3HAC025755 PM IRB 660-En
3HAC025755 PM IRB 660-En
3HAC025755 PM IRB 660-En
Product manual
IRB 660
Trace back information:
Workspace 21D version a17
Checked in 2021-12-16
Skribenta version 5.4.005
Product manual
IRB 660 - 180/3.15
IRB 660 - 250/3.15
IRC5
Table of contents
Overview of this manual ................................................................................................................... 9
Product documentation .................................................................................................................... 16
How to read the product manual ...................................................................................................... 18
1 Safety 19
1.1 Safety information ............................................................................................. 19
1.1.1 Limitation of liability ................................................................................. 19
1.1.2 Requirements on personnel ...................................................................... 20
1.2 Safety signals and symbols ................................................................................. 21
1.2.1 Safety signals in the manual ...................................................................... 21
1.2.2 Safety symbols on manipulator labels ......................................................... 23
1.3 Robot stopping functions .................................................................................... 29
1.4 Installation and commissioning ............................................................................ 30
1.5 Operation ........................................................................................................ 33
1.6 Maintenance and repair ...................................................................................... 34
1.6.1 Maintenance and repair ............................................................................ 34
1.6.2 Emergency release of the robot axes .......................................................... 37
1.6.3 Brake testing .......................................................................................... 38
1.7 Troubleshooting ................................................................................................ 39
1.8 Decommissioning .............................................................................................. 40
3 Maintenance 95
3.1 Introduction ...................................................................................................... 95
3.2 Maintenance schedule and expected component life ............................................... 96
3.2.1 Specification of maintenance intervals ........................................................ 96
3.2.2 Maintenance schedule ............................................................................. 97
3.2.3 Expected component life ......................................................................... 99
4 Repair 145
4.1 Introduction ...................................................................................................... 145
4.2 General procedures ........................................................................................... 146
4.2.1 Performing a leak-down test ...................................................................... 146
4.2.2 Mounting instructions for bearings ............................................................. 147
4.2.3 Mounting instructions for sealings .............................................................. 149
4.2.4 Cut the paint or surface on the robot before replacing parts ............................ 152
4.2.5 The brake release buttons may be jammed after service work ......................... 153
4.3 Complete robot ................................................................................................. 154
4.3.1 Replacing cable harness, lower end (axes 1-3) ............................................. 154
4.3.2 Replacing the cable harness, upper end (incl. axis 6) ..................................... 162
4.3.3 Replacing the base, including axis 1 gearbox ............................................... 168
4.4 Upper and lower arm ......................................................................................... 176
4.4.1 Replacing the turning disk ........................................................................ 176
4.4.2 Replacement of tilthouse unit .................................................................... 180
4.4.3 Replacement of upper arm ........................................................................ 194
4.4.4 Replacement of linkage - upper rod ............................................................ 204
4.4.5 Replacing the linkage - lower rod ............................................................... 208
4.4.6 Replacement of linkage - link ..................................................................... 212
4.4.7 Replacing the parallel rod ......................................................................... 219
4.4.8 Replacing the complete lower arm .............................................................. 224
4.4.9 Replacement of parallel arm ...................................................................... 232
4.5 Frame and base ................................................................................................ 240
4.5.1 Replacing the balancing device .................................................................. 240
4.5.2 Replacing the SMB unit ............................................................................ 248
4.5.3 Replacing the brake release board ............................................................. 251
4.6 Motors ............................................................................................................ 255
4.6.1 Replacing motor, axis 1 ............................................................................ 255
4.6.2 Replacing motors, axes 2 and 3 ................................................................. 262
4.6.3 Replacing motor, axis 6 ............................................................................ 273
4.7 Gearboxes ....................................................................................................... 280
4.7.1 Replacing the axis 1 gearbox ..................................................................... 280
4.7.2 Replacing the gearbox, axes 2- 3 ............................................................... 291
4.7.3 Replacing gearbox axis 6 .......................................................................... 303
5 Calibration 309
5.1 Introduction to calibration ................................................................................... 309
5.1.1 Introduction and calibration terminology ...................................................... 309
5.1.2 Calibration methods ................................................................................. 310
5.1.3 When to calibrate ................................................................................... 312
5.2 Synchronization marks and axis movement directions ............................................. 313
5.2.1 Synchronization marks and synchronization position for axes ......................... 313
5.2.2 Calibration movement directions for all axes ................................................ 314
5.3 Updating revolution counters ............................................................................... 315
5.3.1 Updating revolution counters on IRC5 robots ............................................... 315
5.4 Calibrating with Axis Calibration method ............................................................... 319
5.4.1 Description of Axis Calibration .................................................................. 319
5.4.2 Calibration tools for Axis Calibration ........................................................... 322
5.4.3 Installation locations for the calibration tools ............................................... 324
5.4.4 Axis Calibration - Running the calibration procedure ...................................... 326
5.4.5 Reference calibration ............................................................................... 330
5.5 Calibrating with Calibration Pendulum method ....................................................... 332
5.6 Verifying the calibration ...................................................................................... 333
5.7 Checking the synchronization position .................................................................. 334
6 Decommissioning 335
6.1 Environmental information .................................................................................. 335
6.2 Scrapping of robot ............................................................................................. 337
6.3 Decommissioning of balancing device ................................................................... 338
Index 359
Usage
This manual should be used during:
• installation, from lifting the robot to its work site and securing it to the
foundation, to making it ready for operation
• maintenance work
• repair work.
Prerequisites
Maintenance/repair/installation personnel working with an ABB Robot must:
• be trained by ABB and have the required knowledge of mechanical and
electrical installation/repair/maintenance work.
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Safety Safety information that must be read through before performing
any installation or service work on robot. Contains general safety
aspects as well as more specific information about how to avoid
personal injuries and damage to the product.
Installation and commis- Required information about lifting and installation of the robot.
sioning
Maintenance Step-by-step procedures that describe how to perform mainten-
ance of the robot. Based on a maintenance schedule that may
be used in the work of planning periodical maintenance.
Chapter Contents
Repair Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Calibration Calibration procedures and general information about calibra-
tion.
Decommissioning Environmental information about the robot and its components.
Reference information Useful information when performing installation, maintenance
or repair work. Includes lists of necessary tools, additional
documents, safety standards etc.
Spare part / part list Complete spare part list of the robot components, shown in
exploded views.
Exploded views Detailed illustrations of the robot with reference numbers to the
part list.
Circuit diagram Reference to the circuit diagram for the robot.
References
Revisions
Revision Description
- First edition
A Detailed illustrations added in some procedures.
Art. no. on tools added.
Chapter "Replacement of tilthouse unit" has been changed, in order to
make it easier to follow the procedure.
Revision Description
B Changes made in:
• Prerequisites in section Overview
• Oil change in section Maintenance
This revision also includes the following additions and/or changes:
• The section "Type of oil in gearboxes" in chapter Maintenance has
been updated according to changes made in oil types and intervals
for oil change.
• Section "Replacement of Cable harness lower end" in chapter Repair
has been updated.
• Section "Replacement of Parallel rod" in chapter Repair has been
updated.
• Section "Replacement of Balancing device" in chapter Repair has
been updated.
• Section "Replacement of Gearbox axis 6" in chapter Repair has
been updated.
• Values for tightening torque on M24 screws in chapter Reference
information, added.
• New revision on Circuit diagrams.
C This revision includes the following addtions and/or changes:
• Section "Securing the robot" in Installation chapter has been re-
moved. Content is not applicable to IRB 660.
• Section What is an emergency stop? added to chapter Safety
• Section Maintenance schedule in chapter Maintenance: Intervals
for inspection activities and oilchanges have been revised
• Section Maintenance schedule in chapter Maintenance: Overhaul
of robot is new
• Section Maintenance schedule in chapter Maintenance: The inform-
ation about Service Information System (SIS) has been updated
• Section Maintenance schedule in chapter Maintenance: Intervals
for replacement of battery pack changed
• Section Expected lifetime in chapter Maintenance: The lifetime of
certain parts has been revised
• Section Cleaning of robot updated
D This revision includes the following addtions and/or changes:
• Instruction for how to inspect oil level corrected, see Inspecting, oil
level gearbox axis 6 on page 105.
• Circuit diagrams are not included in this document but delivered as
separate files. See Circuit diagrams on page 357.
• List of safety standards updated.
• Decommissioning chapter added.
• The lifetime of certain parts has been updated, see Expected com-
ponent life on page 99.
The chapter Safety updated with:
• Updated safety signal graphics for the levels Danger and Warning,
see Safety signals in the manual on page 21.
• New safety labels on the manipulators, see Safety symbols on ma-
nipulator labels on page 23.
• Revised terminology: robot replaced with manipulator.
E This revision includes the following updates:
• Maximum deviation changed, see Securing the base plate on
page 63.
Revision Description
F This revision includes following updates:
• Added index words throughout the manual.
• Inspection method of oil level in gearbox, axis 6, is changed, see
Inspecting, oil level gearbox axis 6 on page 105.
• Position numbers in figure corrected, see Location of dampers on
page 120.
• Removed information about lubricating attachment screws, removed
tightening torque and screw dimension for axis 2 and 3 and added
screw dimension for axis 1, see Inspecting the additional mechan-
ical stops on page 118.
• Changed tightening torque of fork lift adapters, from 60 Nm to 270
Nm, see Lifting robot with fork lift on page 52.
• Changed article numbers of robot power cables, see Robot cable,
power on page 89.
• Information about restricting and extending the working range of
axis 1 is now separated, see Mechanically restricting the working
range of axis 1 on page 79 and the new section Extended working
range, axis 1 (option) on page 77. Also added signal about option
561-1 in section Inspecting the axis-1 mechanical stop pin on
page 116.
• Added detailed information about how to decommission the balan-
cing device, see Decommissioning of balancing device on page 338.
• Added new safety symbols, see Safety symbols on manipulator la-
bels on page 23.
G This revision includes the following updates:
• A new block, about general illustrations, added in section How to
read the product manual on page 18.
• Added a KM10 socket to the list of required equipment and the in-
structions when replacing the lower rod, see section Replacing the
linkage - lower rod on page 208. The tool is also added to the list of
Special tools in the Reference chapter.
• Added instructions for securing parallel arm and lower arm to each
other before removing the lower arm, see Replacing the complete
lower arm on page 224.
• Added guide sleeves to hold the axes 2/3 sealing in place when re-
fitting the lower arm, see Replacing the complete lower arm on
page 224.
• Made minor corrections and improvements in the complete instruc-
tion for how to replace the lower arm system, see Replacing the
complete lower arm on page 224.
• Made minor corrections and improvements in the complete instruc-
tion for how to replace the parallel arm, see Replacement of parallel
arm on page 232.
• Made minor corrections and improvements in the complete instruc-
tion for how to replace the axis 1 gearbox, see Replacing the axis
1 gearbox on page 280.
• Some general tightening torques have been changed/added, see
updated values in Screw joints on page 345.
• Added information about batteries.
Revision Description
H This revision includes the following updates:
• The maximum allowed deviation in levelness of the base plate is
changed, see Securing the base plate on page 63.
• Reference to Hilti standard added to the foundation recommendation
for the base plate and class designation for foundation is changed
to European standard C25/C30 (previously Swedish standard
K25/K30), see Securing the base plate on page 63.
• Corrections and improvements are made in the instruction for how
to replace the axis-2 and axis-3 gearbox, see Replacing the gearbox,
axes 2- 3 on page 291.
• All data about type of lubrication in gearboxes is moved from the
manual to a separate lubrication manual, see Type and amount of
oil in gearboxes on page 126.
• Added spare part numbers for the customer connection kits and
the base plate, see Spare parts - option in Product manual, spare
parts - IRB 660.
• A new SMB unit and battery is introduced, with longer battery life-
time.
J This revision includes the following updates:
• New article number for painted motor added to spare parts, see
Spare parts - frame to lower arm in Product manual, spare
parts - IRB 660.
• Spare part number on item 102, 104 and 107, frame to base
changed. See Spare parts - frame to Base in Product manual, spare
parts - IRB 660.
• Added information about risks when scrapping a decommissioned
robot, see Scrapping of robot on page 337.
• Spare parts and exploded views are not included in this document
but delivered as a separate document. See Product manual, spare
parts - IRB 660.
• Article number for lubrication tool changed, see Lubricating balan-
cing device bearings and piston rod on page 140
K This revision includes the following updates:
• The maximum allowed deviation in levelness of the base plate and
foundation is changed, see Securing the base plate on page 63.
• Added tightening torque for R1.SMB and 7th axis connector, ses
Replacing cable harness, lower end (axes 1-3) on page 154.
• Minor corrections.
L This revision includes the following updates:
• Lifting tools updated (guide pin 3HAC7601-086 and guide pin
3HAC7601-087 removed)
• Special tools updated (Pressing, inner ring 3HAC023112-008 re-
moved)
• Illustrations of SMB battery RMU improved.
M Published in release R16.2. The following updates are done in this revision:
• Drawing of base plate is not available for purchase, faulty information
removed in Securing the base plate on page 63.
• Corrections due to updates in terminology.
• New standard calibration method is introduced (Axis Calibration).
See Calibration on page 309.
• Information about grounding point added. See Robot cabling and
connection points on page 88.
Revision Description
N Published in release R17.2. The following updates are made in this revision:
• Caution about removing metal residues added in sections about
SMB boards.
• Information about minimum resonance frequency added.
• Bending radius for static floor cables added.
• Updated list of applicable standards.
• Added text regarding overhaul in section specification of mainten-
ance intervals.
• Updated the section Start of robot in cold environments on page 87.
• Updated information regarding replacement of brake release board.
• Updated information regarding disconnecting and reconnecting
battery cable to serial measurement board.
• Updated information regarding replacing of balancing device.
• Definition of reference calibration clarified.
P Published in release R18.1. The following updates are made in this revision:
• Information added about fatigue to Axis Calibration tool, see Calib-
ration tools for Axis Calibration on page 322.
• Added sections in General procedures on page 146.
• Safety restructured.
• New spare part number brake release board (was DSQC563).
• Note added to calibration chapter to emphasize the requirement of
equally dressed robot when using previously created reference
calibration values.
• Information about myABB Business Portal added.
Q Published in release R18.2. The following updates are done in this revision:
• Added locating hole position in mounting flange view.
R Published in release R18.2. The following updates are done in this revision:
• Updated references.
S Published in release 19B. The following updates are made in this revision:
• New touch up color Graphite White available. See Cut the paint or
surface on the robot before replacing parts on page 152.
• Tightening torque for oil plug axis 6 changed to 20 Nm.
• New adapter for axis-3 shaft replacement and updated article
number for KM12 socket for axis-3 and axis-2 shaft replacements.
See Replacement of upper arm on page 194.
T Published in release 19C. The following updates are made in this revision:
• Added information regarding the support rings of the upper arm
housing, see Replacement of upper arm on page 194.
U Published in release 19D. The following updates are made in this revision:
• Added press tool for installation of support rings in the upper arm
housing, see Replacement of upper arm on page 194.
• Sealing compound Permatex No. 3 replaced by Trans7 from Trans
Clear.
V Published in release 20A. The following updates are made in this revision:
• Clarified and added information in mounting instructions for rotating
sealings, see Mounting instructions for sealings on page 149.
• Clarified text about position of robot and added table with depend-
encies between axes during Axis Calibration.
• Changed tightening torque for axis-2 and axis-3 shaft, see Replace-
ment of upper arm on page 194 and increased the torque span for
standard torque wrench, see Standard tools on page 349.
Revision Description
W Published in release 20C. The following updates are made in this revision:
• Changed tightening torques on the wrist oil plugs.
• Removed lifting tool for axis-2 and axis-3 gearbox from the special
tools list (lifting method was changed in previous revision).
X Published in release 21B. The following updates are made in this revision:
• Lubrication tool number changed, see Replacement of linkage - link
on page 212.
• New number and instruction for press tool, parallel arm, see Re-
placement of parallel arm on page 232.
• New number and instruction for press tool, , see Replacement of
tilthouse unit on page 180 .
• New number and instruction for press tool, linkage - link, see Re-
placement of linkage - link on page 212.
• Number for Lubrication tool number changed, see Required equip-
ment on page 141.
• Text regarding fastener quality is updated, see Fastener quality on
page 74.
Y Published in release 21C. The following updates are made in this revision:
• Info about option Extended working range included, see Extended
working range, axis 1 (option) on page 77.
Z Published in release 21D. The following updates are made in this revision:
• New section regarding customer connectors added, see Customer
connectors on the manipulator.
Product documentation
Categories for user documentation from ABB Robotics
The user documentation from ABB Robotics 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.
Tip
Product manuals
Manipulators, controllers, DressPack/SpotPack, and most other hardware is
delivered with a Product manual that generally contains:
• Safety information.
• Installation and commissioning (descriptions of mechanical installation or
electrical connections).
• Maintenance (descriptions of all required preventive maintenance procedures
including intervals and expected life time of parts).
• Repair (descriptions of all recommended repair procedures including spare
parts).
• Calibration.
• Decommissioning.
• Reference information (safety standards, unit conversions, screw joints, lists
of tools).
• Spare parts list with corresponding figures (or references to separate spare
parts lists).
• References to circuit diagrams.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
An application manual generally contains information about:
• The purpose of the application (what it does and when it is useful).
• What is included (for example cables, I/O boards, RAPID instructions, system
parameters, software).
• How to install included or required hardware.
• How to use the application.
• Examples of how to use the application.
Operating manuals
The operating manuals describe hands-on handling of the products. The manuals
are aimed at those having first-hand operational contact with the product, that is
production cell operators, programmers, and troubleshooters.
References to figures
The procedures often include references to components or attachment points
located on the manipulator/controller. The components or attachment points are
marked with italic text in the procedures and completed with a reference to the
figure where the current component or attachment point is shown.
The denomination in the procedure for the component or attachment point
corresponds to the denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a
procedure.
Action Note/Illustration
8. Remove the rear attachment screws, gearbox. Shown in the figure Location of
gearbox on page xx.
Safety information
The manual includes a separate safety chapter that must be read through before
proceeding with any service or installation procedures. All procedures also include
specific safety information when dangerous steps are to be performed.
Read more in the chapter Safety on page 19.
Illustrations
The robot is illustrated with general figures that does not take painting or protection
type in consideration.
Likewise, certain work methods or general information that is valid for several robot
models, can be illustrated with illustrations that show a different robot model than
the one that is described in the current manual.
1 Safety
1.1 Safety information
Limitation of liability
Any information given in this manual regarding safety must not be construed as a
warranty by ABB that the industrial robot will not cause injury or damage even if
all safety instructions are complied with.
The information does not cover how to design, install and operate a robot system,
nor does it cover all peripheral equipment that can influence the safety of the robot
system.
In particular, liability cannot be accepted if injury or damage has been caused for
any of the following reasons:
• Use of the robot in other ways than intended.
• Incorrect operation or maintenance.
• Operation of the robot when the safety devices are defective, not in their
intended location or in any other way not working.
• When instructions for operation and maintenance are not followed.
• Non-authorized design modifications of the robot.
• Repairs on the robot and its spare parts carried out by in-experienced or
non-qualified personnel.
• Foreign objects.
• Force majeure.
General
Only personnel with appropriate training are allowed to install, maintain, service,
repair, and use the robot. This includes electrical, mechanical, hydraulics,
pneumatics, and other hazards identified in the risk assessment.
Persons who are under the influence of alcohol, drugs or any other intoxicating
substances are not allowed to install, maintain, service, repair, or use the robot.
The plant liable must make sure that the personnel is trained on the robot, and on
responding to emergency or abnormal situations.
Hazard levels
The table below defines the captions specifying the hazard levels used throughout
this manual.
Symbol Designation Significance
DANGER Signal word used to indicate an imminently hazard-
ous situation which, if not avoided, will result in ser-
ious injury.
Introduction to symbols
This section describes safety symbols used on labels (stickers) on the manipulator.
Symbols are used in combinations on the labels, describing each specific warning.
The descriptions in this section are generic, the labels can contain additional
information such as values.
Note
The symbols on the labels on the product must be observed. Additional symbols
added by the integrator must also be observed.
Types of symbols
Both the manipulator and the controller are marked with symbols, containing
important information about the product. This is important for all personnel handling
the robot, for example during installation, service, or operation.
The safety labels are language independent, they only use graphics. See Symbols
on safety labels on page 23.
The information labels can contain information in text.
Symbol Description
Warning!
Warns that an accident may occur if the instructions are not
followed that can lead to serious injury, possibly fatal, and/or
great damage to the product. It applies to warnings that apply
xx0900000812
to danger with, for example, contact with high voltage electrical
units, explosion or fire risk, risk of poisonous gases, risk of
crushing, impact, fall from height, etc.
Caution!
Warns that an accident may occur if the instructions are not
followed that can result in injury and/or damage to the product.
It also applies to warnings of risks that include burns, eye injury,
skin injury, hearing damage, crushing or slipping, tripping, im-
xx0900000811 pact, fall from height, etc. Furthermore, it applies to warnings
that include function requirements when fitting and removing
equipment where there is a risk of damaging the product or
causing a breakdown.
Prohibition
Used in combinations with other symbols.
xx0900000839
Symbol Description
See user documentation
Read user documentation for details.
Which manual to read is defined by the symbol:
• No text: Product manual.
• EPS: Application manual - Electronic Position Switches.
xx0900000813
xx0900000816
Do not disassemble
Disassembling this part can cause injury.
xx0900000815
Extended rotation
This axis has extended rotation (working area) compared to
standard.
xx0900000814
Brake release
Pressing this button will release the brakes. This means that
the robot arm can fall down.
xx0900000808
Symbol Description
Tip risk when loosening bolts
The robot can tip over if the bolts are not securely fastened.
xx0900000810
xx1500002402
Crush
Risk of crush injuries.
xx0900000817
Symbol Description
Heat
Risk of heat that can cause burns. (Both signs are used)
xx0900000818
!
3HAC 4431-1/06
xx1300001087
Moving robot
4 6 The robot can move unexpectedly.
3 5
1
xx0900000819
xx1000001141
2 3
xx1500002616
Symbol Description
Brake release buttons
xx0900000820
xx1000001140
Lifting bolt
xx0900000821
xx1000001242
Lifting of robot
xx0900000822
Oil
Can be used in combination with prohibition if oil is not allowed.
xx0900000823
Mechanical stop
xx0900000824
Symbol Description
No mechanical stop
xx1000001144
Stored energy
Warns that this part contains stored energy.
Used in combination with Do not disassemble symbol.
xx0900000825
Pressure
Warns that this part is pressurized. Usually contains additional
text with the pressure level.
xx0900000826
xx0900000827
Do not step
Warns that stepping on these parts can cause damage to the
parts.
xx1400002648
Layout
The robot integrated to a robot system shall be designed to allow safe access to
all spaces during installation, operation, maintenance, and repair.
If robot movement can be initiated from an external control panel then an emergency
stop must also be available.
If the manipulator is delivered with mechanical stops, these can be used for reducing
the working space.
A perimeter safeguarding, for example a fence, shall be dimensioned to withstand
the following:
• The force of the manipulator.
• The force of the load handled by the robot if dropped or released at maximum
speed.
• The maximum possible impact caused by a breaking or malfunctioning
rotating tool or other device fitted to the robot.
The maximum TCP speed and the maximum velocity of the robot axes are detailed
in the section Robot motion in the product specification for the respective
manipulator.
Consider exposure to hazards, such as slipping, tripping, and falling.
Hazards due to the working position and posture for a person working with or near
the robot shall be considered.
Hazards due to noise emission from the robot needs to be considered.
Consider hazards from other equipment in the robot system, for example, that
guards remain active until identified hazards are reduced to an acceptable level.
Allergenic material
See Environmental information on page 335 for specification of allergenic materials
in the product, if any.
Electrical safety
Incoming mains must be installed to fulfill national regulations.
The power supply wiring to the robot must be sufficiently fused and if necessary,
it must be possible to disconnect it manually from the mains power.
The power to the robot must be turned off with the main switch and the mains
power disconnected when performing work inside the controller cabinet. Lock and
tag shall be considered.
Harnesses between controller and manipulator shall be fixed and protected to
avoid tripping and wear.
Wherever possible, power on/off or rebooting the robot controller shall be performed
with all persons outside the safeguarded space.
Note
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot.
Safety devices
The integrator is responsible for that the safety devices necessary to protect people
working with the robot system are designed and installed correctly.
When integrating the robot with external devices to a robot system:
• The integrator of the robot system must ensure that emergency stop functions
are interlocked in accordance with applicable standards.
• The integrator of the robot system must ensure that safety functions are
interlocked in accordance with applicable standards.
Other hazards
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
The risk assessment should also consider other hazards arising from the
application, such as, but not limited to:
• Water
• Compressed air
• Hydraulics
End-effector hazards require particular attention for applications which involve
close human collaboration with the robot.
Note
1.5 Operation
Automatic operation
Verify the application in the operating mode manual reduced speed, before changing
mode to automatic and initiating automatic operation.
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
General
Corrective maintenance must only be carried out by personnel trained on the robot.
Maintenance or repair must be done with all electrical, pneumatic, and hydraulic
power switched off, that is, no remaining hazards.
Hazards due to stored mechanical energy in the manipulator for the purpose of
counterbalancing axes must be considered before maintenance or repair.
Never use the robot as a ladder, which means, do not climb on the controller,
manipulator, including motors, or other parts. There are hazards of slipping and
falling. The robot might be damaged.
Make sure that there are no loose screws, turnings, or other unexpected parts
remaining after work on the robot has been performed.
When the work is completed, verify that the safety functions are working as
intended.
Hot surfaces
Surfaces can be hot after running the robot, and touching these may result in burns.
Allow the surfaces to cool down before maintenance or repair.
Allergic reaction
Allergic reaction
Note
Allergic reaction
When opening the oil or grease Open the plug carefully and keep
plug, there may be pressure away from the opening. Do not
present in the gearbox, causing overfill the gearbox when filling.
lubricant to spray from the
opening.
Possible pressure
build-up in gearbox
Overfilling of gearbox lubricant Make sure not to overfill the
can lead to internal over-pres- gearbox when filling it with oil or
sure inside the gearbox which in grease.
turn may: After filling, verify that the level
• damage seals and gas- is correct.
Do not overfill kets
• completely press out
seals and gaskets
• prevent the robot from
moving freely.
Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the gearbox. mix different types of oil unless
specified in the instructions. Al-
ways use the type of oil specified
for the product.
Do not mix types of oil
Warm oil drains quicker than Run the robot before changing
cold oil. the gearbox oil, if possible.
Contaminated oil in
gearboxes
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
Related information
See also the safety information related to installation and operation.
Description
In an emergency situation, the brakes on a robot axis can be released manually
by pushing a brake release button.
How to release the brakes is described in the section:
• Manually releasing the brakes on page 60.
The robot may be moved manually on smaller robot models, but larger models
may require using an overhead crane or similar equipment.
Increased injury
Before releasing the brakes, make sure that the weight of the manipulator does
not result in additional hazards, for example, even more severe injuries on a trapped
person.
DANGER
When releasing the holding brakes, the robot axes may move very quickly and
sometimes in unexpected ways.
Make sure no personnel is near or beneath the robot.
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 verified as described
below:
1 Run each axis to a position where the combined weight of the manipulator
and any load is maximized (maximum static load).
2 Switch the motor to the MOTORS OFF.
3 Inspect and verify that the axis maintains its position.
If the manipulator does not change position as the motors are switched off,
then the brake function is adequate.
Note
1.7 Troubleshooting
General
When troubleshooting requires work with power switched on, special considerations
must be taken:
• Safety circuits might be muted or disconnected.
• Electrical parts must be considered as live.
• The manipulator can move unexpectedly at any time.
DANGER
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
Related information
See also the safety information related to installation, operation, maintenance, and
repair.
1.8 Decommissioning
General
See section Decommissioning on page 335.
WARNING
Hazards due to the use of brake release devices and/or gravity beneath the
manipulator shall be considered.
A robot may perform unexpected limited movement.
WARNING
Manipulator movements can cause serious injuries on users and may damage
equipment.
General
This chapter contains assembly instructions and information for installing the IRB
660 at the working site.
See also the product manual for the robot controller.
The installation must be done by qualified installation personnel in accordance
with the safety requirements set forth in the applicable national and regional
standards and regulations.
Safety information
Before any installation work is commenced, all safety information must be observed.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 19 before performing any installation
work.
Note
Always connect the IRB 660 and the robot to protective earth and residual current
device (RCD) before connecting to power and starting any installation work.
For more information see:
• Product manual - IRC5
• Product manual - IRC5 Panel Mounted Controller
2.2 Unpacking
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.
Action
1 Make a visual inspection of the packaging and make sure that nothing is damaged.
2 Remove the packaging.
3 Check for any visible transport damage.
Note
Weight, robot
The table shows the weight of the robot.
Robot model Weight
IRB 660 1750 kg
Note
The weight does not include tools and other equipment fitted on the robot.
Txy
Fz
Fxy
Tz
xx1100000521
The table shows the various forces and torques working on the robot during different
kinds of operation.
Note
These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum at the same time!
WARNING
The robot installation is restricted to the mounting options given in following load
table(s).
Floor mounted
Requirements, foundation
The table shows the requirements for the foundation where the weight of the
installed robot is included:
Requirement Value Note
Flatness of foundation 0.3 mm Flat foundations give better repeatability of the
surface resolver calibration compared to original settings
on delivery from ABB.
The value for levelness aims at the circumstance
of the anchoring points in the robot base.
Maximum tilt 5°
Minimum resonance 22 Hz The value is recommended for optimal perform-
frequency ance.
Note Due to foundation stiffness, consider robot mass
including equipment. i
It may affect the For information about compensating for founda-
manipulator life- tion flexibility, see the application manual of the
time to have a controller software, section Motion Process
lower resonance Mode.
frequency than
recommended.
i The minimum resonance frequency given should be interpreted as the frequency of the robot
mass/inertia, robot assumed stiff, when a foundation translational/torsional elasticity is added, i.e.,
the stiffness of the pedestal where the robot is mounted. The minimum resonance frequency should
not be interpreted as the resonance frequency of the building, floor etc. For example, if the equivalent
mass of the floor is very high, it will not affect robot movement, even if the frequency is well below
the stated frequency. The robot should be mounted as rigid as possibly to the floor.
Disturbances from other machinery will affect the robot and the tool accuracy. The robot has
resonance frequencies in the region 10 – 20 Hz and disturbances in this region will be amplified,
although somewhat damped by the servo control. This might be a problem, depending on the
requirements from the applications. If this is a problem, the robot needs to be isolated from the
environment.
Parameter Value
Maximum ambient temperature +50° C
Maximum ambient humidity 95% at constant temperature
i During cold start (0° C - 5° C), see Start of robot in cold environments on page 87.
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).
xx0500002274
H Mechanical stop
J Max working range
Position x (mm) Position z (mm) Angle axis 2 (de- Angle axis 3 (de-
grees) grees)
A 1910 1833 0 0
B 972 1966 -42 -20
C 895 870 -42 28
D 866 207 50 120
E 1160 -505 85 120
F 3139 315 85 15
G 2809 1837 50 -20
Type of motion
The table below specifies the types and ranges of the robot motion in every axis.
Axis Type of motion Range of motion
1 Rotation motion -180° to +180°
2 Arm motion -42° to +85°
3 Arm motion -20° to +120°
2-3 Arm motion 20° to 160°
6 Turn motion -300° to +300°
Risk of tipping
Do not change the robot position before securing it to the foundation.
The shipping position is the most stable position.
xx0500002275
WARNING
The robot will be mechanically unstable if not properly secured to the foundation.
Description
ESD (electrostatic discharge) is the transfer of electrical static charge between two
bodies at different potentials, either through direct contact or through an induced
electrical field. When handling parts or their containers, personnel not grounded
may potentially transfer high static charges. This discharge may destroy sensitive
electronics.
Safe handling
Use one of the following alternatives:
• Use a wrist strap.
Wrist straps must be tested frequently to ensure that they are not damaged
and are operating correctly.
• Use an ESD protective floor mat.
The mat must be grounded through a current-limiting resistor.
• Use a dissipative table mat.
The mat should provide a controlled discharge of static voltages and must
be grounded.
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.
xx0500002276
Required equipment
xx0500002277
xx0500002275
2 Fit the two adapters to the robot and secure. Attachment points are shown in figure
Attachment points on robot on page 50.
Attachment screws, 2 pcs, M16 x 90.
Tightening torque: 270 Nm.
3 Strap up axis 2 motor cable on the adapter.
xx0500002278
• A: Strap, velcro
Action Note
4
CAUTION
5 Secure the longer fork lift pocket to the adapter Always use original screws (or replace-
and frame with four of the horizontal attach- ments of equivalent quality: M16, qual-
ment screws and washers. ity 12.9)!
Attachment points on the robot are
Note
shown in figure Attachment points on
robot on page 50.
The screws, which are attached horizontally
and vertically, are identical. However, they are
tightened with different torque!
xx0500002279
xx0700000655
A Securing screw
Action Note
7 Secure fork lift pocket to robot with two vertical
attachment screws and washers.
Note
xx0500002284
9 Secure the shorter fork lift pocket on the other 4 pcs, M16x60.
side of the robot with the four remaining hori- Tightening torque: 60 Nm.
zontal attachment screws.
Always use original screws (or replace-
ments of equivalent quality: M16, qual-
ity 12.9)!
Attachment points on robot are shown
in figure Attachment points on robot on
page 50.
10 Double-check that pockets are properly se-
cured to the robot! Insert fork lift forks into the
pockets.
11
CAUTION
General
The robot can be lifted with roundslings according to this section.
Sling specification
Action Note
1 Position robot in a secure transport position.
2 Attach roundslings to robot according to fig-
ure Attachment points on page 56.
3
CAUTION
4
WARNING
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.
xx0500002285
General
This section contains a general overview of how to lift the complete robot using
special lifting accessory.
Note
The user manual may be out of date. The latest revision is available for download
via myABB Business Portal, www.abb.com/myABB.
xx0500002460
Required equipment
Note
Please refer to the enclosed user instruction for instruction how to place the
manipulator in an correct position. Attempting to lift a manipulator in any other
position may result in the robot tipping over, causing severe damage or injury!
Action Note
1 Run the overhead crane to a position above
the robot.
2 Position the robot as detailed in enclosed in- Article number is specified in Required
struction! equipment on page 59.
Release the brakes, if required, as de-
tailed in section Manually releasing the
brakes on page 60.
3 Shown in the figure Illustration, lifting
Note accessory on page 58.
4 Fit the lifting accessory to the robot as de- Article number is specified in Required
scribed in the enclosed instruction! equipment on page 59.
5
CAUTION
6
WARNING
7 Raise overhead crane to lift the robot. Make sure all hooks and attachments
maintain their correct positions while
lifting the robot!
Always move the robot at very low
speeds, making sure it does not tip.
Note
xx0500002286
Note
Action Note
3 Release the holding brake on a particular robot
axis by pressing the corresponding button on the
internal brake release unit.
The brake will function again as soon as the button
is released.
xx0600002937
Required equipment
Hole configuration
xx0200000096
Action Note
1
CAUTION
CAUTION
Lift and move the base plate very slowly. If the base
plate starts to swing it is a risk for injuries or damage.
598,31
560,85
B 487,01
(Ø 8 455
00)
950
243,5
F 12x M24 A E
2x 450 Ø1 A
A
0
73,84
231,5
111,30
C C
560,85
634,68
502,04
73,84
0
132,64
317,3
2x 50x45º
857,3
1020
48
4x
(4x)
6,3
)
(48
(2 3x
) 45
º
0.3 Common Zone
E, F, G, H
13
1,6
A
(2)
1,6
)
(2
13
3x
A-A 45
Ø 45P7 º B-B
Ø1.5
47 +0
0 ,5
c
K7
3x R1
45
52,
0,25 c
5º
(2
) (2x R22,5)
4
3x
3x 90º 1,6
C-C D
xx1000001053
E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact
surface to the other)
358 (2x)
861 (2x)
18
Ø16 (5x)
0
Ø22 (16x)
923 (4x)
905
882
813 800
748
565
475
385
202
137 150
68
45 27 (4x)
0 0
0
947 (2x)
37 (2x)
87 (2x)
630 (2x)
991 (2x)
450 (2x)
293 (2x)
813 (2x)
50
(A)
2x206,9
2x219,8
2x365,3
2x311,1
0
831 840,9
811,6
724,2
708,9 699,5
625 (2x)
325 (2x)
241,1 250,5
225,8
138,4
119 109,1
0 0
790 (2x)
874,6 (2x)
290 (2x)
0
706 (2x)
xx1000001054
¤
- Four holes for alternative clamping, 4x Ø18
A Color: RAL 9005. Thickness: 80-100 µm
B A
B
B
A
xx1500000312
xx0300000045
Required equipment
Base plate
This section details how to secure the base plate to the foundation.
Action Note
1 Make sure the foundation is levelled.
Action Note
2
CAUTION
3 Position base plate in relation to the robot Shown in figure Base plate, orienting
work location using the grooves in the base grooves and leveling bolts on page 65.
plate.
4 Lift the base plate to its mounting position. Detailed in section Lifting the base plate
on page 62.
5 Use the base plate as a template and drill at- Attachment holes: 16 pcs.
tachment holes as required by the selected
bolt dimension.
6 Fit the base plate and use the levelling bolts Shown in figure Base plate, orienting
to level the base plate. grooves and leveling bolts on page 65.
7 If required, fit strips of sheet metal underneath
the base plate to fill any gaps.
8 Secure the base plate to the foundation with
screws and sleeves.
9 Recheck the four contact surfaces on the Maximum allowed deviation all over the
base plate to make sure the base plate is base plate, from one contact surface to
levelled and flat. the other: 0.3 mm.
If it is not, use pieces of sheet metal or similar
to bring the base plate to a levelled position.
General
This section details how to orient and secure the robot to the base plate in order
to run the robot safely.
xx0300000566
Attachment screws
The table below specifies the type of securing screws and washers to be used for
securing the robot to the base plate/foundation.
Suitable screws, lightly lubricated: M24 x 140
Quality: Quality 8.8
Suitable washer: Thickness: 4 mm
Outer diameter: 44 mm
Inner diameter: 25 mm
Tightening torque: 725 Nm
Note
4 Guide the robot gently using two M24 screws Make sure the robot base is correctly
while lowering it into its mounting position. fitted onto the guide sleeves!
5 Fit the bolts and washers in the base attach- Specified in Attachment screws on
ment holes. page 68.
Shown in figure Illustration, robot fitted
to base plate on page 68.
Note
xx0600002628
xx0600002629
General
The robot features mounting holes for additional equipment.
Access to any of the following mounting holes may be obstructed by any additional
cabling, equipment, etc., fitted by the robot user. Make sure the required mounting
holes are accessible when planning the robot cell.
Note
All equipment and cables used on the robot, must be designed and fitted not to
damage the robot and/or its parts.
Note
Example: If 35 extra kg is put on the upper arm, this means that the robot only can
handle 180 - 35 = 145 kg or 250 - 35 = 215 kg (depending on model).
xx0500002289
xx0500002505
xx0500002292
- Mounting flange.
(B)
(A) X
xx1800001377
Fastener quality
When fitting tools on the tool flange, only use screws with quality 12.9. For other
equipment use suitable screws and tightening torque for your application.
Description
A signal lamp with a yellow fixed light can be mounted on the robot, as a safety
device.
Installation
See the assembly instruction delivered with the signal lamp.
Function
The lamp is active in MOTORS ON mode.
Further information
Further information about the MOTORS ON/MOTORS OFF mode may be found in
the product manual for the controller.
2.3.10 Loads fitted to the robot, stopping time and braking distances
General
Any loads mounted on the robot must be defined correctly and carefully (with
regard to the position of center of gravity and mass moments of inertia) in order
to avoid jolting movements and overloading motors, gears and structure.
CAUTION
Incorrectly defined loads may result in operational stops or major damage to the
robot.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified
in the product specification. The loads must be defined in the software.
• Operating manual - IRC5 with FlexPendant
Overview
The working range of axis 1 can be extended on a floor-mounted robot, from the
default range limited by mechanical stops. The working range can be extended to
±220°.
CAUTION
The option Extended work range enables an extension of the working range for
axis 1, through a software configuration. With this option installed, the working
range can exceed the range limited by the mechanical stop on axis 1. The working
range shall be limited through the option SafeMove.
A risk analysis must be done to ensure that no risks remain when using option
Extended work range, to limit the working range, and before removing the
mechanical stops.
For information about the option SafeMove, see Application manual - Functional
safety and SafeMove.
If the mechanical stop is removed, then the manipulator should have a marking
for this, for example, a label. If the robot is delivered with the option Extended
work range, then such a label is included on delivery.
Action Note/Illustration
1 Configure the safety setup and verify it by
test.
2 Hold the mechanical stop pin in a firm grip,
and remove it by unscrewing the attach-
ment screw.
xx2100001706
3 In RobotWare, redefine the working range With the option Extended working range,
limitations in the system parameters, topic the maximum value for the system paramet-
Motion. The Arm parameters Upper Joint ers Upper Joint Bound and Lower Joint
Bound and Lower Joint Bound can be Bound is 3.84 respectively -3.84. The val-
changed to the values corresponding to ues are in radians, that is 3.84 radians =
the actual installation. 220 degrees.
Related information
The system parameters are described in detail in the reference manual, see
References on page 10.
For more information about SafeMove, see Application manual - Functional safety
and SafeMove2.
General
When installing the robot, make sure that it can move freely within its entire working
space. If there is a risk that it may collide with other objects, its working space
should be limited.
The working range of the following axes may be restricted:
• Axis 1, hardware (mechanical stop) and software (signal from adjustable
position switch)
As standard configuration, axis 1 is allowed to move ± 180º. The working range
may however be increased to ± 220º with option 561-1 Extended working range
axis 1. Note that this option also requires installation of a position switch on axis
1.
This section describes how to install hardware that restricts the working range.
Note
General
The working range of axis 1 is limited by fixed mechanical stops and adjustment
of the system parameter configuration. The working range can be reduced by
adding additional mechanical stops giving 7.5 or 15 graduation, between 22.5°
and 135° in both directions.
xx0300000049
Required equipment
2 Fit the additional mechanical stop to the Tightening torque: 120 Nm.
frame according to the figure Mechanical
stops, axis 1 on page 79.
3 Adjust the software working range limitations The system parameters that must be
(system parameter configuration) to corres- changed (Upper joint bound and Lower
pond to the mechanical limitations. joint bound) are described in Technical
reference manual - System parameters.
4
WARNING
General
Position switches can be installed on axis 1. The position switches include cams
as shown in the figure below. The system parameter configuration must also be
updated.
The position switch sets may be delivered in one of two ways:
• Fitted by ABB on delivery. In this case, the cams must still be fitted and
locked by the user. For axis 1, the cover for the cams must also be fitted.
• As sets to be completely fitted to the robot and adjusted by the user.
Required equipment
Axis 1
The illustration below shows the position switch for axis 1. The switch is connected
directly to the connector in the base, R1.SW1.
xx0100000158
Specifications
Maximum voltage/current for the position switches:
Parameter Value
Voltage Max. 50 VDC
Current Max. 1 A
Connections
The position switch is connected to different points on the robot system:
• XT8, screw terminal in the controller cabinet when position switch cables are
used.
• R1.SW1 at the robot base. Customer connection set is recommended. Art.no.
is specified in Required equipment on page 81.
Further information about cables and connection points, see section Robot cabling
and connection points on page 88.
xx0500002301
Action Note
3 Remove the rear cover (A) from the robot base.
xx0500002306
xx0600002625
D
xx0600002626
Action Note
9 Adjust the software working range limitations The system parameters that must be
(system parameter configuration) to correspond changed (Upper joint bound and
to the mechanical limitations. Lower joint bound) are described in
Technical reference manual - System
parameters.
10 Recalibrate the robot! Calibration is detailed in a separate
calibration manual enclosed with the
calibration tools.
General calibration information is in-
cluded in section Calibration on
page 309.
11
DANGER
xx0100000113
xx0100000114
Introduction
This section describes how to start the robot in a cold environment if it is not starting
the normal way.
If the program consists of large wrist movements, it is possible that the reorientation
velocity, which is always high in predefined velocities, needs to be included in the
ramping up.
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.
CAUTION
Connect the male and female connectors perfectly aligned horizontally to avoid
any kind of tilt or skew.
CAUTION
Verify that the robot serial number is according to the number(s) in the Declaration
of Incorporation (DoI).
Robot cables
These cables are included in the standard delivery. They are completely
pre-manufactured and ready to plug in.
Cable sub-category Description Connection Connection
point, cabinet point, robot
Robot cable, power Transfers drive power from the XS1 R1.MP
drive units in the control cabinet
to the robot motors.
A
B
xx1600002016
A Diameter
B Diameter x10
xx1600001007
Introduction
The customer cables are routed internally with the manipulator cable harness. For
more information and specifications for the connections. See section Customer
connections in the Product Specification.
xx2100002206
xx2100002207
3 Maintenance
3.1 Introduction
Safety information
Observe all safety information before conducting any service work.
There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter Safety on page 19 before performing any service
work.
The maintenance must be done by qualified personnel in accordance with the
safety requirements set forth in the applicable national and regional standards and
regulations.
Note
If the IRB 660 is connected to power, always make sure that the IRB 660 is
connected to protective earth and a residual current device (RCD) before starting
any maintenance work.
For more information see:
• Product manual - IRC5
• Product manual - IRC5 Panel Mounted Controller
• Robot cabling and connection points on page 88.
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 660:
• Calendar time: specified in months regardless of whether the system is
running or not.
• Operating time: specified in operating hours. More frequent running means
more frequent maintenance activities.
• SIS: specified by the robot's SIS (Service Information System). A typical
value is given for a typical work cycle, but the value will differ depending on
how hard each part is run.
The SIS used in M2004 is further described in the Operating manual - Service
Information System.
Robots with the functionality Service Information System activated can show active
counters in the device browser in RobotStudio, or on the FlexPendant.
Overhaul
Depending on application and operational environment a complete overhaul may
be necessary in average around 40000 hours.
ABB Connected Services and its Assessment tools can help you to identify the
real stress level of your robot, and define the optimal ABB support to maintain your
robot working.
Contact your local ABB Customer Service to get more information.
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 damage
must be attended to immediately.
The inspection intervals do not specify the life of each component. Values for these
are specified in the section Expected component life on page 99
Instructions for how to perform the different maintenance activities are found in
sections:
• Inspection activities on page 100
• Replacement/changing activities on page 126
• Cleaning activities on page 143
General
The expected life of a specific component of the robot can vary greatly depending
on how hard it is run.
Location of gearbox
The axis-1 gearbox is located between the frame and base. See oil plugs in the
following figure.
E
xx0500002479
Required equipment
2
DANGER
3 Make sure that the oil temperature is +25°C ±10°C. This is a precaution to reduce the
temperature dependency of the
measurement.
4 Open the oil plug, inspection. Shown in figure Location of gear-
box on page 100.
5 Measure the oil level. A
Required oil level: max. 10 mm below the oil plug
hole.
C
xx1400002785
xx0500002482
A Gearbox, axis 2
B Oil plug, draining
C Oil plug, filling
D Ventilation hole, gearbox axis 2
xx0500002483
A Gearbox, axis 3
B Oil plug, draining
C Oil plug, filling
D Ventilation hole, gearbox axis 3
Required equipment
Action Note
2
DANGER
Location of gearbox
The axis 6 gearbox is located in the tilthouse unit as shown in this figure.
B
A
C
xx0500002484
A Gearbox, axis 6
B Oil plug, filling
C Oil plug, draining
Required equipment
2
DANGER
3.3.4 Inspecting, balancing device bearings and piston rod guide ring
xx0500002495
A Balancing device
B Piston rod
C Guide ring (not visible in this figure)
Required equipment
Inspecting, bearings
Use this procedure to inspect the bearings, balancing device.
Action Note
1 Move axis 2 to calibration position.
2
DANGER
xx0500002496
Action Note
5 Remove the protection hood from the
M12 hole on top of the balancing device.
xx0600002687
15 Apply locking liquid on the lock nuts Tightening torque on the lock nuts:
(KM10) and refit them. • 120 Nm
xx0600002689
A Guide ring
B Circlip
4
Note
xx0500002497
Required equipment
Visual inspection, no tools are needed.
xx0600002691
Velcro strap
6 Check the cable guide axis 2. Shown in figure Location of cable har-
Replace if damaged. ness, axes 1-6 on page 111.
7 Check the metal clamps on the lower arm. Shown in figure Location of cable har-
ness, axes 1-6 on page 111
Action Note
8 Check the metal clamps holding the cable
harness inside the upper arm, as shown in
figure to the right.
xx0500002498
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 23.
xx0500002499
xx0500002500
C Instruction label
E Instruction label concerning lifting the robot
F Warning label concerning risk of tipping
H Warning label concerning stored energy
L Information label at base, Kyodo Yushi TMO 150 in gearboxes
Inspecting, labels
Action Note
1
DANGER
WARNING
Mechanical stop pin can not be fitted onto robot if option 810-1 Electronic Position
Switch is used.
WARNING
Mechanical stop pin can not be fitted onto robot if option 561-1 Extended work
range axis 1 is used.
xx0600002695
Required equipment
Visual inspection, no tools are required.
Action Note
2 Inspect the axis-1 mechanical stop pin.
If the mechanical stop pin is bent or damaged, it
must be replaced.
Note
xx0300000049
Required equipment
Action Note
2 Make sure no additional stops are damaged. Shown in figure Location of
mechanical stops on page 118.
3 Make sure the stops are properly attached.
Correct tightening torque, additional mechanical
stops:
• Axis 1 = 120 Nm.
4 If any damage is detected, the mechanical stops must Article number is specified in
be replaced. Required equipment on page 118.
Correct attachment screws:
• Axis 1: M16 x 35, quality 12.9.
Location of dampers
This figure shows the location of dampers.
xx0500002501
Required equipment
Inspecting, dampers
Use this procedure to inspect the dampers.
Action Note
1
DANGER
2 Check all dampers for damage, cracks or existing Shown in figure Location of
impressions larger than 1 mm. dampers on page 120.
3 Check attachment screws for deformation.
4 If any damage is detected, the damper must be Art.no. is specified in Required
replaced with a new one. equipment on page 121.
xx0100000158
Required equipment
xx0500002466
A Signal lamp
B Cable straps, outdoor
C Cable
D Connection point to cable gland
Action Note
2
DANGER
3 If the lamp is not lit, trace the fault by: Article number is specified in Re-
• inspecting whether the signal lamp is broken. quired tools and equipment on
If so, replace it. page 124.
• inspecting cable connections.
• measuring the voltage in the connectors of
motor axis 6 (=24V).
• inspecting the cabling. Replace the cabling if
a fault is detected.
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 lubrication.
Location of gearboxes
The figure shows the location of the gearboxes.
xx0500002467
A Gearbox, axis 1
B Gearbox, axis 2
C Gearbox, axis 3
D Gearbox, axis 6
Equipment
Equipment Note
Oil dispenser Includes pump with outlet pipe.
Use the suggested dispenser or a similar one:
• Orion OriCan article number 22590
(pneumatic)
Nipple for quick connect fitting, with o-ring
E
xx0500002479
Required equipment
Action Note
1
DANGER
2
WARNING
xx0200000237
Action Note
7 Open the hose end and drain the oil into a
vessel. Note
2
WARNING
xx0500002482
A Gearbox axis 2
B Oil plug, draining
C Oil plug, filling
D Ventilation hole plug, gearbox axis 2
xx0500002483
A Gearbox, axis 3
B Oil plug, draining
C Oil plug, filling
D Ventilation hole plug, gearbox axis 3
Required equipment
2
WARNING
2
WARNING
Action Note
3 Remove the oil plug, filling. (Ventilation hole Shown in Location of oil plugs on
plug should also be removed.) page 130.
Tightening torque: 24 Nm.
4 Refill gearbox with lubricating oil. Art.no. and total amount are specified
The amount of oil to be filled depends on the in Required equipment on page 131.
amount that was previously drained.
5 Refit oil plug,filling and ventilation hole plug. Shown in Location of oil plugs on
page 130.
Tightening torque: 24 Nm.
B
A
C
xx0500002484
A Gearbox, axis 6
B Oil plug, filling
C Oil plug, draining
Required equipment
Draining, oil
Use this procedure to drain oil from gearbox axis 6.
When using oil change equipment, follow the instructions enclosed with kit.
Action Note
1 Put tilt house in a suitable position.
Action Note
2
DANGER
3 Drain oil from gearbox into a vessel by removing Shown in figure Location of oil plugs
oil plug, draining. on page 134.
Also remove oil plug, filling. Vessel capacity is specified in Re-
quired equipment on page 134.
4 Refit oil plugs, draining and filling. Tightening torque: 20 Nm.
Filling, oil
Use this procedure to fill gearbox axis 6 with oil.
When using oil change equipment, follow the instructions enclosed with kit.
Action Note
1
DANGER
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 a SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or
RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.
For a SMB board with 2-pole battery contact (DSQC), the typical lifetime of a new
battery is 36 months if the robot is powered off 2 days/week or 18 months if the
robot is powered off 16 h/day. The lifetime can be extended for longer production
breaks with a battery shutdown service routine. See Operating manual - IRC5
with FlexPendant for instructions.
WARNING
xx0500002486
A B C D E F G
xx1400002574
Required equipment
Note
There are two variants of SMB units and batteries. One with 2-pole battery contact
(DSQC) and one with 3-pole battery contact (RMU). The variant with the 3-pole
battery contact has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not exchange battery contacts!
Removing, battery
Use this procedure to remove the SMB battery.
Action Note
1 Move the robot to its calibration position. This is done in order to facilitate
updating of the revolution counter.
2
DANGER
3
ELECTROSTATIC DISCHARGE (ESD)
4 Remove the SMB battery cover by unscrewing the Shown in figure Location of SMB
attachment screws. battery on page 136.
CAUTION
5 Pull out the battery and disconnect the battery Shown in figure Location of SMB
cable. battery on page 136.
6 Remove the SMB battery. Shown in figure Location of SMB
Battery includes protection circuits. Only replace battery on page 136.
with a specified spare part or with an ABB- ap-
proved equivalent.
Refitting, battery
Use this procedure to refit the SMB battery.
Action Note
1
DANGER
2
ELECTROSTATIC DISCHARGE (ESD)
3 Reconnect the battery cable and install the battery Art. no. is specified in Required
pack into the SMB/battery recess. equipment on page 137.
Shown in figure Location of SMB
Note battery on page 136.
C
RMU batteries are installed together with a battery
holder to be properly secured inside the recess.
See figure.
Strap the battery cable to the holder.
A
D B
xx1300000307
Overview
This procedure details how to lubricate the balancing device´s bearings and piston
rod.
xx0500002489
Required equipment
Lubricating, bearings
Use this procedure to lubricate the balancing device bearings.
Action Note
1 Move axis 2 to calibration position.
2
DANGER
Action Note
10 Check play between support washer and bearings at Minimum play:
both bearings. • 0.1 mm
DANGER
General
To secure high uptime it is important that the IRB 660 is cleaned regularly. The
frequency of cleaning depends on the environment in which the product works.
Different cleaning methods are allowed depending on the type of protection of the
IRB 660.
Note
Oil spills
Oil spills from gearboxes
Use the following procedure if any oil spills are detected that can be suspected to
originate from a gearbox.
1 Inspect that the oil level in the suspected gearbox is according to the
recommendations, see Inspection activities on page 100.
2 Write down the oil level.
3 Inspect the oil level again after, for example, 6 months.
4 If the oil level is decreased then replace the gearbox.
Cleaning methods
The following table defines what cleaning methods are allowed depending on the
protection type.
Protection Cleaning method
type
Vacuum Wipe with cloth Rinse with water High pressure water or
cleaner steam
Standard Yes Yes. With light Yes. It is highly re- No
cleaning deter- commended that
gent. the water contains
a rust-prevention
solution and that
the manipulator is
dried afterwards.
Cables
Movable cables need to be able to move freely:
• Remove waste material, such as sand, dust and chips, if it prevents cable
movement.
• Clean the cables if they have a crusty surface, for example from dry release
agents.
4 Repair
4.1 Introduction
WARNING
Repair activities not described in this chapter must only be carried out by ABB.
Note
When replacing a part on the IRB 660, report to your local ABB the serial number,
the article number, and the revision of both the replaced unit and the replacement
unit.
This is particularly important for safety equipment to maintain the safety integrity
of the installation.
Safety information
Make sure to read through the chapter Safety on page 19 before commencing any
service work.
Note
If the IRB 660 is connected to power, always make sure that the IRB 660 is
connected to protective earth and a residual current device (RCD) before starting
any repair work.
For more information see:
• Product manual - IRC5
• Product manual - IRC5 Panel Mounted Controller
Required equipment
Action Note
1 Finish the refitting procedure of the motor or gear in
question.
2 Remove the upper oil plug on the gear and replace
it with the leak-down tester.
Regulators, which are included in the leak-down test,
may be required.
3 Use caution, apply compressed air and raise the Correct value:
pressure with the knob until the correct value is 0.2-0.25 bar (20-25 kPa)
shown on the manometer.
CAUTION
General
This section describes how to mount and grease different types of bearings on the
robot.
Equipment
Note
The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out and also rotated during the pre-tensioning sequence.
2 Make sure the bearing is properly aligned as this will directly affect the durab-
ility of the bearing.
Greasing of bearings
Note
General
This section describes how to mount different types of sealings.
Equipment
Rotating sealings
The procedure below describes how to fit rotating sealings.
CAUTION
Action Note
1 Check the sealing to ensure that:
• The sealing is of the correct type.
• There is no damage on the main lip.
2 Inspect the shaft surface before mounting. If scratches
or damage are found, the shaft must be replaced since
it may result in future leakage. Do not try to grind or
polish the shaft surface to get rid of the defect.
3 Lubricate the sealing with grease just before fitting. Article number is specified in
(Not too early - there is a risk of dirt and foreign Equipment on page 149.
particles adhering to the sealing.)
Fill 2/3 of the space between the dust lip and the main
lip with grease. If the sealing is without dust lip, just
lubricate the main lip with a thin layer of grease.
A B C
xx2000000071
A Main lip
B Grease
C Dust lip
Action Note
4 Mount the sealing correctly with a mounting tool. A
Never hammer directly on the sealing as this may
result in leakage.
xx2000000072
A Gap
O-rings
The following procedure describes how to fit o-rings.
Action Note
1 Ensure that the correct o-ring size is used.
2 Check the o-ring for surface defects, burrs, Defective o-rings, including damaged
shape accuracy, or deformation. or deformed o-rings, may not be used.
Action Note
3 Check the o-ring grooves.
The grooves must be geometrically correct and
should be free of pores and contamination.
4 Lubricate the o-ring with grease.
5 Tighten the screws evenly while assembling.
6 Check that the o-ring is not squashed outside
the o-ring groove.
4.2.4 Cut the paint or surface on the robot before replacing parts
General
Follow the procedures in this section whenever breaking the paint of the robot
during replacement of parts.
Required equipment
Removing
Action Description
1 Cut the paint with a knife in the joint between
the part that will be removed and the struc-
ture, to avoid that the paint cracks.
xx0900000121
4.2.5 The brake release buttons may be jammed after service work
Description
The brake release unit has push-buttons for the brake release of each axis motor.
When service work is performed inside the SMB recess that includes removal and
refitting of the brake release unit, the brake release buttons may be jammed after
refitting.
DANGER
Elimination
To eliminate the danger after service work has been performed inside the SMB
recess, follow the procedure below.
Action
1 Make sure the power is turned off.
2 Remove the push-button guard, if necessary.
3 Verify that the push-buttons of the brake release unit are working by pressing them
down, one by one.
Make sure none of the buttons are jammed in the tube.
4 If a button gets jammed in the depressed position, the alignment of the brake release
unit must be adjusted so that the buttons can move freely in their tubes.
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. How to replace the upper end can be found in section Replacing
the cable harness, upper end (incl. axis 6) on page 162.
xx0600002608
xx0700000070
The motors axes 2-3 are located on either side of the robot as shown in the figure
below.
xx0600002599
A Motor, axis 2
B Motor, axis 3
C Motor attachment screws and washers
D Cable gland cover (located on the lower side of the motor)
E Motor cover
Required equipment
Action Note
2
DANGER
3 Remove the rear cover plate from the robot by Shown in Location of cable harness -
removing its attachment screws. lower end (axes 1-3) on page 154.
4 Disconnect the earth cable. Shown in Location of cable harness -
lower end (axes 1-3) on page 154.
5 Disconnect the connectors R1.MP and R1.SMB. See the figure Location of cable har-
ness - lower end (axes 1-3) on
page 154.
6 Unscrew the screws of the cable guide axis 2
inside the lower arm and loosen the cable
guide.
xx0600002698
• A: Cable guide ax 2
7 Unscrew the screws in the metal clamps hold- Shown in Location of cable harness -
ing the cable harness in the frame and lower lower end (axes 1-3) on page 154.
arm.
8 Unscrew the screws of the motor covers for
axes 1, 2 and 3 and lift away the covers. This
is done in order to reach the motor connectors.
Action Note
9 Disconnect all connectors at motors for axes See sections:
1, 2 and 3. • Replacing motor, axis 1 on
page 255
• Replacing motors, axes 2 and 3
on page 262
10 Open the SMB cover carefully.
xx0600002700
Note
xx1000001330
Action Note
16 Gently pull the cable harness out from the base
through the cable guide, axis 1 and frame.
xx0600002699
17 Continue removing the cable harness in the See section Replacing the cable har-
upper arm. ness, upper end (incl. axis 6) on
page 162.
CAUTION
xx1000001331
Action Note
2 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.
xx1000001330
3 Reconnect connectors R1.MP and R1.SMB at Tightening torque for R1.SMB: 10 Nm.
the robot base. Attachment points are shown in the
figure Location of cable harness -
lower end (axes 1-3) on page 154.
4 Reconnect the earth cable.
xx1000001314
5 Refit the rear cover plate to the robot base with Shown in Location of cable harness -
its attachment screws. lower end (axes 1-3) on page 154.
6 Reconnect all connectors at motors axes 1, 2 See sections:
and 3 and refit the motor covers. • Replacing motor, axis 1 on
page 255
• Replacing motors, axes 2 and
3 on page 262
7 Reconnect connectors R2.SMB, R1.SMB1-3,
R1.SMB6 of the SMB unit.
Reconnect X8, X9 and X10 to the brake release
unit.
Reconnect R1.G.
Action Note
8 Secure the SMB cover with its attachment
screws.
If cabling is used for 7th axis (option), refit the
connector R2.FB7 to the SMB cover and tighten
with 6 Nm.
9
WARNING
xx1100000157
13 Continue refitting the cable harness in the upper See section Replacing the cable har-
arm. ness, upper end (incl. axis 6) on
page 162.
14 Update the revolution counter! See section Updating revolution
counters on IRC5 robots on page 315.
15
DANGER
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 (axis 1-3)
is detailed in section Replacing cable harness, lower end (axes 1-3) on page 154.
xx0600002608
xx0600002600
A Motor, axis 6
B Attachment screws and washers
C Cable gland cover
D Motor cover
Required equipment
Action Note
2
DANGER
3 If the complete cable harness is being re- Detailed in section Replacing cable har-
placed, start removal by removing the cable ness, lower end (axes 1-3) on page 154.
harness, lower end.
4 Remove the axis 6 motor cover by removing
its attachment screws, in order to reach the
connectors.
xx1000001106
Note
xx0600002694
Action Note
6 Remove the metal clamp that holds the
cable at the tilt house, by removing its nuts.
xx1000001336
xx1000001338
xx1000001338
xx1000001336
Action Note
5 Push the axis 6 motor cables carefully
through the cable gland.
Note
xx0600002694
Note
xx1000001106
Introduction
The term complete arm system used in this procedure is defined as the complete
robot excluding:
• base
• gearbox axis 1
xx0600002612
A Parallel rod
B Linkage
C Complete upper arm (incl. tilthouse)
D Balancing device
E Frame
F Gearbox, axis 1
G Base
H Base attachment screws
Required equipment
Action Note
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 320.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
xx0500002275
3
DANGER
Action Note
5 Remove the block for calibration and the axis
1 calibration plate.
xx0600002734
10 Fit the lifting accessories and adjust it as Make sure the lift is done completely
described in the enclosed user instructions. level.
This is detailed in section Lifting robot
with lifting accessory on page 58.
Action Note
11 Unfasten the arm system from the base by
unscrewing the attachment screws.
xx0600003070
CAUTION
14 If needed, continue to remove the axis 1 See Replacing the axis 1 gearbox on
gearbox from the base. page 280.
2 Refit the axis 1 gearbox, if it has been re- See Replacing the axis 1 gearbox on
moved. page 280.
Action Note
3
CAUTION
4 Fit the lifting accessories and adjust it as Article number is specified in Required
described in the enclosed user instructions. equipment on page 169.
Also fit a hoisting block to the front chain, Make sure the lift is done completely
used to adjust the balance of the arm system level! How to adjust the lift is described
in order to lift it completely level! in the enclosed instruction to the lifting
accessory! Follow the instructions be-
fore lifting!
This is detailed in section Lifting robot
with lifting accessory on page 58.
5 Lift the complete arm system and move it at
very low speed to the mounting site, making Note
sure it does not tip!
Make sure all hooks and attachments stay
Note in the correct position while lifting the arm
system and that the lifting accessory does
The refitting must be made completely level! not wear against sharp edges.
Make sure the roundslings are adjusted prior
to refitting the arm system.
Tip
xx0600002632
Note
Action Note
7 Look through the empty mounting hole of the
axis 1 motor to assist in aligning the as-
sembly during refitting of the complete arm
system.
8 Lower the complete arm system with guid-
ance from the guide pins previously fitted to CAUTION
the axis 1 gearbox.
This is a complex task to be performed
Note with utmost care in order to avoid injury
or damage!
The refitting must be made completely level! Use a crank to turn the gearbox in order
Make sure the roundslings are adjusted prior to find the right position for the holes.
to refitting the arm system.
9 Place the serrated lock washers on the attach- Reused screws can be used providing
ment screws. they are lubricated as described in Screw
joints on page 345.
Note
xx0600003070
Parts:
A Serrated lock washer (24 pcs)
B Axis 1 gearbox
C Attachment screws M12x110 qual-
ity 12.9 gleitmo (24 pcs)
10 Fit 22 of the 24 attachment screws before the
arm system is completely lowered.
This is done in order to be able to attach all
screws into the threads correctly.
11 Replace the guide pins with the remaining
attachment screws and secure the complete
arm system to the base with its attachment
screws and washers.
12 Lower the arm system completely.
13 Secure the complete arm system with its at- Tightening torque:
tachment screws. • 115 Nm.
14 Refit the cable harness in the base and the See Replacing cable harness, lower end
frame. (axes 1-3) on page 154.
15 Refit the axis 1 motor. See Replacing motor, axis 1 on page 255.
Action Note
16 Refit the block for calibration and the axis 1
calibration plate.
xx0600002734
xx0600002627
A Turning disk
B Attachment screws (6 pcs) turning disk
C Tilthouse unit
D Gearbox, axis 6
E Attachment screws, axis 6
Required equipment
xx0200000218
xx1400000995
3 Secure the turning disk with its attachment 6 pcs M14 x 25, 12.9 quality.
screws. Tightening torque: 175 Nm
Reused screws may be used, providing
they are lubricated as detailed in sec-
tion Screw joints on page 345 before fit-
ting.
4 Perform a leak-down test of the gearbox axis Detailed in the section Performing a
6. leak-down test on page 146.
5 Refill the axis 6 gearbox with oil. See section
• Changing oil, gearbox axis 6 on
page 134
6 Refit any equipment removed during disas-
sembly to the turning disk.
Action Note
7
DANGER
xx0600002616
A Tilthouse unit
B Upper arm
C Upper rod
D Screw M6x10
E Washer 6.4x12x1.6
F Ballplug
G Protection cap
xx0600002743
xx0600002742
A Axis 2 side
B Axis 3 side
C VK cover, VK 19 x 6, 2 pcs
D VK cover, VK 68 x 8, 2 pcs
E Screw M6 x 10 Steel 8.8-A2F + Washers, 4 + 4 pcs (for filling bearing grease)
F Retaining ring fore bores, 2 pcs
G Rust protection, Dinitrol 490
H Upper arm
I Tilthouse
J Bearing, 2 pcs (on the outside of the tilthouse)
K Bearing, 2 pcs (on the inside of the tilthouse)
L Ring
M Shaft, 2 pcs
N Radial seal with dustlip, 2 pcs
O Lock nut, KM7 2 pcs
P Screw M6x16 + washer (for locking the shafts), 2 + 2 pcs
Required equipment
xx0600002750
¤
Note! The parts cannot be ordered separatly, but are inluded when ordering the
complete tool. The article numbers are given only for identification.
A Hydraulic cylinder, 3HAC 11731-1
B Mounting washer, 3HAC 023075-004
C Bushing, 3HAC 023075-006
D Screw M6x25, 2 pcs (MC6S)
E Threaded washer, 3HAC 5507-1
F Press washer, 3HAC 023075-002
G Threaded bar, M16 L = 300 mm
Action Note
If the robot is to be calibrated with refer- Follow the instructions given in the refer-
ence calibration: ence calibration routine on the FlexPendant
Find previous reference values for the axis to create reference values.
or create new reference values. These val- Creating new values requires possibility to
ues are to be used after the repair proced- move the robot.
ure is completed, for calibration of the ro- Read more about reference calibration for
bot. Axis Calibration in Reference calibration
If no previous reference values exist, and routine on page 320.
no new reference values can be created, Read more about reference calibration for
then reference calibration is not possible. Pendulum Calibration in Operating manu-
al - Calibration Pendulum.
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Removal, tilthouse
This procedure describes how to remove the tilthouse unit.
The item letters within parentheses refer to the figure Cut away view of the assembly
of the tilthouse unit on page 181.
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning the
repair procedure.
2 Move the robot to a position where the tilthouse
rests on a workbench, pallets or similar.
3
DANGER
DANGER
xx1000001067
Action Note
5 Disassemble the upper link from the tilt house Detailed in section Replacement of
unit. linkage - upper rod on page 204
Note
xx1000001065
Part:
Upper link
6 Disconnect motor cables from motor axis 6. Detailed in section Replacing the
Place the motor cables in a way that it will not cable harness, upper end (incl. axis
be damaged. 6) on page 162
xx0600002735
Action Note
10 Use compressed air in the M6 hole for filling Put a hand with some paper over the
grease, in order to remove the VK cover. VK cover in order to catch it.
CAUTION
xx1000001072
Parts:
M6 screw in hole for filling
grease
VK cover
11 Remove the screw that locks the shaft.
xx0600002703
• A: Screw M6x16
• B: Shaft
• C: Upper arm
Action Note
12 Remove the small VK cover from the inside with
the help of a punch.
xx1000001073
xx1000001074
14 Apply the press tool, mounting axis 6 in the Art.no. is specified in Required equip-
following way: ment on page 182.
• Push the threaded bar M16 through the
holes in the shafts.
• Apply the washer and the nut on the right
side of the right shaft.
• Put the distance ring on the bar on the
left side of the shaft
• Apply the hydraulic pump on the bar
• Secure the hydraulic pump with a nut.
Remove the shaft with the press tool, mounting
axis 6.
Note
Action Note
15 Press out the shaft.
xx1000001075
A Shaft
16 Remove the press tool, mounting axis 6 and
the shaft.
xx1000001076
Action Note
19 Lift the tilthouse to a safe place. Check that bearings are kept clean, if
being refitted.
xx1000001077
20 Force away the sealing ring (N) with a screw- The sealing must be replaced with a
driver or similar. new one when refitting.
21 If needed change the bearings.
Action Note
6 Thread the race of the outer bearing (J) on the Shown in the figure Cut away view of
bushing (C) of the pressing tool, premounting the assembly of the tilthouse unit on
bearings. page 181.
Shown in the figure Press tool pre-
mounting bearing on page 183.
Art.no. is specified in Required equip-
ment on page 182.
7 Fit the pressing tool and press the parts togeth-
er.
Action Note
1 Secure the tilthouse with a roundsling in an
overhead crane and lift it to its mounting posi-
tion on the upper arm.
Action Note
2 Apply Dinitrol 490 (G) on the surfaces where Shown in the figure Cut away view of
the tilthouse faces the upper arm for rust pro- the assembly of the tilthouse unit on
tection. page 181.
3 Apply some grease in the holes for the shafts Art. no. is specified in Required
(M) in the upper arm. equipment on page 182.
Shown in the figure Cut away view of
the assembly of the tilthouse unit on
page 181.
4 Note! Fit the axis 2 side first. Shown in the figure Location of axes
2 and 3 sides of the robot on page 181.
5 Push the axis 2 shaft (M) into its hole, from the Shown in the figure Cut away view of
inside. the assembly of the tilthouse unit on
page 181.
6 Thread the race of the bearing (J) facing the Shown in the figure Cut away view of
outside of the tilthouse, on the press housing the assembly of the tilthouse unit on
(C) of the press tool, mounting axis 6 and fit it page 181.
on the shaft (M). Shown in the figure Press tool mount-
ing axis 6.
Art. no. is specified in Required
equipment on page 182.
xx0900000813
DANGER
7 Fit the rest of the press tool, mounting axis 6 Art. no. is specified in Required
from the outside of the tilthouse.Secure the equipment on page 182.
parts with the flange locknut (F). Shown in the figure Press tool mount-
ing axis 6.
Action Note
8 Insert the shims in the space between the tilt- Art. no. is specified in Required
house and the upper arm on the axis 2 side. equipment on page 182.
xx0600002748
• Shims, width = 3 mm
• A: 68 mm
9 Press the parts together.
10 Fit the axis 3 side in the same way, by following
steps 4 through 6.
11 Insert the shims in the space between the tilt-
house and the upper arm on the axis 3 side.
12 Press the parts together.
13 Apply locking liquid on the lock nut, KM7 axis Loctite 243.
2 side and fit it with the flat surface facing in- Tightening torque: 90 Nm
side.
14 Apply locking liquid on the lock nut, KM7 axis Loctite 243.
3 side and fit it with the flat surface facing in- Tightening torque: 90 Nm
side.
15 Apply locking liquid in the holes for the screws
locking the shafts and fit screws and washers
on both sides, locking the shafts.
xx0600002703
• A: Screw M6x16
• B: Shaft
• C: Upper arm
Action Note
16 Fit the inner VK cover (C) on both axes. Shown in the figure Cut away view of
the assembly of the tilthouse unit on
page 181.
17 Fit the outer VK cover (D) on both axes. Shown in the figure Cut away view of
the assembly of the tilthouse unit on
page 181.
18 Fill bearings with grease. Specified in Required equipment on
page 182.
19 Refit the motor cable, axis 6. Detailed in section Replacing the
cable harness, upper end (incl. axis
6) on page 162
20 Refit the M6 screw and washer at the cover for
filling grease.
xx0600002735
xx0600002609
A Upper arm
B Motor axis 6
C Balancing device
D Lower arm
E Parallel rod
F Linkage
xx0600002692
A Shaft, axis 2
B Shaft, axis 3
C Set screw, cup point (M10 x 20)
D Lubricant paste (Molycote 1000)
E Sealing ring (V-ring)
F Sealing ring
G Taper roller bearing
H O-ring
I Sealing ring
J Sealing assembly
K Lock nut (KM12)
L O-ring (Di = 54.2 mm, t = 5.7 mm)
Required equipment
Action Note
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Action Note
12 Remove the shaft, axis 3 (B): Shown in the figure View of the assembly
1 Remove the lock nut (K). of the upper arm components on page 195.
2 Remove the set screw (C) holding Perform the removal with care. Threads
the shaft. can otherwise be damaged!
3 Put the adapter on the shaft. Art.no. is specified in Required equipment
4 Remove the shaft. on page 196
13 Then remove the shaft, axis 2 (A) in the Shown in the figure View of the assembly
same order: of the upper arm components on page 195.
1 Remove the lock nut (K)
2 Remove the set screw (C) holding Note
the shaft
3 Remove the shaft axis 2. The adapter is not needed on this shaft!
Note
Note
xx1400001124
Action Note
3 Install two support rings to the upper arm: Art. no. is specified Required equipment
1 Fit a support ring to the press tool and on page 196
lubricate with grease for easier as-
sembly.
2 Press in the support ring to the upper
arm housing by screwing on the press
tool assembly. Tighten with 120 Nm.
3 Remove the press tool. The support
ring is now fitted to the upper arm
housing.
4 Repeat the procedure on the other
side.
CAUTION
xx1900001714
xx1900001205
Action Note
3 Lift the upper arm with an overhead crane
and move it to its mounting position.
Make sure that the upper arm is placed in
a horizontal position.
4
Note
5 Refit the axis-3 shaft: Shown in the figure View of the assembly
1 Carefully refit the shaft, axis 3 (B) by of the upper arm components on page 195.
hand only. Art. no. is specified Required equipment
Do not use force since the threads on page 196
can be damaged if fitting is not done Loctite 243.
in the correct way.
2 Put the adapter on the shaft and fit
it.
Secure the shaft.
Tightening torque: 800 Nm.
3 Refit the sealing ring (F) on the shaft.
4 Refit the bearing (G) on the shaft with
the pressing tool, upper arm.
5 Fit an o-ring (H) on the sealing ring
(I) and fit it on the shaft.
Note
Action Note
6 Refit the axis-2 shaft: Shown in the figure View of the assembly
1 Carefully refit the shaft, axis 2 (A) by of the upper arm components on page 195.
hand only. Art. no. is specified Required equipment
Do not use force since the threads on page 196
can be damaged if fitting is not done Loctite 243.
in the correct way.
2 Secure the shaft.
Tightening torque: 800 Nm.
3 Refit the sealing ring (F) on the shaft.
4 Refit the bearing (G) on the shaft with
the pressing tool, upper arm.
5 Fit an o-ring (H) on the sealing ring
(I) and fit it on the shaft.
Note
Action Note
14
DANGER
Overview
The link system consists of three basic parts - upper rod, lower rod and link. These
procedures describes how to remove and refit the upper rod.
xx0600002592
A Lower rod
B Upper rod
C Link
Required equipment
xx1000001132
3
DANGER
Action Note
4 Remove the lock nuts and support washers
holding the upper rod at each end.
xx1000001080
Note
xx1000001081
Action Note
2 Lubricate the bearings properly with bearing Specified in Required equipment on
grease. page 204.
3 Refit the sealing rings on the shaft ends of
the link and tilthouse.
4 Refit the support washers on the shaft ends.
5 Lubricate the shaft ends lightly with grease.
6 Refit the upper rod to its place on the shafts. Check that the rod is pushed in com-
pletely.
7 Refit the support washers on the outside of
the upper rod on the shaft ends.
xx1000001080
Overview
The linkage consists of three basic parts - upper rod, lower rod and link. The
procedures below details how to remove and refit the lower rod.
How to replace the upper rod and link, see:
• Replacement of linkage - upper rod on page 204.
• Replacement of linkage - link on page 212
xx0600002592
A Lower rod
B Upper rod
C Link
Required equipment
xx1000001252
Action Note
3 Remove the lock nuts and support washers
that hold the lower rod at each end.
Note
4
CAUTION
Note
Action Note
6
CAUTION
Note
Overview
The linkage consists of three basic parts - upper rod, lower rod and link. The
procedures below details how to remove and refit the link.
How to replace the upper rod and lower rod, see:
• Replacement of linkage - upper rod on page 204.
• Replacing the linkage - lower rod on page 208.
Location of link
The link is located as shown in the figure.
xx0600002592
A Lower rod
B Upper rod
C Link
Required equipment
Action Note
If the robot is to be calibrated with fine
calibration:
Remove all external cable packages
(DressPack) and tools from the robot.
Removal, link
Use this procedure to remove the link of the linkage.
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
2
DANGER
xx1000001265
4 Remove the upper rod and lower rod. Detailed in section Replacement of linkage
- upper rod on page 204
Detailed in section Replacing the linkage
- lower rod on page 208
5 Fit the auxiliary shaft on the shaft. Art.no. is specified in Required equipment
on page 213
Action Note
6 Remove screw and washer in the hole for
filling grease.
xx1000001266
CAUTION
xx1000001267
Action Note
8 Remove the lock nut (KM8).
xx1000001268
9
CAUTION
10 Put the end of the link facing the upper rod, Normally a not too hard knock is needed
downwards in order to find room to knock to loosen the link.
on it from the inside as close to its center Note! Loosen the roundsling some before
as possible. knocking! Otherwise the link may be
locked by the lifting power.
11 Use a pair of levers, to bend the link loose.
12 Remove the link.
13 Remove the support ring with the radial
seal.
14 Wipe off residual grease.
15 If needed, replace the bearings and radial
seal.
Action Note
1 Put the link on a workbench.
Action Note
2 Fit the new outer races using the mounting Art.no. is specified in Required equipment
tool. on page 213
xx0900000813
DANGER
Refitting, link
Use this procedure to refit the link of the linkage.
Action Note
1
CAUTION
Action Note
9 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 90 Nm.
Note
xx1000001266
xx0600002610
A Parallel rod
Required equipment
2
CAUTION
3 Foundry Plus:
Remove the protection plugs
4 Remove the upper lock screw and washer,
that secure the parallel rod in position.
xx0600002741
Action Note
5 Remove the upper shaft (A) and cover Art. no. is specified in Required equipment
washer (B), using the fitting/removing tool. on page 219.
xx0700000065
Parts:
A Shaft
B Cover washer
C Parallel rod
D Sealed spherical bearing
E Bearing grease
F Thrust washer
6 Remove the thrust washer (F). See figure above!
7
CAUTION
8 Move the parallel rod backwards from its See figure above and Location of parallel
upper connection point and let it rest rod on page 219!
against the frame and base.
9 Secure the parallel rod with a roundsling in
an overhead crane or similar.
10 Remove the lower end of the parallel rod in See figure above!
the same way as the upper end:
1 Remove the lower lock screw and
washer.
2 Remove the lower shaft (A )and cover
washer (B).
3 Remove the thrust washer (F).
11 Remove the parallel rod from the robot.
12 Replace the bearings (D), if necessary. See figure above!
Note
xx1400001126
xx0700000065
Parts:
A Shaft
B Cover washer
C Parallel rod
D Sealed spherical bearing
E Bearing grease
F Thrust washer
7 Put the cover washer (B) on the axis 3 side See figure above!
of the parallel rod.
Action Note
8 Refit the shaft (A) by pressing it through the Art. no. is specified in Required equip-
parallel bar with the fitting/removing tool. ment on page 219.
See figure above!
9 Apply locking liquid in the hole of the lock Loctite 243
screw.
10 Refit the lock screw and plain washer.
xx0600002741
xx0600002611
A Lower arm
B Parallel arm
Required equipment
Action Note
2
DANGER
CAUTION
Tighten by hand!
xx1000001101
Action Note
12 Secure the complete lower arm system (includ- Specified in Required equipment on
ing the parallel arm) with a lifting tool, lower arm page 224.
complete in an overhead crane or similar.
13 Remove the lock screw that secures the lower
arm system.
xx1000001101
Note
15
DANGER
xx1000001359
16
CAUTION
Action Note
17 Move the parallel arm and secure it to the lower
arm as shown in the figure, to prevent it from
falling down.
xx1000001357
19
CAUTION
xx1000001358
3 Fit a lifting tool, lower arm complete, to the lower Specified in Required equipment on
arm system and lift it up. page 224.
DANGER
4 Fit two guide sleeves for the axes 2/3 sealings Art. no. is specified in Required
to the lower arm and put the sealings on them. equipment on page 224.
See figure.
xx1000001368
Action Note
5 Put the lower arm in its mounting position. Art. no. is specified in Required
If the hole pattern needs to be adjusted, use a equipment on page 224.
crank to move the gears in order to find the cor-
rect hole pattern.
xx1000001370
6
Note
Note
Action Note
13 Secure the lower arm by fitting a lock screw. Dimension is specified in Required
equipment on page 224.
CAUTION
Tighten by hand!
xx1000001101
14 Refit the axes 2 and 3 gearboxes. See Replacing the gearbox, axes 2-
3 on page 291.
15 Refit the axes 2 and 3 motors. See Replacing motors, axes 2 and 3
on page 262.
16 Refit the complete upper arm. See Replacement of upper arm on
page 194.
17 Refit the cable harness. Also see
18 Refit the parallel rod. See Replacing the parallel rod on
page 219
19 Refit the balancing device. Also see
20 Refit the linkage. See Replacement of linkage - upper
rod on page 204
See Replacing the linkage - lower rod
on page 208
See Replacement of linkage - link on
page 212
21 Remove the lock screw.
22 Recalibrate the robot. Pendulum Calibration is described in
Operating manual - Calibration Pen-
dulum, enclosed with the calibration
tools.
Axis Calibration is described in Calib-
rating with Axis Calibration method
on page 319.
General calibration information is in-
cluded in section Calibration on
page 309.
23
DANGER
xx0600002611
A Lower arm
B Parallel arm
Required equipment
Action Note
2
DANGER
3 Remove the complete lower arm. See Replacing the complete lower
arm on page 224.
4 Put the complete lower arm on a workbench as
shown in the figure.
Tip
xx1000001024
xx1000001371
Action Note
6 Fit the lifting accessory, parallel arm on the parallel Art. no. is specified in Required
arm. Lift the parallel arm to the position shown in equipment on page 232.
the figure.
xx1000001375
7 Disassemble the parallel arm from the lower arm Art. no. is specified in Required
by using the pressing tool, lower arm. equipment on page 232.
8
CAUTION
xx1000001018
Action Note
10 If needed, replace bearings, using the press equip-
ment, parallel arm, according to user instructions
enclosed with the equipment.
xx1100000218
xx0900000813
DANGER
xx1000001376
Action Note
5 Refit a bearing on each shaft with pressing tool, Art. no. is specified in Required
lower arm. equipment on page 232
xx0900000813
DANGER
xx1000001377
6 Foundry Plus:
Apply rust preventive on the highlighted areas.
xx1400001127
10 Fit the lifting accessory, parallel arm. Art. no. is specified in Required
equipment on page 232.
11 Lift the parallel arm onto the workbench where the Art. no. is specified in Required
lower arm is placed. equipment on page 232
12 Adjust the lower arm in a way that both holes are
parallel.
Use a level.
Action Note
13 Apply some grease in the holes in the lower arm
(thick blue arrows).
Note
xx1000001380
xx1000001379
15 Carefully press the parallel arm onto the lower arm Art. no. is specified in Required
using the pressing tool, lower arm. equipment on page 232.
16 Fit the big and small VK cover.
17 Refit the complete lower arm. Detailed in section Replacing the
complete lower arm on page 224.
18 Recalibrate the robot. Pendulum Calibration is described
in Operating manual - Calibration
Pendulum, enclosed with the cal-
ibration tools.
Axis Calibration is described in
Calibrating with Axis Calibration
method on page 319.
General calibration information is
included in section Calibration on
page 309.
Action Note
19
DANGER
xx0600002604
A Balancing device
B Hole to neutralize the spring force. (M12)
C Hole on lifting ear
D Hole for lock screw
Required equipment
CAUTION
Tighten by hand!
xx1000001101
Action Note
3
DANGER
xx1000001112
Action Note
7 Remove the upper and lower lock nuts and
support washers (2+2 pcs).
Note
xx1000001113
8 Fit the auxiliary shafts on the upper and lower Art.no. is specified in Required equip-
pivot shaft. ment on page 240
Fit the short auxiliary shaft on the upper shaft
and the longer on the lower shaft.
9 Stretch the roundsling.
10 Apply a ball bearing puller behind the lower ear
of the balancing device.
Note
xx1000001115
11
CAUTION
Action Note
12 With the help of the ball bearing puller carefully
remove the balancing device from its upper and
lower attachments.
xx1000001114
xx1000001116
Action Note
2 Refit the inner sealing rings and support
washers in both ends.
xx1000001116
xx1000001112
Action Note
7 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 than 0.1 mm too long. If the distance is
too long the bearings may be damaged when
erecting the balancing device.
xx1000001111
xx1000001271
Action Note
14 Refit the lock nuts and support washers. Tightening torque: 120 Nm
xx1000001113
xx1000001101
18
DANGER
xx0600002621
A SMB cover
B SMB unit
C Battery cable
D SMB battery
E SMB battery, cover
Required equipment
Note
There are different variants of SMB units and batteries. The variant with the
3-pole battery contact has longer lifetime for the battery.
It is important that the SMB unit uses the correct battery. Make sure to order the
correct spare parts. Do not replace the battery contact!
3
ELECTROSTATIC DISCHARGE (ESD)
4 Remove the SMB cover by unscrewing its attachment Shown in the figure Location of
screws. SMB unit on page 248.
CAUTION
xx1700000993
2
ELECTROSTATIC DISCHARGE (ESD)
3 Connect the battery cable to the SMB unit. Shown in the figure Location of SMB
Make sure the lock on the battery cable connect- unit on page 248.
or R2.G snaps into place during refitting.
4 Connect all connectors to the SMB board: Art. no. is specified in Required
R1.SMB1-3, R1.SMB6 and R2.SMB equipment on page 248.
Shown in the figure Location of SMB
unit on page 248.
5 Fit the SMB unit onto the guide pins.
6 Secure the SMB unit to the pins with the nuts
and washers.
7 If disconnected, reconnect the connectors X8,
X9 and X10 to the brake release board.
Be careful not to damage the sockets or pins.
Make sure the connector and its locking arms X8
X10
X9
are snapped down properly.
xx1700000978
8 Secure the SMB cover with its attachment Shown in the figure Location of SMB
screws. unit on page 248.
If cabling is used for 7th axis (option), refit the
7th axis connector to the SMB cover and tighten
with 6 Nm.
9 Update the revolution counters. See Updating revolution counters on
IRC5 robots on page 315.
10
DANGER
xx0600002621
A SMB cover
B SMB unit
C Battery cable
D SMB battery
E SMB battery, cover
Required equipment
2
ELECTROSTATIC DISCHARGE
(ESD)
3 Remove the push button guard from the SMB Shown in the figure Location of brake
cover. release board on page 251.
The guard must be removed to ensure
a correct refitting of the brake release
board.
4 Open the SMB cover by unscrewing the attach- Shown in the figure Location of brake
ment screws. release board on page 251.
Let the battery stay connected, to avoid the
need of synchronization of the robot!
CAUTION
X8
X10
X9
xx1700000978
Action Note
8 Remove the brake release board from the
bracket by removing the four attachment
screws.
xx1700000978
3 Fasten the brake release board on the bracket Maximum tightening torque: 5 Nm.
with the attachment screws. Shown in the figure Location of brake
Make sure the board is positioned as straight release board on page 251.
as possible on the bracket! The push buttons
can otherwise get jammed when the SMB Art. no. is specified in Required equip-
cover is refitted. ment on page 251.
WARNING
6 Refit the SMB cover with its attachment Shown in the figure Location of brake
screws. release board on page 251.
7
WARNING
8 Refit the push button guard to the SMB cover. Shown in the figure Location of brake
release board on page 251.
Action Note
9 Press the push buttons 1 to 6, one at a time,
to make sure that the buttons are moving
freely and do not stay in a locked position.
10 If the battery has been disconnected the revolu- Detailed in the Calibration chapter -
tion counter must be updated. section Updating revolution counters
on IRC5 robots on page 315.
11
DANGER
4.6 Motors
A Motor axis 1
B Motor attachment screws and washers
C Cable gland cover (located on the left hand side of the motor)
D Motor cover
Required equipment
Action Note
2
DANGER
Note
Action Note
8 If required, press the motor out of position by Always use removal screws and tools
fitting two screws in the holes on the motor for in pairs!
pressing out the motor.
9
CAUTION
CAUTION
Parts:
A Circumference of motor
B O-ring
Note
2
CAUTION
Note
Note
Action Note
5 Secure the motor with its four attachment
screws and plain washers. Use the bits exten-
sion.
Attachment screws:
• M10x40 quality 12.9 Gleitmo
Tightening torque:
• 50 Nm
6 Disconnect the brake release voltage.
7 Reconnect all connectors beneath the motor
cover.
8 Refit the cable gland cover at the cable exit with
its attachment screws.
Note
Note
Action Note
11
DANGER
xx0600002599
A Motor, axis 2
B Motor, axis 3
C Motor attachment screws and washers
D Cable gland cover (located on the lower side of the motor)
E Motor cover
F Hole for lock screw
Required equipment
xx1000001101
3 Lock the lower arm by inserting the lock screw See figure above.
into the hole of the frame.
This is done in order to secure axis 2 from col-
lapsing when the axis 2 motor is being removed.
CAUTION
Tighten by hand!
Action Note
7 Remove the motor cover.
xx1000001102
Note
xx1000001103
Action Note
11 Unscrew attachment screws and washers of
the motor. Use the bits extension.
xx1000001104
12 Fit two guide pins in two of the motors attach- Art. no. is specified in Required
ment holes. equipment on page 262.
xx1000001131
Action Note
13 If required, press the motor out of position by M12x70, fully threaded.
fitting two screws in the remaining attachment Always use the removal screws and
holes of the motor, diagonal to each other. tools in pairs!
xx1000001184
14 Remove the two screws and fit the lifting tool, Art. no. is specified in Required
motor axes 2-3 to the motor. equipment on page 262.
15
CAUTION
16 Pull out the motor on the guide pins to get the The figure shows IRB 760 but the
pinion away from the gear. principle is the same.
Make sure the pinion does not get damaged!
xx1000001105
Action Note
18 Disconnect the brake release voltage!
19 Check the pinion. If there is any damage, the
motor pinion must be replaced.
xx1000001096
Parts:
A Circumference
B O-ring
2 In order to release the brake, connect the 24 Connect to connector R2.MP1
VDC power supply. • + : pin 2
• -: pin 5
3 Fit the lifting tool, motor axes 2-3 to the motor. Art. no. is specified in Required
equipment on page 262.
Action Note
4 Fit the two guide pins in the two lower motor Art. no. is specified in Required
attachment holes. equipment on page 262.
The figure shows IRB 760 but the
principle is the same.
xx1000001131
5
CAUTION
6 Lift the motor and guide it on to the guide pins, The figure shows IRB 760 but the
as close to the correct position as possible principle is the same.
without pushing the motor pinion into the gear.
Note
xx1000001185
Action Note
8 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
Part:
Rotation tool
9 Remove the guide pins.
10 Secure the motor with its four attachment
screws and plain washers. Use the bits exten-
sion.
Reused screws can be used, providing they are
lubricated as detailed in section Screw joints
on page 345 before fitting.
xx1000001104
Attachment screws:
• M10 x 40 quality 12.9 Gleitmo
Tightening torque:
• 50 Nm
11 Disconnect the brake release voltage.
12 Reconnect all connectors beneath the motor Connect in accordance with markings
cover. on connectors.
Action Note
13 Refit the cable gland cover at the cable exit with
its two attachment screws.
Note
xx1000001103
Note
xx1000001102
xx1000001101
Action Note
18 Recalibrate the robot! Pendulum Calibration is described in
Operating manual - Calibration Pendu-
lum, enclosed with the calibration
tools.
Axis Calibration is described in Calib-
rating with Axis Calibration method on
page 319.
General calibration information is in-
cluded in section Calibration on
page 309.
19
DANGER
xx0600002600
A Motor, axis 6
B Attachment screws and washers
C Cable gland cover
D Motor cover
Required equipment
Note
Action Information
3
DANGER
xx1000001106
Note
xx0600002694
B
6 Disconnect all connectors beneath the
cover.
A
Note
xx0500002466
Action Information
7 In order to release the brake, connect the Connect to connector R2.MP6
24 VDC power supply. • + : pin 2
• -: pin 5
8 Remove attachment screws and washers.
Use the bits extension.
xx1000001012
9 If required, press the motor out of position Always use the screws for removal in
by fitting two screws in the motor attach- pairs!
ment holes diagonal to each other
10 Lift the motor carefully to get the pinion
away from the gear.
Note
xx1000001108
Note
xx1000001109
Parts:
• A: Pinion
• B: O-ring
• C: Circumference
2 In order to release the brake, connect the 24 Connect to connector R2.MP6
VDC power supply. • + : pin 2
• -: pin 5
3 Fit the two guide pins in two of the motor attach- Art. no. is specified in Required
ment holes. equipment on page 273.
4 Lift the motor carefully in place.
Make sure the motor pinion is properly mated
to the gearbox, axis 6.
Note
xx1000001108
Action Information
7 Secure the motor with its four attachment
screws and washers.
Reused screws may be used, providing they
are lubricated as detailed in section Screw joints
on page 345 before fitting.
xx1000001012
Washers:
• 8.4x16x1.6 quality Steel-A2F
Attachment screws:
• M10 x 40 quality 8.8-A2F
Tightening torque:
• 50 Nm
8 Disconnect the brake release voltage.
9 Perform a leak-down test of the axis 6 gearbox. See section Performing a leak-down
test on page 146.
10 Reconnect all connectors in motor axis 6. Connect in accordance with markings
on connectors.
11 Refit the connections to the UL lamp, if the ro-
bot is equipped with one.
12 Check the gasket. If damaged, replace it.
xx1000001224
Action Information
13 Refit the cable gland with its attachment screw.
xx0600002694
Note
xx1000001106
4.7 Gearboxes
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure.
xx0600002631
A Gearbox, axis 1
B Frame
C Base
Required equipment
xx0500002275
3
DANGER
Action Note
7 Attach the lifting accessory, base and gear
1 and the lifting tool (chain) to the gearbox
and base.
xx1000001395
9 Lift the robot base including the axis 1 Art. no. is specified in Required equip-
gearbox to allow the base and gear 1 sup- ment on page 280.
port be fitted on each sides of the base.
10 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!
xx1000000364
Action Note
11 Remove the bottom plate from underneath
the base in order to get access to the attach-
ment screws.
It may be necessary to also remove the rear
connector plate.
xx1000001385
xx0300000612
A Bottom plate
B Rear connector plate
C Attachment screw
D Groove
12 Unscrew the attachment screws and re-
move the washers.
xx0200000227
Action Note
13 Remove the cable guide in the center of
gearbox 1 by unscrewing its attachment
screws.
xx1000001387
14
CAUTION
Note
xx1400000786
xx1000000364
xx0200000055
• A: Guide pin
• C: O-ring 3HAB 3772-54
• D: O-ring 3HAB 3772-55
• E: Sealing ring 3HAC 11581-4
Action Note
3 Make sure the small o-ring around the oil hole
is fitted properly!
xx1000001392
4 Attach the lifting accessory, base and gear 1 Specified in Required equipment on
and the lifting tool (chain) to the gearbox. page 280.
xx1000001395
5 Fit two guide pins in two of the attachment Specified in Required equipment on
holes in the gearbox, parallel to each other. page 280.
6
CAUTION
Action Note
7 Lift the gearbox.
Make sure the guide pin in the bottom face of
the gearbox is properly aligned with the base.
xx1000001389
xx1000001391
8 Lift gearbox axis 1 onto the guide pins and Always use guide pins in pairs!
lower it carefully to its mounting position.
Action Note
9 Secure the gearbox with its attachment 18 pcs, M16 x 70, 12.9 quality UN-
screws and washers. BRAKO.
Tightening torque: 300 Nm
Reused screws may be used, providing
they are lubricated as detailed in sec-
tion Screw joints on page 345 before fit-
ting.
xx0200000227
xx1000001393
Action Note
11 Refit the bottom plate underneath the robot 1 screw: M6 x 8.
base by pushing it into the groove and fitting
the attachment screw.
If removed, also refit the rear connector plate.
Note
xx0300000612
• A: Bottom plate
• B: Rear connector plate
• C: Attachment screw
• D: Groove
12
CAUTION
xx0500002467
A Gearbox, axis 1
B Gearbox, axis 2
C Gearbox, axis 3
D Gearbox, axis 6
Required equipment
Note
Do not replace both gearboxes at the same time, unless the complete arm system
is already removed!
Action Note
1 Decide which calibration routine to use, and
take actions accordingly prior to beginning
the repair procedure.
2 When removing axis 2 gearbox: Run the
axis 2 to -42° and all other axes to 0° (cal-
ibration position).
When removing axis 3 gearbox: Run the
axis 2 to -40°, axis 3 to +15° and all other
axes to 0°.
3 When removing axis 2 gearbox: Remove Axis 2:
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.
xx1100000623
Axis 3:
xx1100000624
Action Note
5 Fit the lock screw in the lower arm to secure
axis 2.
CAUTION
Tighten by hand!
xx1000001101
Note
xx1000001111
Action Note
11 Insert two screws, M12x50 in the holes to See the previous figure!
neutralize the spring force. Screw in the
screws until they have proper contact with
the cylinder inside.
The length of the cylinder is now locked
and the balancing device is unloaded. It
should now be possible to easily rotate the
balancing device.
12
DANGER
Note
Time-consuming activity!
xx1000001405
Action Note
18 Remove the gearbox cover by removing its
attachment screws.
xx1200000628
Action Note
25 Remove the gearbox axis 2-3 using an
overhead crane or similar, with guidance
from the fitted guide pins.
xx1200000629
Note
xx1200000630
xx1000001404
4 Fit the lifting accessory to the gearbox and Specified in Required equipment on
lift it with an overhead crane. page 291.
Action Note
5 Fit a new sealing to the gearbox and secure Art. no. is specified in Required equipment
it to the gearbox by using two guide on page 291.
sleeves. Axis 2:
When refitting axis 2 gearbox:Insert the
guide sleeves in the two middle holes of
the upper screw areas.
When refitting axis 3 gearbox: Insert one
guide sleeve in the middle screw hole in
the upper back area and one guide sleeve
in the middle screw hole in the the lower
area.
xx1100000621
Axis 3:
xx1100000622
6 Foundry Plus:
Apply bearing grease on the highlighted
areas on both sides of the sealing.
Note
xx1400000993
Action Note
Foundry Plus:
Apply rust preventive on the highlighted
area.
xx1400001132
Note
xx1000001406
Action Note
13 Clean the gearbox of residual grease.
14 Apply locking liquid in the attachment holes Loctite 243.
for the gearbox cover.
15 Fit the o-ring in the cover.
xx1000001407
16 Refit the cover with its attachment screws M8x35 quality 8.8-A2F (12 pcs)
and washers. Tightening torque: 24 Nm
Note
xx1000001408
17 Refit the motors axes 2-3. See Replacing motors, axes 2 and 3 on
page 262
18 Perform a leakdown test. See Performing a leak-down test on
page 146.
Action Note
19 Refill the gearbox axes 2-3 with oil. See Filling, axes 2 and 3 on page 132
20 Remove the screws that unload the balan-
cing device and put back the plastic
screws.
xx1000001111
xx0600002627
A Turning disk
B Attachment screws (6 pcs) turning disk
C Tilthouse unit
D Gearbox, axis 6
E Attachment screws and washers, gearbox axis 6
Required equipment
Action Note
3
DANGER
xx0200000220
Action Note
8 Remove gearbox axis 6 carefully without
damaging pinion or gear.
xx1000001412
Action Note
2 Make sure the o-ring is undamaged and fit- For art. no. see: Required equipment on
ted to the gearbox. If the o-ring is damaged, page 303.
replace!
Lubricate the o-ring with grease.
xx0200000221
CAUTION
6 Secure the gearbox with its attachment 8 pcs or 18 pcs (depending on wrist ver-
screws and washers. sion): M8 x 40, 12.9 quality Gleitmo,
Reused screws may be used, providing they Tightening torque: 30 Nm.
are lubricated as detailed in section Screw
joints on page 345 before fitting.
7 Refit the turning disk. See section
• Replacing the turning disk on
page 176
8 Perform a leak-down test. See section
• See section Performing a leak-
down test on page 146.
9 Refill the gearbox with oil. See section
• Changing oil, gearbox axis 6 on
page 134
Action Note
10 Re-calibrate the robot. Pendulum Calibration is described in Op-
erating manual - Calibration Pendulum,
enclosed with the calibration tools.
Axis Calibration is described in Calibrating
with Axis Calibration method on page 319.
General calibration information is included
in section Calibration on page 309.
11
DANGER
5 Calibration
5.1 Introduction to calibration
Calibration information
This chapter includes general information about the recommended calibration
methods and also the detailed procedures for updating the revolution counters,
checking the calibration position etc.
Detailed instructions of how to perform Axis Calibration are given on the
FlexPendant during the calibration procedure. To prepare calibration with Axis
Calibration method, see Calibrating with Axis Calibration method on page 319.
Detailed instructions of how to perform Pendulum Calibration are given in the
documentation enclosed with the calibration tools.
Calibration terminology
Term Definition
Calibration method A collective term for several methods that might be
available for calibrating the ABB robot. Each method
contains calibration routines.
Synchronization position Known position of the complete robot where the
angle of each axis can be checked against visual
synchronization marks.
Calibration position Known position of the complete robot that is used
for calibration of the robot.
Standard calibration A generic term for all calibration methods that aim
to move the robot to calibration position.
Fine calibration A calibration routine that generates a new zero posi-
tion of the robot.
Reference calibration A calibration routine that in the first step generates
a reference to current zero position of the robot. The
same calibration routine can later on be used to re-
calibrate the robot back to the same position as when
the reference was stored.
This routine is more flexible compared to fine calib-
ration and is used when tools and process equipment
are installed.
Requires that a reference is created before being
used for recalibrating the robot.
Requires that the robot is dressed with the same
tools and process equipment during calibration as
during creation of the reference values.
Update revolution counter A calibration routine to make a rough calibration of
each manipulator axis.
Synchronization mark Visual marks on the robot axes. When marks are
aligned, the robot is in synchronization position.
Overview
This section specifies the different types of calibration and the calibration methods
that are supplied by ABB.
Types of calibration
References
Article numbers for the calibration tools are listed in the section Special tools on
page 350.
The calibration equipment for Calibration Pendulum is delivered as a complete
toolkit, including the Operating manual - Calibration Pendulum, which describes
the method and the different routines further.
When to calibrate
The system must be calibrated if any of the following situations occur.
Introduction
This section shows the position of the synchronization marks and the
synchronization position for each axis.
xx0500002487
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.
Calibration service routines will handle the calibration movements automatically
and these might be different from the positive directions shown below.
xx0500001927
Introduction
This section describes how to do a rough calibration of each manipulator axis by
updating the revolution counter for each axis, using the FlexPendant.
If the synchronization marks seem to be wrong (even if the motor calibration data
is correct), try to rotate the axis one turn, update the revolution counter and check
the synchronization marks again (try both directions, if needed).
xx1500000942
2 All mechanical units connected to the system are shown with their calibration status.
Tap the mechanical unit in question.
xx1500000943
Action
3 This step is valid for RobotWare 6.02 and later.
Calibration method used at factory for each axis is shown, as well as calibration
method used during last field calibration.
Tap Manual Method (Advanced).
xx1500000944
en0400000771
Action
5 Tap Update Revolution Counters....
A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to update the revolution counters.
• Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
6 Select the axis to have its revolution counter updated by:
• Ticking in the box to the left
• Tapping Select all to update all axes.
Then tap Update.
7 A dialog box is displayed, warning that the updating operation cannot be undone:
• Tap Update to proceed with updating the revolution counters.
• Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the selected revolution counters and removes the tick from
the list of axes.
8
CAUTION
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools
from ABB. Using other pins in the calibration bushings may cause severe
damage to the robot and/or personnel.
WARNING
The calibration tool must be fully inserted into the calibration bushing, until
the steel spring ring snaps into place.
2 During the calibration procedure, RobotWare moves the robot axis chosen
for calibration so that the calibration tools get into contact. RobotWare records
values of the axis position and repeats the coming-in-contact procedure
several times to get an exact value of the axis position.
WARNING
Risk of pinching! The contact force for large robots can be up to 150 kg.
Keep a safe distance to the robot.
3 The axis position is stored in RobotWare with an active choice from the
operator.
Note
When calibrating the robot with the reference calibration routine, the robot must
be dressed with the same tools, process cabling and any other equipment as
when the reference values were created.
If calibrating the robot with reference calibration there must be reference values
created before repair is made to the robot, if values are not already available.
Creating new values requires possibility to move the robot. The reference values
contain positions of all axes, torque of axes and technical data about the tool
installed. A benefit with reference calibration is that the current state of the robot
is stored and not the state when the robot left the ABB factory. The reference value
will be named according to tool name, date etc.
Follow the instructions given in the reference calibration routine on the FlexPendant
to create reference values.
When reference calibration is performed, the robot is restored to the status given
by the reference values.
Validation
In the mentioned routines, it is also possible to validate the calibration data.
These axes are marked with Unrestricted in the FlexPendant window. Also the
following table shows the dependencies between the axes.
Axis to calibrate
Required Axis 1 Axis 2 Axis 3 Axis 4 Axis 5 Axis 6
position of
axis
Axis 1 - * * *
Axis 2 0 - 0 *
Axis 3 0 0 - *
Axis 6 * * * -
- Axis to be calibrated
* Unrestricted. Axis is allowed to be jogged to other position than 0 degrees.
0 Axis must be put in position 0 degrees.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools from
ABB. Using other pins in the calibration bushings may cause severe damage to
the robot and/or personnel.
WARNING
xx1500001914
A Tube insert
B Plastic protection
C Steel spring ring
xx1500000951
A Outer diameter
Note
Action Note
1 It is possible to use any RFID solution, with the
correct dimensions. ABB has verifed function on
some suppliers fulfilling the requirements of NFC
compatible devices (13.56 Mhz) according to ISO
14443 or ISO 15693.
Note
xx1600000699
The fixed calibration pin for axis 1 is installed on a removable tower. The tower will
need to be removed if electronic position switches are fitted to the robot. Keep the
tower in a safe location for future recalibration needs and mark it with robot serial
number to ensure that the correct one is refitted.
Spare parts
When calibration is not being performed, a protective cover and an o-ring should
always be installed on the fixed calibration pin as well as a protective plug, included
a sealing, in the bushing. Replace damaged parts with new.
Spare part Article number Note
Protection cover and plug set 3HAC056806-001 Contains replacement calibration
pin covers and protective plugs
for the bushing.
Required tools
The calibration tools used for Axis Calibration are designed to meet requirements
for calibration performance, durability and safety in case of accidental damage.
WARNING
Calibrating the robot with Axis Calibration requires special calibration tools from
ABB. Using other pins in the calibration holes may cause severe damage to the
robot and/or personnel.
Required consumables
Consumable Article number Note
Clean cloth -
Spare parts
7 The robot performs a measurement sequence by rotating the axis back and
forth.
8 Remove the calibration tool and reinstall the protective cover on the fixed
pin and the protection plug in the bushing, if any.
9 The robot moves to verify that the calibration tool is removed.
10 Choose whether to save the calibration data or not.
Calibration of the robot is not finished until the calibration data is saved, as last
step of the calibration procedure.
Note
CAUTION
After calibration
Action Note
1 Check the o-ring on the fixed calibration pin.
Replace if damaged or missing.
2 Reinstall the protective cover on the fixed calibra-
tion pin on each axis, directly after the axis has
been calibrated.
Replace the cover with new spare part, if missing
or damaged.
xx1600002102
Action Note
3 Reinstall the protective plug and sealing in the
bushing on each axis, directly after the axis has
been calibrated. Ensure that the sealing is not
damaged.
Replace the plug and the sealing with new spare
part, if missing or damaged.
xx1500000952
Introduction
Always verify the results after calibrating any robot axis to verify that all calibration
positions are correct.
Introduction
Check the synchronization position of the robot 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.
6 Decommissioning
6.1 Environmental information
Introduction
ABB robots contain components in different materials. During decommissioning,
all materials should be dismantled, recycled, or reused responsibly, according to
the relevant laws and industrial standards. Robots or parts that can be reused or
upcycled helps to reduce the usage of natural resources.
Symbol
The following symbol indicates that the product must not be disposed of as common
garbage. Handle each product according to local regulations for the respective
content (see table below).
xx1800000058
Hazardous material
The table specifies some of the materials in the product and their respective use
throughout the product.
Dispose components properly according to local regulations to prevent health or
environmental hazards.
Material Example application
DANGER
General
There is much energy stored in the balancing device. Therefore a special procedure
is required to dismantle it. The coil springs inside the balancing device exert a
potentially lethal force unless dismantled properly.
The device must be dismantled by a decommissioning company.
Required equipment
DANGER
Do not under any circumstances, deal with the balancing device in any other
way than that detailed in the product documentation! For example, attempting
to open the balancing device is potentially lethal!
4
DANGER
5 Cut a hole in the housing as shown in the Use a cutting torch with a long shaft.
figure.
xx1100000096
Action Note
6
DANGER
7 Cut at least eight coils of the spring inside Use a cutting torch with a long shaft.
the housing.
8 Double-check the number of coils cut and
make sure all the tension in the spring is
removed.
Cut more coils if there is still tension in the
spring.
7 Reference information
7.1 Introduction
General
This chapter includes general information, complementing the more specific
information in the different procedures in the manual.
Note
The listed standards are valid at the time of the release of this document. Phased
out or replaced standards are removed from the list when needed.
General
The product is designed in accordance with ISO 10218-1:2011, Robots for industrial
environments - Safety requirements -Part 1 Robots, and applicable parts in the
normative references, as referred to from ISO 10218-1:2011. In case of deviations
from ISO 10218-1:2011, these are listed in the declaration of incorporation which
is part of the product delivery.
Standard Description
ISO 9283:1998 Manipulating industrial robots - Performance criteria and related
test methods
ISO 10218-2 Robots and robotic devices - Safety requirements for industrial
robots - Part 2: Robot systems and integration
ISO 12100 Safety of machinery - General principles for design - Risk as-
sessment and risk reduction
ISO 13849-1:2006 Safety of machinery - Safety related parts of control systems
- Part 1: General principles for design
ISO 13850 Safety of machinery - Emergency stop - Principles for design
IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part
1: General requirements
Standard Description
ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems
ANSI/UL 1740 Safety standard for robots and robotic equipment
CAN/CSA Z 434-03 Industrial robots and robot Systems - General safety require-
ments
Standard Description
ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion
nomenclatures
IEC 61000-6-2 Electromagnetic compatibility (EMC) – Part 6-2: Generic
standards – Immunity standard for industrial environments
IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic
standards – Emission standard for industrial environments
ISO 13732-1:2006 Ergonomics of the thermal environment - Part 1
IEC 60974-1:2012 i Arc welding equipment - Part 1: Welding power sources
Standard Description
IEC 60974-10:2014 i Arc welding equipment - Part 10: EMC requirements
ISO 14644-1:2015 ii Classification of air cleanliness
IEC 60529:1989 + A2:2013 Degrees of protection provided by enclosures (IP code)
i Only valid for arc welding robots. Replaces IEC 61000-6-4 for arc welding robots.
ii Only robots with protection Clean Room.
Converter table
Use the following table to convert units used in this manual.
Quantity Units
Length 1m 3.28 ft. 39.37 in
Weight 1 kg 2.21 lb.
Weight 1g 0.035 ounces
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.225 lbf
Moment 1 Nm 0.738 lbf-ft
Volume 1L 0.264 US gal
General
This section describes how to tighten the various types of screw joints on ABB
robots.
The instructions and torque values are valid for screw joints comprised of metallic
materials and do not apply to soft or brittle materials.
UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints.
It features special surface treatment (Gleitmo as described below) and is extremely
resistant to fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other
type of replacement screw is allowed. Using other types of screws will void any
warranty and may potentially cause serious damage or injury.
Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be
applied. The standard torques are specified in the following tables. Any
special torques are specified in the repair, maintenance or installation
procedure descriptions. Any special torque specified overrides the standard
torque!
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.
• Always tighten the joint by hand, and never use pneumatic tools.
• Use the correct tightening technique, that is do not jerk. Tighten the screw
in a slow, flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
Note
Note
Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm)
Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric-
ated ated
M5 6 - -
M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340
M20 400 560 670
M24 680 960 1150
Note
Note
Definition
In installation, repair, and maintenance procedures, weights of the components
handled are sometimes specified. All components exceeding 22 kg (50 lbs) are
highlighted in this way.
To avoid injury, ABB recommends the use of a lifting accessory when handling
components with a weight exceeding 22 kg. A wide range of lifting accessories
and devices are available for each manipulator model.
Example
Following is an example of a weight specification in a procedure:
Action Note
CAUTION
General
All service (repairs, maintenance, and installation) procedures contains lists of
tools required to perform the specified activity.
All special tools required are listed directly in the procedures while all the tools
that are considered standard are gathered in the standard toolkit and defined in
the following table.
This way, the tools required are the sum of the standard toolkit and any tools listed
in the instruction.
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 349, and of special tools, listed directly in the instructions
and also gathered in this section.
Basic tools
The following table specifies the tools in the basic toolkit that are used for the
current robot model. This toolkit is necessary primarily when removing and refitting
the motors.
The tools are also listed directly in the instructions.
Description Qty Art. no.
Guide pins M10 x 100 2 3HAC15521-1
Guide pins M10 x 150 2 3HAC15521-2
Lifting tool, motor ax 1 1 3HAC14459-1
Lifting tool, motor ax 2, 3 1 3HAC15534-1
Removal tool, motor M12x Fits motors axes 1, 2 and 3.
Rotation tool 1 3HAC17105-1
Bits extension 1 3HAC12342-1
Standard toolkit (content described in sec- 1 -
tion Standard tools on page 349)
Lifting tools
The following table specifies the lifting tools required during several of the service
procedures. The tools may be ordered separately and are also specified directly
in concerned instructions in the Product manual, procedures.
Description Qty Article no.
Lifting tool, tilt house 3HAC023154-001
Lifting tool, motor 3HAC15534-1
Lifting tool, frame 3HAC023308-001
Lifting tool, complete robot 3HAC15607-1
Lifting tool, parallel arm 3HAC023098-001
Lifting tool, turning device gearbox ax.1 3HAC14406-1
Lifting tool, base 3HAC14868-1
Special tools
The following table specifies the special tools required during several of the service
procedures. The tools may be ordered separately and are also specified directly
in concerned instructions.
Description Qty Article no.
Lower arm fixture 3HAC7035-1
Pressing, link 3HAC023081-001
Pressing, outer ring on link 3HAC077981-001
KM7 socket 6369901-438
KM8 socket Standard
KM10 socket Standard
KM12 socket extended 3HAC023739-001
Pinion crank 3HAC023132-001
Press tool, support ring 3HAC072616-001
Pressing, lower arm/balancing weight 3HAC076749-001
Pressing, upper arm 3HAC023084-001
Pressing, tie rod 3HAC5021-1
Pressing, tilt house 3HAC077982-001
Pressing, outer ring, tilt house 3HAC023075-001
Auxiliary shaft, long 3HAC5275-1
Auxiliary shaft, short 3HAC5276-1
Support shaft/bearing race 3HAC5281-1
Axis 1 pinion 3HAC022436-001
Tool for lubrication 3HAC5222-1
Adapter for shaft axis 3 3HAC071308-001
Guide sleeves 3HAC14446-1
General
Many repair and maintenance activities require different pieces of lifting accessories,
which are specified in each procedure.
The use of each piece of lifting accessories is not detailed in the activity procedure,
but in the instruction delivered with each piece of lifting accessories.
The instructions delivered with the lifting accessories should be stored for later
reference.
Location
Spare parts and exploded views are not included in the manual but delivered as
a separate document for registered users on myABB Business Portal,
www.abb.com/myABB.
Tip
9 Circuit diagrams
9.1 Circuit diagrams
Overview
The circuit diagrams are not included in this manual, but are available for registered
users on myABB Business Portal, www.abb.com/myABB.
See the article numbers in the tables below.
Controllers
Manipulators
ABB AS
Robotics & Discrete Automation
Nordlysvegen 7, N-4340 BRYNE, Norway
Box 265, N-4349 BRYNE, Norway
Telephone: +47 22 87 2000
ABB Inc.
Robotics & Discrete Automation
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
abb.com/robotics
3HAC025755-001, Rev Z, en