toolkit
94
Note
Action
Note/Illustration
1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
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 94.
3.
4.
Warning!
If the mechanical stop has been deformed
after a hard collision, it must be replaced!
95
xx0300000048
Required equipment
96
Equipment, etc.
Art. no.
Note
Standard toolkit
Action
Note/Illustration
1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
Mount and tighten the additional stops in a Shown in the figure Mechanical stops,
row, starting from the fixed stop.
axis 3 on page 96
Tightening torque: 115 Nm.
3.
4.
Warning!
If the mechanical stop has been deformed
after a hard collision, it must be replaced!
97
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.
Required equipment
Description
Art. no.
3HAC 12750-1
3HAC 12785-1
3HAC 12788-1
Axis 1
The illustration below shows the position switch for axis 1:
xx0100000158
98
Cam
Protection sheet
Rail
Rail attachment
Axis 2
The illustration below shows the position switch for axis 2:
xx0100000159
Cam
Rail
Rail Attachment
99
Axis 3
The illustration below shows the position switch for axis 3:
xx0100000160
Cam
Rail
Rail attachment
Specifications
Maximum voltage/current for the position switches:
100
Parameter
Value
Voltage
Max. 50 VDC
Current
Max. 1 A
Connections
The position switches may be connected to different points on the robot system:
XT8, screw terminal in the controller cabinet when position switch cables are used.
R1.SW1 at the robot base. Customer connection kit is recommended, art. no. is
specified in Required equipment on page 98!
R1.SW2/3 at the robot base. Customer connection kit is recommended, art. no. is
specified in Required equipment on page 98!
Further information about the cables and connection points, see section Robot cabling and
connection points on page 103.
Fitting and adjusting cams and stops
The instruction below details how to fit and adjust the parts of the position switches:
Step
Action
Info/Illustration
1.
2.
3.
4.
5.
Fit the cam with the M5 screw and nut. Tighten the M5 Shown in Illustration, adjust
screw to secure the cam.
and secure cams on page
102.
101
xx0100000113
Adjustable cam
Profile
xx0100000114
102
Cable category
Description
Robot cables
These categories are divided into sub-categories which are specified below:
Robot cables
These cables are included in the standard delivery. They are completely pre-manufactured
and ready to plug in.
Connection
Connection
point, cabinet point, robot
R1.MP
R1.SMB
103
Art. no.
3HAC 11818-1
3HAC 11818-2
3HAC 11818-4
Cable
Art. no.
3HAC 7998-1
3HAC 7998-2
3HAC 7998-3
3HAC 7998-4
104
Cable
Art. no.
Connection
Connection
point,
point, robot
cabinet
3HAC 13175-1
XS8
R1.SW
3HAC 13175-2
XS8
R1.SW
3HAC 13175-4
XS8
R1.SW
3HAC 13176-1
XS8
R1.SW2/3
XS8
R1.SW2/3
XS8
R1.SW2/3
3 Maintenance
3.1. Introduction
3 Maintenance
3.1. Introduction
Structure of this chapter
This chapter details all maintenance activities recommended for the robot and any external
units of the robot.
It is based on the maintenance schedule, located in the beginning of the chapter. The schedule
contains information about required maintenance activities including periodicity and refers to
procedures for the activities.
Each procedure contains all information required to perform the activity, e.g. required tools
and materials.
The procedures are gathered in different sections, divided according to the maintenance
activity.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing the procedures. Make sure
to read through the chapter Safety on page 13.
105
3 Maintenance
3.2.1. Specification of maintenance intervals
106
Calendar time: specified in months regardless of whether the robot system is run or not
Operating time: specified in operating hours. More frequent running of the robot
means more frequent maintenance activities.
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 section Service Information System on page
183
3 Maintenance
3.2.2. Maintenance schedule
Maintenance
activity
Equipment
Interval
Inspection
12 mths
Inspection
12 mths 1
Inspection
12 mths 1
Inspection
12 mths
Inspection
12 mths
Inspection
12 mths 1
Inspection
Balancing device
12 mths
Inspection, balancing
device on page 128
Inspection
Manipulator harness
12 mths
Inspection, cable
harness on page 134
Inspection
Information labels
12 mths
Inspection,
information labels on
page 147
Inspection
12 mths
Inspection, damper
axes 2-5 on page 141
Inspection
12 mths
Inspection,
mechanical stop, axis
1 on page 137
Changing
12 000 h
Detailed in
section
1
3 Maintenance
3.2.2. Maintenance schedule
Maintenance
activity
108
Equipment
Detailed in
section
Interval
Changing
Changing
Changing
Changing
Changing
Changing
Changing
Changing
Changing
Changing
Changing
Changing
Changing
Replacement
Axis 1 gear
As specified by the
SIS, or typically 96
mths
Replacement of
gearbox, axis 1 on
page 320
Replacement
Axis 2 gear
As specified by the
SIS, or typically 96
mths
Removal of gearbox,
axis 2 on page 328
Replacement
Axis 3 gear
As specified by the
SIS, or typically 96
mths
Removal of gearbox,
axis 3 on page 337
Replacement
Axis 4 gear
96 mths
Removal of gearbox,
axis 4 on page 344
Replacement
Axis 5 gear
96 mths
Removal of gearbox,
axis 5 on page 350
Replacement
Axis 6 gear
As specified by the
SIS, or typically 96
mths
Removal of gearbox,
axis 6 on page 360
Replacement
Manipulator harness
Replacement of cable
harness, axes 1-4 on
page 200
Replacement
12- 36 mths 3
Removal of SMB
related equipment on
page 250
12 000 h 1
12 000 h 1
-5
-5
12 000 h1
3 Maintenance
3.2.2. Maintenance schedule
Maintenance
activity
Equipment
Interval
Lubrication
12 000 h 4
Detailed in
section
Lubrication, balancing
device bearing on
page 177
1. If the robot is run at ambient temperatures higher than 50C, the manipulator may
require maintenance more frequently.
2. Replace when damage is detected or when approaching the life limit, specified in
Expected component life on page 110.
3. The battery is used as a back-up when the robot system is switched off. Therefore, the
life of a lithium battery depends on how frequently the power to the system is switched
off and also if the environment temperature is higher than recommended operating
temperature. The life varies from 12 - 36 mths, depending on current conditions. An
alert is given on the TPU when the battery is nearly discharged and it must then be
replaced within a month.
4. The interval is the same as with the interval for changing axis 2 gear oil, because the
type and degree of operation is similar.
5. In case the gearbox is lubricated with Shell Tivela S 150, no preventive maintenance
in terms of changing the gear oil is needed. Read more about the different types of oil
in section Oil in gearboxes on page 152.
Activities and intervals, optional equipment
The table below specifies the required maintenance activities and intervals for common
optional equipment. Maintenance of other external equipment for the robot is detailed in
separate documentation.
Maintenance
activity
Equipment
Inspection
UL lamp
Inspection
Inspection
Position
12 mths
switches, axis 1,
2 and 3
Interval
Note
Detailed in
section
Inspection, ULlamp on page 150
Mechanical stops in
addition to the fixed
stops
Inspection,
mechanical stop,
axes 1, 2 and 3 on
page 139
Inspection, position
switch axes 1, 2
and 3 on page 143
109
3 Maintenance
3.2.3. Expected component life
Expected life
Note
See note 1)
Balancing device
2,000,000 cycles
See note 2)
Gearbox
40,000 h
See note 3)
1. The expected life can also be affected by grouping harnesses/cables other than
standard options.
2. The given life for the balancing device is based on a test cycle that goes from the initial
position to maximum extension, and back again. Deviations from this test cycle will
result in differences in expected life! The given life is based on a test cycle that for
every axis goes from the calibration position to minimum angle, to maximum angle
and back to the calibration position. Deviations from this test cycle will result in
differences in expected life!
3. The robot is dimensioned for a service life of 8 years (350,000 cycles per year) in a
normal spot welding application. Depending on the actual application, the life of
individual gearboxes may vary greatly from this specification. The SIS (Service
Information System) integrated in the robot software keeps track of the gearbox life in
each individual case and will notify the user when a service is due. The SIS is
described in section Service Information System on page 183.
110
3 Maintenance
3.3.1. Inspection, oil level gearbox axis 1
xx0200000111
Gearbox axis 1
Motor, axis 1
Required equipment
Equipment, etc.
Art. no.
Note
Lubricating oil
3HAC 16843-1 /
3HAC 021469-001
Standard toolkit
3HAC 15571-1
111
3 Maintenance
3.3.1. Inspection, oil level gearbox axis 1
Equipment, etc.
Art. no.
Note
These procedures include
references to the tools required.
Action
Note
1.
Warning!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING Safety risks during work with gearbox oil on
page 38.
2.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.
4.
5.
6.
7.
Warning!
Do not mix the oil types! If wrong oil is refilled,
the gearbox must be rinsed as detailed in
section WARNING - Mixed oils may cause
severe damage to gearbox! on page 40!
112
3 Maintenance
3.3.1. Inspection, oil level gearbox axis 1
Action
Note
1.
Warning!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING Safety risks during work with gearbox oil on
page 38.
2.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.
4.
5.
6.
7.
Warning!
Do not mix the oil types! If wrong oil is refilled,
the gearbox must be rinsed as detailed in
section WARNING - Mixed oils may cause
severe damage to gearbox! on page 40!
113
3 Maintenance
3.3.2. Inspection, oil level gearbox axis 2
xx0300000068
114
3 Maintenance
3.3.2. Inspection, oil level gearbox axis 2
xx0200000112
Required equipment
Equipment etc.
Art. no.
Note
Lubricating oil
3HAC 16483-1 /
3HAC 021469-001
Standard toolkit
3HAC 15571-1
115
3 Maintenance
3.3.2. Inspection, oil level gearbox axis 2
Action
Note
1.
Warning!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING Safety risks during work with gearbox oil on
page 38.
2.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.
4.
5.
6.
7.
Warning!
Do not mix the oil types! If wrong oil is refilled,
the gearbox must be rinsed as detailed in
section WARNING - Mixed oils may cause
severe damage to gearbox! on page 40!
116
3 Maintenance
3.3.3. Inspection, oil level gearbox axis 3
xx0200000113
Gearbox, axis 3
Required equipment
Equipment
Art. no.
Note
Lubricating oil
3HAC 16843-1 /
3HAC 021469-001
117
3 Maintenance
3.3.3. Inspection, oil level gearbox axis 3
Equipment
Art. no.
Note
Standard toolkit
3HAC 15571-1
Action
Note
1.
Warning!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING - Safety
risks during work with gearbox oil on page 38.
2.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Run the robot to the calibration position.
118
3 Maintenance
3.3.3. Inspection, oil level gearbox axis 3
Step
Action
Note
8.
Warning!
Do not mix the oil types! If wrong oil is refilled,
the gearbox must be rinsed as detailed in
section WARNING - Mixed oils may cause
severe damage to gearbox! on page 40!
119
3 Maintenance
3.3.4. Inspection, oil level gearbox axis 4
xx0200000107
120
3 Maintenance
3.3.4. Inspection, oil level gearbox axis 4
Required equipment
Equipment, etc.
Art. no.
Note
Lubricating oil
1171 2016-604 /
3HAC 021469-001
Lubricating oil
3HAC 021469-001
Standard toolkit
3HAC 15571-1
Action
Note
1.
Warning!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING - Safety
risks during work with gearbox oil on page 38.
2.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
121
3 Maintenance
3.3.4. Inspection, oil level gearbox axis 4
Step
Action
Note
3.
4.
5.
6.
7.
8.
9.
11.
Warning!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe
damage to gearbox! on page 40!
122
3 Maintenance
3.3.5. Inspection, oil level, gearbox axis 5
xx0200000108
Wrist housing
Oil plug, filling, primary gearbox (draining on opposite side of wrist housing, not
shown in figure)
123
3 Maintenance
3.3.5. Inspection, oil level, gearbox axis 5
Required equipment
Equipment etc.
Art. no.
Note
Lubricating oil
1171 2016-604 /
3HAC 021469-001
Lubricating oil
3HAC 021469-001
Standard toolkit
3HAC 15571-1
Action
Note
1.
Warning!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING - Safety
risks during work with gearbox oil on page 38.
2.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
124
3 Maintenance
3.3.5. Inspection, oil level, gearbox axis 5
Step
Action
Note
3.
4.
Open the oil plug, filling, in the primary gearbox. Shown in the figure Location of
gearbox on page 123!
5.
6.
7.
Open the oil plug, filling, in the secondary gear . Shown in the figure Location of
gearbox on page 123!
8.
9.
11.
Warning!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe
damage to gearbox! on page 40!
125
3 Maintenance
3.3.6. Inspection, oil level gearbox axis 6
xx0200000114
Gearbox, axis 6
Required equipment
Equipment
Art. no.
Note
Lubricating oil
3HAC 021469-001
Standard toolkit
3HAC 15571-1
126
3 Maintenance
3.3.6. Inspection, oil level gearbox axis 6
Action
Note
1.
Warning!
Handling gearbox oil involves several safety risks.
Before proceeding, please observe the safety
information in section WARNING - Safety risks during
work with gearbox oil on page 38.
2.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
3.
4.
5.
6.
7.
Warning!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe damage to
gearbox! on page 40!
127
3 Maintenance
3.3.7. Inspection, balancing device
dissonance
damage
leakage
128
3HAC 10538-1
Upgrade
3HAC 14675-1
Maintenance
3 Maintenance
3.3.7. Inspection, balancing device
xx0300000580
Balancing device
129
3 Maintenance
3.3.7. Inspection, balancing device
Required equipment
The table below specifies the equipment used if damage is detected on the balancing device.
See section Action at detected faults on page 128 to determine whether to perform
maintenance or upgrade!
Equipment, etc.
Art. no.
Maintenance kit,
complete
3HAC 15834-1
Includes:
complete kit including the
kit with bearings and
seals
instructions for
maintenance.
Maintenance kit,
bearings and seals
3HAC 14962-1
Includes:
kit with bearings, o-rings
and seals only
instructions for
maintenance.
Upgrade kit
3HAC 14965-1
Includes
kit with piston rod, support
shaft etc.
instruction for conversion,
3HAC 15864-2.
Securing screw
Toolkit for
maintenance
3HAC 15943-1
4552-2
(Bahco)
Separator
4551-C
(Bahco)
Standard toolkit
130
Note
3 Maintenance
3.3.7. Inspection, balancing device
If dissonance is detected...
1.
2.
3.
1.
2.
If damage is detected...
the piston rod (part of the piston rod ... perform maintenance or upgrade
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 equipment on page 130.
To decide whether to perform
maintenance or upgrade, see section
Action at detected faults on page 128.
131
3 Maintenance
3.3.7. Inspection, balancing device
xx0300000284
Sealing spacer
Shaft
Step
132
Action
1.
2.
Note
3 Maintenance
3.3.7. Inspection, balancing device
Step
Action
Note
3.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
4.
Action
1.
Danger!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2.
Check that there are no obstacles inside the frame, that could prevent the balancing
device from moving freely. See the figure Inspection points, balancing device on
page 129.
Keep the areas around the balancing device clean and free from objects, such as
service tools.
133
3 Maintenance
3.3.8. Inspection, cable harness
xx0200000097
Lower arm
Connectors at base
Required equipment
134
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
Circuit diagram
3 Maintenance
3.3.8. Inspection, cable harness
Action
Note
1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
3.
4.
5.
xx0200000155
135
3 Maintenance
3.3.8. Inspection, cable harness
Action
Note
1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
136
2.
3.
4.
3 Maintenance
3.3.9. Inspection, mechanical stop, axis 1
xx0200000151
Required equipment
Equipment, etc.
Art. no.
Note
Mechanical stop ax 1
3HAC 10499-3
Standard toolkit
3HAC 15571-1
137
3 Maintenance
3.3.9. Inspection, mechanical stop, axis 1
Action
Note/Illustration
1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
138
2.
3.
4.
If the stop pin is bent or damaged, it must be Art. no. is specified in Required
replaced!
equipment on page 137!
3 Maintenance
3.3.10. Inspection, mechanical stop, axes 1, 2 and 3
xx0200000150
Additional stop
Fixed stop
Required equipment
Equipment etc.
Art. no.
Note
Mechanical stop ax 1
3HAC 11076-1
Mechanical stop ax 1
3HAC 11076-2
Mechanical stop ax 2
3HAC 11077-1
Mechanical stop ax 3
3HAC 13128-2
Standard toolkit
3HAC 15571-1
139
3 Maintenance
3.3.10. Inspection, mechanical stop, axes 1, 2 and 3
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Step
140
Action
1.
2.
3.
Note/Illustration
Shown in the figure Location
of the mechanical stops on
page 139!
3 Maintenance
3.3.11. Inspection, damper axes 2-5
xx0200000099
141
3 Maintenance
3.3.11. Inspection, damper axes 2-5
Required equipment
Equipment
Art. no.
Note
Damper axis 2
3HAC 12990-1
Replace if damaged!
Damper axis 3
3HAC 11750-1
Replace if damaged!
Damper axis 4
3HAC 13564-1
Replace if damaged!
Damper axis 5
3HAC 10503-8
Replace if damaged!
Standard toolkit
3HAC 15571-1
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Step
142
Action
Note/Illustration
1.
Check all dampers for damage, such as cracks or Shown in the figure Location
existing impressions larger than 1 mm.
of dampers on page 141!
In order to inspect dampers, axis 4, the two covers on
top of the upper arm must be removed!
2.
3.
3 Maintenance
3.3.12. Inspection, position switch axes 1, 2 and 3
xx0100000158
Cam
Protection sheet
Rail
Rail attachment
143
3 Maintenance
3.3.12. Inspection, position switch axes 1, 2 and 3
xx0100000159
144
Cam
Rail
Rail attachment
3 Maintenance
3.3.12. Inspection, position switch axes 1, 2 and 3
xx0100000160
Cam
Rail
Rail attachment
Required equipment
Equipment, etc.
3HAC 15715-1
To be replaced in case of
detected damage.
3HAC 15715-2
To be replaced in case of
detected damage.
3HAC 15715-2
To be replaced in case of
detected damage.
Art. no.
Note
145
3 Maintenance
3.3.12. Inspection, position switch axes 1, 2 and 3
Equipment, etc.
Standard toolkit
Art. no.
Note
3HAC 15571-1
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Step
146
Action
1.
2.
3.
4.
5.
3 Maintenance
3.3.13. Inspection, information labels
xx0200000100
Warning sign, symbol of a lightning flash (located on motor cover), 3HAC 1589-1
Warning label, tools are not allowed around the balancing device during operation,
3HAC 020611-001
Information labels at gearboxes and at robot base, if gearboxes are filled with
Shell Tivela S 150
147
3 Maintenance
3.3.13. Inspection, information labels
xx0200000101
Required equipment
148
Equipment
Art. no.
Note
3HAC 13191-1
3HAC 021670-002
3 Maintenance
3.3.13. Inspection, information labels
Inspection, labels
Step
Action
Note/Illustration
1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
3.
149
3 Maintenance
3.3.14. Inspection, UL-lamp
xx0200000117
UL signal lamp
Warning sign
Warning label
Required equipment
Equipment, etc.
Note
Signal lamp
3HAC 10830-1
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
150
3HAC 15571-1
3 Maintenance
3.3.14. Inspection, UL-lamp
Equipment, etc.
Note
These procedures include
references to the tools
required.
Inspection, UL-lamp
The procedure below details how to inspect the function of the UL-lamp.
Step
Action
Note/Illustration
1.
2.
151
3 Maintenance
3.4.1. Oil in gearboxes
xx0400000798
152
Axis 1 gearbox
Axis 2 gearbox
Axis 3 gearbox
Axis 4 gearbox
Axis 5 gearbox
Axis 6 gearbox
3 Maintenance
3.4.1. Oil in gearboxes
Type of oil
The table below specifies the types of oil used in the gearboxes of each axis. For some of the
axes, there are two different types specified. Normally, the same oil should be refilled as the
one drained. Read the sectionWhich type of oil does the gearbox contain? on page 154 in
order to determine which type of oil is currently used in the gearbox.
As the Shell Tivela S 150 is not compatible with mineral oil, contamination with other types
of oils used in the gearboxes is not accepted. Equipment used in handling of Tivela S 150
must be carefully cleaned. In case of changing the type of oil to another, the gearbox must
therefor be thoroughly rinsed! Contact ABB for further instructions.
The primary gearboxes of axes 4 and 5 are rinsed as detailed in section Flushing a
contaminated gearbox on page 179.
The Shell Global Product Code for Shell Tivela S 150 is specified within parentheses in table.
Gearbox
Type of oil
Axis 1
7,600 ml
Axis 2
4,800 ml
Axis 3
4,200 ml
Axis 4, primary
gear
900 ml
1171 2016-604 /
3HAC 021469-001
Art. no.
1171 2016-604 /
3HAC 021469-001
Amount
3,850 ml
750 ml
3,800 ml
850 ml
WARNING!
When filling gearbox oil, do not mix different types of oil as this may cause severe damage
to the gearbox! Always use the type of oil specified by the manufacturer!
If the oils are mixed, the gearbox must be thoroughly rinsed! Contact ABB for further
instructions!
153
3 Maintenance
3.4.1. Oil in gearboxes
Type of oil
76-27000
Tivela S 150
76-34000
Tivela S 150
76-51000
Tivela S 150
Notice that robots with earlier serial numbers might have been changed to Tivela after
delivery!
Labels on the robot
In case there are gearboxes filled with Tivela S 150, there are also labels attached to the robot.
The figures below show the labels and describe their location on the robot.
If the oil is changed to Tivela S 150 after delivery, the robot must be completed with these
labels!
xx0500001399
154
3 Maintenance
3.4.1. Oil in gearboxes
xx0500001397
Note
3HAC 021469-001
Label set
3HAC 021670-002
155
3 Maintenance
3.4.2. Oil change, gearbox axis 1
xx0200000111
156
Gearbox, axis 1
Motor, axis 1
3 Maintenance
3.4.2. Oil change, gearbox axis 1
xx0300000065
Required equipment
Equipment, etc.
Art. no.
Amount Note
Lubricating oil
3HAC 16843-1 /
3HAC 021469-001
7,600 ml
3HAC 17313-1
Standard toolkit
3HAC 15571-1
157
3 Maintenance
3.4.2. Oil change, gearbox axis 1
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 1
The procedure below details how to drain the oil in gearbox axis 1.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 157.
Step
Action
Note
1.
Warning!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING Safety risks during work with gearbox oil on
page 38.
2.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
158
3.
4.
5.
6.
7.
Open the hose end and drain the oil into the
vessel.
8.
9.
3 Maintenance
3.4.2. Oil change, gearbox axis 1
Action
Note
1.
Warning!
Handling gearbox oil involves several safety risks.
Before proceeding, please observe the safety
information in section WARNING - Safety risks
during work with gearbox oil on page 38.
2.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
3.
4.
5.
Warning!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe damage
to gearbox! on page 40!
6.
159
3 Maintenance
3.4.3. Oil change, gearbox axis 2
xx0200000112
Gearbox, axis 2
Required equipment
Equipment, etc. Art. no.
Lubricating oil
3HAC 16483-1 /
4,800 ml
3HAC 021469-001
160
Amount
Note
Optimol Optigear RMO 150 /
Shell Tivela S 150 (001A9646)
Do not mix the oils! Check
which oil is currently filled in
the gearbox, as detailed in
section Which type of oil does
the gearbox contain? on page
154!
Capacity: 5,000 ml.
3 Maintenance
3.4.3. Oil change, gearbox axis 2
Amount
Note
Oil exchange
equipment
3HAC 021745-001
Standard toolkit
3HAC 15571-1
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 160.
Step
Action
Note/Illustration
1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
Warning!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING Safety risks during work with gearbox oil on
page 38.
3.
Remove the oil plug, draining, and drain the Shown in the figure Location of oil
gearbox oil using a hose with nipple and an oil plugs on page 160!
collecting vessel.
Vessel capacity is specified in
Required equipment on page 160!
Draining is time-consuming.
Elapsed time varies depending on
the temperature of the oil.
4.
161
3 Maintenance
3.4.3. Oil change, gearbox axis 2
Filling, oil
The procedure below details how to fill oil into the gearbox, axis 2.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 160.
Step
Action
Note
1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
Warning!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING - Safety
risks during work with gearbox oil on page 38.
3.
Remove the oil plug, filling and the plug from the Shown in the figure Location of
vent hole.
oil plugs on page 160!
4.
5.
Warning!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe
damage to gearbox! on page 40!
6.
162
3 Maintenance
3.4.4. Oil change, gearbox, axis 3
xx0200000113
Gearbox, axis 3
163
3 Maintenance
3.4.4. Oil change, gearbox, axis 3
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil
3HAC 16843-1 /
4,200 ml
3HAC 021469-001
Oil exchange
equipment
3HAC 021745-001
Standard toolkit
3HAC 15571-1
Draining, oil
The procedure below details how to drain oil from the gearbox, axis 3.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 164.
Step
Action
Note
1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
Warning!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING Safety risks during work with gearbox oil on
page 38.
164
3 Maintenance
3.4.4. Oil change, gearbox, axis 3
Step
Action
Note
3.
4.
Filling, oil
The procedure below details how to fill oil to the gearbox, axis 3.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 164.
Step
Action
Note
1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
Warning!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING - Safety
risks during work with gearbox oil on page 38.
3.
4.
5.
Warning!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe
damage to gearbox! on page 40!
6.
165
3 Maintenance
3.4.5. Oil change, gearbox, axis 4
xx0200000107
166
Oil plug, filling, primary gearbox (draining not shown in figure, located further down
on the motor flange)
3 Maintenance
3.4.5. Oil change, gearbox, axis 4
Required equipment
Equipment, etc.
Art. no.
Amount Note
Lubricating oil
Lubricating oil
1171 2016-604 /
3,850 ml
3HAC 021469-001
Oil exchange
equipment
3HAC 17313-1
Standard toolkit
3HAC 15571-1
167
3 Maintenance
3.4.5. Oil change, gearbox, axis 4
Action
Note
1.
Warning!
Handling gearbox oil involves several safety risks.
Before proceeding, please observe the safety
information in section WARNING - Safety risks
during work with gearbox oil on page 38.
2.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
168
3.
4.
Drain the oil from the secondary gearbox by running Vessel capacity specified in
the upper arm -45 from calibration position.
Required equipment on page
167.
5.
6.
7.
3 Maintenance
3.4.5. Oil change, gearbox, axis 4
Action
Note
1.
Warning!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING - Safety
risks during work with gearbox oil on page 38.
2.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.
4.
5.
Warning!
Do not mix the oil types! If wrong oil is refilled,
the gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe
damage to gearbox! on page 40!
6.
169
3 Maintenance
3.4.6. Oil change, gearbox, axis 5
xx0200000108
170
Wrist housing
Oil plug, filling primary gearbox (draining on opposite side of wrist housing, not
shown in figure)
3 Maintenance
3.4.6. Oil change, gearbox, axis 5
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil
3HAC 021469-001
750 ml
Lubricating oil
1171 2016-604 /
3HAC 021469-001
3,800 ml
Oil exchange
equipment
3HAC 17313-1
Standard toolkit
3HAC 15571-1
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.
171
3 Maintenance
3.4.6. Oil change, gearbox, axis 5
Action
Note
1.
Warning!
Handling gearbox oil involves several safety risks.
Before proceeding, please observe the safety
information in section WARNING - Safety risks during
work with gearbox oil on page 38.
2.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
172
3.
4.
5.
6.
7.
8.
3 Maintenance
3.4.6. Oil change, gearbox, axis 5
Action
Note
1.
Warning!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING - Safety
risks during work with gearbox oil on page 38.
2.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.
4.
5.
Warning!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe
damage to gearbox! on page 40!
6.
173
3 Maintenance
3.4.7. Oil change, gearbox axis 6
xx0200000114
Gearbox, axis 6
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil
3HAC 021469-001
850 ml
3HAC 17313-1
Standard toolkit
3HAC 15571-1
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.
174
3 Maintenance
3.4.7. Oil change, gearbox axis 6
Action
Note
1.
Warning!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING Safety risks during work with gearbox oil on
page 38.
2.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.
Move the wrist so that the oil plug, filling of axis Shown in the figure Location of
6 gearbox faces upwards. Turn the turning disk gearbox on page 174!
so that the oil plug, draining faces downwards.
4.
Drain the oil from gearbox 6 by removing the oil Vessel capacity: 1000 ml.
plug. Collect the oil with a suitable vessel.
175
3 Maintenance
3.4.7. Oil change, gearbox axis 6
Action
Note
1.
Warning!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING Safety risks during work with gearbox oil on
page 38.
2.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.
4.
5.
6.
Warning!
Do not mix the oil types! If wrong oil is refilled,
the gearbox must be rinsed as detailed in
section WARNING - Mixed oils may cause
severe damage to gearbox! on page 40!
7.
176
3 Maintenance
3.5.1. Lubrication, balancing device bearing
xx0200000109
Lubrication nipple
Sealing spacer
Required equipment
Equipment, etc.
Art. no.
Note
Grease
3HAA 1001-294
Grease pump
177
3 Maintenance
3.5.1. Lubrication, balancing device bearing
Action
Note
1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
178
2.
3.
3 Maintenance
3.6.1. Flushing a contaminated gearbox
Art. no.
Note
Lubricating oil
3HAC 021469-001
Standard toolkit
3HAC 15571-1
Service program
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.
Recommended motion
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).
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.
179
3 Maintenance
3.6.1. Flushing a contaminated gearbox
Flushing
The procedure below details how to flush a contaminated gearbox. The procedure is the same
for all gearboxes.
Step
180
Action
Note
1.
2.
3.
4.
5.
6.
7.
3 Maintenance
3.6.2. Cleaning, manipulator
xx0100000265
Inside of base/axis 1
181
3 Maintenance
3.6.2. Cleaning, manipulator
Required equipment
Equipment, etc.
Art. no.
Steam cleaner
Note
Always use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of paintwork, rust inhibitors, signs, or labels!
Always check that all protective covers are fitted to the robot before cleaning!
Never!
Never point the water jet at bearing seals, contacts, and other seals!
Never remove any covers or other protective devices before cleaning the robot!
Never use any cleaning agents, e.g. compressed air or solvents, other than those
specified above!
Never spray with a high pressure cleaner onto the sealing cup at the bottom of the
motor 6 spiral cable (item A in the figure Special points)!
Although the robot is watertight, avoid spraying connectors and similar items with a
high pressure cleaner!
Foundry versions
In working environments, e.g. foundries, where the manipulator may be exposed to fluids that
dry to make a crusty surface, e.g. release agents, clean the cable harnesses so that the crust
does not damage the cables:
182
Clean the spiral wound cables to motor 5 (item A in the figure Special points on page
181!) with water and a cloth!
3 Maintenance
3.7.1. Using the SIS system
Basic procedure
Step
Action
Reference
1.
Determine which of the system functions you These are described in Description of
require.
Service Information System (SIS) on
page 184.
2.
3.
4.
5.
Reset the counter if a repair is made, or if a The TPU displays for resetting any
counter for any other reason is restarted.
SIS value are shown in Description of
Service Information System (SIS) on
page 184.
6.
7.
183
3 Maintenance
3.7.2. Description of Service Information System (SIS)
Gearbox 1 operation time counter, based on percentage of the axis 1 gearbox service
interval
Gearbox 2 operation time counter, based on percentage of the axis 2 gearbox service
interval
Gearbox 3 operation time counter, based on percentage of the axis 3 gearbox service
interval
Gearbox 6 operation time counter, based on percentage of the axis 6 gearbox service
interval
184
3 Maintenance
3.7.2. Description of Service Information System (SIS)
Calendar time
This is a clock within the control system that keeps track of the service interval, based on
calendar time.
When the calendar time limit for maintenance is reached, a message is displayed on the TPU
(for M2000 robot systems) or the FlexPendant (for M2004 robot systems). How to access this
is detailed in section Reading the SIS output logs on page 192.
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
Remaining time
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
(for M2000 robot systems) or the FlexPendant (for M2004 robot systems). How to access this
is detailed in section Reading the SIS output logs on page 192.
The following information is available about the operation time in the service routine.
Service interval
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
(for M2000 robot systems) or the FlexPendant (for M2004 robot systems). How to access this
is detailed in section Reading the SIS output logs on page 192.
The following information is available about the joint service status in the service routine.
Joint x OK
Joint x NOK
The service interval for the axis in question has been reached.
Joint x N/A
The following information is available for the axis service status in the service routine.
Consumed time
Elapsed time
185
3 Maintenance
3.7.2. Description of Service Information System (SIS)
Remaining time
Remaining operation time for axis x until the service time parameter
value has been reached.
Reset values
Counters may be reset at any time by running the service routine.
When resetting, the counter variables are reset. The variables are described in section
Exporting the SIS data on page 193!
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.
SIS for MultiMove robot systems
SIS information is only available for IRB 66X0 and IRB 7600 robots. This means that in a
M2004 robot system with the option MultiMove, SIS information can only be displayed for
these robot models. If another robot model is part of the system, it will be displayed in the
SIS information list, but there is no information available.
186
3 Maintenance
3.7.3. SIS system parameters
en0200000049
en0400001266
187
3 Maintenance
3.7.3. SIS system parameters
188
other variables
3 Maintenance
3.7.4. Setting the SIS parameters
Action
Rem.
1.
Open "System
parameters" using the
TPU.
2.
Go to "System parameters/
Manipulator/types 2".
xx0200000045
en0200000046
189
3 Maintenance
3.7.4. Setting the SIS parameters
Step
3.
Action
Rem.
en0200000047
xx0100000200
4.
en0200000048
en0200000049
5.
190
3 Maintenance
3.7.4. Setting the SIS parameters
Procedure M2004
This is an instruction of how to enter SIS parameters to the M2004 robot system.
Step
Action
Rem.
1.
2.
3.
191
3 Maintenance
3.7.5. Reading the SIS output logs
Available in:
192
SIS message in
the log:
Meaning:
Calendar time
Service Message
Service is due!
X calendar days
since last service.
Calendar time
Service Message
X calendar days to
next service.
Operation time
Service Message
Service is due!
X production hours
since last service.
Operation time
Service Message
X production hours
to next service.
Gearbox time
Service Message
Gearbox x requires
service!
Gearbox time
Service Message
X% of the service
interval has expired
for gearbox x!
3 Maintenance
3.7.6. Exporting the SIS data
Signal
Unit
Counter type
Function
sisRestartDate
hrs*
Calendar time
sisCalendarT
hrs*
Calendar time
sisTotRunT
hrs*
Operation time
sisRunT
hrs*
Operation time
sisL10h_1
hrs
Gearbox time
sisL10h_Time_1
hrs*
Gearbox time
sisL10h_2
hrs
Gearbox time
sisL10h_Time_2
hrs*
Gearbox time
sisL10h_3
hrs
Gearbox time
sisL10h_Time_3
hrs*
Gearbox time
sisL10h_6
hrs
Gearbox time
sisL10h_Time_6
hrs
Gearbox time
193
3 Maintenance
3.7.6. Exporting the SIS data
194
4 Repair
4.1. Introduction
4 Repair
4.1. Introduction
Structure of this chapter
This chapter details all repair activities recommended for the robot and any external units of
the robot.
It is made up of separate procedures, each detailing a specific repair activity. Each procedure
contains all information required to perform the activity, e.g. spare parts numbers, required
special tools and materials.
The procedures are gathered in sections, divided according to the component location on the
robot.
Required equipment
All equipment required to perform a specific repair activity is listed together with the current
procedure.
The equipment is also gathered in different lists in the Product manual, reference information.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing specific steps in a
procedure. Make sure to read through the chapter Safety on page 13 before commencing any
service work.
195
4 Repair
4.2.1. Performing a leak-down test
Art. no.
Leakdown tester
3HAC 0207-1
Note
Procedure
Step
196
Action
Note/Illustration
1.
2.
Remove the topmost oil plug on the gear in question, Art. no. is specified above!
and replace it with the leakdown tester .
Adapters may be required, which are included in the
leakdown tester kit.
3.
Apply compressed air, and raise the pressure with the Recommended value: 0.2 knob until the correct value is shown on the
0.25 bar (20 - 25 kPa)
manometer.
4.
5.
Wait for approx. 8-10 minutes. No pressure loss must If the compressed air is
be detected.
significantly colder or
warmer than the gearbox to
be tested, a slight pressure
increase or decrease
respectively may occur. This
is quite normal.
6.
7.
Spray suspected leak areas with leak detection spray Art. no. is specified above!
.
Bubbles indicate a leak.
8.
4 Repair
4.2.2. Mounting instructions for bearings
Art. no.
Note
Grease
3HAB 3537-1
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.
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.
197
4 Repair
4.2.3. Mounting instructions for seals
Art. no.
Note
Grease
3HAB 3537-1
Rotating seals
The procedure below details how to fit rotating seals.
CAUTION!
Please observe the following before commencing any assembly of seals:
Keep the seal in its original wrappings or protect it well before actual mounting.
The fitting of seals and gears must be carried out on clean workbenches.
Use a protective sleeve for the sealing lip during mounting, when sliding over threads,
keyways, etc.
Step
198
Action
Note
1.
2.
3.
Lubricate the seal with grease just before fitting. (Not too
Art. no. is specified in
early as there is a risk of dirt and foreign particles adhering Equipment on page
to the seal.)
198.
Fill the space between the dust tongue and sealing lip to 2/
3 with grease. The rubber coated external diameter must
also be greased, unless otherwise specified.
4.
4 Repair
4.2.3. Mounting instructions for seals
Action
Note
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 compund).
If the flange surfaces are defective, the parts may not be used
beacuse leakage could occur.
2.
3.
4.
O-rings
The procedure below details how to fit o-rings.
Step
Action
Note
1.
2.
Check the o-ring for surface defects, burrs, shape accuracy, etc. Defective o-rings
may not be used.
3.
4.
5.
199
4 Repair
4.3.1. Replacement of cable harness, axes 1-4
xx0100000140
200
Connectors at motor 3; R2.FB3 and R2.MP3 and for signal lamp R2.H1 and
R2.H2
4 Repair
4.3.1. Replacement of cable harness, axes 1-4
Connector R1.MP
Connector R1.SMB
Required equipment
Equipment, etc.
Note
3HAC 12782-1
3HAC 14940-1
Locking liquid
Standard toolkit
Loctite 638
Used to secure the
attachment screws for the
attachment plate inside the
frame.
3HAC 15571-1
Circuit Diagram
Action
Note/Illustration
In order to facilitate refitting of cable harness, run Axes 2 and 3 may be tilted
the manipulator 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
201
4 Repair
4.3.1. Replacement of cable harness, axes 1-4
Step
Action
Note/Illustration
2.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.
4.
5.
6.
7.
Disconnect all connectors at motor 1 and motor 2. Specified and shown in the figure
Location of cable harness on
page 200!
8.
9.
xx0200000118.wmf
202
4 Repair
4.3.1. Replacement of cable harness, axes 1-4
Step
Action
Note/Illustration
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 manipulator 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.
xx0300000560
A: Cable gland
B: Attachment screws,
cable gland
C: Attachment plate
D: Velcro strap
203
4 Repair
4.3.1. Replacement of cable harness, axes 1-4
Step
Action
Note/Illustration
xx0100000143.wmf
13. Remove the velcro strap from the harness at the Shown in the figure Location of
cable fixing bracket at the arm house.
cable harness on page 200.
14. Disconnect connector R2.M5/6 at the cable
division point.
15. Disconnect all connectors at motor 3 and motor 4. Specified and shown in the figure
Location of cable harness on
page 200!
16. Gently pull the cable harness out.
Action
Note/Illustration
1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
204
In order to facilitate refitting of cable harness, Axes 2 and 3 may be tilted slightly to
move the manipulator to the specified position: improve access.
Axis 1: 0 degrees
Axis 2: 0 degrees
Axis 3: 0 degrees
Axis 4: 0 degrees
Axis 5: +90 degrees
Axis 6: no significance
4 Repair
4.3.1. Replacement of cable harness, axes 1-4
Step
Action
Note/Illustration
3.
4.
Reconnect connectors R1.MP and R1.SMB at Make a note of the correct positions
the rear cover plate.
of the connectors!
Attachment point is shown in the
figure Location of cable harness on
page 200.
5.
6.
7.
205
4 Repair
4.3.1. Replacement of cable harness, axes 1-4
Step
8.
Action
Note/Illustration
xx0300000560
206
A: Cable gland
B: Attachment screws, cable
gland
C: Attachment plate
D: Velcro strap
4 Repair
4.3.1. Replacement of cable harness, axes 1-4
Step
9.
Action
Note/Illustration
xx0200000118
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 36!
12. Pull the cable harness through the lower arm.
13. Refit the cable gland securing the cables
inside the lower arm.
xx0100000142
207
4 Repair
4.3.1. Replacement of cable harness, axes 1-4
Step
Action
Note/Illustration
xx0100000143
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
208
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
4 Repair
4.3.2. Replacement of cable harness, axes 5-6
xx0100000145
Required equipment
Equipment, etc.
Note
3HAC 11440-1
Cable harness axis 5
Standard toolkit
3HAC 15571-1
209
4 Repair
4.3.2. Replacement of cable harness, axes 5-6
Equipment, etc.
Note
Circuit Diagram
Action
Note
1.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2.
3.
Note!
Axis 5 must be oriented in the correct position (+90)
to allow the motor 6 cover to open!
4.
5.
6.
7.
8.
9.
210
4 Repair
4.3.2. Replacement of cable harness, axes 5-6
Action
Note
1.
Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2.
3.
Gently insert the cable harness from the rear into the
upper arm.
4.
5.
6.
7.
8.
9.
10. Refit the left hand side wrist cover with its attachment
screws.
11. Reconnect connector R2.M5/6 gently at thecable
harness division with two screws, M6.
Be careful not to bend the attachment plate when
fastening the screws!
12. Refit the plastic cover on the rear of the upper arm.
13. Update the revolution counters.
Detailed in chapter
Calibration - section
Updating revolution counters
on page 370.
211
4 Repair
4.3.2. Replacement of cable harness, axes 5-6
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
212
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
4 Repair
4.3.3. Removal of complete arm system
xx0100000150
Gearbox, axis 1
Motor, axis 1
Upper arm
Lower arm
Frame
Balancing device
213
4 Repair
4.3.3. Removal of complete arm system
Required equipment
Equipment, etc.
Art. no.
Note
3HAC 15607-1
Standard toolkit
3HAC 15571-1
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The complete arm system weighs 2000 kg! All lifting equipment used must be dimensioned
accordingly!
Step
Action
Note/Illustration
1.
2.
xx0100000103
214
4 Repair
4.3.3. Removal of complete arm system
Step
Action
Note/Illustration
3.
4.
5.
6.
Remove the block for calibration from the bottom of Shown in the figure Location
the frame.
of complete arm system on
page 213!
7.
8.
215
4 Repair
4.3.4. Refitting of complete arm system
xx0100000150
216
Gearbox, axis 1
Motor, axis 1
Upper arm
Lower arm
Frame
Balancing device
4 Repair
4.3.4. Refitting of complete arm system
Required equipment
Equipment, etc.
Art. no.
Note
3HAC 15607-1
Standard toolkit
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The complete arm system weighs 2000 kg! All lifting equipment used must be dimensioned
accordingly!
Step
Action
Note/Illustration
1.
2.
Lift the complete arm system and move it Make sure all the hooks and
at very low speed, making sure it does not attachments maintain in correct position
tip!
while lifting the manipulator!
Make sure the lift is done completely level,
adjust the length of the chains as detailed
in enclosed instruction!
217
4 Repair
4.3.4. Refitting of complete arm system
Step
3.
Action
Note/Illustration
xx0300000070
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
assembly during refitting of the arm
or damage!
system.
The guiding pin in the gearbox must be
fitted to the guiding hole of the frame (B).
Lower the arm system with guidance from
the guide pins previously fitted to the
frame.
5.
6.
7.
Refit the block for calibration at the bottom Shown in the figure Location of
of the frame.
complete arm system on page 216!
8.
9.
218
4 Repair
4.3.4. Refitting of complete arm system
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
219
4 Repair
4.4.1. Removal of turning disk
xx0100000129
Turning disk
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
220
4 Repair
4.4.1. Removal of turning disk
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Step
Action
Note/Illustration
1.
2.
3.
221
4 Repair
4.4.2. Refitting of turning disk
xx0100000129
Turning disk
Required equipment
Equipment, etc.
Note
Turning disk
3HAC 13193-1
O-ring
2152 2012-433
Grease
3HAB 3537-1
Standard toolkit
3HAC 15571-1
222
4 Repair
4.4.2. Refitting of turning disk
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Step
1.
Action
Note/Illustration
xx0100000130
2.
3.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
223
4 Repair
4.4.3. Removal of complete wrist unit
xx0100000147
Wrist unit
Turning disc
Cover, axis 5
Rear cover
Required equipment
224
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
3HAC 12734-1
4 Repair
4.4.3. Removal of complete wrist unit
Equipment, etc.
Art. no.
Note
Circuit diagram
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The wrist unit weighs 200 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
2.
3.
4.
Fit the Lifting tool, wrist unit to the two holes on the
sealing surface against the cover, axis 5.
5.
6.
7.
8.
9.
10. Pull the cabling forwards through the upper arm tube. Make sure the attachments
do not get stuck inside the
tube!
225
4 Repair
4.4.3. Removal of complete wrist unit
Step
Action
Note/Illustration
A new washer must always
be used on reassembly.
226
4 Repair
4.4.4. Refitting of complete wrist unit
xx0100000147
Wrist unit
Turning disc
Cover, axis 5
Rear cover
Required equipment
Equipment, etc.
Note
Wrist unit
3HAC 16628-1
227
4 Repair
4.4.4. Refitting of complete wrist unit
Equipment, etc.
Note
Friction washer
3HAC 11755-1
Standard toolkit
3HAC 15571-1
3HAC 12734-1
These procedures
include references to the
tools required.
Circuit Diagram
Calibration Pendulum
Instruction
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The wrist unit weighs 200 kg! All lifting equipment used must be dimensioned accordingly!
Step
228
Action
Note/Illustration
1.
2.
3.
4.
4 Repair
4.4.4. Refitting of complete wrist unit
Step
Action
Note/Illustration
5.
6.
7.
Remove the lifting tool, wrist unit and refit the cover, Shown in the figure Location
axis 5 with its attachment screws.
of wrist unit on page 227!
8.
9.
Detailed in sections
Inspection, oil level,
gearbox axis 5 on
page 123
Inspection, oil level
gearbox axis 6 on
page 126.
Calibration is detailed in
separate calibration
manuals.
Art. no. for the manuals are
specified in section
Document references in the
Product manual, reference
information.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
229
4 Repair
4.4.5. Removal of complete upper arm
xx0100000148
230
Upper arm
4 Repair
4.4.5. Removal of complete upper arm
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
3HAC 14457-3
3HAC 15536-1
3HAC 15556-1
Hoisting block
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The complete upper arm weighs 450 kg without any additional equipment fitted! Use a
suitable lifting device to avoid injury to personnel!
Step
Action
Note/Illustration
1.
2.
3.
4.
Run the lifting chain from the rear lifting point through Part no. is specified in
the overhead crane hook, through the hoisting block to Required equipment on
the lifting eye in the front.
page 231!
231
4 Repair
4.4.5. Removal of complete upper arm
Step
Action
Note/Illustration
5.
6.
7.
8.
9.
232
4 Repair
4.4.6. Refitting of complete upper arm
xx0100000148
Upper arm
233
4 Repair
4.4.6. Refitting of complete upper arm
Required equipment
Equipment, etc.
Art. no.
Note
3HAC 11054-1
Washer
3HAC 11828-1
Standard toolkit
3HAC 15571-1
3HAC 14457-3
3HAC 15536-1
3HAC 15556-1
Hoisting block
234
3HAC 14627-2
80 mm.
For guiding "Sealing, axis 2/3".
3HAC 14627-3
100 mm.
For guiding "Sealing, axis 2/3".
Calibration Pendulum
Instruction
4 Repair
4.4.6. Refitting of complete upper arm
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
CAUTION!
The complete upper arm weighs 450 kg without any additional equipment fitted! Use a
suitable lifting device to avoid injury to personnel!
Step
1.
Action
Note/Illustration
Fit the two guide pins, sealing axis 2/3 in two of the
attachment screw holes on gearbox 3, see figure
beside.
Guide the new sealing, axis 2/3 into position with the
guide pins, on gearbox 3.
xx0200000125
2.
Fit the lifting eye to the attachment hole in the wrist Shown in the figure Location
unit.
of upper arm on page 233!
Art. no. is specified in
Required equipment on
page 234!
3.
4.
Run the lifting chain from the rear lifting point through Art. no. is specified in
the overhead crane hook, through the hoisting block Required equipment on
to the lifting eye in the front.
page 234!
235
4 Repair
4.4.6. Refitting of complete upper arm
Step
Action
Note/Illustration
5.
6.
7.
8.
9.
10. Remove the guide pins and fit the two remaining
attachment screws. Tighten them as detailed above!
11. Refit any cabling removed during the removal
process.
12. Reconnect all connectors inside motors 3 and 4.
13. Reconnect connector R2.M5/6 gently at the rear
cable division point.
Be careful not to bend the attachment plate when
fastening the screws!
236
Calibration is detailed in
separate calibration
manuals.
Art. no. for the manuals are
specified in section
Document references in the
Product manual, reference
information.
4 Repair
4.4.6. Refitting of complete upper arm
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
237
4 Repair
4.5.1. Removal of complete lower arm
xx0100000149
238
Lower arm
4 Repair
4.5.1. Removal of complete lower arm
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!).
xx0200000031
Gear box
Lower arm
Frame
Shaft hole
201
202
Attachment screw
204
Washer
401
Bearing
402
Thrust washer
403
Bushing
404
Retaining ring
405
Shaft
406
Protection plug
409
Protection washer
239
4 Repair
4.5.1. Removal of complete lower arm
Required equipment
Equipment, etc.
Art. no.
Note
3HAC 14691-1
3HAC 13452-1
3HAC 14457-3
3HAC 12475-1
3HAC 13086-1
3HAC 13086-2
Standard toolkit
3HAC 15571-1
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The lower arm weighs 225 kg! All lifting equipment used must be dimensioned accordingly!
DANGER!
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Step
1.
240
Action
Note/Illustration
4 Repair
4.5.1. Removal of complete lower arm
Step
Action
Note/Illustration
2.
3.
Apply the lifting eye to the balancing device Art. no. is specified in Required
and raise to unload the device.
equipment on page 240.
Attachment shown in the figure
Location of lower arm on page 238.
4.
5.
6.
xx0300000060
8.
9.
xx0300000015
241
4 Repair
4.5.1. Removal of complete lower arm
Step
Action
Note/Illustration
Shown in the figure Attachment points,
lower arm on page 239!
Use a pliers for the retaining ring.
14. Fit the press (/puller) tool as shown in the Art. no. is specified in Required
figure to the right and mount both the
equipment on page 240!
hydraulic pump and the glycerin pump to it.
xx0300000010
15. Increase the pressure of the glycerin pump Do not exceed the limit of maximum
and, at the same time, pull out the shaft
pressure classified for the pumps!
with the puller tool by increasing the
pressure of the hydraulic pump.
16. Remove the lower arm attachment screws Shown in the figure Attachment points,
and washers that attaches the lower arm lower arm on page 239!
to the gearbox 2.
17. Lift the lower arm down and place it on a
secure surface.
242
4 Repair
4.5.2. Refitting of complete lower arm
xx0100000149
Lower arm
243
4 Repair
4.5.2. Refitting of complete lower arm
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!).
xx0200000031
244
Gear box
Lower arm
Frame
Shaft hole
201
202
Attachment screw
204
Washer
401
Bearing
402
Thrust washer
403
Bushing
404
Retaining ring
405
Shaft
406
Protection plug
409
Protection washer
4 Repair
4.5.2. Refitting of complete lower arm
Required equipment
Equipment, etc.
Note
Bearing
3HAC 4310-1
3HAC 11054-1
VK-cover
3HAA 2166-23
3HAC 14691-1
Guidings
3HAC 14445-1
3HAC 17105-1
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
3HAC 13452-1
3HAC 13453-1
3HAC 13086-1
3HAC 13086-2
Grease
3HAB 3537-1
Standard toolkit
3HAC 15571-1
Calibration Pendulum
Instruction
245
4 Repair
4.5.2. Refitting of complete lower arm
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The lower arm weighs 225 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
2.
xx0200000262
246
3.
4.
5.
4 Repair
4.5.2. Refitting of complete lower arm
Step
6.
Action
Note/Illustration
In case the holes of the lower arm and the Connect power supply to connector
ones of the gearbox axis 2 doesnt match, R2.MP2:
use power supply to release the motor axis
+ : pin 2
2 brakes and rotate the pinion and gear
- : pin 5
with the rotation tool.
xx0200000165
8.
9.
xx0300000014
A: Retaining ring
B: Protection washer
C: Bearing
D: Thrust washer
E: Shaft
F: Protection washer
247
4 Repair
4.5.2. Refitting of complete lower arm
Step
Action
Note/Illustration
248
4 Repair
4.5.2. Refitting of complete lower arm
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
249
4 Repair
4.6.1. Removal of SMB related equipment
xx0100000138
SMB battery
SMB cover
SMB unit
Battery cable
Pins
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
Circuit Diagram
250
4 Repair
4.6.1. Removal of SMB related equipment
Removal, battery
The procedure below details how to remove the SMB battery.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
DANGER!
Follow these instruction to prevent the unit to be damaged from ESD:
Before handling, make sure you are grounded through a special ESD wrist bracelet or
similar.
Step
Action
Note/Illustration
1.
2.
3.
4.
251
4 Repair
4.6.1. Removal of SMB related equipment
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
DANGER!
Follow these instruction to prevent the unit to be damaged from ESD:
Before handling, make sure you are grounded through a special ESD wrist bracelet or
similar.
Step
Action
Note/Illustration
1.
Danger!
Danger!
Make sure that the main power has been switched
off!
252
2.
3.
4.
Remove the two locknuts and washers from the pins Shown in the figure Location
securing the board.
of SMB related equipment
on page 250!
5.
Gently disconnect the connectors from the SMB unit Connectors R1.SMB1-3,
when pulling the board out.
R1.SMB4-6 and R2.SMB
6.
4 Repair
4.6.2. Refitting of SMB related equipment
xx0100000138
SMB battery
SMB cover
SMB unit
Battery cable
Pins
Required equipment
Equipment, etc. Spare part no. Art. no.
SMB Unit
3HAC 16014-1
SMB Battery
3HAC 16831-1
Cable, battery/
SMB board
Note
Battery includes protection circuits.
Replace it only with given spare
part no. or an ABB approved
eqvivalent.
3HAC 13151-1
253
4 Repair
4.6.2. Refitting of SMB related equipment
Note
Standard toolkit
3HAC 15571-1
Circuit Diagram
Refitting, battery
The procedure below details how to refit the SMB battery.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
DANGER!
Follow these instruction to prevent the unit to be damaged from ESD:
Before handling, make sure you are grounded through a special ESD wrist bracelet or
similar.
Step
254
Action
Note/Illustration
1.
2.
3.
Detailed in chapter
Calibration information on
page 365.
4 Repair
4.6.2. Refitting of SMB related equipment
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
DANGER!
Follow these instruction to prevent the unit to be damaged from ESD:
Before handling, make sure you are grounded through a special ESD wrist bracelet or
similar.
Step
Action
Note/Illustration
1.
2.
Fit the SMB unit onto the pins and connect all
connectors to the board.
3.
Secure the SMB unit to the pins with two locknuts and
washers.
4.
5.
Secure the SMB cover with its attachment screws. Shown in the figure Location
If the brake release unit is located at the frame, the of SMB related equipment
push buttons must be checked as detailed below! The on page 253!
push button guard must first be removed!
6.
Warning!
Make sure the power is turned off and that the push
button guard is removed.
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.
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!
255
4 Repair
4.6.2. Refitting of SMB related equipment
Step
Action
Note/Illustration
7.
8.
Detailed in chapter
Calibration information on
page 365.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
256
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
4 Repair
4.6.3. Removal of brake release unit
xx0200000127
257
4 Repair
4.6.3. Removal of brake release unit
xx0200000226
Buttons
SMB cover
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
258
4 Repair
4.6.3. Removal of brake release unit
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Step
Action
Note/Illustration
1.
Danger!
Danger!
Make sure that the main power has been switched
off!
2.
3.
Unscrew the four attachment screws, brake release Shown in the figure Location
circuit on the outside of the base.
of brake release unit, base
on page 257!
4.
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
DANGER!
Follow these instruction to prevent the unit to be damaged from ESD:
Before handling, make sure you are grounded through a special ESD wrist bracelet or
similar.
259
4 Repair
4.6.3. Removal of brake release unit
Step
Action
Note/Illustration
1.
Danger!
Danger!
Make sure that the main power has been
switched off!
2.
Remove the push button guardfrom the Shown in the figure Location of brake
SMB cover.
release unit, frame on page 258.
The guard must be removed to ensure a
correct refitting of the brake release unit.
3.
Remove the SMB cover by unscrewing Shown in the figure Location of brake
the attachment screws.
release unit, frame on page 258.
Let the battery stay connected, to avoid
the need of synchronization of the robot!
4.
xx0200000129
5.
260
A: Connector X8
B: Connector X9
C: Connector X10
D: Push buttons for each axis
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 258!
screws, brake release unit.
4 Repair
4.6.4. Refitting of brake release unit
xx0200000127
261
4 Repair
4.6.4. Refitting of brake release unit
xx0200000226
Buttons
SMB cover
Required equipment
262
Equipment, etc.
Note
3HAC 14219-1
3HAC 12989-1
3HAC 16036-1
4 Repair
4.6.4. Refitting of brake release unit
Equipment, etc.
3HAC 2744-1
Standard toolkit
3HAC 15571-1
Note
The contents are defined
in section Standard toolkit
in the Product manual,
reference information.
These procedures include
references to the tools
required.
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Step
Action
Note/Illustration
1.
2.
3.
4.
263
4 Repair
4.6.4. Refitting of brake release unit
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
DANGER!
Follow these instruction to prevent the unit to be damaged from ESD:
Before handling, make sure you are grounded through a special ESD wrist bracelet or
similar.
Step
Action
Note/Illustration
1.
2.
xx0200000129
3.
264
A: Connector X8
B: Connector X9
C: Connector X10
D: Push buttons
4 Repair
4.6.4. Refitting of brake release unit
Step
Action
Note/Illustration
4.
Warning!
6.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
265
4 Repair
4.6.5. Removal of balancing device
xx0100000139
266
Balancing device
Bearing attachment
Rear cover
Balancing device front eye shaft, including securing screw and washer
Plug
4 Repair
4.6.5. Removal of balancing device
Required equipment
Equipment, etc
Art. no.
Note
3HAB 3409-90
M16 x 90
3HAC 14457-3
3HAC 12475-1
Hydraulic cylinder
3HAC 11731-1
Hydraulic pump
3HAC 13086-1
Securing screw
9ADA 183-66
3HAC 13120-5
Standard toolkit
3HAC 15571-1
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The balancing device weighs 300 kg! All lifting equipment used must be dimensioned
accordingly!
Step
1.
Action
Note/Illustration
267
4 Repair
4.6.5. Removal of balancing device
Step
2.
Action
Note/Illustration
xx0200000454
4.
Unload the balancing device with the press Detailed in section Unloading the
tool in order to make the piston rod and front balancing device on page 274
ear adjustable when pulling the shaft out.
Art. no. is specified in Required
equipment on page 267!
5.
6.
xx0300000060
8.
Secure the two bearing attachments to the Shown in the figure Location of
balancing device by replacing the plug on
balancing device on page 266!
the outside of each attachment, with a
M12 x 35
screw.
9.
Remove the two bearing attachments from Shown in the figure Location of
the frame by unscrewing their four
balancing device on page 266!
attachment screws.
Make sure the parallel pins are not
lost!
10. Fit two guide pins, through the upper holes Art. no. is specified in Required
of the bearing attachments, to the frame.
equipment on page 267!
11. Lift the balancing device gently backwards
to a secure area, allowing the bearing
attachments to slide on the guide pins.
268
4 Repair
4.6.6. Refitting of balancing device
xx0100000139
Balancing device
Bearing attachment
Rear cover
Balancing device front eye shaft, including securing screw and washer
Plug
269
4 Repair
4.6.6. Refitting of balancing device
Required equipment
Equipment
Note
Balancing device
3HAC 14214-1
O-ring, 2 pcs
3HAB 3772-44
3HAB 3409-90
M16 x 90
Securing screw
9ADA 183-66
Bearing grease
3HAB 3537-1
Grease
Locking liquid
Loctite 243.
To apply to the securing screw
in the shaft.
Grease pump
3HAC 13120-5
3HAC 14457-3
Hydraulic pump
3HAC 13086-1
Hydraulic cylinder
3HAC 11731-1
3HAC 15767-1
3HAC 17129-1
Standard toolkit
3HAC 15571-1
270
4 Repair
4.6.6. Refitting of balancing device
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
DANGER!
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
CAUTION!
The balancing device weighs 300 kg! All lifting equipment used must be dimensioned
accordingly!
Step
1.
Action
Secure the lower arm to the frame by inserting the
locking screw into the hole (1).
Note/Illustration
Shown in the figure Location
of balancing device on page
269!
xx0200000454
M12 x 35.
3.
4.
271
4 Repair
4.6.6. Refitting of balancing device
Step
Action
Note/Illustration
5.
6.
7.
8.
Secure the rear of the balancing device by fitting the Shown in the figure Location
two bearing attachments with their four attachment of balancing device on page
screws to the frame.
269!
4 pcs, M16x90; 12.9 quality
UNBRAKO, tightening
torque: 300 Nm 30 Nm.
Reused screws may be
used, providing they are
lubricated as detailed in
section Screw joints in the
Product manual, reference
information before fitting.
9.
272
Detailed in section
Unloading the balancing
device on page 274.
Art. no. is specified in
Required equipment on
page 270!
4 Repair
4.6.6. Refitting of balancing device
Step
Action
Note/Illustration
Danger!
Danger!
The rear cover of the balancing device must be
mounted before commissioning of the robot! The rear
cover is a safety device for the piston rod during
operation!
17. Remove the locking screw (1) that secures the lower
arm to the frame.
xx0200000454
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
273
4 Repair
4.6.7. Unloading the balancing device
xx0200000174
274
Press block
Hydraulic cylinder
Press device
Bolt (4 pcs)
4 Repair
4.6.7. Unloading the balancing device
Required equipment
Equipment, etc.
Art. no.
Note
Hydraulic cylinder
3HAC 11731-1
3HAC 13086-1
Standard toolkit
3HAC 15571-1
Balancing device
Press device
xx0300000605
xx0300000600
275
4 Repair
4.6.7. Unloading the balancing device
Action
Note/Illustration
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 275.
The moving pin is shown in the
figure Press tool and hydraulic
cylinder on page 274.
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 274.
device.
Note! Make sure the bolt is secured properly!
3.
xx0200000175
4.
5.
6.
7.
8.
9.
Turn the fix plate to position "Closed" in order See the figure Press tool and
to lock the tool in loaded condition.
hydraulic cylinder on page 274!
276
4 Repair
4.6.8. Restoring the balancing device
xx0200000174
Press block
Hydraulic cylinder
Press device
Bolt (4 pcs)
Required equipment
Equipment, etc.
Art. no.
Note
Hydraulic cylinder
3HAC 11731-1
3HAC 13086-1
277
4 Repair
4.6.8. Restoring the balancing device
Equipment, etc.
Art. no.
Note
Locking liquid
Loctite 577
Used to secure the attachment screws
of the rear cover at the end of the
balancing device.
Standard toolkit
3HAC 15571-1
Action
Note/Illustration
1.
Refit the hydraulic cylinder to the press tool, Shown in the figure Press tool and
in case it has been removed.
hydraulic cylinder on page 277!
2.
3.
4.
5.
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.
8.
9.
xx0200000175
278
4 Repair
4.6.8. Restoring the balancing device
Step
Action
Note/Illustration
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 commissioning of the robot!
279
4 Repair
4.7.1. Removal of motor, axis 1
4.7 Motors
4.7.1. Removal of motor, axis 1
Location of motor
The motor axis 1 is located on the left hand side of the manipulator as shown in the figure
below:
xx0100000123
Motor, axis 1
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
3HAC 14459-1
Power supply
Extension, 300 mm for bits 1/2"
280
24 VDC, 1.5 A.
For releasing the brakes.
3HAC 12342-1
4 Repair
4.7.1. Removal of motor, axis 1
Equipment, etc.
Art. no.
Note
3HAC 14973-1
Circuit Diagram
Removal, motor
The procedure below details how to remove motor, axis 1.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
CAUTION!
The motor weighs 32 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
Remove the Cover for connector access on top of Shown in the figure Location
the motor by unscrewing its four attachment screws. of motor on page 280!
2.
xx0200000199
4.
281
4 Repair
4.7.1. Removal of motor, axis 1
Step
282
Action
Note/Illustration
5.
Connect to connector
R2.MP1
+: pin 2
-: pin 5
6.
Remove the motor by unscrewing its four attachment Art. no. is specified in
screws and plain washers.
Required equipment on
page 280!
If required, use the Extension 300mm for bits 1/2.
7.
8.
Lift the motor to get the pinion away from the gear and
disconnect the brake release voltage.
9.
4 Repair
4.7.2. Refitting of motor, axis 1
xx0100000123
Motor, axis 1
Required equipment
Equipment, etc.
Note
Motor, axis 1
3HAC 14207-1
O-ring
2152 2012-430
Grease
3HAB 3537-1
283
4 Repair
4.7.2. Refitting of motor, axis 1
Equipment, etc.
Standard toolkit
3HAC 15571-1
3HAC 14459-1
Extension, 300 mm
for bits 1/2"
3HAC 12342-1
Note
The contents are defined in
section Standard toolkit in the
Product manual, reference
information.
Power supply
Circuit Diagram
Calibration Pendulum
Instruction
Refitting, motor
The procedure below details how to refit motor, axis 1.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
CAUTION!
The motor weighs 32 kg! All lifting equipment used must be dimensioned accordingly!
Step
284
Action
Note/Illustration
1.
2.
4 Repair
4.7.2. Refitting of motor, axis 1
Step
Action
Note/Illustration
3.
Connect to connector
R2.MP1
+: pin 2
-: pin 5
4.
Fit the motor, making sure the motor pinion is properly Make sure the motor is
mated to gearbox 1.
turned the right way, i.e.
connections forwards.
Make sure the motor pinion
does not get damaged!
5.
6.
7.
8.
Refit the cable gland cover at the cable exit with its
two attachment screws.
9.
Detailed in section
Performing a leak-down test
on page 196.
Calibration is detailed in
separate calibration
manuals.
Art. no. for the manuals are
specified in section
Document references in the
Product manual, reference
information.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
285
4 Repair
4.7.3. Removal of motor, axis 2
xx0100000124
Motor, axis 2
Required equipment
286
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
3HAC 15534-1
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
Lock screw
M16 x 60 8.8.
For securing the lower arm.
3HAC 12342-1
3HAC 14973-1
3HAC 15521-1
3HAC 15521-2
4 Repair
4.7.3. Removal of motor, axis 2
Equipment, etc.
Art. no.
Note
Circuit Diagram
Removal, motor
The procedure below details how to remove the motor, axis 2.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
CAUTION!
The motor weighs 32 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
Run the manipulator to a position close enough to its Calibration positions are
calibration position, to allow the lock screw to be
shown in chapter Calibration
inserted into the lock screw hole .
information on page 365.
Shown in the figure Location
of motor on page 286!
Dimension is specified in
Required equipment on
page 286!
2.
3.
4.
5.
287
4 Repair
4.7.3. Removal of motor, axis 2
Step
Action
Note/Illustration
6.
7.
8.
9.
Fit the two guide pins in two of the motor attachment Art. no. is specified in
holes.
Required equipment on
page 286!
Connect to connector
R2.MP2
+: pin 2
-: pin 5
12. Lift the motor to get the pinion away from the gear and
disconnect the brake release voltage.
13. Remove the motor by gently lifting it straight out.
288
4 Repair
4.7.4. Refitting of motor, axis 2
xx0100000124
Motor, axis 2
Required equipment
Equipment, etc.
Note
Motor, axis 2
3HAC 14209-1
O-ring
2152 2012-430
Grease
3HAB 3537-1
Standard toolkit
3HAC 15571-1
3HAC 15521-1
3HAC 15521-2
289
4 Repair
4.7.4. Refitting of motor, axis 2
Equipment, etc.
Note
3HAC 15534-1
3HAC 12342-1
Power supply
Rotation tool, motor
24 VDC, 1.5 A.
For releasing the brakes.
3HAC 17105-1
Circuit Diagram
Calibration Pendulum
Instruction
Refitting, motor
The procedure below details how to refit motor, axis 2.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
CAUTION!
The motor weighs 32 kg! All lifting equipment used must be dimensioned accordingly!
Step
290
Action
Note/Illustration
1.
Make sure the o-ring on the circumference Art no. is specified in Required
of the motor is seated properly. Lightly
equipment on page 289!
lubricate the o-ring with grease .
2.
Fit the Lifting tool, motor axis 2, 3, 4 to the Art no. is specified in Required
motor.
equipment on page 289!
4 Repair
4.7.4. Refitting of motor, axis 2
Step
Action
Note/Illustration
3.
4.
5.
Fit the motor, with guidance from the guide Make sure the motor pinion does not
pins, making sure the motor pinion is
get damaged!
properly mated to the gear of gearbox 2.
Make sure the motor is turned the right
direction, i.e. the cables facing
downwards.
6.
If necessary, use the rotation tool in order to Art no. is specified in Required
rotate the motor pinion when mating it to the equipment on page 289!
gear!
xx0200000165
8.
9.
11. Refit the cable gland cover at the cable exit Make sure the cover is tightly sealed!
with its two attachment screws.
Shown in the figure Location of motor
on page 289!
12. Refit the cover on top of the motor with its
four attachment screws.
13. Remove the lock screw from the lock screw Shown in the figure Location of motor
hole .
on page 289!
14. Perform a leak-down test.
291
4 Repair
4.7.4. Refitting of motor, axis 2
Step
Action
Note/Illustration
Calibration is detailed in separate
calibration manuals.
Art. no. for the manuals are specified
in section Document references in the
Product manual, reference
information.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
292
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
4 Repair
4.7.5. Removal of motor, axis 3
xx0100000125
Motor, axis 3
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
3HAC 15534-1
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
3HAC 14973-1
3HAC 15521-1
3HAC 15521-2
3HAC 12708-2
3HAA 1001-186
293
4 Repair
4.7.5. Removal of motor, axis 3
Equipment, etc.
Art. no.
Note
Circuit Diagram
Removal, motor
The procedure below details how to remove motor, axis 3.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
CAUTION!
The motor weighs 32 kg! All lifting equipment used must be dimensioned accordingly!
Step
294
Action
Note/Illustration
1.
2.
3.
4.
4 Repair
4.7.5. Removal of motor, axis 3
Step
Action
Note/Illustration
5.
6.
7.
8.
9.
11. Apply the Lifting tool, motor axis 2, 3, 4 to the Art. no. is specified in Required
motor.
equipment on page 293!
12. Lift the motor to get the pinion away from the
gear and disconnect the brake release
voltage.
13. Remove the motor by gently lifting it straight
out.
295
4 Repair
4.7.6. Refitting of motor, axis 3
xx0100000125
Motor, axis 3
Required equipment
296
Equipment, etc.
Note
Motor, axis 3
3HAC 14209-1
O-ring
2152 2012-430
Grease
3HAB 3537-1
Standard toolkit
3HAC 15571-1
3HAC 15521-1
3HAC 15521-2
3HAC 15534-1
4 Repair
4.7.6. Refitting of motor, axis 3
Equipment, etc.
Extension 300 mm for bits
1/2"
Note
3HAC 12342-1
Power supply
Rotation tool, motor
Circuit Diagram
Calibration Pendulum
Instruction
Refitting, motor
The procedure below details how to refit motor, axis 3.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever mating motor and gearbox, misalignment of the gears may severely damage them.
Avoid this risk:
Turn the gears of the gearbox to the correct position using the gearbox crank. The part
number is specified in the table above!
CAUTION!
The motor weighs 32 kg! All lifting equipment used must be dimensioned accordingly!
Step
1.
Action
Note/Illustration
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 296!
the o-ring with grease .
297
4 Repair
4.7.6. Refitting of motor, axis 3
Step
Action
Note/Illustration
2.
3.
4.
5.
6.
xx0200000165
8.
Secure the motor with four attachment screws M10 x 40, tightening torque: 50 Nm.
and plain washers.
Art. no. is specified in Required
If required, use the Extension 300mm for bits equipment on page 296.
1/2.
9.
12. Refit the cover on top of the motor with its four Make sure the cover is tightly
attachment screws.
sealed!
298
4 Repair
4.7.6. Refitting of motor, axis 3
Step
Action
Note/Illustration
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
299
4 Repair
4.7.7. Removal of motor, axis 4
xx0100000126
Motor, axis 4
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
3HAC 15534-1
3HAC 14459-1
Power supply
300
24 VDC, 1.5 A.
For releasing the brakes.
3HAC 12342-1
3HAC 14973-1
3HAC 15521-1
3HAC 15521-2
Circuit Diagram
4 Repair
4.7.7. Removal of motor, axis 4
Removal, motor
The procedure below details how to remove motor, axis 4.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
CAUTION!
The motor weighs 22 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
2.
3.
4.
5.
6.
7.
301
4 Repair
4.7.7. Removal of motor, axis 4
Step
Action
8.
9.
Note/Illustration
11. Lift the motor to get the pinion away from the gear and
disconnect the brake release voltage.
12. Remove the motor by gently lifting it straight out.
302
4 Repair
4.7.8. Refitting of motor, axis 4
xx0100000126
Motor, axis 4
Required equipment
Equipment, etc.
Motor, axis 4
3HAC 14210-1
Art. no.
Note
Includes motor 3HAC
17484-2.
Includes pinion 3HAC
10122-17.
Includes o-ring 2152
2012-430.
O-ring
2152 2012-430
Must be replaced
when replacing motor!
Grease
3HAC 3537-1
Standard toolkit
3HAC 15571-1
3HAC 15534-1
To be used when
lifting when the motor
is in a horizontal
position.
303
4 Repair
4.7.8. Refitting of motor, axis 4
Equipment, etc.
Art. no.
Note
3HAC 14459-1
To be used when
lifting when the motor
is in a vertical position.
3HAC 15521-1
3HAC 15521-2
Power supply
304
3HAC 17105-1
3HAC 12342-1
These procedures
include references to
the tools required.
Circuit Diagram
Calibration Pendulum
Instruction
4 Repair
4.7.8. Refitting of motor, axis 4
Refitting, motor
The procedure below details how to refit motor, axis 4.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
CAUTION!
The motor weighs 22 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
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 303!
the o-ring with grease .
2.
3.
4.
5.
Fit the motor, with guidance of the pins, making Make sure the motor pinion does
sure the motor pinion is properly mated to the not get damaged!
gear of gearbox 4.
Make sure the motor is turned the
right direction, i.e. the cables facing
downwards.
305
4 Repair
4.7.8. Refitting of motor, axis 4
Step
6.
Action
Note/Illustration
xx0200000165
8.
Secure the motor with four attachment screws M10 x 80, tightening torque: 50 Nm.
and plain washers.
Art. no. is specified in Required
If required, use the "Extension 300mm for bits equipment on page 303!
1/2".
9.
12. Refit the cover on top of the motor with its four Make sure the cover is tightly
attachment screws.
sealed!
13. Remove the equipment used to unload the
upper arm:
Run the manipulator to a normal
position.
Fork lift.
Lifting slings.
306
4 Repair
4.7.8. Refitting of motor, axis 4
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
307
4 Repair
4.7.9. Removal of motor, axis 5
xx0100000127
Motor, axis 5
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
3HAC 14459-1
Power supply
308
24 VDC, 1.5 A.
For releasing the brakes.
3HAC 12342-1
3HAC 14973-1
3HAC 15521-1
3HAC 15521-2
Circuit Diagram
4 Repair
4.7.9. Removal of motor, axis 5
Removal, motor
The procedure below details how to remove motor, axis 5.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
CAUTION!
The motor weighs 22 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
2.
3.
Remove the heat protection plate by unscrewing its Shown in the figure Location
two attachment screws.
of motor on page 308!
4.
5.
6.
7.
8.
Remove the motor by unscrewing its four attachment Art. no. is specified in
screws and plain washers.
Required equipment on
page 308!
If required, use the Extension 300 mm for bits 1/2.
9.
Apply the lifting tool, motor axis 1, 4, 5 to the motor Art. no. is specified in
for a vertical lift.
Required equipment on
page 308!
10. Fit the two guide pins in two of the motor attachment Art. no. is specified in
screw holes.
Required equipment on
page 308!
309
4 Repair
4.7.9. Removal of motor, axis 5
Step
Action
Note/Illustration
Art. no. is specified in
Required equipment on
page 308!
Always use the removal
tools in pairs and diagonally!
12. Lift the motor to get the pinion away from the gear and
disconnect the brake release voltage.
13. Remove the motor by gently lifting it straight out.
310
4 Repair
4.7.10. Refitting of motor, axis 5
xx0100000127
Motor, axis 5
Required equipment
Equipment, etc.
Note
Motor, axis 5
3HAC 14725-1
O-ring
2152 2012-430
Grease
3HAC 3537-1
Standard toolkit
3HAC 15571-1
3HAC 15521-1
3HAC 15521-2
3HAC 14459-1
311
4 Repair
4.7.10. Refitting of motor, axis 5
Equipment, etc.
Note
3HAC 12342-1
Power supply
Rotation tool, motor
24 VDC, 1.5 A.
For releasing the brakes.
3HAC 17105-1
Calibration Pendulum
Instruction
Calibration Pendulum
Instruction
Refitting, motor
The procedure below details how to refit motor, axis 5.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
CAUTION!
The motor weighs 22 kg! All lifting equipment used must be dimensioned accordingly!
Step
312
Action
Note/Illustration
1.
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 311!
the o-ring with grease .
2.
4 Repair
4.7.10. Refitting of motor, axis 5
Step
Action
Note/Illustration
3.
4.
5.
6.
If necessary, use the rotation tool in order to Art. no. is specified in Required
rotate the motor pinion when mating it to the equipment on page 311!
gear!
xx0200000165
8.
9.
10. Refit the cable gland cover at the cable exit Shown in the figure Location of motor
with its two attachment screws.
on page 311!
11. Refit the cover on top of the motor with its
four attachment screws.
313
4 Repair
4.7.10. Refitting of motor, axis 5
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
314
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
4 Repair
4.7.11. Removal of motor, axis 6
xx0100000128
Motor, axis 6
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
Power supply
24 VDC, 1.5 A.
For releasing the brakes.
3HAC 14972-1
3HAC 12342-1
Circuit Diagram
315
4 Repair
4.7.11. Removal of motor, axis 6
Removal, motor
The procedure below details how to remove motor, axis 6.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
Step
316
Action
Note/Illustration
1.
2.
In horizontal position: drain the oil from gearbox, axis Detailed in section Oil
6.
change, gearbox axis 6 on
page 174.
3.
4.
5.
6.
Remove the motor by unscrewing its four attachment Art. no. is specified in
screws and plain washers.
Required equipment on
If required, use the "Extension 300mm for bits 1/2". page 315!
7.
8.
Lift the motor to get the pinion away from the gear and
disconnect the brake release voltage.
9.
Connect to connector
R3.MP6
+: pin 2
-: pin 5
4 Repair
4.7.12. Refitting of motor, axis 6
xx0100000128
Motor, axis 6
Required equipment
Equipment, etc.
Note
Motor, axis 6
3HAC 14211-1
O-ring
2152 2012-430
Must be replaced
when replacing motor!
Standard toolkit
3HAC 15571-1
3HAC 15520-1
317
4 Repair
4.7.12. Refitting of motor, axis 6
Equipment, etc.
Note
3HAC 15520-2
3HAC 12342-1
Power supply
Grease
3HAB 3537-1
These procedures
include references to
the tools required.
Circuit Diagram
Calibration Pendulum
Instruction
Refitting, motor
The procedure below details how to refit motor, axis 6.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
Step
318
Action
Note/Illustration
1.
2.
Connect to connector
R3.MP6
+: pin 2
-: pin 5
3.
Fit the two guide pins in two of the motor attachment Art. no. is specified in
holes.
Required equipment on
page 317!
4 Repair
4.7.12. Refitting of motor, axis 6
Step
Action
Note/Illustration
4.
5.
6.
7.
8.
9.
Detailed in section
Performing a leak-down test
on page 196.
Calibration is detailed in
separate calibration
manuals.
Art. no. for the manuals are
specified in section
Document references in the
Product manual, reference
information.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
319
4 Repair
4.8.1. Replacement of gearbox, axis 1
4.8 Gearboxes
4.8.1. 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 in the Product manual, reference information.
xx0100000133
320
Gearbox, axis 1
Frame
Base
4 Repair
4.8.1. Replacement of gearbox, axis 1
Required equipment
Equipment, etc.
Gearbox axis 1
Note
Includes:
gearbox
all o-rings and sealing
rings
O-ring
3HAB 3772-54
O-ring
3HAB 3772-55
Sealing ring
3HAC 11581-4
Grease
3HAC 3537-1
Support, base
3HAC 15535-1
3HAC 15560-1
3HAC 15556-1
Standard toolkit
3HAC 15571-1
Action
Note/Illustration
1.
Danger!
Turn off all electric power, hydraulic
and pneumatic pressure supplies to
the robot!
321
4 Repair
4.8.1. Replacement of gearbox, axis 1
Step
2.
Action
Note/Illustration
xx0300000022
3.
4.
5.
6.
7.
8.
9.
Caution!
The base (without gearbox 1) weighs
310 kg! All lifting equipment used must
be dimensioned accordingly!
10. Lift the manipulator base to allow
fitting the support, base and gear 1
on each sides of the base.
322
4 Repair
4.8.1. Replacement of gearbox, axis 1
Step
Action
Note/Illustration
xx0300000612
A: Bottom plate
B: Rear connector plate
C: Attachment screw
D: Groove
xx0200000227
xx0200000256
323
4 Repair
4.8.1. Replacement of gearbox, axis 1
Step
Action
Note/Illustration
15.
Caution!
The gearbox weighs 200 kg! All lifting
equipment used must be dimensioned
accordingly!
16. Lift the gearbox away with the already
mounted lifting tools.
Action
Note/Illustration
1.
Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.
If the base is not supported with support, Mounting of the support, base and gear
base and gear 1, this should be done first. 1 is detailed in section Removal,
gearbox axis 1 on page 321.
3.
xx0200000055
324
A: Guide pin
C: O-ring 3HAB 3772-54
D: O-ring 3HAB 3772-55
E: Sealing ring 3HAC 11581-4
4 Repair
4.8.1. Replacement of gearbox, axis 1
Step
4.
Action
Note/Illustration
xx0200000256
5.
Fit the lifting device, base and the lifting Art no. is specified in Required
tool (chain) to the gearbox.
equipment on page 321!
6.
Caution!
The gearbox weighs 200 kg! All lifting
equipment used must be dimensioned
accordingly!
7.
8.
Make sure the guide pin in the bottom face Shown in the figure xx0200000055
of the gearbox is properly aligned with the above!
base.
9.
Secure the gearbox and the three washers 18 pcs, M16 x 90, 12.9 quality
with the 18 attachment screws, gearbox UNBRAKO, tightening torque: 300 Nm.
axis 1 .
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints in the Product manual,
reference information before fitting.
xx0200000227
325
4 Repair
4.8.1. Replacement of gearbox, axis 1
Step
Action
Note/Illustration
1 screw: M6 x 8.
xx0300000612
A: Bottom plate
B: Rear connector plate
C: Attachment screw
D: Groove
11.
Caution!
The base (without gearbox 1) weighs 310
kg! All lifting equipment used must be
dimensioned accordingly!
12. Lift the manipulator base and gearbox 1 to
allow removing the support, base and
gear.
13. Secure the base to the mounting site.
326
4 Repair
4.8.1. Replacement of gearbox, axis 1
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
327
4 Repair
4.8.2. Removal of gearbox, axis 2
xx0100000135
328
Motor, axis 2
Motor attachment
4 Repair
4.8.2. Removal of gearbox, axis 2
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
3HAC 12731-1
3HAC 13660-1
M16 x 60 8.8.
Included in the fixture, lower arm.
3HAC 13120-5
Removal, gearbox
The procedure below details how to remove gearbox, axis 2.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
CAUTION!
The gearbox weighs 125 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
1.
2.
Note/Illustration
xx0200000260
329
4 Repair
4.8.2. Removal of gearbox, axis 2
Step
Action
Note/Illustration
3.
4.
5.
xx0200000261
6.
7.
8.
9.
xx0300000064
330
4 Repair
4.8.2. Removal of gearbox, axis 2
Step
Action
Note/Illustration
Shown in the figure Location of
gearbox on page 328!
11. 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
equipment on page 329!
tool.
Remove the motor attachment.
12. Fit the Lifting tool, gearbox axis 2 , to the
gearbox.
13. Fit two guide pins in 180 relation to each other Art. no. is specified in Required
instead of the removed front attachment screws. equipment on page 329!
14. If required, apply an M16 screw to the hole
shown in the figure to press it free.
xx0200000033
331
4 Repair
4.8.3. Refitting of gearbox, axis 2
xx0100000135
332
Motor, axis 2
Motor attachment
4 Repair
4.8.3. Refitting of gearbox, axis 2
Required equipment
Equipment, etc.
Note
Gearbox, axis 2
3HAC 12641-1
O-ring
3HAB 3772-51
3HAC 17213-1
Grease
3HAB 3537-1
Standard toolkit
3HAC 15571-1
3HAC 12731-1
3HAC 13120-2
3HAC 13120-3
3HAC 14627-2
80 mm.
For guiding "Sealing, axis
2/3".
Guide are to be used in
pairs.
3HAC 14627-3
100 mm.
For guiding "Sealing, axis
2/3".
Guide are to be used in
pairs.
These procedures
include references to the
tools required.
Calibration Pendulum
Instruction
333
4 Repair
4.8.3. Refitting of gearbox, axis 2
Refitting, gearbox
The procedure below details how to refit gearbox, axis 2.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
CAUTION!
The gearbox weighs 125 kg! All lifting equipment used must be dimensioned accordingly!
Step
1.
Action
Note/Illustration
xx0200000125
334
2.
3.
4.
4 Repair
4.8.3. Refitting of gearbox, axis 2
Step
5.
Action
Note/Illustration
Make sure the o-ring is fitted to the Art. no. is specified in Required equipment on
rear of the gearbox. Lightly grease page 333!
the o-ring.
xx0100000136
6.
7.
8.
9.
xx0300000064
335
4 Repair
4.8.3. Refitting of gearbox, axis 2
Step
Action
Note/Illustration
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
336
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
4 Repair
4.8.4. Removal of gearbox, axis 3
xx0100000137
Gearbox, axis 3
Motor, axis 3
337
4 Repair
4.8.4. Removal of gearbox, axis 3
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
3HAC 14457-4
3HAC 12708-2
3HAA 1001-186
Removal, gearbox
The procedure below details how to remove gearbox, axis 3.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
CAUTION!
The gearbox weighs 125 kg! All lifting equipment used must be dimensioned accordingly!
Step
1.
Action
Note/Illustration
xx0300000051
338
4 Repair
4.8.4. Removal of gearbox, axis 3
Step
Action
Note/Illustration
2.
3.
4.
5.
6.
7.
xx0200000033
8.
9.
339
4 Repair
4.8.5. Refitting of gearbox, axis 3
xx0100000137
340
Gearbox, axis 3
Motor, axis 3
4 Repair
4.8.5. Refitting of gearbox, axis 3
Required equipment
Equipment, etc.
Spare part
no.
Gearbox, axis 3
3HAC 12641-1
Art. no.
Note
Includes gearbox 3HAC
10122-21.
Includes all o-rings!
Does not include "Sealing, axis
2/3"!
3HAC 17213-1
O-ring
3HAB 3772-51
Grease
3HAB 3537-1
Standard toolkit
3HAC 15571-1
3HAC 14457-4
3HAC 13120-4
3HAC 13120-5
3HAC 14627-2
80 mm.
For guiding "Sealing, axis 2/3".
Guide are to be used in pairs.
3HAC 14627-3
100 mm.
For guiding "Sealing, axis 2/3".
Guide are to be used in pairs.
Calibration Pendulum
Instruction
341
4 Repair
4.8.5. Refitting of gearbox, axis 3
Refitting, gearbox
The procedure below details how to refit gearbox, axis 2.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
CAUTION!
The gearbox weighs 125 kg! All lifting equipment used must be dimensioned accordingly!
Step
Action
Note/Illustration
1.
2.
3.
4.
xx0100000136
342
5.
6.
4 Repair
4.8.5. Refitting of gearbox, axis 3
Step
Action
Note/Illustration
7.
Fit the gearbox onto the guide pins and slide Make sure the gearbox and o-ring are
it into position.
seated properly and correctly
oriented!
8.
9.
10. Refit the upper arm with a new sealing, axis Detailed in section Refitting of
2/3 .
complete upper arm on page 233.
Art. no. is specified in Required
equipment on page 341!
11. Refit the motor.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
343
4 Repair
4.8.6. Removal of gearbox, axis 4
xx0100000144
344
Gearbox, axis 4
Gear, Z3
Motor, axis 4
Motor flange
4 Repair
4.8.6. Removal of gearbox, axis 4
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
Removal, gearbox
The procedure below details how to remove gearbox, axis 4.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
Step
Action
Note/Illustration
1.
2.
Drain the gearbox oil from the secondary gearbox Detailed in section Oil change,
through the oil plug, draining.
gearbox, axis 4 on page 166.
3.
4.
5.
6.
7.
8.
9.
M10.
345
4 Repair
4.8.7. Refitting of gearbox, axis 4
xx0100000144
346
Gearbox, axis 4
Gear, Z3
Motor, axis 4
Motor flange
4 Repair
4.8.7. Refitting of gearbox, axis 4
Required equipment
Equipment, etc
Note
Gearbox, axis 4
3HAC 11384-3
Gear, Z3
3HAC 11488-1
O-ring
3HAB 3772-49
O-ring
3HAB 3772-50
Friction washer
3HAC 10122-27
Must be replaced at
assembly!
2 pcs needed at
assembly!
3HAC 11423-3
Grease
3HAB 3537-1
For lubrication of
gearbox, motor and
motor attachment
mating surfaces.
Standard toolkit
3HAC 15571-1
3HAC 15521-1
3HAC 15521-2
These procedures
include references to
the tools required.
Calibration Pendulum
Instruction
347
4 Repair
4.8.7. Refitting of gearbox, axis 4
Refitting, gearbox
The procedure below details how to refit gearbox, axis 4.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Step
Action
Note/Illustration
1.
2.
3.
xx0200000067
348
4.
5.
Push in the gearbox, axis 4, and the motor Shown in the figure Location of gearbox
flange .
on page 346!
If necessary, use screws in the attachment Note! Make sure the motor flange is
holes to press in the motor flange.
oriented correctly by observing the oil
plugs as shown in the figure Location of
gearbox on page 346!
6.
Secure the motor flange to the upper arm 18 pcs: M10 x 40; tightening torque: 65
housing with 16 of the 18 washers and
Nm.
attachment screws.
Secure with locking liquid.
4 Repair
4.8.7. Refitting of gearbox, axis 4
Step
Action
Note/Illustration
7.
8.
9.
Refit gear Z3 to the gearbox with its gear Art. no. is specified in Required
attachment screws .
equipment on page 347!
Shown in the figure Location of gearbox
on page 346!
9 pcs: M12 x 50; tightening torque: 115
Nm.
6 pcs: M16 x 60: tightening torque: 300
Nm.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
349
4 Repair
4.8.8. Removal of gearbox, axis 5
xx0100000146
350
Wrist housing
Gear, Z3
Wheel unit
Gearbox, axis 5
4 Repair
4.8.8. Removal of gearbox, axis 5
Oil plug, primary, filling (draining plug on the opposite side of the wrist
housing, not shown in figure)
VK-cover
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
3HAC 14457-3
2 pcs required!
For lifting the gearbox.
3HAC 15814-1
Removal, gearbox
The procedure below details how to remove gearbox, axis 5.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Step
Action
Note/Illustration
1.
2.
3.
4.
5.
6.
351
4 Repair
4.8.8. Removal of gearbox, axis 5
Step
Action
Note/Illustration
7.
8.
9.
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Step
352
Action
Note/Illustration
1.
2.
3.
Make a short cut in the centre of the VKcoverand remove it from the wheel unit by
bending.
4.
4 Repair
4.8.8. Removal of gearbox, axis 5
Step
5.
Action
Note/Illustration
xx0200000068
A: Gear Z4
B: Surface beneath VKcover
C: VK-cover
D: Attachment screws, gear
Z4, 21 pcs: M16
E: Attachment screws,
bearing washer, 7 pcs: M6
6.
Apply removal tool to the center hole of gear Art. no. is specified in Required
Z4 to press the wheel unit free.
equipment on page 351!
7.
353
4 Repair
4.8.9. Refitting of gearbox, axis 5
xx0100000146
354
Wrist housing
Gear, Z3
Wheel unit
Gearbox, axis 5
4 Repair
4.8.9. Refitting of gearbox, axis 5
Oil plug, primary, filling (draining plug on the opposite side of the wrist
housing, not shown in figure)
VK-cover
Required equipment
Equipment, etc.
Note
Gearbox, axis 5
3HAC 11384-3
Includes:
gearbox 3HAC
11384-1
all o-rings.
O-ring
3HAB 3772-49
O-ring
3HAB 3772-50
Friction washer
3HAC 10122-27
Must be replaced at
assembly!
2 pcs needed at assembly!
Gear, Z3
3HAC 11488-1
VK-cover, 170 x 15
3HAA 2166-24
Gasket, cover
3HAC 11409-5
Grease
3HAC 3537-1
Locking liquid
3HAB 7116-1
Loctite 243
Isopropanol
1177 1012-208
Standard toolkit
3HAC 15571-1
3HAC 14457-3
2 pcs required!
For lifting the gearbox.
3HAC 15814-1
M12.
For lifting the wheel unit.
3HAC 15521-1
3HAC 15521-2
Must be replaced!
Calibration Pendulum
Instruction
355
4 Repair
4.8.9. Refitting of gearbox, axis 5
Refitting, gearbox
The procedure below details how to refit gearbox, axis 5.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
Step
356
Action
Note/Illustration
1.
2.
3.
4.
Apply two lifting eyes to the gearbox, axis Art. no. is specified in Required
5 , in opposite positions.
equipment on page 355!
Shown in the figure Location of gearbox
on page 354!
5.
6.
7.
8.
Refit gear Z3 to the gearbox, axis 5 with Shown in the figure Location of gearbox
its attachment screws.
on page 354!
9 pcs: M12 x 50; 12.9 quality
UNBRAKO, tightening torque: 115 Nm.
6 pcs: M16 x 60: tightening torque: 300
Nm.
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints in the Product manual,
reference information before fitting.
4 Repair
4.8.9. Refitting of gearbox, axis 5
Step
9.
Action
Refit wheel unit.
Note/Illustration
Detailed below in Refitting, wheel unit
on page 357.
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Step
Action
Note/Illustration
1.
2.
3.
Apply removal tool to the center hole of Art. no. is specified in Required
the gear Z4.
equipment on page 355!
4.
357
4 Repair
4.8.9. Refitting of gearbox, axis 5
Step
Action
Note/Illustration
5.
6.
xx0200000068
A: Gear Z4
B: Surface beneath VK-cover
C: VK-cover
D: Attachment screws, gear Z4
E: Attachment screws, bearing
washer
7 pcs: M6 x 16; tightening torque 10 Nm.
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints in the Product manual,
reference information before fitting.
Art. no. is specified in Required
equipment on page 355!
358
7.
8.
9.
4 Repair
4.8.9. Refitting of gearbox, axis 5
Step
Action
Note/Illustration
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
359
4 Repair
4.8.10. Removal of gearbox, axis 6
xx0100000131
Gearbox, axis 6
Washers
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
3HAC 14972-1
360
4 Repair
4.8.10. Removal of gearbox, axis 6
Removal, gearbox
The procedure below details how to remove gearbox, axis 6.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is
used!
Step
Action
Note/Illustration
1.
2.
3.
4.
xx0200000032
361
4 Repair
4.8.11. Refitting of gearbox, axis 6
xx0100000131
Gearbox, axis 6
Washers
Required equipment
362
Equipment, etc.
Note
Gearbox, axis 6
3HAC 10122-22
Washers
O-ring
3HAB 3772-49
4 Repair
4.8.11. Refitting of gearbox, axis 6
Equipment, etc.
Note
Grease
3HAB 3537-1
Standard toolkit
3HAC 15571-1
These procedures
include references to the
tools required.
Calibration Pendulum
Instruction
Refitting, gearbox
The procedure below details how to refit gearbox, axis 6.
WARNING!
Please observe the following before commencing any repair work on the manipulator:
Motors and gears are HOT after running the robot! Touching the motors and gears may
result in burns!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Take any necessary measures to ensure that the manipulator does not collapse as parts
are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
Step
1.
Action
Note/Illustration
Make sure the o-ring is fitted to the rear of the Art. no. is specified in Required
gearbox. Lightly lubricate the o-ring with
equipment on page 362!
grease.
xx0100000132
363
4 Repair
4.8.11. Refitting of gearbox, axis 6
Step
Action
Note/Illustration
2.
3.
Fit the washers and secure the washers and Shown in the figure Location of
gearbox with the attachment screws.
gearbox on page 362!
18 pcs: M10 x 50; 12.9 quality
UNBRAKO, tightening torque: 65
Nm.
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints in
the Product manual, reference
information before fitting.
4.
5.
6.
7.
DANGER!
When performing the first test run after a service activity (repair, installation or maintenance,
it is vital that:
364
all the service tools and other foreign objects are removed from the manipulator!
all normal safety equipment is installed properly, e.g. TPU enabling device.
all personnel are standing at a safe distance from the manipulator, i.e. out of its reach
behind any safety fences, etc.
5 Calibration information
5.1. Introduction
5 Calibration information
5.1. Introduction
General
This chapter includes general information about different calibration methods and details also
procedures that does not require specific calibration equipment.
When the robot system must be recalibrated, it is done according to documentation enclosed
with the calibration tools.
When to calibrate
The system must be calibrated if any of the below occurs.
The resolver values are changed
If resolver values are changed, the robot must be recalibrated using the calibration methods
supplied from ABB. Calibrate the robot carefully with standard calibration. The different
methods are briefly described in section Calibration methods on page 366, and further
detailed in separate Calibration manuals.
If the robot has Absolute Accuracy calibration, it is also recommended but not always needed
to be calibrated for new Absolute Accuracy.
The resolver values will change when parts affecting the calibration position are replaced on
the robot, e.g. motors, wrist or part of transmission.
Contents of the revolution counter memory are lost
If the contents of the revolution counter memory are lost, the counters must be updated as
detailed in section Updating revolution counters on page 370. This will occur when:
The revolution counters must also be updated after the robot and controller are connected at
the first installation.
The robot is rebuilt
If the robot has been rebuilt, e.g. after a crash or when the robot has been changed for other
reachability, it needs to be recalibrated for new resolver values.
If the robot has Absolute Accuracy calibration, it needs to be calibrated for new Absolute
Accuracy.
References
The article numbers for the Calibration manuals are listed in section Document references in
the Product manual (part 2 of 2), reference information. Article numbers for the calibration
tools are also listed in part 2 of the Product manual.
365
5 Calibration information
5.2. Calibration methods
Description
Calibration method
Standard
calibration
Calibration Pendulum
(standard method)
or
Levelmeter calibration
(alternative method)
Absolute Accuracy
calibration
(optional)
xx0400001197
366
5 Calibration information
5.2. Calibration methods
Calibration methods
Each calibration method is detailed in separate manuals. Below is a brief description of the
methods available.
Calibration Pendulum - standard method
Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB
6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the
standard type of calibration. It is the recommended method in order to achieve proper
performance.
The calibration equipment for Calibration Pendulum is delivered as a complete toolkit,
including the manual Calibration Pendulum Instruction.
Levelmeter Calibration - alternative method
Levelmeter Calibration is referred to as the alternative method for calibration of ABB robots,
because of the less accurate values obtained during calibration. The method uses the same
principles as Calibration Pendulum but has not as good mechanical tolerances to the toolkit
parts as the standard method with Calibration Pendulum.
This method may, after calibration, require modifications in the robot program, and is
therefore not recommended.
The calibration equipment for Levelmeter Calibration is ordered as separate parts for each
robot and the manual Instruction for Levelmeter Calibration is enclosed with the Levelmeter
2000.
CalibWare - Absolute Accuracy calibration
In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy
is used as a TCP calibration. The tool CalibWare guides through the calibration process and
calculates new compensation parameters. This is detailed further in the manual xx.
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.
367
5 Calibration information
5.3. Calibration scales and correct axis position
xx0200000176
A1
A2
B1
B2
C1
C2
368
5 Calibration information
5.4. Calibration movement directions for all axes
xx0200000089
369
5 Calibration information
5.5. Updating revolution counters
Action
Note
1.
2.
Jog the robot so that the calibration marks lie Shown in section Calibration scales
within the tolerance zone.
and correct axis position on page 368
in either of the manuals: Instructions
for Levelmeter Calibration or
Calibration Pendulum Instruction,
depending on which calibration
method to be used.
3.
Detailed in sections:
Storing the revolution counter setting
with the TPU on page 371
(RobotWare 4.0).
Storing the revolution counter setting
with the FlexPendant on page 372
(RobotWare 5.0).
370
Robot variant
Axis 4
Axis 6
IRB7600
Yes
Yes
5 Calibration information
5.5. Updating revolution counters
Action
Note
xx0100000194
2.
xx0100000201
3.
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.
371
5 Calibration information
5.5. Updating revolution counters
Step
Action
Note
6.
7.
Not required.
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 374.
Action
1.
2.
en0400000771
372
5 Calibration information
5.5. Updating revolution counters
Step
Action
3.
4.
5.
A dialog box is displayed, warning that the updating operation cannot be undone:
Tap Update to proceed with updating the revolution counters.
Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the ticked revolution counters and removes the tick from
the list of axes.
6.
Caution!
If a revolution counter is incorrectly updated, it will cause incorrect robot positioning,
which in turn may cause damage or injury!
Check the calibration position very carefully after each update.
See section Checking the calibration position on page 374.
373
5 Calibration information
5.6. Checking the calibration position
Action
1.
2.
Use MoveAbsJ
3.
4.
5.
Note
374
Action
1.
2.
3.
4.
5.
6.
Note
5 Calibration information
5.6. Checking the calibration position
Action
Illustration/information
1.
2.
3.
4.
Check that the calibration marks for the axes align The calibration marks are
correctly. If they do not, update the revolution
shown in section Calibration
counters!
scales and correct axis
position on page 368.
Detailed in section Updating
revolution counters on page
370.
xx0100000195
xx0100000196
Action
1.
2.
3.
4.
5.
Note
375
5 Calibration information
5.6. Checking the calibration position
376
6 Decommissioning
5.6. Checking the calibration position
6 Decommissioning
377
6 Decommissioning
6.1. Environmental information
Material
Example application
Copper
Cables, motors
Steel
Neodymium
Brakes, motors
Oil, grease
Gearboxes
Aluminium
378
Spills may form a film on water surfaces causing damage to organisms. Oxygen
transfer could also be impaired.
6 Decommissioning
6.2. Decommissioning of balancing device
Art. no.
Note
Standard toolkit
3HAC 15571-1
Cutting torch
DANGER!
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Procedure
The instruction below details how to cut open the balancing device housing and removing the
tension in the coil springs before opening the device.
Contact ABB Robotics for further consultation.
Step
Action
Info/Illustration
1.
2.
379
6 Decommissioning
6.2. Decommissioning of balancing device
Step
3.
Action
Info/Illustration
xx0200000082
380
4.
5.
6.
Index
C
cabling, position switch 104
cabling, robot 103
cabling, robot axes 1-4 201
cabling, robot axes 5-6 209
calibration position 370
calibration position, checking 374
calibration position, jog to 375
Connection of external safety devices 15
D
direction of axes 369
G
gearbox oil 152
L
Limitation of Liability 16
N
negative directions, axes 369
O
oil, amount 152
oil, types 152
P
positive directions, axes 369
R
Revolution counters 370
S
Safety, service 15
securing, base plate 70
securing, robot 74
U
Updating revolution counters 370
V
Validity and responsibility 15
381
6 Decommissioning
6.2. Decommissioning of balancing device
382