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ABB IRB 760 Product Manual

Summary of IRB 760

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    Abb robotics product manual irb 760

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    Trace back information: workspace r13-1 version a6 checked in 2013-03-31 skribenta version 1184.

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    Product manual irb 760 - 450/3.2 m2004 document id: 3hac039838-001 revision: c © copyright 2013 abb. All rights reserved..

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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...

  • Page 5: Table Of Contents

    Table of contents 9 overview of this manual ................................................................................................................... 12 how to read the product manual ...................................................................................................... 13 ...

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    92 2.4 restricting the working range .............................................................................. 92 2.4.1 introduction ............................................................................................ 93 2.4.2 mechanically restricting the working range of axis 1 ..........

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    265 4.5 frame and base ................................................................................................ 265 4.5.1 replacing the balancing device ................................................................. 274 4.5.2 replacing the balancing weight ...................................

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  • Page 9: Overview Of This Manual

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

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    Contents chapter useful information when performing installation, maintenance or repair work. Includes lists of necessary tools, additional documents, safety standards etc. Reference information reference to the spare part list for the robot. Spare part / part list reference to the circuit diagram f...

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    Description revision this revision includes the following updates: • a new block, about general illustrations, added in section how to read the product manual on page 12 . • added safety section, see balancing device on page 20 . • added safety section, see signal lamp (optional) on page 34 . • adde...

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    How to read the product manual reading the procedures the procedures contain references to figures, tools, material, and so on. The references are read as described below. References to figures the procedures often include references to components or attachment points located on the manipulator/cont...

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    Product documentation, m2004 categories for manipulator documentation the manipulator documentation is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional. All documents listed can be orde...

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    An application manual generally contains information about: • the purpose of the application (what it does and when it is useful). • what is included (for example cables, i/o boards, rapid instructions, system parameters, dvd with pc software). • how to install included or required hardware. • how t...

  • Page 15: 1 Safety

    1 safety 1.1 introduction to safety information overview the safety information in this manual is divided into two categories: • general safety aspects, important to attend to before performing any service work on the robot. These are applicable for all service work and are found in general safety i...

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    1.2 general safety information 1.2.1 introduction to general safety information definitions this section details general safety information for personnel performing installation, repair and maintenance work. Sections the general safety information is divided into the following sections. Containing c...

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    1.2.2 safety in the manipulator system validity and responsibility the information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment that can influence the safety of the entire system. To protect personnel, the complete system must be des...

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    1.2.3 safety risks 1.2.3.1 safety risks during installation and service work on manipulators overview this section includes information on general safety risks to be considered when performing installation and service work on the manipulator. These safety instructions have to be read and followed by...

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    • the axes are affected by the force of gravity when the brakes are released. In addition to the risk of being hit by moving manipulator parts, there is a risk of being crushed by the parallel arm (if there is one). • energy stored in the manipulator for the purpose of counterbalancing certain axes ...

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    Cabling description safety risk caution the cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them! Cable packs are sensitive to mechanical damage! Gearboxes and motors description safety risk caution whenever partin...

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    1.2.3.2 caution - hot parts may cause burns! Description during normal operation, many manipulator parts become hot, especially the drive motors and gears. Sometimes areas around these parts also become hot. Touching these may cause burns of various severity. Because of a higher environment temperat...

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    1.2.3.3 safety risks related to tools/work pieces safe handling it must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating. It should be possible to release parts by manual operation (valves). Safe design grippers/e...

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    1.2.3.4 safety risks related to pneumatic/hydraulic systems general special safety regulations apply to pneumatic and hydraulic systems. Note all components that remain pressurized after separating the machine from the power supply must be provided with clearly visible drain facilities and a warning...

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    1.2.3.5 safety risks during operational disturbances general • the industrial manipulator is a flexible tool that can be used in many different industrial applications. • all work must be carried out professionally and in accordance with the applicable safety regulations. • care must be taken at all...

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    1.2.3.6 risks associated with live electric parts voltage related risks, general work on the electrical equipment of the manipulator must be performed by a qualified electrician in accordance with electrical regulations. • although troubleshooting may, on occasion, need to be carried out while the p...

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    Voltage related risks, manipulator a danger of high voltage is associated with the manipulator in: • the power supply for the motors (up to 800 vdc). • the user connections for tools or other parts of the installation (max. 230 vac). See chapter installation and commissioning on page 53 . Voltage re...

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    1.2.4 safety actions 1.2.4.1 safety fence dimensions general install a safety cell around the manipulator to ensure safe manipulator installation and operation. Dimensioning dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the manipulator is d...

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    1.2.4.2 fire extinguishing note use a carbon dioxide (co 2 ) extinguisher in the event of a fire in the manipulator system (manipulator or controller)! 28 3hac039838-001 revision: c © copyright 2013 abb. All rights reserved. 1 safety 1.2.4.2 fire extinguishing.

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    1.2.4.3 emergency release of the manipulator’s arm description in an emergency situation, any of the manipulator's axes may be released manually by pushing the brake release buttons on the manipulator. How to release the brakes is detailed in the section: • manually releasing the brakes on page 73 ....

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    1.2.4.4 brake testing when to test during operation, the holding brake of each axis normally wears down. A test can be performed to determine whether the brake can still perform its function. How to test the function of the holding brake of each axis motor may be checked as described below: 1 run ea...

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    1.2.4.5 risk of disabling function "reduced speed 250 mm/s" note do not change transm gear ratio or other kinematic system parameters from the flexpendant or a pc. This will affect the safety function "reduced speed 250 mm/s". 3hac039838-001 revision: c 31 © copyright 2013 abb. All rights reserved. ...

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    1.2.4.6 safe use of the flexpendant enabling device the enabling device is a manually operated, constant pressure push-button which, when continuously activated in one position only, allows potentially hazardous functions but does not initiate them. In any other position, hazardous functions are sto...

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    1.2.4.7 work inside the manipulator's working range warning if work must be carried out within the manipulator’s work area, the following points must be observed: • the operating mode selector on the controller must be in the manual mode position to render the enabling device operational and to bloc...

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    1.2.4.8 signal lamp (optional) description a signal lamp with a yellow fixed light can be mounted on the manipulator, as a safety device. Function the lamp is active in motors on mode. Further information further information about the motors on/motors off mode may be found in the product manual for ...

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    1.2.5 safety stops 1.2.5.1 what is an emergency stop? Definition of emergency stop an emergency stop is a state that overrides any other manipulator control, disconnects drive power from the manipulator motors, stops all moving parts, and disconnects power from any potentially dangerous functions co...

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

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    1.3 safety related instructions 1.3.1 safety signals in the manual introduction to safety signals this section specifies all dangers that can arise when doing the work described in this manual. Each danger consists of: • a caption specifying the danger level (danger, warning, or caution) and the typ...

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    Significance designation symbol describes important facts and conditions. Note xx0100000004 describes where to find additional information or how to do an operation in an easier way. Tip xx0100000098 38 3hac039838-001 revision: c © copyright 2013 abb. All rights reserved. 1 safety 1.3.1 safety signa...

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    1.3.2 safety symbols on manipulator labels introduction to labels this section describes safety symbols used on labels (stickers) on the manipulator. Symbols are used in combinations on the labels, describing each specific warning. The descriptions in this section are generic, the labels can contain...

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    Description symbol see user documentation xx0900000813 read user documentation for details. Which manual to read is defined by the symbol: • no text: product manual . • eps: application manual - electronic position switches . Before dismantling see product manual xx0900000816 do not dismantle xx0900...

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    Description symbol crush xx0900000817 risk of crush injuries. Heat xx0900000818 risk of heat that can cause burns. Moving robot xx0900000819 the robot can move unexpectedly. Xx1000001141 brake release buttons xx0900000820 xx1000001140 continues on next page 3hac039838-001 revision: c 41 © copyright ...

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    Description symbol lifting bolt xx0900000821 chain sling with shortener xx1000001242 lifting of robot xx0900000822 oil xx0900000823 can be used in combination with prohibition if oil is not allowed. Mechanical stop xx0900000824 no mechanical stop xx1000001144 stored energy xx0900000825 warns that th...

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    Description symbol pressure xx0900000826 warns that this part is pressurized. Usually contains additional text with the pressure level. Shut off with handle xx0900000827 use the power switch on the controller. 3hac039838-001 revision: c 43 © copyright 2013 abb. All rights reserved. 1 safety 1.3.2 sa...

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    1.3.3 danger - moving manipulators are potentially lethal! Description any moving manipulator is a potentially lethal machine. When running, the manipulator may perform unexpected and sometimes irrational movements. Moreover, all movements are performed with great force and may seriously injure any ...

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    1.3.4 danger - first test run may cause injury or damage! Description since performing a service activity often requires disassembly of the robot, there are several safety risks to take into consideration before the first test run. Elimination follow the procedure below when performing the first tes...

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    1.3.5 warning - the brake release buttons may be jammed after service work description the brake release unit has push-buttons for the brake release of each axis motor. When service work is performed inside the smb recess that includes removal and refitting of the brake release unit, the brake relea...

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    1.3.6 danger - make sure that the main power has been switched off! Description working with high voltage is potentially lethal. Persons subjected to high voltage may suffer cardiac arrest, burn injuries, or other severe injuries. To avoid these dangers, do not proceed working before eliminating the...

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    1.3.7 warning - the unit is sensitive to esd! Description esd (electrostatic discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not...

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    1.3.8 warning - safety risks during handling of batteries description under normal conditions of use, the electrode materials and liquid electrolyte in the batteries are not exposed to the outside, provided the battery integrity is maintained and seals remain intact. There is a risk of exposure only...

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    1.3.9 warning - safety risks during work with gearbox lubricants (oil or grease) description when handling gearbox lubricants, there is a risk of both personal injury and product damage occurring. The following safety information must be regarded before performing any work with lubricants in the gea...

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    Elimination/action description warning make sure not to overfill the gearbox when filling it with oil or grease! Overfilling of gearbox lubricant can lead to internal over-pres- sure inside the gearbox which in turn may: • damage seals and gas- kets • completely press out seals and gaskets • prevent...

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    2 installation and commissioning 2.1 introduction general this chapter contains information for installing the irb 760 at the working site. More detailed technical data can be found in the product specification for the irb 760, such as: • load diagram • permitted extra loads (equipment) • location o...

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    2.2 unpacking 2.2.1 pre-installation procedure introduction this section is intended for use when unpacking and installing the robot for the first time. It also contains information useful during later re-installation of the robot. Checking the pre-requisites for installation installation craftsmen ...

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    Loads on foundation, robot the illustration shows the directions of the robots stress forces. The directions are valid for all floor mounted and suspended robots. Xy xy z z t f f t xx1100000521 force in any direction in the xy plane f xy force in the z plane f z bending torque in any direction in th...

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    Requirements, foundation the table shows the requirements for the foundation where the weight of the installed robot is included: note value requirement flat foundations give better repeatability of the resolver calibration compared to original settings on delivery from abb. 0.5 mm maximum deviation...

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    2.2.2 working range and type of motion working range the following figures show the working ranges of the robot variants. The extreme positions of the robot arm are specified at the wrist center (dimensions in mm). Irb 760 - 450/3.2 the illustration below shows the unrestricted working range of irb ...

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    Type of motion the table below specifies the types and ranges of the robot motion in every axis. Range of motion type of motion axis -180° to +180° rotation motion 1 can be extended, with use of option, to: -220° to +220° (option 561-1) -42° to +85° arm motion 2 -20° to +120° arm motion 3 20° to 160...

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    Turning radius xx1000001068 motor, axis 3 (a) 3hac039838-001 revision: c 59 © copyright 2013 abb. All rights reserved. 2 installation and commissioning 2.2.2 working range and type of motion continued.

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    2.2.3 risk of tipping/stability risk of tipping if the robot is not fastened to the foundation and standing still, the robot is not stable in the whole working area. Moving the arms will displace the center of gravity, which may cause the robot to tip over. The shipping position is the most stable p...

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    Warning the robot is likely to be mechanically unstable if not secured to the foundation! 3hac039838-001 revision: c 61 © copyright 2013 abb. All rights reserved. 2 installation and commissioning 2.2.3 risk of tipping/stability continued.

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    2.3 on-site installation 2.3.1 lifting robot with fork lift general the robot may be moved using a fork lift, provided that available special aids are used. This section describes how to attach the fork lift equipment to the robot. Attachment points on robot the attachment points for the fork lift e...

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    Fork lift set, 3hac023044-001 the fork lift set 3hac023044-001, is fitted to the robot as shown in the figure below. Xx0500002277 fork lift pocket (2 pcs, one long and one short) a adapter (2 pcs) b horizontal attachment screws (4 pcs / fork lift pocket) c attachment screw for adapter (1 pc / adapte...

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    Lifting robot with fork lift this section details how to secure the fork lift set to the robot in order to lift and move the robot using the fork lift only! Note action if a cooling fan for the axis 1 motor is used, it must be removed in order to use the fork lift device! Release the brakes if requi...

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    Note action xx0500002278 strap up axis 2 motor cable on the adapter. 3 • a: strap, velcro caution the fork lift pocket weighs 60 kg! 4 always use original screws (or replace- ments of equivalent quality: m16, qual- ity 12.9)! Secure the longer fork lift pocket to the adapter and frame with four of t...

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    Note action xx0700000655 make sure the securing screw is removed from the fork lift pocket! It is only used for robot model irb 6650s. 6 a securing screw xx0500002284 secure fork lift pocket to robot with two vertical attachment screws and washers. Note vertically and the horizontally attached screw...

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    Note action caution the irb 760 robot weighs 2300 kg. All lifting accessories used must be sized ac- cordingly! 11 carefully lift the robot and move it to its install- ation site. 12 warning personnel must not, under any circumstances, be present under the suspended load! 13 refit the cooling fan to...

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    2.3.2 lifting robot with roundslings general the robot can be lifted with roundslings according to this section. Sling specification length / note lifting capacity qty sling type 0.460 m 4 000 kg 4 pcs chain sling with shortener 0.670 m (2 pcs) 0.790 m 1 m (2 pcs) 2 000 kg 5 pcs roundsling, robot 1....

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    Attachment points this figure shows how to attach the roundslings to the robot. The illustration is similar with the label attached to the robot’s frame. Xx1000001091 roundslings, 2 m (2 pcs). Lifting capacity: 2,000 kg. A chain slings with shortener (4 pcs). Lifting capacity: 4,000 kg. B roundsling...

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    2.3.3 lifting robot with lifting slings general this section contains a general overview of how to lift the complete robot using special lifting equipment. More detailed instructions are included with the equipment. Note move the robot to the recommended position shown in the figure and in the instr...

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    Illustration, lifting slings the figure below shows how to lift the complete robot with lifting slings. Xx1000001173 lifting slings a roundsling that secures against rotation, 1 m. Lifting capacity: 2,000 kg. B swivelling lifting eyes and hooks c note! Make sure to run lifting sling between parallel...

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    Note art. No. Equipment 1 m, lifting capacity: 2,000 kg. - roundsling used to secure against rotation. Slings attached directly onto robot this section details how to lift and move the robot using lifting slings when these are attached directly onto the robot frame. Note action run the overhead cran...

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    2.3.4 manually releasing the brakes general this section details how to release the holding brakes of each axis motor. Location of brake release unit the internal brake release unit is located as shown in the figure. Note axes 4 and 5 do not exist! Xx0500002286 releasing the brakes this procedure de...

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    Note action release the holding brake on a particular robot axis by pressing the corresponding button on the internal brake release unit. 3 the brake will function again as soon as the button is released. Supplying power to connector r1.Mp if the robot is not connected to the controller, power must ...

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    2.3.5 lifting the base plate required equipment note art. No. Equipment 3 pcs 3hac14457-4 lifting eye, m16 3 pcs lifting slings length: approx. 2 m hole configuration xx0200000096 attachment holes for lifting eyes (x3) a lifting, base plate note action caution the base plate weighs 353 kg! All lifti...

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    2.3.6 securing the base plate base plate, dimensions a a b b c d g h e f 2x r525 598,31 560,85 487,01 243,5 0 73,84 111,30 1020 857,3 7 3 ,8 4 1 3 2 ,6 4 3 1 7 ,3 5 0 2 ,0 4 5 6 0 ,8 5 6 3 4 ,6 8 0 2x 50x45º 2 3 1 ,5 2 x 4 5 0 9 5 0 (Ø 80 0) 12x m24 Ø1 a 455 c a 4x4 8 13 (2 ) 1 ,6 3x4 5º 0.2 Ø 45p7 ...

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    Xx1000001054 ¤ four holes for alternative clamping, 4x Ø18 - color: ral 9005. Thickness: 80-100 µm a continues on next page 3hac039838-001 revision: c 77 © copyright 2013 abb. All rights reserved. 2 installation and commissioning 2.3.6 securing the base plate continued.

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    Base plate, grooves and holes the illustration below shows the orienting grooves and guide sleeve holes in the base plate. Xx0300000045 guide sleeve holes (2 pcs) a orienting grooves (3 pcs) b levelling bolts, attachment holes (4 pcs) c required equipment note art. No. Equipment includes • guide sle...

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    Recommendations, quality the table specifies any recommendations made by abb: recommendation variable hilti hda-p, m20 x 250/50 (maximum thickness of base plate = 50 mm) recommended bolt quality and dimen- sion hilti hda-p, m20 x 250/100 (maximum thickness of base plate = 100 mm) steel fibre reinfor...

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    2.3.7 orienting and securing the robot general this section details how to orient and secure the robot to the base plate in order to run the robot safely. Illustration, robot fitted to base plate this illustration shows the robot base fitted to the base plate. Xx0100000107 robot attachment bolts and...

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    Securing the robot use this procedure to secure robot to base plate after fitting plate to the foundation. Note action see section lifting robot with lifting slings on page 70 . Lift the robot. 1 see section lifting robot with round- slings on page 68 . Move robot to the vicinity of its installation...

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    Hole configuration, base this illustration shows the hole configuration used when securing the robot. Xx1000001050 continues on next page 82 3hac039838-001 revision: c © copyright 2013 abb. All rights reserved. 2 installation and commissioning 2.3.7 orienting and securing the robot continued.

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    Cross section, guide sleeve hole this illustration shows the cross section of the guide sleeve holes. Xx1000001051 3hac039838-001 revision: c 83 © copyright 2013 abb. All rights reserved. 2 installation and commissioning 2.3.7 orienting and securing the robot continued.

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    2.3.8 fitting equipment on robot general the robot features mounting holes for additional equipment. Access to any of the following mounting holes may be obstructed by any additional cabling, equipment, etc., fitted by the robot user. Make sure the required mounting holes are accessible when plannin...

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    Illustration, fitting of extra equipment on frame the illustration below shows the mounting holes available for fitting extra equipment on the frame. Xx1000001070 continues on next page 3hac039838-001 revision: c 85 © copyright 2013 abb. All rights reserved. 2 installation and commissioning 2.3.8 fi...

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    Illustration, fitting on turning disk the illustration below shows the mounting holes available for fitting equipment on the turning disk. Xx1000001058 mounting flange a fastener quality when fitting tools on the turning disk (see the figures above), only use screws with quality 12.9. When fitting o...

  • Page 87

    2.3.9 installation of signal lamp, upper arm (option) general as an option, a signal lamp can be installed on the robot. The lamp is activated when the controller is in the motors on state. Location of signal lamp, upper arm the signal lamp is located on the tilthouse unit, as shown in figure. Xx100...

  • Page 88

    Note art. No. Equipment, etc. Content is defined in section stand- ard tools on page 351 . Standard toolkit other tools and procedures may be required. See references to these procedures in the step-by- step instructions below. Signal lamp kit figure shows signal lamp kit on irb 760. X x x - x a b c...

  • Page 89

    Installation, signal lamp use this procedure to install the signal lamp to the robot. Note action see figure signal lamp kit on page 88 . Fit the signal lamp bracket to the tilthouse, with two attachment screws . 1 see figure signal lamp kit on page 88 . Fit the signal lamp to the bracket, with two ...

  • Page 90

    Note action see figure signal lamp kit on page 88 . A xx0600002694 remove the cable gland cover at the cable exit by removing the attachment screw. Replace the screw with a longer one, when refit- ting in following steps (enclosed in the signal lamp kit). 4 a screw that holds the cable gland enclose...

  • Page 91

    2.3.10 loads general any loads mounted on the robot must be defined correctly and carefully (with regard to the position of center of gravity and mass moments of inertia) in order to avoid jolting movements and overloading motors, gears and structure. Caution incorrectly defined loads may result in ...

  • Page 92

    2.4 restricting the working range 2.4.1 introduction general when installing the robot, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited. The working range of the following axes may be re...

  • Page 93

    2.4.2 mechanically restricting the working range of axis 1 general the working range of axis 1 is limited by fixed mechanical stops and adjustment of the system parameter configuration. The working range can be reduced by adding additional mechanical stops giving 7.5 or 15 graduation, between 22.5° ...

  • Page 94

    Installation, mechanical stops axis 1 use this procedure to fit mechanical stops to axis 1 of the robot. An assembly drawing is also enclosed with the product. Note action danger turn off all: • electric power supply to the robot • hydraulic pressure supply to the robot • air pressure supply to the ...

  • Page 95

    2.4.3 extended working range, axis 1 (option 561-1) overview the working range of axis 1 can be increased from standard range to extended ± 220º. Extending the working range note/illustration action xx0400001034 remove the mechanical stop pin from axis 1 (a). 1 see application manual - electronic po...

  • Page 96

    2.5 robot in cold environments 2.5.1 start of robot in cold environments introduction this procedure describes how to start the robot in a cold environment. Starting in cold environment note action start the robot the normal way. Proceed to next step, if the robot does not start. 1 velocity can be r...

  • Page 97

    2.6 electrical connections 2.6.1 robot cabling and connection points introduction connect the robot and controller to each other after securing them to the foundation. The lists below specify which cables to use for each respective application. Main cable categories all cables between the robot and ...

  • Page 98

    Art. No. Cable 3hac7998-2 robot cable signal, shielded: 15 m 3hac7998-3 robot cable signal, shielded: 22 m 3hac7998-4 robot cable signal, shielded: 30 m 98 3hac039838-001 revision: c © copyright 2013 abb. All rights reserved. 2 installation and commissioning 2.6.1 robot cabling and connection points...

  • Page 99: 3 Maintenance

    3 maintenance 3.1 introduction structure of this chapter this chapter describes all the maintenance activities recommended for the irb 760. It is based on the maintenance schedule found at the beginning of the chapter. The schedule contains information about required maintenance activities including...

  • Page 100

    3.2 maintenance schedule and expected component life 3.2.1 specification of maintenance intervals introduction the intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the irb 760: • calendar time: specified in months...

  • Page 101

    3.2.2 maintenance schedule general the robot must be maintained regularly to ensure proper function. The maintenance activities and intervals are specified in the table below. Non-predictable situations also give rise to inspections of the robot. Any damages must be attended to immediately! The insp...

  • Page 102

    Interval equipment maintenance activity first change when dtc ii reads: • 6,000 hours second change when dtc ii reads: • 24,000 hours following changes: • every 24,000 hours axis-3 gear oil changing first change when dtc ii reads: • 6,000 hours second change when dtc ii reads: • 24,000 hours followi...

  • Page 103

    3.2.3 expected component life general the expected life of a specific component of the robot can vary greatly depending on how hard it is run. Expected component life - protection type standard note expected life component not including: • possible spotpack harnesses • optional upper arm harnesses 4...

  • Page 104

    3.3 inspection activities 3.3.1 inspecting, oil level gearbox axis 1 location of gearbox the axis 1 gearbox is located between the frame and base. See oil plugs in figure. A b c d e xx0500002479 oil plug, inspection a gearbox, axis 1 b oil plug filling c motor, axis 1 d drain hose (behind cover) e r...

  • Page 105

    Note art. No. Equipment these procedures include refer- ences to the tools required. Other tools and procedures may be required. See references to these procedures in the step-by- step instructions below. Inspecting, oil level gearbox, axis 1 use this procedure to inspect the oil level in gearbox ax...

  • Page 106

    3.3.2 inspecting, oil level gearbox axes 2 - 3 location of gearbox, axes 2-3 the gearboxes axes 2-3 are located in the lower arm rotational center, underneath the motor attachment. Xx0500002482 gearbox, axis 2 a oil plug, draining b oil plug, filling c ventilation hole, gearbox axis 2 d continues on...

  • Page 107

    Xx0500002483 gearbox, axis 3 a oil plug, draining b oil plug, filling c ventilation hole, gearbox axis 3 d required equipment note art.No. Equipment etc. Note do not mix with other oils! See type and amount of oil in gearboxes on page 127 . Lubricating oil content is defined in section standard tool...

  • Page 108

    Note action danger turn off all: • electric power supply to the robot • hydraulic pressure supply to the robot • air pressure supply to the robot before entering the robot working area. 2 see location of gearbox, axes 2-3 on page 106 . Open oil plug, filling 3 measure oil level at the oil plug, fill...

  • Page 109

    3.3.3 inspecting, oil level gearbox axis 6 location of gearbox the axis 6 gearbox is located in the tilthouse unit as shown in this figure. Xx1000001236 oil plug, filling a oil plug, draining b gearbox, axis 6 c required equipment note art. No. Equipment kyodo yushi tmo 150 3hac0860-1 lubricating oi...

  • Page 110

    Inspection, oil level axis-6 gearbox use this procedure to inspect the oil level in the axis-6 gearbox. Note action warning handling gearbox oil involves several safety risks. Before proceeding, please read the safety informa- tion in the section warning - safety risks during work with gearbox lubri...

  • Page 111

    3.3.4 inspecting, balancing device bearings and piston rod guide ring location of balancing device the figure shows the location of the balancing device. Xx1000001237 balancing device a guide ring (not visible in this figure) b required equipment note art.No equipment 3hab3537-1 grease loctite 243 -...

  • Page 112

    Inspecting, bearings use this procedure to inspect the bearings, balancing device. Note action xx1000001130 check for dissonance from the bearings at ear and from the piston rod attachment. Replace the bearing, if dissonance is detected. 1 replacement is detailed in section re- placing the balancing...

  • Page 113

    Note action shown in previous figure. Check the support washers for wear. Replace if necessary. 3 see lubricating balancing device bearings and piston rod on page 142 . Lubricate the bearings and piston rod, if re- quired. 4 inspecting, piston rod guide ring use this procedure to inspect the piston ...

  • Page 114

    3.3.5 inspecting, cable harness location of cable harness, axes 1-6 the axes-1-6 cable harness is shown below. Xx1000001367 cable harness robot, axes 1-6 a connectors at base b motor cables (4 locations) c cable guide, axis 2 d cable guide, axis 3 e metal clamps with nuts f continues on next page 11...

  • Page 115

    Required equipment note art. No. Equipment, etc. Detailed in section standard tools on page 351 . - standard toolkit these procedures include refer- ences to the tools required. Other tools and procedures may be required. See references to these procedures in the step-by-step instruc- tions below. S...

  • Page 116

    Note action detailed in section: replace the cable harness if wear or damage is detected! 9 replacing cable harness, lower end (axes 1-3) on page 153 . Replacing the cable harness, upper end (incl. Axis 6) on page 163 . 116 3hac039838-001 revision: c © copyright 2013 abb. All rights reserved. 3 main...

  • Page 117

    3.3.6 inspection, information labels location of labels these figures show the location of the information labels to be inspected. The symbols are described in section safety symbols on manipulator labels on page 39 . Xx1000001139 warning label "heat", 29454489-16 (4 pcs) a warning label, symbol of ...

  • Page 118

    Combined warning label "do not dismantle" and "stored energy", 3hac3981-1 f instruction label for lifting of robot, 3hac039840-001 g warning label "tip risk when loosening bolts", 3hac9191-1 h instruction label "before dismantling see product manual", 3hac4591-1 j label, calibration, 3hac024307-001 ...

  • Page 119

    3.3.7 inspecting, mechanical stop pin, axis 1 warning mechanical stop pin can not be mounted on robot if option 810-1 electronic position switch is used. Warning mechanical stop pin can not be mounted on robot if option 561-1 extended work range axis 1 is used. Location of mechanical stop pin the me...

  • Page 120

    Inspecting, mechanical stop pin use this procedure to inspect the mechanical stop pin axis 1. Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 1 shown in figure location of mechan- ical st...

  • Page 121

    3.3.8 inspecting, additional mechanical stops location of mechanical stops this figure shows the location of the additional mechanical stop on axis 1. Xx0300000049 additional mechanical stop a stop pin b required equipment note art. No. Equipment etc. Limits the robot working range by 7.5°. 3hac1107...

  • Page 122

    Note action shown in figure location of mechanical stops on page 121 . Check additional stops on axis 1 for damage. 2 make sure stops are properly attached. 3 correct tightening torque, mechanical stops: • axis 1 = 115 nm art. No. Is specified in required equipment on page 121 . If any damage is det...

  • Page 123

    3.3.9 inspection, dampers location of dampers this figure shows the location of dampers. Xx1000001238 damper, lower arm, upper (2 pcs) a damper, lower arm, lower (1 pc) b damper, axis 2 (2 pcs) c damper, axis 3 (2 pcs). Not visible in this view. - continues on next page 3hac039838-001 revision: c 12...

  • Page 124

    Required equipment note art.No. Equipment to be replaced if damaged. 3hac 022338-001 damper lower arm, upper to be replaced if damaged. 3hac 022339-001 damper lower arm, lower to be replaced if damaged. 3hac 12991-1 damper axis 2, 3 inspecting, dampers use this procedure to inspect the dampers. Note...

  • Page 125

    3.3.10 inspecting, signal lamp (option) location of signal lamp the signal lamp is located as shown in this figure. Xx1000001372 signal lamp a cable straps, outdoor (2 pcs) b cable c connection point to cable gland d required equipment note art. No. Equipment, etc. To be replaced if damage is detect...

  • Page 126

    Note art. No. Equipment, etc. These procedures include references to the tools required. Other tools and procedures may be required. See references to these procedures in the step-by- step instructions below. Inspecting, signal lamp use this procedure to inspect the function of the signal lamp. Note...

  • Page 127

    3.4 replacement/changing activities 3.4.1 type of lubrication in gearboxes introduction this section describes where to find information about the type of lubrication , article number and the amount of lubrication in the specific gearbox. It also describes the equipment needed when working with lubr...

  • Page 128

    Equipment note equipment includes pump with outlet pipe. Oil dispenser use the suggested dispenser or a similar one: • orion orican art. No. 22590 (pneumatic) nipple for quick connect fitting, with o-ring 128 3hac039838-001 revision: c © copyright 2013 abb. All rights reserved. 3 maintenance 3.4.1 t...

  • Page 129

    3.4.2 changing oil, axis-1 gearbox location of oil plugs axis 1 gearbox is located between the frame and base. Oil plugs are shown in the figure. Truethe oil is drained through a hose, which is located at the rear of the robot base. A b c d e xx0500002479 oil plug, inspection a gearbox axis 1 b oil ...

  • Page 130

    Note amount art. No. Equipment, etc. Content is defined in section special tools on page 352 . 3hac021745-001 oil exchange equip- ment content is defined in section standard tools on page 351 . - standard toolkit draining oil, axis 1 use this procedure to drain the oil in gearbox axis 1. When using ...

  • Page 131

    Note action note draining is time-consuming. Elapsed time depends on the temperature of the oil. Open the hose end and drain the oil into a vessel. 7 close the oil drain hose, and put it back inside the base. 8 refit rear cover by securing it with its attach- ment screws. 9 filling oil, axis 1 use t...

  • Page 132

    3.4.3 changing oil, gearbox axes 2 and 3 location of oil plugs gearboxes, axes 2 and 3, are located in lower arm rotational center, underneath motor attachment. The figure shows the position of gearbox, axis 2. Xx0500002482 gearbox axis 2 a oil plug, draining b oil plug, filling c ventilation hole p...

  • Page 133

    The figure shows position of gearbox, axis 3. Xx0500002483 gearbox, axis 3 a oil plug, draining b oil plug, filling c ventilation hole plug, gearbox axis 3 d required equipment note amount art. No. Equipment etc. Note do not mix with other oils! See type and amount of oil in gearboxes on page 127 . ...

  • Page 134

    Note action warning handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section warning - safety risks during work with gearbox lubric- ants (oil or grease) on page 50 . 2 shown in location of oil plugs on page 132 . Remove the ventilation...

  • Page 135

    3.4.4 changing oil, gearbox axis 6 location of oil plugs gearbox axis 6 is located in the center of the tilt house unit. Xx1000001236 oil plug, filling a oil plug, draining b gearbox, axis 6 c required equipment note amount art. No. Equipment, etc. Kyodo yushi tmo 150 850 ml 3hac032140-001 lubricati...

  • Page 136

    Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 2 shown in figure location of oil plugs on page 135 . Drain oil from gearbox into a vessel by removing oil plug, draining . Also remove oil...

  • Page 137

    3.4.5 replacing the smb battery note the battery low alert (38213 battery charge low ) is displayed when the battery needs to be replaced. The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced. For an smb board with 3...

  • Page 138

    Location of smb battery the smb battery (smb = serial measurement board) is located on the left hand side of the frame as shown in the figure below. Battery pack with a 2-pole battery contact xx0500002486 smb battery cover a smb battery pack b battery cable c continues on next page 138 3hac039838-00...

  • Page 139

    Battery pack with a 3-pole battery contact a b d c xx1300000307 a battery pack rmu b battery holder c battery cable d strap required equipment note there are two variants of smb units and batteries. One with 2-pole battery contact and one with 3-pole battery contact. The variant with the 3-pole batt...

  • Page 140

    Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. 2 xx0200000023 3 warning the unit is sensitive to esd. Before handling the unit please read the safety information in the sec- tion warning...

  • Page 141

    Note action art. No. Is specified in required equipment on page 139 . Reconnect the battery cable and install the battery pack into the smb/battery recess. Rmu batteries are installed together with a battery holder to be properly secured inside the recess. See figure. 3 shown in figure location of s...

  • Page 142

    3.5 lubrication activities 3.5.1 lubricating balancing device bearings and piston rod overview this procedure details how to lubricate the balancing device´s bearings and piston rod. Location of bearings and piston rod this figure shows the location of bearings and piston rod. Note! Balancing device...

  • Page 143

    Required equipment note art. No. Equipment 3hac039296- 001 lubrication tool equivalent: • optimol longtime pd2 3hac9408-1 bearing grease isopropanol - cleaning agent choose any of following equivalents: • shell: srs grease 4000 • preem: novatex heavy ep 2 • castrol: entrepenadfett • statoil: uniway ...

  • Page 144

    Lubricating, piston rod use this procedure to lubricate the balancing device piston rod. Note action position axis 2 so that the balancing device is hori- zontal and the piston rod is extended to the greatest extent possible. 1 danger turn off all: • electric power supply • hydraulic pressure supply...

  • Page 145

    3.6 cleaning activities 3.6.1 cleaning, robot warning turn off all electrical power supplies to the manipulator before entering its work space. General to secure high uptime it is important that the robot is cleaned regularly. The frequency of cleaning depends on the environment in which the robot w...

  • Page 146

    Note equipment, etc. • water pressure at nozzle: max. 2,500 kn/m 2 (25 bar) • type of nozzle: fan jet, min. 45° spread • distance from nozzle to encapsulation: min. 0.4 m • water temperature: max. 80° c steam cleaner i typical tap water pressure and flow cables movable cables need to be able to move...

  • Page 147: 4 Repair

    4 repair 4.1 introduction structure of this chapter this chapter describes all repair activities recommended for the irb 760 and any external unit. It is made up of separate procedures, each describing a specific repair activity. Each procedure contains all the information required to perform the ac...

  • Page 148

    4.2 general procedures 4.2.1 performing a leak-down test general after refitting any motor and gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equipment note art. No. Equipment, etc. 3hac0207-1 leakdown tester - leak detection ...

  • Page 149

    4.2.2 mounting instructions for bearings general this section describes how to mount and grease different types of bearings on the robot. Equipment note art. No. Equipment, etc. Used to grease the bearings, if not specified otherwise. 3hab3537-1 grease assembly of all bearings follow the following i...

  • Page 150

    • ensure that grease is handled and stored properly to avoid contamination. Grease the different types of bearings as following description: • grooved ball bearings must be filled with grease from both sides. • tapered roller bearings and axial needle bearings must be greased in the split condition....

  • Page 151

    4.2.3 mounting instructions for seals general this section describes how to mount different types of seals onto the robot. Equipment note art. No. Equipment, etc. Used to lubricate the seals. 3hab3537-1 grease rotating seals the procedure below describes how to fit rotating seals. Caution please obs...

  • Page 152

    Flange seals and static seals the following procedure describes how to fit flange seals and static seals. Action check the flange surfaces. They must be even and free from pores. 1 it is easy to check flatness using a gauge on the fastened joint (without sealing com- pound). If the flange surfaces a...

  • Page 153

    4.3 complete robot 4.3.1 replacing cable harness, lower end (axes 1-3) overview the cable harness 1-6 is undivided. How to replace the cable harness is described in two steps - lower end (axes 1-3) and upper end (axis 6). This procedure describes how to replace the lower end of the cable harness. Ho...

  • Page 154

    Location of cable harness - lower end (axes 1-3) the cable harness, lower end (axes 1-3) is located throughout the base, frame and lower arm as shown in the figure. Xx1000001177 continues on next page 154 3hac039838-001 revision: c © copyright 2013 abb. All rights reserved. 4 repair 4.3.1 replacing ...

  • Page 155

    The figure shows irb 660 but is also valid for irb 760. Xx0700000070 cable guide, axis 2 a metal clamp b connector at base c cable guide, axis 1 d cable harness, axes 1-6 e cover plate f rear cover plate g attachment point for earth lug h required equipment note art.No. Equipment, etc. For spare par...

  • Page 156

    Note art.No. Equipment, etc. These procedures include refer- ences to the tools required. - other tools and proced- ures may be required. See references to these proced- ures in the step-by-step in- structions below. See circuit diagrams on page 357 . - circuit diagram removing the cable harness - l...

  • Page 157

    Note action xx1000001315 unscrew the screws of the cable guide axis 2 inside the lower arm and loosen the cable guide. 6 xx1000001328 unscrew the nuts (outside the lower arm) that secure the metal clamp that hold the cable harness inside the lower arm. 7 unscrew the screws of the motor covers for ax...

  • Page 158

    Note action xx0600002700 open the smb cover carefully. 10 disconnect connector r1.G on the battery cable between the battery and the smb unit. Note this causes a necessary updating of the revolu- tion counter after refitting! 11 disconnect connectors r2.Smb, r1.Smb1-3, r1.Smb6 from the smb unit. 12 ...

  • Page 159

    Note action xx1000001331 gently pull the cable harness out from the base through the cable guide , axis 1 and frame. 16 see section replacing the cable har- ness, upper end (incl. Axis 6) on page 163 . Continue removing the cable harness in the upper arm. 17 refitting, cable harness - lower end (axe...

  • Page 160

    Note action xx1000001330 pull out the cables and connectors of the smb unit through the frame and refit the cable gland with its attachment screws from inside the smb recess. Perform this refitting with care, in order not to damage any of the components inside the smb recess. 2 attachment points are...

  • Page 161

    Note action xx1100000041 refit the rear cover plate to the robot base with its attachment screws. 5 see sections: • replacing motor, axis 1 on page 278 • replacing motors, axes 2 and 3 on page 284 reconnect all connectors at motors axes 1, 2 and 3 and refit the motor covers. 6 reconnect connectors r...

  • Page 162

    Note action xx1100000157 refit the cable guide, axis 2 . 12 see section replacing the cable har- ness, upper end (incl. Axis 6) on page 163 . Continue refitting the cable harness in the upper arm. 13 see section updating revolution counters on page 335 . Update the revolution counter! 14 danger make...

  • Page 163

    4.3.2 replacing the cable harness, upper end (incl. Axis 6) overview replacement of the cable harness is detailed in two steps - lower end (axes 1-3) and upper end. The procedure below details replacement of the cable harness in the upper end (incl. Axis 6). The procedure for replacing the lower end...

  • Page 164

    The motor axis 6 is located as shown in the figure below. A r2.Mp6 r2.Fb6 b xx1100000159 • a: metal clamps with nuts (upper arm) • b: metal clamp (tilthouse) • r2.Mp6, r2.Fb6 = connectors to the axis 6 motor required equipment note art.No. Equipment, etc for spare part no. See: • spare parts on page...

  • Page 165

    Note art.No. Equipment, etc these procedures include references to the tools re- quired. Other tools and procedures may be required. See references to these procedures in the step-by- step instructions below. See chapter circuit dia- grams on page 357 . Circuit diagram removing cable harness, upper ...

  • Page 166

    Note action a xx0600002694 remove the cable gland cover at the cable exit by unscrewing its attachment screw on the inside. Note make sure the gasket is not damaged! • a: screw securing the cable gland disconnect connectors at axis 6 motor. 5 xx1000001336 remove the metal clamp that holds the cable ...

  • Page 167

    Note action xx1000001339 remove the axis 3 cable guide . 8 xx1000001338 remove the nuts (on the outside of the up- per arm) that secure the cable harness metal clamps inside the upper arm (2 + 2 pcs). 9 carefully pull out the cable harness from the upper and lower arm. 10 refitting cable harness, up...

  • Page 168

    Note action push the cable harness through the upper arm tube. 2 xx1000001338 refit the cable harness inside the upper arm by refitting the cable clamps with the nuts (2 + 2 pcs) from the outside of the upper arm. Twist the cable one turn between the cable clamps. 3 xx1000001340 refit the axis 3 cab...

  • Page 169

    Note action xx1000001336 refit the metal clamp at the tilthouse with its nuts. 5 push the axis 6 motor cables carefully through the cable gland. Note do not twist the cables! 6 reconnect all connectors in motor axis 6. 7 check the gasket . If damaged, replace it. 8 a xx0600002694 refit the cable gla...

  • Page 170

    Note action xx1000001106 refit the cover , motor axis 6 with its attach- ment screws and washers . Make sure the cabling is placed correctly when refitting the cover and does not get jammed. Note make sure the cover is tightly sealed! 10 detailed in section updating revolution counters on page 335 ....

  • Page 171

    4.3.3 replacing the smb unit location of smb unit the smb unit (smb = serial measurement board) is located on the left hand side of the frame as shown in the figure below. Xx0600002621 smb cover a smb unit b battery cable c smb battery d smb battery, cover e required equipment note there are differe...

  • Page 172

    Note art. No. Equipment, etc. See chapter circuit diagrams on page 357 . - circuit diagram removing, smb unit use this procedure to remove the smb unit. Note action move the robot to the calibration position. 1 danger turn off all: • electric power supply • hydraulic pressure supply • air pressure s...

  • Page 173

    Note action xx0200000023 2 warning! The unit is sensitive to esd. Before handling the unit please read the safety information in the section warning - the unit is sensitive to esd! On page 48 shown in the figure location of smb unit on page 171 . Connect the battery cable to the smb unit. 3 art. No....

  • Page 174

    4.3.4 replacing the brake release unit location of brake release unit the brake release unit is located together with the smb unit on the left hand side of the frame, right next to the gearbox, axis 2, as shown in figure below. Xx0600002621 smb cover a smb unit b battery cable c smb battery d smb ba...

  • Page 175

    Removing, brake release unit use this procedure to remove the brake release unit. Note action danger turn off all: • electric power supply to the robot • hydraulic pressure supply to the robot • air pressure supply to the robot before entering the robot working area. 1 xx0200000023 2 warning! The un...

  • Page 176

    Note action remove the brake release unit from the bracket by removing the four attachment screws. 7 refitting, brake release unit use this procedure to refit the brake release unit. Note action xx0200000023 1 warning! The unit is sensitive to esd. Before handling the unit please read the safety inf...

  • Page 177

    Note action 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 46 ! 6 shown in the figure location of brake release unit on page 174 . Refit the push button guard to the smb cover. ...

  • Page 178

    4.3.5 replacing the base, including axis 1 gearbox introduction the term complete arm system used in this procedure is defined as the complete robot excluding: • base • gearbox axis 1 location of the base the location of the base, including gearbox axis 1, is shown in the figure. It also shows the c...

  • Page 179

    Note art. No. Equipment, etc. Includes: • user instructions, 3hac15971-2 3hac15607-1 lifting accessory 24 vdc, max. 1.5 a - power supply for releasing the brakes. Used to turn the gear when mating it to the frame. - crank content is defined in section standard tools on page 351 . - standard toolkit ...

  • Page 180

    Note action xx1000001417 remove the block for calibration and the axis 1 calibration plate . 4 see changing oil, axis-1 gearbox on page 129 . Drain the axis 1 gearbox. 5 see replacing cable harness, lower end (axes 1-3) on page 153 . Loosen the cable connectors from the base and pull up the cabling ...

  • Page 181

    Note action article number is specified in required equipment on page 178 . Fit two guide pins in the holes. This will fas- cilitate the removal of the complete arm sys- tem and prevent damage on the gearbox. 11 note make sure all hooks and attachments stay in the correct position while lifting the ...

  • Page 182

    Note action note make sure all hooks and attachments stay in the correct position while lifting the arm system and that the lifting accessory does not wear against sharp edges. Lift the complete arm system and move it at very low speed to the mounting site, making sure it does not tip! Note the refi...

  • Page 183

    Note action reused screws can be used providing they are lubricated as described in screw joints on page 347 . Xx0600003070 place the serrated lock washers on the attach- ment screws. Note check that the serrated lock washers are turned the correct way. See figure! 9 parts: a serrated lock washer (2...

  • Page 184

    Note action xx1000001417 refit the block for calibration and the axis 1 calibration plate . 16 see performing a leak-down test on page 148 . Perform a leak-down test of the axis 1 gear- box. 17 see changing oil, axis-1 gearbox on page 129 . Refill the axis 1 gearbox with lubricating oil. 18 calibrat...

  • Page 185

    4.4 upper and lower arm 4.4.1 replacing the turning disk location of turning disk the turning disk is located in the front of the wrist housing as shown in the figure below. Xx1000001341 required equipment note art. No. Equipment, etc. O-rings are not included! For spare part no. See: spare parts on...

  • Page 186

    Removing, turning disk use this procedure to remove the turning disk. Note action run the robot to a position where the tilthouse is best positioned for the turning disk to be replaced. 1 see calibration scale and correct axis position on page 332 . Note this is done in order to fascilitate fitting ...

  • Page 187

    Note action xx1000001135 remove the turning disk . 7 refitting, turning disk use this procedure to refit the turning disk. Note action art. No. Is specified in required equip- ment on page 185 . Xx1000001285 lubricate the o-ring of the turning disk with grease and fit it to the turning disk. 1 conti...

  • Page 188

    Note action xx1000001310 locate the calibration mark on the turning disk and place the turning disk at the tilthouse so that the calibration mark matches the calibration scale at the tilthouse. The hole pattern of the turning disk allows the turning disk to be fitted in three different rotated posit...

  • Page 189

    Note action danger make sure all safety requirements are met when performing the first test run. These are further detailed in the section danger - first test run may cause injury or damage! On page 45 . 7 3hac039838-001 revision: c 189 © copyright 2013 abb. All rights reserved. 4 repair 4.4.1 repla...

  • Page 190

    4.4.2 replacing the tilthouse unit introduction this section describes how to replace the tilthouse unit. The section consists of these parts: • location of tilthouse unit on page 190 • location of axes 2 and 3 sides of the robot on page 191 • cut away view of the assembly of the tilthouse unit on p...

  • Page 191

    Location of axes 2 and 3 sides of the robot the figures shows the location of the axes 2 and 3 sides of the robot. See markings on the lower arm ( axis 2 ) and the parallel arm ( axis 3 ). These two sides of the robot will be referred to in the replacing procedures. Xx1000001427 axis 2 side (see mar...

  • Page 192

    Xx1000001428 axis 3 side (see marking on parallel arm) continues on next page 192 3hac039838-001 revision: c © copyright 2013 abb. All rights reserved. 4 repair 4.4.2 replacing the tilthouse unit continued.

  • Page 193

    Cut away view of the assembly of the tilthouse unit the figure shows a cut away view of how the tilthouse unit is fitted to the upper arm. Xx1000001424 axis 2 side a axis 3 side b vk cover vk 90x8 (2 pcs) c vk cover vk 19x6 (2 pcs) d screw m6x10 quality 8.8-a2f (4 pcs) + washers (4 pcs) e retaining ...

  • Page 194

    Rust preventive (mercasol 3106) g upper arm h tilthouse j taper roller bearing, d=50/80 t=24(2 + 2 pcs) k ring l shaft (2 pcs) m sealing ring with dustlip, d=70/85 t=8 (2 pcs) n lock nut km (din981), dimension m45 o required equipment note art.No. Equipment, etc. Vk 19x6 (2 pcs) vk cover vk cover d=...

  • Page 195

    Press tool premounting bearing the press tool used for premounting the bearing race, bearing complete, radial seal with dustlip and ring in the tilthouse, consists of the parts shown in the figure. Xx1000001431 note ! Parts of the tool cannot be ordered separatly. All parts (except the hydraulic cyl...

  • Page 196

    Press tool assembly/disassembly axis 6 the press tool used for assembly/disassembly of the tilthouse on the upper arm, consists of the parts shown in the figure. Xx1000001432 note! Parts of the tool cannot be ordered separatly. All parts are included when ordering the complete tool. Note! The hydrau...

  • Page 197

    Removing the tilthouse unit use this procedure to remove the tilthouse unit. Note action xx1000001132 move the robot to a position where the tilthouse rests on a workbench, some pallets or similar. 1 xx1000001067 this is done in order to prevent the tilthouse from falling down when the upper link is...

  • Page 198

    Note action see replacing motor, axis 6 on page 294 . Disconnect motor cables from motor axis 6. Place the motor cables in a way that it will not be damaged. 5 see section replacing linkage - upper link arm on page 221 xx1000001065 loosen the upper link from the tilthouse unit. Tip it might be neces...

  • Page 199

    Note action xx1000001419 be careful not to damage the ball plug ! Note do not remove the ball plug! 8 remove one shaft at a time by following the steps below, starting on axis 2 side. 9 xx1000001072 use compressed air in the m6 hole for filling grease , in order to remove the vk cover . Do this on b...

  • Page 200

    Note action xx1000001073 remove the small vk cover inside with the help of a short punch or similar. 11 xx1000001074 remove the lock nut . 12 art.No. Is specified in required equip- ment on page 194 . Apply the press tool, mounting axis 6 in the following way: • push the torsion bar l=900 through th...

  • Page 201

    Note action xx1000001075 press out the shaft with the press tool. 14 xx1000001076 remove the press tool, mounting axis 6 and the shaft . 15 check that the tilthouse is secured in a over- head crane or similar before proceeding with the next shaft. 16 follow steps above. Remove the shaft on the axis ...

  • Page 202

    Note action xx1000001077 remove the tilthouse and lift the tilthouse to a safe place. Check that bearings are kept clean, if not being refitted. 19 xx1000001422 force away the sealing ring with a screwdriver or similar. The sealing must be replaced with a new one when refitting. 20 check bearings. 2...

  • Page 203

    Note action art.No. Is specified in required equip- ment on page 194 . Apply some grease in the hole for the bearings . 3 shown in the figure cut away view of the assembly of the tilthouse unit on page 193 . Fit two retaining rings for bores in the hole. 4 xx1000001434 fit the outer races of the bea...

  • Page 204

    Premounting the outer races of the bearings and other parts, axis 3 side use this procedure to fit the outer races of the bearings and other parts in the tilthouse on the axis 3 side, before fitting the tilthouse to the upper arm. This work is best done on a workbench or similar. Note action art.No....

  • Page 205

    • premounting the outer races of the bearings and other parts, axis 3 side on page 204 use this procedure to refit the shafts of the tilthouse unit. Note action caution the robot tilt house weighs 85 kg. All lifting accessories used must be sized ac- cordingly! 1 secure the tilthouse with a roundsli...

  • Page 206

    Note action xx1000001438 push the shaft of the axis 3 side into its hole, from the inside. 6 shown in the figure cut away view of the assembly of the tilthouse unit on page 193 . Push the torsion bar l=650 through the hole in the shaft. 7 shown in the figure cut away view of the assembly of the tilt...

  • Page 207

    Note action art. No. Is specified in required equipment on page 194 . Xx1000001439 insert the shims in the space between the tilt- house and the upper arm on the axis 3 side. Caution do not insert the shims too deep! If it is inserted too deep, it will be clamped up by the shaft. Xx0600002748 • shim...

  • Page 208

    Note action fit the small vk covers on axes 2 and 3 using a plastic mallet. 5 fit the big vk covers on axes 2 and 3 using a plastic mallet. 6 fill bearings with grease by removing both m6 screws on either side. One hole is used for filling and the other for letting out air. Fill until grease spills ...

  • Page 209

    4.4.3 replacing the upper arm location of the upper arm the upper arm is located as shown in the figure. Xx1100000016 continues on next page 3hac039838-001 revision: c 209 © copyright 2013 abb. All rights reserved. 4 repair 4.4.3 replacing the upper arm.

  • Page 210

    Cut away view of the assembly of the upper arm components the figure shows a cut away view how the upper arm is fitted to the lower arm. 2 2 3 3 a c d e f f g, h g, h e j k k l l j b m n xx1100000009 axis 2 side 2 axis 3 side 3 shaft axis 3 a lock nut axis 3 b shaft axis 2 c lock nut axis 2 d radial...

  • Page 211

    Required equipment note art.No. Equipment, etc. Includes: • 3hac037314-001 bushing (2 pcs) for spare part no. See: • spare parts on page355 upper arm, axis 4 conical roller bearing 3hac039571-002 grease filling tool optimol longtime pd 2 3hac9408-1 bearing grease mercasol 3106 3hac034903-001 rust pr...

  • Page 212

    Note action danger turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot work- ing area. 7 see section: • replacing the cable harness, upper end (incl. Axis 6) on page 163 remove the cable harness in the upper arm. 8 see secti...

  • Page 213

    Note action shown in the figure: • cut away view of the assembly of the upper arm components on page 210 remove the oil plug . 16 shown in the figure: • cut away view of the assembly of the upper arm components on page 210 remove the radial sealing . 17 for art. No. See: • required equipment on page...

  • Page 214

    Note action fit the radial sealings in the upper arm. Note do not put grease on the sealing rings! 1 shown in the figure: • cut away view of the assembly of the upper arm components on page 210 for art. No. See: • required equipment on page 211 fill the bearings with bearing grease using the grease ...

  • Page 215

    Note action note there must be no grease on the radial sealing when fitting the shaft. Otherwise grease will appear on the surface sup- posed to be cleaned from grease with isopropanol . Clean the shafts and the shaft holes in the upper and lower arms with isopropanol . 8 apply a thin layer of glyce...

  • Page 216

    Refitting the upper arm - securing the shaft use this procedure to secure the shaft of the upper arm. Continue the refitting procedure starting on the axis 2 side. Note action shown in the figure: • cut away view of the assembly of the upper arm components on page 210 check that there is no grease o...

  • Page 217

    Note action xx1100000028 parts: • a: shaft axis 2 • c: tapered roller bearing • d: sealing ring with o-ring • e: sealing • f: lock nut + loctite 243 only applicable to the axis 2 side! See the exploded view of the parts in the continued procedure of fitting the axis 2 side. 3 shown in the figure: • ...

  • Page 218

    Note action shown in the figure: • cut away view of the assembly of the upper arm components on page 210 fit o-ring on the sealing ring . 9 specified in required equipment on page 211 . Lubricate the bearing with bearing grease . 10 shown in the figure: • cut away view of the assembly of the upper a...

  • Page 219

    Note action xx1100000040 only applicable to the axis 2 side! Measure the distance between the slide cal- iper and the lower arm on the side shown in the figure, using a feeler gage (0.3 mm). The measure shall be 0.3 mm . 20 wipe off residual grease from the shaft. 21 xx1100000044 fill the gaps betwe...

  • Page 220

    Note action see sections: • replacing linkage - upper link arm on page 221 • replacing the linkage - lower link arm on page 228 • replacement of linkage - link on page 235 refit the linkage system . 3 see section: • replacing the cable harness, upper end (incl. Axis 6) on page 163 refit the cable ha...

  • Page 221

    4.4.4 replacing linkage - upper link arm overview the linkage consists of three basic parts - upper link arm , lower link arm and link . This procedure describes how to remove and refit the upper link arm. How to replace lower link arm and link see: • replacing the linkage - lower link arm on page 2...

  • Page 222

    Required equipment note art no. Equipment for spare part no. See: • spare parts on page 355 upper link arm replace if damaged. For spare part no. See: • spare parts on page 355 spherical roller bearing (2 pcs) replace if damaged. For spare part no. See: • spare parts on page 355 support washer (2 pc...

  • Page 223

    Note action xx1000001252 caution if the lower link arm is removed, secure the link with a roundsling in an overhead crane. Use the hole in the middle of the link. This is done in order to prevent the link from moving if both the upper and lower link arms are removed. 3 danger turn off all: • electri...

  • Page 224

    Note action art. No. Is specified in required equip- ment on page 222 . Xx1000001081 remove the upper link arm as shown in the figure, by using the assembly tool as a puller tool. Note the support washers on the inside of the link arm can stick to the grease of the bearings when the link arm is bein...

  • Page 225

    Note action for art. No. See: required equipment on page 222 . Lubricate the bearings properly with bearing grease . 2 for art. No. See: • required equipment on page 222 xx1000001086 apply sealing compound permatex no. 3 on the surface of both shaft ends where the spacer rings complete will be fitte...

  • Page 226

    Note action xx1000001264 refit the support washers on the spacer rings complete. 5 check that the bearings in the upper link arm are fitted correctly, that is in the center of the hole. (the same distance from bearing to the edge of the link arm on both sides.) 6 caution the link weighs 23 kg. All l...

  • Page 227

    Note action xx1000001080 refit the support washers on the outside of the upper link arm , on the lock nuts. 9 for art. No. See: • required equipment on page 222 apply locking liquid on the threads of the lock nuts. 10 for art. No. See: • required equipment on page 222 tightening torque: 120 nm. Xx10...

  • Page 228

    4.4.5 replacing the linkage - lower link arm overview the linkage consists of three basic parts - upper link arm, lower link arm and link. The procedures below details how to remove and refit the lower link arm. How to replace the upper link arm and link, see: • replacing linkage - upper link arm on...

  • Page 229

    Required equipment note art no. Equipment for spare part no. See: • spare parts on page 355 lower link arm for spare part no. See: • spare parts on page 355 spherical roller bearing replace if damaged. For spare part no. See: • spare parts on page 355 support washer optimol longtime pd2 3hab9408-1 b...

  • Page 230

    Note action xx1000001252 if the upper link arm is removed, secure the link with a roundsling in a crane. Use the hole in the middle of the link. 2 this is done in order to prevent the link from moving if both the upper link arm and lower link arm are removed. Xx1000001251 remove the lock nuts and su...

  • Page 231

    Note action xx1000001253 remove the lower link arm by lifting it straight out. Note the support washers on the inside of the rod can stick to the grease of the bearings when the rod is being removed. Remove them from the rod! 5 xx1000001255 support washers: 1 + 1 pc spacer rings, complete: 1 + 1 pc ...

  • Page 232

    Note action specified in required equipment on page 229 . Lubricate the bearings properly with bearing grease . 2 specified in required equipment on page 229 . Xx1000001086 apply sealing compound on the surface of both shaft ends wher the spacer rings will be fitted. 3 xx1000001258 refit the sealing...

  • Page 233

    Note action replace if damaged. Xx1000001259 refit the support washers on the seal- ing/spacer rings. 5 tip putting some grease on the support washers will keep them in position. Check that the bearings in the lower link arm are fitted correctly, that is in the center of the hole. (the same distance...

  • Page 234

    Note action specified in required equipment on page 229 . Apply locking liquid on the threads of the lock nuts. 9 replace if damaged. Fit the support washers on the lock nuts. 10 xx1000001262 refit the lock nuts on the shaft ends. Use a km10 socket. 11 tightening torque: 120 nm. Danger make sure all...

  • Page 235

    4.4.6 replacement of linkage - link overview the linkage consists of three basic parts - upper link arm, lower link arm and link. The procedures below details how to remove and refit the link. How to replace the upper link arm and lower link arm, see: • replacing linkage - upper link arm on page 221...

  • Page 236

    Cut away view of the assembly of the link the figure shows a cut view of how the link is fitted. A c, d e f, g h j b k n m l xx1100000010 vk cover d=120 mm, t=12 mm a small vk cover b lock nut c locking liquid (loctite 243) d bearing, outer races (2 pcs) e bearing, inner races (2 pcs) f bearing grea...

  • Page 237

    Radial sealing with dust lip k rust preventive, mercasol 3106 l o-ring 85x2 m shaft n required equipment note art. No. Equipment, etc. For spare part no. See: • spare parts on page 355 link used for bearings. 3hac5281-1 auxiliary shaft used to press the link on the shaft 3hac039304-002 pressing tool...

  • Page 238

    Note action xx1000001265 secure the link with a roundsling in a crane. Use the hole in the middle of the link. This is done to prevent the link from moving when the upper link arm and lower link arm are removed. 2 detailed in section replacing linkage - upper link arm on page 221 remove the upper li...

  • Page 239

    Note action xx1000001267 use compressed air to remove the vk cov- er . Blow with a very low air pressure into the hole for filling grease. Caution only a very low air pressure is needed! 5 put one hand with some paper on top of the vk cover in order to catch it when re- leased. Shown in cut away vie...

  • Page 240

    Note action wipe off residual grease. 12 if needed, replace the bearings and radial seal. 13 preparations - fitting outer races of the bearing and sealing in the link use this procedure to fit the outer races of the bearings in the link. The figure shows parts and press tool placed in the link, read...

  • Page 241

    Note action put the link on a workbench. 1 check that the parts and the tool are ap- plied correctly, as shown in the previous figure. Apply outer races and radial sealing with dust lip on the pressing tool in following or- der: 1 radial sealing wit dust lip 2 outer race 3 link 4 outer race 2 replac...

  • Page 242

    Refitting, link use this procedure to refit the link of the linkage. Note action caution the link weighs 46 kg. All lifting accessories used must be sized accordingly! 1 secure the link with a roundsling in an overhead crane and lift it to the mounting position. 2 art.No. Is specified in required eq...

  • Page 243

    Note action secure the lock nut in these three steps: 1 tighten with a torque of 300 nm. 2 unscrew the lock nut. 3 tighten the lock nut finally with a tightening torque of 175 nm. Note the recommended order of tightening the lock nut is important to follow to avoid future problems with the shaft. 9 ...

  • Page 244

    4.4.7 replacing the parallel rod location of parallel rod the parallel rod is located as shown in the figure. Xx1000001347 required equipment note art.No. Equipment, etc. For spare part no. See: • spare parts on page 355 . Parallel rod 3hac5021-1 mounting/demounting tool loctite 243 3hab7116-1 locki...

  • Page 245

    Note art.No. Equipment, etc. These procedures include refer- ences to the tools required. Other tools and procedures may be required. See refer- ences to these procedures in the step-by-step instruc- tions below. Removing, parallel rod use this procedure to remove the parallel rod. The procedure is ...

  • Page 246

    Note action xx1000001349 remove the upper lock screw and washer , that secure the parallel rod in position. 3 art. No. Is specified in required equipment on page 244 . Xx0700000065 parts: a shaft b cover washer c parallel rod d sealed spherical bearing e bearing grease f thrust washer remove the upp...

  • Page 247

    Note action caution the parallel rod weighs 45 kg. All lifting accessories used must be sized accordingly! 6 xx1000001350 move the parallel rod backwards from its upper connection point and let it rest against the balancing weight. 7 secure the parallel rod with a roundsling in an overhead crane or ...

  • Page 248

    Note action caution the parallel rod weighs 45 kg. All lifting accessories used must be sized accordingly! 3 xx1000001354 lift the parallel rod to the mounting position of the lower end, and let it rest on the the balancing weight. 4 xx0700000065 parts: a shaft b cover washer c parallel rod d sealed...

  • Page 249

    Note action art. No. Is specified in required equip- ment on page 244 . Refit the shaft (a) by pressing it through the parallel bar with the fitting/removing tool . 7 see figure above! Loctite 243 apply locking liquid in the hole of the lock screw. 8 xx1000001349 lock screw: m6x16 plain washer: 6.4x...

  • Page 250

    Note action danger make sure all safety requirements are met when performing the first test run. These are further detailed in the section danger - first test run may cause injury or damage! On page 45 . 12 250 3hac039838-001 revision: c © copyright 2013 abb. All rights reserved. 4 repair 4.4.7 repl...

  • Page 251

    4.4.8 replacing the complete lower arm location of lower arm the complete lower arm is located as shown in the figure below. Xx1000001355 lower arm a parallel arm b required equipment note art.No. Equipment, etc. For spare part no. See: • spare parts on page 355 . Lower arm always change the sealing...

  • Page 252

    Note art.No. Equipment, etc. Content is defined in section standard tools on page 351 . - standard toolkit these procedures include refer- ences to the tools required. Other tools and procedures may be required. See refer- ences to these procedures in the step-by-step instructions below. See chapter...

  • Page 253

    Note action see . Remove the cable harness in the upper and lower arm. 7 secure the cable harness in a way that it is pro- tected from oil spill and damage. See replacing the upper arm on page 209 . Remove the complete upper arm. 8 see replacing motors, axes 2 and 3 on page 284 . Remove the axes 2 a...

  • Page 254

    Note action xx1000001356 remove all m12 and m16 screws that hold the lower arm, on both sides. Note the axis 3 side has no m16 screws! 14 xx1000001359 danger secure the parallel arm to the lower arm before lifting the lower arm system. If not secured, the parallel arm can fall down and cause a serio...

  • Page 255

    Note action xx1000001357 move the parallel arm and secure it to the lower arm as shown in the figure, to prevent it from falling down. 17 note if the parts are not pushed together, it will be difficult to remove the com- plete lower arm. The space between the gearboxes is cramp. Push therefor the lo...

  • Page 256

    Refitting, lower arm use this procedure to refit the lower arm system. Note action see replacement of parallel arm on page 259 . Fit the parallel arm to the lower arm. 1 caution the robot lower arm weighs 270 kg. All lifting accessories used must be sized accord- ingly! 2 xx1000001369 fit a roundsli...

  • Page 257

    Note action art. No. Is specified in required equipment on page 251 . Xx1000001370 put the lower arm in its mounting position. If the hole pattern needs to be adjusted, use a crank to move the gears in order to find the cor- rect hole pattern. 5 note refit the axis 2 side first! 6 verify that the se...

  • Page 258

    Note action dimension is specified in required equipment on page 251 . Xx1000001101 secure the lower arm by fitting a lock screw . Caution tighten by hand! 13 see replacing the gearbox, axes 2- 3 on page 311 . Refit the axes 2 and 3 gearboxes. 14 see replacing motors, axes 2 and 3 on page 284 . Refi...

  • Page 259

    4.4.9 replacement of parallel arm location of parallel arm the parallel arm is located as shown in the figure below. Xx1000001381 required equipment note art.No. Equipment, etc. For spare part no. See: • spare parts on page 355 . Parallel arm d=120 mm, t=12 mm 3haa2166-23 vk cover d=35 mm, t=8 mm 3h...

  • Page 260

    Note art.No. Equipment, etc. 3hac038377-002 lifting accessory, parallel arm - level content is defined in section standard tools on page 351 . - standard toolkit these procedures include refer- ences to the tools required. Other tools and procedures may be required. See refer- ences to these procedu...

  • Page 261

    Note action xx1000001371 remove the two vk covers. 4 art. No. Is specified in required equipment on page 259 . Xx1000001375 fit the lifting accessory, parallel arm on the parallel arm. Lift the parallel arm to the position shown in the figure. 5 art. No. Is specified in required equipment on page 25...

  • Page 262

    Note action xx1000001018 remove the parallel arm. 8 if needed, change the bearings. 9 refitting, parallel arm use this procedure to refit the parallel arm. Note action refitting of the parallel arm is best performed on a workbench. 1 specified in required equipment on page 259 apply some grease on t...

  • Page 263

    Note action art. No. Is specified in required equipment on page 259 xx1000001377 refit a bearing on each shaft with pressing tool, lower arm . 4 caution the parallel arm system weighs 125 kg. All lifting accessories used must be sized accord- ingly! 5 art. No. Is specified in required equipment on p...

  • Page 264

    Note action xx1000001379 lift the parallel arm, lower it and put it in mounting position with the lower arm. 10 art. No. Is specified in required equipment on page 259 . Carefully press the parallel arm onto the lower arm using the pressing tool, lower arm . 11 fit the big and small vk cover. 12 det...

  • Page 265

    4.5 frame and base 4.5.1 replacing the balancing device location, balancing device the balancing device is located as shown in the figure. Xx1000001110 balancing device a required equipment note art.No. Equipment, etc. For spare part num- ber, see spare parts on page 355 . Balancing device replace i...

  • Page 266

    Note art.No. Equipment, etc. 2 pcs, m12 x 50 screw for neutralizing the spring force of the balancing cylinder. 3hac039296-002 lubrication tool - lifting accessories permatex no. 3. 12360012-202 sealing compound loctite 243 3hab7116-1 locking liquid content is defined in section standard tools on pa...

  • Page 267

    Note action xx1000001111 remove the plastic screws in the upper end of the balancing device. 4 insert two screws, m12x50 in the holes to neutralize the spring force. Screw in the screws until they have proper contact with the cylinder inside. 5 the length of the cylinder is now locked and the balanc...

  • Page 268

    Note action xx1000001113 remove the upper and lower lock nuts and support washers (2+2 pcs). 7 stretch the roundsling . 8 xx1000001115 apply a ball bearing puller behind the lower ear of the balancing device. Note the ball bearing puller must be applied around the spacer ring . See figure! 9 caution...

  • Page 269

    Note action xx1000001114 with the help of the ball bearing puller carefully remove the balancing device from its upper and lower attachments. 11 remove the balancing device and put it in a safe place. 12 xx1000001116 remove upper and lower spacer rings and support washers (2+2 pcs). 13 remove residu...

  • Page 270

    Note action xx1000001270 apply sealing compound on the surface for the sealing ring. Tip apply the sealing compund on the sealing rings. 2 xx1000001116 refit the inner sealing rings and support washers in both ends. 3 check that the bearings in the balancing device are fitted correctly, that is in t...

  • Page 271

    Note action xx1000001112 attach lifting accessory to the balancing device and lift it on to the auxiliary shafts. 6 xx1000001111 adjust the length between the upper and lower bearings by means of the m12 screws, used to neutralize the spring force. This length should preferably be 0.5 mm too short t...

  • Page 272

    Note action xx1000001271 carefully refit the balancing device on the upper and lower shafts. 8 art.No. Is specified in section required equipment on page 265 . Fit the lubricating tool . The tool should be tightened to the bottom po- sition by hand power only. 9 fill the bearings with grease through...

  • Page 273

    Note action xx1000001111 refit the plastic screws in the m12 hole of the balancing device. 16 xx1000001101 remove the lock screw . 17 danger make sure all safety requirements are met when performing the first test run. These are further detailed in the section danger - first test run may cause injur...

  • Page 274

    4.5.2 replacing the balancing weight location of the balancing weight the balancing weight is located as shown in the figure. Xx1000001286 required equipment note art. No. Equipment etc. For art. No. See: • spare parts on page 355 balancing weight m16 - lifting lugs (2 pcs) loctite 243 3hab7116-1 lo...

  • Page 275

    Note art. No. Equipment etc. Content is defined in section standard tools on page 351 . - standard toolkit these procedures include references to the tools re- quired. Other tools and procedures may be required. See refer- ences to these procedures in the step-by-step instructions below. Removing th...

  • Page 276

    Note action xx1000001296 remove the attachment screws securing the balancing weight. 6 xx1000001299 lift the balancing weight and put it some- where safe. 7 refitting the balancing weight use this procedure to refit the balancing weight. Note action xx1000001298 fit two lifting lugs (m16) in the bal...

  • Page 277

    Note action secure the balancing weight with round- slings (using the lifting lugs) in an overhead crane or similar. 3 xx1000001300 lift the balancing weight and put it in its position on the parallel arm. 4 for art. No. See: • required equipment attachment screws: m16x120 (2 pcs) put locking liquid...

  • Page 278

    4.6 motors 4.6.1 replacing motor, axis 1 location of motor axis 1 the motor axis 1 is located on the left hand side of the robot as shown in the figure. Xx1000001175 required equipment note art.No. Equipment, etc includes: • motor • pinion • o-ring (the old o-ring must be replaced when replacing the...

  • Page 279

    Note art.No. Equipment, etc used to lubricate the o-ring 3hab3537-1 grease used to reach the attachment screws for the motor. 3hac023760-001 bits extension 24 vdc, max. 1,5 a - power supply for releasing the brakes. Content is defined in section stand- ard tools on page 351 . - standard toolkit thes...

  • Page 280

    Note action xx1000001094 remove the cable gland cover at the cable exit of the motor. Note make sure the gasket is undamaged! Replace if damaged. 3 disconnect all connectors beneath the motor cover. 4 connect to connector r2.Mp1 • + : pin 2 • - : pin 5 in order to release the brake, connect the 24 v...

  • Page 281

    Note action xx1000001021 remove the motor by carefully lifting it straight up to get the pinion away from gear. Caution be careful not to damage the pinion in the pro- cess! 9 disconnect the brake release voltage. 10 check the pinion. If there is any damage, the pinion must be replaced. 11 refitting...

  • Page 282

    Note action connect to connector r2.Mp1 • + : pin 2 • - : pin 5 in order to release the brake, connect the 24 vdc power supply. 3 xx1000001269 gently lower the motor into the gear, making sure the pinion is properly mated to the gearbox of axis 1. Note make sure the motor is turned the right way. Se...

  • Page 283

    Note action xx1000001092 refit the motor cover with its attachment screws. Note make sure the cover is tightly sealed! 9 calibration is detailed in a separate calibration manual enclosed with the calibration tools. Recalibrate the robot! 10 general calibration information is in- cluded in section ca...

  • Page 284

    4.6.2 replacing motors, axes 2 and 3 location of motors, axes 2 and 3 the motors axes 2 and 3 are located on either side of the robot as shown in the figure. The procedure is the same for both motors. Xx1000001100 required equipment note art. No. Equipment, etc. Includes • motor • pinion • o-ring (t...

  • Page 285

    Note art. No. Equipment, etc. For lubricating the o-ring. 3hab3537-1 grease m10x150 3hac13120-2 guide pins for guiding the motor. Guide pins are to be used in pairs! 3hac14586-1 lifting accessory, motor axes 2-3 m16x55 - lock screw for securing the lower arm. Used to reach the attachment screws for ...

  • Page 286

    Note action see figure above. Lock the lower arm by inserting the lock screw into the hole of the frame. 2 this is done in order to secure axis 2 from col- lapsing when the axis 2 motor is being removed. Caution tighten by hand! Run axis 3 to the end position so that it rests against the mechanical ...

  • Page 287

    Note action xx1000001103 remove the cable gland cover at the cable exit . Note make sure the gasket is not damaged! Replace if damaged. 7 disconnect all connectors beneath the motor cover. 8 connect to connector r2.Mp2 • + : pin 2 • - : pin 5 in order to release the brake, connect the 24 vdc power s...

  • Page 288

    Note action art. No. Is specified in required equipment on page 284 . Xx1000001131 fit two guide pins in two of the motors attach- ment holes. 11 m12x70, fully threaded. If required, press the motor out of position by fitting two screws in the remaining attachment holes of the motor, diagonal to eac...

  • Page 289

    Note action xx1000001105 pull out the motor on the guide pins to get the pinion away from the gear. Make sure the pinion does not get damaged! 15 remove the motor by gently lifting it straight out and place it on a secure surface. 16 disconnect the brake release voltage! 17 check the pinion. If ther...

  • Page 290

    Note action connect to connector r2.Mp1 • + : pin 2 • - : pin 5 in order to release the brake, connect the 24 vdc power supply. 2 art. No. Is specified in required equipment on page 284 . Fit the lifting tool, motor axes 2-3 to the motor. 3 art. No. Is specified in required equipment on page 284 . X...

  • Page 291

    Note action xx0200000165 use the rotation tool in order to rotate the motor pinion when mating it to the gear (see figure). Fit the motor, making sure the motor pinion is properly mated to the gear of gearbox axis 2-3 and that it doesn´t get damaged. Note the rotation tool is used beneath the motor ...

  • Page 292

    Note action xx1000001103 refit the cable gland cover at the cable exit with its two attachment screws. Note use a new gasket! 13 xx1000001102 refit the motor cover with its attachment screws and washers. Note make sure the cover is tightly sealed! 14 xx1000001101 remove the lock screw from the hole ...

  • Page 293

    Note action calibration is described in a separate calibration manual enclosed with the calibration tools. Recalibrate the robot! 18 general calibration information is in- cluded in section calibration informa- tion on page 329 . Danger make sure all safety requirements are met when performing the f...

  • Page 294

    4.6.3 replacing motor, axis 6 location of motor axis 6 motor axis 6 is located in the center of the tilthouse as shown in the figure. Xx1000001239 required equipment note art.No. Equipment, etc. Includes • motor • pinion • o-ring (the o-ring must be replaced when the motor is replaced) for spare par...

  • Page 295

    Note art.No. Equipment, etc. Loctite 243 3hab7116-1 locking liquid 24 vdc, 1.5 a - power supply for releasing the brakes. For lubricating the o-ring. 3hab3537-1 grease content is defined in section standard tools on page 351 . - standard toolkit these procedures include refer- ences to the tools req...

  • Page 296

    Info action a xx0600002694 remove the cable gland cover at the cable exit by unscrewing its attachment screw (a) on the inside. Note make sure the gasket is not damaged! 4 a b c d xx0500002466 a signal lamp (ul lamp) b cable straps, outdoor c cable d connection point to the cable gland disconnect al...

  • Page 297

    Info action xx1000001108 lift the motor carefully to get the pinion away from the gear. Note make sure the pinion does not get dam- aged! 9 disconnect the brake release voltage. 10 remove the motor by gently lifting it straight up and place it on a secure surface. 11 refitting, motor axis 6 use this...

  • Page 298

    Info action art. No. Is specified in required equipment on page 294 . Fit the two guide pins in two of the motor attach- ment holes. 3 xx1000001108 lift the motor carefully in place. Make sure the motor pinion is properly mated to the gearbox, axis 6. Note make sure the motor is turned the correct w...

  • Page 299

    Info action xx1000001224 check the gasket . If damaged, replace it. 12 a xx0600002694 refit the cable gland with its attachment screw. 13 • a: screw holding the cable gland make sure the gasket is not damaged! Replace if damaged. Xx1000001106 refit the cover, motor axis 6 with its attachment screws ...

  • Page 300

    Info action calibration is detailed in a separate calibration manual enclosed with the calibration tools. Recalibrate the robot! 15 general calibration information is in- cluded in section calibration informa- tion on page 329 . Danger make sure all safety requirements are met when performing the fi...

  • Page 301

    4.7 gearboxes 4.7.1 replacing the axis 1 gearbox location of gearbox the axis 1 gearbox is located between the frame and base as shown in the figure. Xx1000001309 required equipment note art. No. Equipment, etc. Includes: • gearbox • all o-rings and sealing rings for spare part no. See: • spare part...

  • Page 302

    Note art. No. Equipment, etc. Replace if damaged! 3hab3772-55 o-ring replace if damaged! 3hac11732-2 washer for lubricating the o-rings. 3hab3537-1 grease 3hac15535-1 support, base and gear 1 3hac15560-1 lifting accessory, base 3hac15556-1 lifting accessory (chain) 2 pcs, m16x150. Guide pins used fo...

  • Page 303

    Note action see changing oil, axis-1 gearbox on page 129 . Drain the axis 1 gearbox. 3 see replacing the base, including axis 1 gearbox on page 178 . Remove the complete arm system. 4 unfasten the robot base from the foundation by removing the base attachment screws. 5 xx1000001395 attach the liftin...

  • Page 304

    Note action xx1000000364 a support base (4 pcs) secure the support to the base and to the foundation. Make sure the base remains in a stable position before performing any work under- neath the base! 9 xx1000001385 remove the bottom plate from underneath the base in order to get access to the attach...

  • Page 305

    Note action xx1000001386 attachment screws: 18 pcs. Washers: 3 pcs. Unscrew the attachment screws and re- move the washers. 11 xx1000001387 remove the cable guide in the center of gearbox 1 by unscrewing its attachment screws. 12 caution the gearbox weighs 200 kg. All lifting accessories used must b...

  • Page 306

    Refitting, gearbox axis 1 use this procedure to refit gearbox, axis 1. Note action mounting of the support, base and gear 1 is detailed in section removal, gear- box axis 1 on page 302 . Xx1000000364 a support base (4 pcs) fit the support, base and gear 1 to the base. 1 art no. Is specified in requi...

  • Page 307

    Note action xx1000001392 make sure the small o-ring around the oil hole is fitted properly! 3 specified in required equipment on page 301 . Xx1000001395 attach the lifting accessory, base and gear 1 and a roundsling , to the gearbox. 4 specified in required equipment on page 301 . Fit two guide pins...

  • Page 308

    Note action xx1000001389 lift the gearbox. Make sure the guide pin in the bottom face of the gearbox is properly aligned with the base. 7 xx1000001391 always use guide pins in pairs! Lift gearbox axis 1 onto the guide pins and lower it carefully to its mounting position. 8 continues on next page 308...

  • Page 309

    Note action 18 pcs, m16 x 70, 12.9 quality un- brako. Secure the gearbox with its attachment screws and washers. 9 tightening torque: 300 nm reused screws may be used, providing they are lubricated as detailed in sec- tion screw joints on page 347 before fit- ting. Xx1000001394 xx1000001393 refit th...

  • Page 310

    Note action 1 screw: m6 x 8. Xx0300000612 refit the bottom plate underneath the robot base by pushing it into the groove and fitting the attachment screw. If removed, also refit the rear connector plate. Note direct the bends on the bottom plate down- wards! 11 • a: bottom plate • b: rear connector ...

  • Page 311

    4.7.2 replacing the gearbox, axes 2- 3 location of gearbox, axes 2-3 the axis-2 and axis-3 gearboxes are located on either side of the frame as shown in the figure. Xx1000001399 required equipment note art.No equipment, etc. For spare part no. See: • spare parts on page 355 . Gearbox, axes 2-3 alway...

  • Page 312

    Note art.No equipment, etc. Roundsling and a rotating lifting point. - lifting accessory lifting capacity: 100 kg. Used to lift the gearbox. Use to keep the sealing in place. 3hac14628-1/2 guide sleeves use to lubricate surfaces on the gearbox for easier assembly. Grease content is defined in sectio...

  • Page 313

    Note action axis 2: xx1100000623 when removing axis 2 gearbox: remove all screws in the lower screw area on the inside of the lower arm (7 pcs m12, 2 pcs m16). See figure. When removing axis 3 gearbox: remove all screws in the upper front screw area and three screws in the upper back area. 2 axis 3:...

  • Page 314

    Note action release the brakes of axis 2 to rest the weight of the axis against the lock screw. 6 release the brakes of axis 3 to rest the weight of the axis against the pallets. 7 xx1000001111 remove the two plastic screws in the upper end of the balancing device. Note keep the plastic screws. They...

  • Page 315

    Note action xx1000001405 remove all remaining attachment screws that secure the gearbox to the lower arm system. Axis 2: m16 and m12. Axis 3: m12. 15 xx1000001400 remove the gearbox cover by removing its attachment screws. 16 note always use guide pins in pairs! Remove two opposite screws of the att...

  • Page 316

    Note action caution the gearbox weighs 69 kg. All lifting accessories used must be sized accordingly! 20 if required, apply two screws, m12x100 to the holes in the gearbox, in order to press it free. (the screws need to have a full thread.) 21 caution when the gearbox comes free from the frame and c...

  • Page 317

    Note action xx1000001403 remove the sealing from the lower arm and clean it. Note the sealing can hang onto the gearbox, sticking to the oil. 24 refitting, axis-2 / axis-3 gearbox use this procedure to refit the axes-2 or axis-3 gearbox. Note action xx1000001404 make sure that the o-ring is fitted t...

  • Page 318

    Note action caution the gearbox weighs 69 kg! All lifting equipment used must be sized accordingly! 3 specified in required equipment on page 311 . Fit the lifting accessory to the gearbox and lift it with an overhead crane. 4 art. No. Is specified in required equipment on page 311 . Fit a new seali...

  • Page 319

    Note action xx1000001406 put the gearbox onto the guide pins and slide it carefully into place in the frame. Note check that the sealing is in place during the procedure. 7 use a crank to move the gears in order to find the holes for the attachment screws. 8 axis 2 secure the gearbox to the lower ar...

  • Page 320

    Note action xx1000001407 fit the o-ring in the cover. 14 m8x35 quality 8.8-a2f (12 pcs) refit the cover with its attachment screws and washers. Note fit the cover so that the arrow on the cover points upwards! 15 tightening torque: 24 nm xx1000001408 see replacing motors, axes 2 and 3 on page 284 re...

  • Page 321

    Note action xx1000001111 remove the screws that unload the balan- cing device and put back the plastic screws. 19 remove the lock screw from the lower arm. 20 axis 2 run the axes 2 and 3 to a position where the remaining screws in the lower arm can be fitted. 21 m12x60 quality 12.9 gleitmo (6 pcs) •...

  • Page 322

    4.7.3 replacing gearbox axis 6 location of gearbox axis 6 the axis 6 gearbox is located in the center of the wrist as shown in the figure. Xx1000001409 required equipment note art. No. Equipment includes o-ring for spare part no. See: • spare parts on page 355 . Gearbox axis 6 for spare part no. See...

  • Page 323

    Note art. No. Equipment for lubricating o-ring 3hab3537-1 grease always use guide pins in pairs! - guide pins the content is defined in the section standard tools on page 351 . Standard toolkit these procedures include references to the tools re- quired. Other tools and propcedures may be rquired. S...

  • Page 324

    Note action xx1000001411 remove the gearbox by unscrewing the at- tachment screws and washers that secure it. 6 xx0200000220 if required apply two m8 screws in the holes shown in the figure, and press out the gearbox. 7 a: m8 holes for pressing out the gearbox continues on next page 324 3hac039838-0...

  • Page 325

    Note action xx1000001412 remove gearbox axis 6 carefully without damaging pinion or gear. 8 xx1000001413 check the pinion. A damaged pinion must be replaced! 9 refitting gearbox axis 6 use this procedure to refit gearbox axis 6. Note action danger turn off all: • electric power supply • hydraulic pr...

  • Page 326

    Note action for art. No. See: required equipment on page 322 . Xx1000001414 make sure the o-ring is undamaged and fit- ted to the gearbox. If the o-ring is damaged, replace! Lubricate the o-ring with grease. 2 see section: • manually releasing the brakes on page 73 release the brakes of the axis 6 m...

  • Page 327

    Note action xx1000001412 carefully insert the axis 6 gearbox into the tilthouse, using guide pins. Make sure the gears of the gearbox mate with the pinion of the axis 6 motor. Caution do not damage pinion or gears in the pro- cess! 5 xx1000001411 m10x50 quality 12.9 gleitmo (18 pcs) tightening torqu...

  • Page 328

    Note action xx1000001410 refit the calibration plate . 10 calibration is described in a separate calibration manual enclosed with the cal- ibration tools. Recalibrate the robot. 11 general calibration information is included in section calibration information on page 329 . Danger make sure all safet...

  • Page 329: 5 Calibration Information

    5 calibration information 5.1 introduction general this chapter includes general information about the different calibration methods and also the detailed procedures that do not require specific calibration equipment. When the robot system must be recalibrated, it is done according to the documentat...

  • Page 330

    5.2 calibration methods overview this section specifies the different types of calibration and the calibration methods that are supplied by abb. Types of calibration calibration method description type of calibration calibration pendulum (standard method) the calibrated robot is positioned at home p...

  • Page 331

    Calibration methods each calibration method is detailed in a separate manual. Following is a brief description of the methods available. Calibration pendulum - standard method calibration pendulum is the standard method for calibration of all abb robots (except irb 6400r, irb 640, irb 1400h, and irb...

  • Page 332

    5.3 calibration scale and correct axis position introduction this section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration scales / marks, irb 760 the illustration shows calibration scale positions on irb 760. Xx1000001146 calibration plate, ax...

  • Page 333

    Calibration marks at axes 2, 3 and 6 the calibration marks at axes 2, 3 and 6, shown in the figure above, consist of two single marks that should be positioned opposite to one another when the robot is standing in its calibration position. One of the marks is more narrow than the other and should be...

  • Page 334

    5.4 calibration movement directions for all axes overview when calibrating, the axis must consistently be run towards the calibration position in the same direction in order to avoid position errors caused by backlash in gears and so on. Positive directions are shown in the graphic below. This is no...

  • Page 335

    5.5 updating revolution counters introduction this section describes how to do a rough calibration of each manipulator axis, which is updating the revolution counter value for each axis using the flexpendant. Step 1 - manually running the manipulator to the calibration position use this procedure to...

  • Page 336

    Action tap the mechanical unit in question. 2 a screen is displayed, tap rev. Counters . En0400000771 tap update revolution counters... . A dialog box is displayed warning that updating the revolution counters may change programmed manipulator positions: • tap yes to update the revolution counters. ...

  • Page 337

    5.6 checking the calibration position introduction check the calibration position before beginning any programming of the robot system. This may be done: • using a moveabsj instruction with argument zero on all axes. • using the jogging window on the flexpendant. Using a moveabsj instruction use thi...

  • Page 338

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  • Page 339: 6 Decommissioning

    6 decommissioning 6.1 environmental information hazardous material the table specifies some of the materials in the product and their respective use throughout the product. Dispose components properly to prevent health or environmental hazards. Example application material serial measurement board b...

  • Page 340

    6.2 decommissioning of balancing device general there is much energy stored in the balancing device. Therefore a special procedure is required to dismantle it. The coil springs inside the balancing device exert a potentially lethal force unless dismantled properly. The device must be dismantled by a...

  • Page 341

    Decommissioning at decommissioning company, balancing device the instruction below details how to decommission the balancing device. Contact abb robotics for further consultation. Note action danger there is stored energy built up by high tensioned compression springs inside the balancing device! Wh...

  • Page 342

    Note action danger there is stored energy built up by high tensioned compression springs inside the balancing device! When a coil is cut the released tension creates a spatter of sparks and flames. The working area must be free of flam- mable materials. Position the balancing device so that the spat...

  • Page 343: 7 Reference Information

    7 reference information 7.1 introduction general this chapter includes general information, complementing the more specific information in the different procedures in the manual. 3hac039838-001 revision: c 343 © copyright 2013 abb. All rights reserved. 7 reference information 7.1 introduction.

  • Page 344

    7.2 applicable safety standards standards, en iso the manipulator system is designed in accordance with the requirements of: description standard safety of machinery - basic concepts, general principles for design - part 1: basic terminology, methodology en iso 12100 -1 safety of machinery - basic c...

  • Page 345

    Description standard safety standard for robots and robotic equipment ansi/ul 1740 (option 429-1) industrial robots and robot systems - general safety require- ments can/csa z 434-03 (option 429-1) 3hac039838-001 revision: c 345 © copyright 2013 abb. All rights reserved. 7 reference information 7.2 ...

  • Page 346

    7.3 unit conversion converter table use the following table to convert units used in this manual. Units quantity 39.37 in 3.28 ft. 1 m length 2.21 lb. 1 kg weight 0.035 ounces 1 g weight 14.5 psi 100 kpa 1 bar pressure 0.225 lbf 1 n force 0.738 lbf-ft 1 nm moment 0.264 us gal 1 l volume 346 3hac0398...

  • Page 347

    7.4 screw joints general this section describes how to tighten the various types of screw joints on the irb 760. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials. Unbrako screws unbrako is a special type of sc...

  • Page 348

    • always tighten the joint by hand, and never use pneumatic tools. • use the correct tightening technique , that is do not jerk. Tighten the screw in a slow, flowing motion. • maximum allowed total deviation from the specified value is 10% ! Oil-lubricated screws with slotted or cross-recess head sc...

  • Page 349

    Tightening torque (nm) class 12.9, lubricated i tightening torque (nm) class 10.9, lubricated i dimension 950 790 m24 i lubricated with molycote 1000, gleitmo 603 or equivalent water and air connectors the following table specifies the recommended standard tightening torque for water and air connect...

  • Page 350

    7.5 weight specifications definition in installation, repair, and maintenance procedures, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are highlighted in this way. To avoid injury, abb recommends the use of a lifting accessory when handling compo...

  • Page 351

    7.6 standard tools general all service (repairs, maintenance, and installation) procedures contains lists of tools required to perform the specified activity. All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the standar...

  • Page 352

    7.7 special tools general all service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in the section standard tools on page 351 , and of special tools, listed directly in the instructions and also gathered in thi...

  • Page 353

    Article no. Qty description 3hac039277-006 shims t= 2 mm 3hac038147-031 shims t= 2.5 mm 3hac5281-1 auxiliary shaft 3hac039296-001 lubrication tool, spherical roller bearing 3hac039571-002 lubrication tool, conical roller bearing 3hac023132-001 pinion crank rv 450e 3hac023760-001 bits extension 3hac1...

  • Page 354

    7.8 lifting accessories and lifting instructions general many repair and maintenance activities require different pieces of lifting accessories, which are specified in each procedure. The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction deliv...

  • Page 355: 8 Spare Parts

    8 spare parts 8.1 spare part lists and illustrations location spare parts and exploded views are not included in the manual but delivered as a separate document on the documentation dvd. 3hac039838-001 revision: c 355 © copyright 2013 abb. All rights reserved. 8 spare parts 8.1 spare part lists and ...

  • Page 356

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  • Page 357: 9 Circuit Diagrams

    9 circuit diagrams 9.1 about circuit diagrams overview the circuit diagrams are not included in this manual, but delivered as separate documents on the documentation dvd. See the article numbers in the tables below. Controllers article numbers for circuit diagrams product 3hac024480-005 circuit diag...

  • Page 358

    Article numbers for circuit diagrams product 3hac13347-1 circuit diagram - irb 6650s 3hac025744-001 3hac025744-001 circuit diagram - irb 6660 3hac029940-001 3hac13347-1 circuit diagram - irb 7600 3hac025744-001 358 3hac039838-001 revision: c © copyright 2013 abb. All rights reserved. 9 circuit diagr...

  • Page 359: Index

    Index a absolute accuracy, calibration, 331 additional mechanical stop location, 121 aluminum disposal, 339 b balancing device inspecting bearing, 111 inspecting piston rod guide ring, 111 lubricating bearing, 142 lubricating piston rod, 142 base plate securing, 76 batteries disposal, 339 handling, ...

  • Page 360

    I information labels location, 117 inspecting additional mechanical stop, 121 balancing device bearing, 111 balancing device piston rod guide ring, 111 cable harness, 114 information lables, 117 mechanical stop, 119 inspecting oil levels axes 2-3, 106 axis 1, 104 axis 6, 109 inspection dampers, 123 ...

  • Page 361

    Safety risk electric parts, 25 hot parts, 21 hydraulic system, 23 installation, 18 oil change, 50 operational disturbance, 24 pneumatic system, 23 service work, 18 tools, 22 voltage, 25 work pieces, 22 safety signals in manual, 37 safety standards, 344 scales on robot, 332 schedule for maintenance, ...

  • Page 364

    Contact us abb ab discrete automation and motion robotics s-721 68 vÄsterÅs, sweden telephone +46 (0) 21 344 400 abb as, robotics discrete automation and motion box 265 n-4349 bryne, norway telephone: +47 51489000 abb engineering (shanghai) ltd. 5 lane 369, chuangye road kangqiao town, pudong distri...