Page 1 ABB Robotics Product manual IRB 760...
Page 2 Trace back information: Workspace R13-1 version a6 Checked in 2013-03-31 Skribenta version 1184...
Page 4 The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
Securing the base plate ................2.3.7 Orienting and securing the robot ..............2.3.8 Fitting equipment on robot ............... 2.3.9 Installation of signal lamp, upper arm (option) ..........2.3.10 Loads ....................3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 6 Replacing the linkage - lower link arm ............4.4.6 Replacement of linkage - link ..............4.4.7 Replacing the parallel rod ................. 4.4.8 Replacing the complete lower arm .............. 4.4.9 Replacement of parallel arm ..............3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 7 Weight specifications ..................Standard tools ....................Special tools ....................Lifting accessories and lifting instructions .............. Spare parts Spare part lists and illustrations ................Circuit diagrams About circuit diagrams ..................Index 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
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Page 9: Overview Of This Manual
Prerequisites A maintenance/repair/installation craftsman 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...
Page 10 Reference to the spare part list for the robot. Circuit diagram Reference to the circuit diagram for the robot. References Reference Document ID Product manual - Spare parts - IRB 760 3HAC040446-001 Product specification - IRB 760 3HAC039612-001 Product manual - IRC5 3HAC021313-001...
Page 12: How To Read The Product Manual
Likewise certain work methods or general information, that is valid for several robot models, can be illustrated with pictures that show a different robot model that the one described in the current manual. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 13: Product Documentation, M2004
All documents listed can be ordered from ABB on a DVD. The documents listed are valid for M2004 manipulator systems. Product manuals...
Page 14 Operating manual - Introduction to RAPID • Operating manual - IRC5 with FlexPendant • Operating manual - RobotStudio • Operating manual - Trouble shooting IRC5, for the controller and manipulator. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 15: Safety
Specific safety information, pointed out in the procedures. How to avoid and eliminate the danger is either described directly in the procedure, or in specific instructions in the section Safety related instructions on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 16: General Safety Information
• stopping functions Safety stops describes different types of • description of emergency stop stops. • description of safety stop • description of safeguarding 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 17: Safety In The Manipulator System
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial manipulator will not cause injury or damage even if all safety instructions are complied with. Related information...
Page 18: Safety Risks
ABB is not liable for damages caused by the use of non-original spare parts and special equipment. ABB is not liable for damages or injuries caused by unauthorized modifications to the manipulator system.
Page 19 Removed cables to the measurement sys- WARNING If the internal cables for the measurement system have been disconnected during repair or maintenance, then the revolution counters must be updated. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 20 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 balan- cing device is potentially lethal! 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 21: Caution - Hot Parts May Cause Burns
Wait until the potentially hot component has cooled if it is to be removed or handled in any other way. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 22: Safety Risks Related To Tools/Work Pieces
Unauthorized modifications of the originally delivered manipulator are prohibited. Without the consent of ABB it is forbidden to attach additional parts through welding, riveting, or drilling of new holes into the castings. The strength could be affected.
Page 23: Safety Risks Related To Pneumatic/Hydraulic Systems
Gravity may cause any parts or objects held by these systems to drop. • Dump valves should be used in case of emergency. • Shot bolts should be used to prevent tools, etc., from falling due to gravity. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 24: Safety Risks During Operational Disturbances
If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 25: Risks Associated With Live Electric Parts
The power supply unit for additional tools, or special power supply units for the machining process. • The external voltage connected to the controller remains live even when the robot is disconnected from the mains. • Additional connections. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 26 Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 27: Safety Actions
(see the section Robot motion in the Product specification). Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the manipulator. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 28: Fire Extinguishing
1 Safety 1.2.4.2 Fire extinguishing 1.2.4.2 Fire extinguishing Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator system (manipulator or controller)! 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 29: Emergency Release Of The Manipulator's Arm
Increased injury Before releasing the brakes, make sure that the weight of the arms does not increase the pressure on the trapped person, further increasing any injury! 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 30: Brake Testing
3 Check that the axis maintains its position. If the manipulator does not change position as the motors are switched off, then the brake function is adequate. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 31: Risk Of Disabling Function "Reduced Speed 250 Mm/S
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" Note Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s". 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 32: Safe Use Of The Flexpendant
The hold-to-run function can only be used in manual mode. How to operate the hold-to-run function for IRC5 is described in Operating manual - IRC5 with FlexPendant. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 33: Work Inside The Manipulator's Working Range
NEVER, under any circumstances, stay beneath any of the manipulator’s axes! There is always a risk that the manipulator will move unexpectedly when manipulator axes are moved using the enabling device or during other work inside the manipulator’s working range. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 34: Signal Lamp (Optional)
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. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 35: Safety Stops
Emergency stop should not be used for normal program stops as this causes extra, unnecessary wear on the manipulator. For how to perform normal program stops, see section Stopping programs in Operating manual - IRC5 with FlexPendant. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 36 Dual Cabinet Controller). There can also be other types of emergency stops on your manipulator. Consult your plant or cell documentation to see how your manipulator system is configured. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 37: Safety Related Instructions
ELECTROSTATIC Warns for electrostatic hazards which could result DISCHARGE (ESD) in severe damage to the product. xx0200000023 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 38 1.3.1 Safety signals in the manual Continued Symbol Designation Significance NOTE Describes important facts and conditions. xx0100000004 Describes where to find additional information or how to do an operation in an easier way. xx0100000098 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 39: Safety Symbols On Manipulator Labels
Prohibition Used in combinations with other symbols. xx0900000839 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 40 Pressing this button will release the brakes. This means that the manipulator arm can fall down. xx0900000808 Tip risk when loosening bolts The manipulator can tip over if the bolts are not securely fastened. xx0900000810 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 41 Risk of crush injuries. xx0900000817 Heat Risk of heat that can cause burns. xx0900000818 Moving robot The robot can move unexpectedly. xx0900000819 xx1000001141 Brake release buttons xx0900000820 xx1000001140 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 42 Mechanical stop xx0900000824 No mechanical stop xx1000001144 Stored energy Warns that this part contains stored energy. Used in combination with Do not dismantle symbol. xx0900000825 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 43 Symbol Description Pressure Warns that this part is pressurized. Usually contains additional text with the pressure level. xx0900000826 Shut off with handle Use the power switch on the controller. xx0900000827 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 44: Danger - Moving Manipulators Are Potentially Lethal
The hold-to-run function is used in manual mode, not in automatic mode. Make sure no personnel are present within the working range of the manipulator be- fore pressing the start button. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 45: Danger - First Test Run May Cause Injury Or Damage
Pay special attention to the function of the part previously serviced Collision risks CAUTION When programming the movements of the manipulator always check potential collision risks before the first test run. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 46: Warning - The Brake Release Buttons May Be Jammed After Service Work
Make sure none of the buttons are jammed in the tube. If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes! 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 47: Danger - Make Sure That The Main Power Has Been Switched Off
Note/illustration Switch off the main switch on the Drive Module. xx0600002783 K: Main switch, Drive Module Switch off the main switch on the Control A: Main switch, Control Module Module. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 48: Warning - The Unit Is Sensitive To Esd
Location of wrist strap button The location of the wrist strap button is shown in the following illustration. IRC5 The wrist strap button is located in the top right corner. xx0500002171 Wrist strap button 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 49: Warning - Safety Risks During Handling Of Batteries
Risk of fire or explosion. page Use safety glasses when handling the batteries. In the event of leakage, wear gloves and chemical apron. In the event of fire, use self-contained breathing apparatus. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 50: Warning - Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)
Do not present in the gearbox, causing overfill the gearbox when filling. lubricant to spray from the xx0100000002 opening. Possible pressure build-up in gearbox Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
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Page 53: Installation And Commissioning
Safety on page 15 before performing any installation work. Note If the IRB 760 is connected to power, always make sure that the robot is connected to protective earth before starting any installation work! For more information see: • Product manual - IRC5 3HAC039838-001 Revision: C ©...
Page 54: Unpacking
It also contains information useful during later re-installation of the robot. Checking the pre-requisites for installation Installation craftsmen working with an ABB robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/maintenance/repair work • conform to all national and local codes.
Page 56 Maximum tilt 0.1° The limit for the maximum payload on the robot is reduced if the robot is tilted from 0°. Contact ABB for further information about accept- able loads. Minimum resonance 15 Hz frequency Storage conditions, robot...
Page 57: Working Range And Type Of Motion
The following figures show the working ranges of the robot variants. The extreme positions of the robot arm are specified at the wrist center (dimensions in mm). IRB 760 - 450/3.2 The illustration below shows the unrestricted working range of IRB 760 - 450/3.2. xx1000001066 Mechanical stop...
Page 58 Option 610-1 "Independent axis" can be used for resetting the revolution counter after the axis has been rotated (no need for "rewinding" the axis). Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 59 2 Installation and commissioning 2.2.2 Working range and type of motion Continued Turning radius xx1000001068 Motor, axis 3 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 60: Risk Of Tipping/Stability
Do not change the robot position before securing it to the foundation! Shipping and transport position This figure shows the robot in its shipping position, which also is a recommended transport position. xx1000001161 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 61 2 Installation and commissioning 2.2.3 Risk of tipping/stability Continued WARNING The robot is likely to be mechanically unstable if not secured to the foundation! 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 62: On-Site Installation
Fork lift set, incl. all required 3HAC023044-001 See figure Fork lift set, 3HAC023044-001 hardware on page Standard toolkit Content is defined in section Standard tools on page 351. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 63 Fork lift pocket (2 pcs, one long and one short) Adapter (2 pcs) Horizontal attachment screws (4 pcs / fork lift pocket) Attachment screw for adapter (1 pc / adapter) Vertical attachment screws (2 pcs) Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 64 Fit the two adapters to the robot and secure. Attachment points are shown in figure Attachment points on robot on page Attachment screws, 2 pcs, M16 x 90. Tightening torque: 270 Nm. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 65 However, they are tightened with different torque! xx0500002279 A Horizontal attachment screws, 4 pcs, M16 x 60. Tightening torque: 60 Nm. B Adapter Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 66 Attachment points on robot are shown in figure Attachment points on robot on page Double-check that pockets are properly se- cured to the robot! Insert fork lift forks into the pockets. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 67 2 Installation and commissioning 2.3.1 Lifting robot with fork lift Continued Action Note CAUTION The IRB 760 robot weighs 2300 kg. All lifting accessories used must be sized ac- cordingly! Carefully lift the robot and move it to its install- ation site. WARNING...
Page 68: Lifting Robot With Roundslings
Position robot in a secure transport position. xx1000001093 Attach roundslings to robot according to fig- Attachment points on page CAUTION The IRB 760 robot weighs 2300 kg. All lifting accessories used must be sized accordingly! WARNING Personnel must not, under any circum-...
Page 69 Chain slings with shortener (4 pcs). Lifting capacity: 4,000 kg. Roundsling, 1.5 m. Lifting capacity: 2,000 kg. Roundsling, 1 m. Lifting capacity: 2,000 kg. Roundsling, 1 m. Lifting capacity: 2,000 kg. Note! No sharp edges! 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 70: Lifting Robot With Lifting Slings
Move the robot to the recommended position shown in the figure and in the instruction! Attempting to lift a robot in any other position may result in the robot tipping over, causing severe damage or injury! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 71 Note! Make sure to run lifting sling between parallel stag and frame! Required equipment Equipment Art. no. Note Lifting device, robot 3HAC15607-1 Includes: • user instructions (3HAC15971-2). Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 72 Art. no. is specified in Required equip- scribed in enclosed instruction! ment on page CAUTION The IRB 760 robot weighs 2300 kg. All lifting accessories used must be sized ac- cordingly! WARNING Personnel must not, under any circumstances, be present under the suspended load! Raise overhead crane to lift the robot.
Page 73: Manually Releasing The Brakes
When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpec- ted ways! Make sure no personnel is near or beneath the robot arm! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 74 DANGER Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously! Supply 0V on pin 12 and 24V on pin 11. xx0600002937 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 75: Lifting The Base Plate
Fit lifting eyes in specified holes. Shown in figure Hole configur- ation on page Fit lifting slings to the eyes and to the lifting device. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 76: Securing The Base Plate
0,25 c (2x R22,5) 3x 90º xx1000001053 E, F, G, H Common tolerance zone (accuracy all over the base plate from one contact surface to the other) Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 77 2 Installation and commissioning 2.3.6 Securing the base plate Continued xx1000001054 ¤ Four holes for alternative clamping, 4x Ø18 Color: RAL 9005. Thickness: 80-100 µm Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 78 Other tools and procedures may These procedures include references be required. See references to to the tools required. these procedures in the step-by- step instructions below. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 79 2 Installation and commissioning 2.3.6 Securing the base plate Continued Recommendations, quality The table specifies any recommendations made by ABB: Variable Recommendation Recommended bolt quality and dimen- Hilti HDA-P, M20 x 250/50 (maximum thickness of sion base plate = 50 mm)
Page 80: Orienting And Securing The Robot
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 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 81 Note Lightly lubricate screws before as- sembly! Tighten bolts in a criss-cross pattern to ensure that the base is not distorted. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 82 2 Installation and commissioning 2.3.7 Orienting and securing the robot Continued Hole configuration, base This illustration shows the hole configuration used when securing the robot. xx1000001050 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 83 2 Installation and commissioning 2.3.7 Orienting and securing the robot Continued Cross section, guide sleeve hole This illustration shows the cross section of the guide sleeve holes. xx1000001051 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 84: Fitting Equipment On Robot
Max. extra weight on the upper arm: • IRB 760 - 450/3.2 = 35 kg Note! The weight of the extra equipment on the upper arm must be deducted from the maximal handling capacity. Example: If 35 extra kg is put on the upper arm, this means that the robot only can handle 450- 35 = 415 kg.
Page 85 2.3.8 Fitting equipment on robot Continued Illustration, fitting of extra equipment on frame The illustration below shows the mounting holes available for fitting extra equipment on the frame. xx1000001070 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 86 When fitting tools on the turning disk (see the figures above), only use screws with quality 12.9. When fitting other equipment to mounting holes standard screws with quality 8.8 may be used. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 87: Installation Of Signal Lamp, Upper Arm (Option)
Spare parts on Complete kit with signal lamp, page 355. cables, adapter, gasket, screws etc. Gasket 3HAC033206-001 Fitted between motor and cable gland, replace if damaged. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 88 Other tools and procedures may be required. See references to these procedures in the step-by- step instructions below. Signal lamp kit Figure shows signal lamp kit on IRB 760. x - x xx1000001064 Signal lamp bracket Attachment screws for the bracket, M8x12 (2 pcs)
Page 89 Remove the motor cover by unscrewing the four See figure Location of signal lamp, attachment screws. upper arm on page Disconnect the motor connectors. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 90 Secure motor cables at cable gland again. Fit the motor cover with the attachment screws. Make sure the cabling is placed correctly when refitting the cover and does not get jammed. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 91: Loads
Operating manual - IRC5 with FlexPendant (M2004) Stop time and braking distances Robot motor brake performance depends on any loads attached. For information about brake performance, read the product specification for the robot. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 92: Restricting The Working Range
This section describes how to install hardware that restricts the working range. Note Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 93: Mechanically Restricting The Working Range Of Axis 1
Standard toolkit Content is defined in section Standard tools on page 351. Technical reference manual - System Art. no. is specified in section parameters References on page Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 94 If the mechanical stop pin is deformed after a hard collision, it must be replaced! Deformed movable stops and/or additional stops as well as deformed attachment screws must also be replaced after a hard collision. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 95: Extended Working Range, Axis 1 (Option 561-1)
Technical Boundand Lower Joint Bound must be reference manual - System parameters. changed to 3.84 respectively -3.84. The values are in radians, that is 3.84 radians = 220 degrees. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 96: Robot In Cold Environments
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. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 97: Electrical Connections
3HAC026787-002 Robot cable, power: 22 m 3HAC026787-003 Robot cable, power: 30 m 3HAC026787-004 Robot cable, signals Cable Art. no. Robot cable signal, shielded: 7 m 3HAC7998-1 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 98 2.6.1 Robot cabling and connection points Continued Cable Art. no. Robot cable signal, shielded: 15 m 3HAC7998-2 Robot cable signal, shielded: 22 m 3HAC7998-3 Robot cable signal, shielded: 30 m 3HAC7998-4 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 99: Maintenance
Safety on page 15 before performing any service work! Note If the IRB 760 is connected to power, always make sure that the IRB 760 is connected to protective earth before starting any maintenance work! For more information see: •...
Page 100: Maintenance Schedule And Expected Component Life
3.2.1 Specification of maintenance intervals Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the IRB 760: • Calendar time: specified in months regardless of whether the system is running or not.
Page 101: Maintenance Schedule
Axis 2 gear oil First change when DTC reads: • 6,000 hours Second change when DTC reads: • 24,000 hours Following changes: • Every 24,000 hours Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 102 The table below specifies the required maintenance activities and intervals for common optional equipment. The maintenance of other external equipment for the robot is detailed in separate documentation. Maintenance activity Equipment Interval Inspection Signal lamp Every: 12 months 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 103: Expected Component Life
Deviations from this cycle will result in differences in expected life! The SIS for an M2004 system is described in the Operating manual - Service Information System. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 104: Inspection Activities
Do not mix with other oils! page 127. Standard toolkit Content is defined in section Standard tools on page 351. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 105 127. Further information about how to fill with oil is found in section Changing oil, axis-1 gearbox on page 129. Refit the oil plug, inspection. Tightening torque: 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 106: Inspecting, Oil Level Gearbox Axes 2 - 3
The gearboxes axes 2-3 are located in the lower arm rotational center, underneath the motor attachment. xx0500002482 Gearbox, axis 2 Oil plug, draining Oil plug, filling Ventilation hole, gearbox axis 2 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 107 Handling gearbox oil involves several safety risks. Before proceeding, please read the safety inform- ation in the section WARNING - Safety risks during work with gearbox lubricants (oil or grease) on page Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 108 107. Filling of oil is detailed further in section Changing oil, gearbox axes 2 and 3 on page 132. Refit oil plug, filling. Tightening torque: 24 Nm. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 109: Inspecting, Oil Level Gearbox Axis 6
Other tools and procedures may These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 110 Further information about how to fill the oil may be found in the section Changing oil, gearbox axis 6 on page 135. Refit oil plug, filling. Tightening torque: 24 Nm. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 111: Inspecting, Balancing Device Bearings And Piston Rod Guide Ring
Other tools and procedures may These procedures include refer- be required. See references to ences to the tools required. these procedures in the step-by- step instructions below. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 113 Replace if necessary. xx0600002689 A Guide ring B Circlip Note If there is a risk of metallic contact between the piston rod and the end cover, the guide ring must be replaced! 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 114: Inspecting, Cable Harness
The axes-1-6 cable harness is shown below. xx1000001367 Cable harness robot, axes 1-6 Connectors at base Motor cables (4 locations) Cable guide, axis 2 Cable guide, axis 3 Metal clamps with nuts Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 115 A: Metal clamp inside upper arm Check the metal clamp holding the motor cable Shown in figure Location of cable har- on axis 6. ness, axes 1-6 on page 114. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 116 Replace the cable harness if wear or damage Detailed in section: is detected! Replacing cable harness, lower end (axes 1-3) on page 153. Replacing the cable harness, upper end (incl. axis 6) on page 163. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 117: Inspection, Information Labels
3HAC17804-1 Combined warning label "Brake release", "Brake release buttons" and "Moving robot", 3HAC024985-001 Combined warning label "Extended rotation", "See user documentation" and "No mechanical stop", 3HAC021761-001 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 118 Check the labels, located as shown in the figures. Replace any missing or damaged labels. Art. no. is specified in Required equipment on page 118. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 119: Inspecting, Mechanical Stop Pin, Axis 1
Mechanical stop pin axis 1 Spare parts on To be replaced when damaged. page 355 Standard toolkit Content is defined in section Standard tools on page 351. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 120 Art. no. is specified in Required must be replaced! equipment on page 119. Note The expected life of gearboxes can be reduced as a result of collisions with the mechanical stop. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 121: Inspecting, Additional Mechanical Stops
Note DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 122 If any damage is detected, the mechanical stops Art. no. is specified in Required must be replaced! equipment on page 121. Correct attachment screws: • Axis 1: M16 x 35, quality 12.9. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 123: Inspection, Dampers
Damper, lower arm, upper (2 pcs) Damper, lower arm, lower (1 pc) Damper, axis 2 (2 pcs) Damper, axis 3 (2 pcs). Not visible in this view. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 124 123. Check attachment screws for deformation. If any damage is detected, the damper must be Art.no. is specified in Required replaced with a new one. equipment on page 124. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 125: Inspecting, Signal Lamp (Option)
Signal lamp kit Spare parts on To be replaced if damage is detected. page 355. Standard toolkit Content is defined in section Stand- ard tools on page 351. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 126 If so, replace it. • Checking cable connections. • Measuring the voltage in the connectors of motor axis 6 (=24V). • Checking the cabling. Replace the cabling if a fault is detected. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 127: Replacement/Changing Activities
10. In order to always get the latest information of updates about lubrication in gearboxes, always check on ABB Library for the latest revision of the manual. A new revision will be published on ABB Library immediatly after any updates.
Page 128 Note Oil dispenser Includes pump with outlet pipe. Use the suggested dispenser or a similar one: • Orion OriCan art. no. 22590 (pneumatic) Nipple for quick connect fitting, with o-ring 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 129: Changing Oil, Axis-1 Gearbox
Do not mix with other oils! page 127. oil in gear- boxes on page 127. Oil collecting vessel Capacity: 8,000 ml. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 130 Vessel capacity is specified in quired equipment on page 129. Remove oil plug, filling in order to drain oil Shown in figure Location of oil plugs quicker! on page 129. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 132: Changing Oil, Gearbox Axes 2 And 3
The figure shows the position of gearbox, axis 2. xx0500002482 Gearbox axis 2 Oil plug, draining Oil plug, filling Ventilation hole plug, gearbox axis 2 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 133 Note DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 134 The amount of oil to be filled depends on the amount that was previously drained. Refit oil plug,filling and ventilation hole plug. Shown in Location of oil plugs on page 132. Tightening torque: 24 Nm. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 135: Changing Oil, Gearbox Axis 6
Use this procedure to drain oil from gearbox axis 6. When using oil change equipment, follow the instructions enclosed with kit. Action Note Put tilt house in a suitable position. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 136 135. amount that was previously drained. Correct oil level is detailed in section Inspection, oil level axis-6 gearbox on page 110. Refit the oil plug. Tightening torque: 24 Nm. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 137: Replacing The Smb Battery
See Operating manual - IRC5 with FlexPendant for instructions. WARNING See instructions for batteries, WARNING - Safety risks during handling of batteries on page Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 138 Battery pack with a 2-pole battery contact xx0500002486 SMB battery cover SMB battery pack Battery cable Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 139 Spare part no. Note Battery pack For spare part no. Battery includes protection circuits. Only re- see: place with a specified spare part or an ABB- • Spare parts approved equivalent. on page 355 Standard toolkit Content is defined in section...
Page 140 Shown in figure Location of SMB Battery includes protection circuits. Only replace battery on page 138. with a specified spare part or with an ABB- ap- proved equivalent. Refitting, battery Use this procedure to refit the SMB battery. Action Note...
Page 141 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 142: Lubrication Activities
Note! Balancing device must be fitted on robot when lubricating bearings! xx0500002489 Ear (bearing located inside) Support washer Lock nut Piston rod Guide ring (not visible in this view) Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 143 Apply some grease to the support washers. Apply locking liquid on the lock nuts (KM10). Tightening torque on lock nuts: • 120 Nm Note Do not apply locking liquid on the shafts! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 144 Clean piston rod with isopropanol before applying new grease. Apply new grease. Type of grease is specified in Required equipment on page143. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 145: Cleaning Activities
Cleaning with water and steam Cleaning methods that can be used for ABB robots with protection Standard, Foundry Plus, Wash and Foundry Prime. Equipment, etc. Note Vacuum cleaner Cloth with mild detergent •...
Page 146 Never point the water jet at connectors, joints, sealings, or gaskets! • Never use compressed air to clean the robot! • Never use solvents that are not approved by ABB to clean the robot! • Never spray from a distance closer than 0.4 meters! •...
Page 147: Repair
Make sure to read through the chapter Safety on page 15 before commencing any service work. Note If the IRB 760 is connected to power, always make sure that the IRB 760 is connected to earth before starting any repair work. For more information see: •...
Page 148: General Procedures
The test is complete. Spray suspected leak areas with leak detection spray. Bubbles indicate a leak. When the leak has been localized, take the necessary measures to correct the leak. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 149: Mounting Instructions For Bearings
• During operation, the bearing should be filled to 70-80% of the available volume. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 150 Grease the different types of bearings as following description: • Grooved ball bearings must be filled with grease from both sides. • Tapered roller bearings and axial needle bearings must be greased in the split condition. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 151: Mounting Instructions For Seals
Mount the seal correctly with a mounting tool. Never hammer directly on the seal as this may result in leakage. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 152 If the flange surfaces are defective, the parts may not be used because leakage could occur. Clean the surfaces properly in accordance with the recommendations of ABB. Distribute the sealing compound evenly over the surface, preferably with a brush. Tighten the screws evenly when fastening the flange joint.
Page 153: Complete Robot
How to replace the upper end can be found in section Replacing the cable harness, upper end (incl. axis 6) on page 163. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 154 Location of cable harness - lower end (axes 1-3) The cable harness, lower end (axes 1-3) is located throughout the base, frame and lower arm as shown in the figure. xx1000001177 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 155 4 Repair 4.3.1 Replacing cable harness, lower end (axes 1-3) Continued The figure shows IRB 660 but is also valid for IRB 760. xx0700000070 Cable guide, axis 2 Metal clamp Connector at base Cable guide, axis 1 Cable harness, axes 1-6...
Page 156 (axes 1-3) on page 154. Disconnect the connectors R1.MP and R1.SMB. See the figure Location of cable har- ness - lower end (axes 1-3) on page 154. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 157 Disconnect all connectors at motors for axes See sections: 1, 2 and 3. • Replacing motor, axis 1 on page 278 • Replacing motors, axes 2 and 3 on page 284 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 158 SMB recess and lift the cable gland out. Perform this removal with care, in order not to damage any of the components inside the SMB recess. xx1000001330 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 159 1 in the center of the frame. CAUTION Make sure the cables are not twisted with each other or with customer harness (if any)! xx1000001331 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 160 Attachment points are shown in the the robot base. figure Location of cable harness - lower end (axes 1-3) on page 154. Reconnect the earth cable. xx1000001314 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 161 Push the cable harness up through the lower arm. Fasten the metal clamp that hold the cable harness in the lower arm with the nuts. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 162 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 163: Replacing The Cable Harness, Upper End (Incl. Axis 6)
Replacing cable harness, lower end (axes 1-3) on page 153. Location of cable harness, upper end The upper end of the cable harness is located as shown in the figure. xx1000001176 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 164 For spare part no. see: • Spare parts on page 355 Gasket Motor, axis 6 Standard toolkit Content is defined in section Standard tools on page 351. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 165 (axes 1-3) on page 153. harness, lower end. Remove the axis 6 motor cover by removing its attachment screws, in order to reach the connectors. xx1000001106 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 166 Remove the metal clamp that holds the cable at the tilt house, by removing its nuts. xx1000001336 Carefully pull the cable harness out of motor axis 6. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 167 Start by fitting the cable harness, lower end Detailed in section Replacing cable har- if it has been removed. ness, lower end (axes 1-3) on page 153 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 168 (2 + 2 pcs) from the outside of the upper arm. Twist the cable one turn between the cable clamps. xx1000001338 Refit the axis 3 cable guide. xx1000001340 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 169 Refit the cable gland with its attachment screw. xx0600002694 • A: Screw holding the cable gland Make sure the gasket is not damaged! Replace if damaged. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 170 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 171: Replacing The Smb Unit
355. Battery pack For spare part number, see: Spare parts on page 355. Standard toolkit Content is defined in section Standard tools on page 351. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 172 Note DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 173 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 174: Replacing The Brake Release Unit
Other tools and procedures may These procedures include references be required. See references to to the tools required. these procedures in the step-by- step instructions below. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 175 C: Connector X10 • D: Push buttons Location of the brake release unit is shown in the figure Location of brake release unit on page 174. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 176 174. The push button guard must not be mounted on the cover before the check described in following warning is made! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 177 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 178: Replacing The Base, Including Axis 1 Gearbox
Always use the guide pins in pairs! Guide pins that are longer than 140 mm will not be pos- sible to remove because the lack of space. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 179 • air pressure supply to the robot, before entering the robot work- ing area. Run an overhead crane to a position above the robot. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 180 Unfasten the arm system from the base by unscrewing the attachment screws. xx0600003070 A Serrated lock washer B Axis 1 gearbox C Attachment screws M12x80 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 181 How to adjust the lift is described in the enclosed instruction to the lifting accessory! Follow the instructions be- fore lifting! More information in section Lifting robot with lifting slings on page Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 182 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. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 183 Refit the cable harness in the base and the Replacing cable harness, lower end frame. (axes 1-3) on page 153. Refit the axis 1 motor. Replacing motor, axis 1 on page 278. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 184 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 185: Upper And Lower Arm
Other tools and procedures may These procedures include refer- be required. See references to ences to the tools required. these procedures in the step- by-step instructions below. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 186 Drain the axis 6 gearbox. See section: • Changing oil, gearbox axis 6 on page 135 Remove the attachment screws that secure the turning disk. xx1000001134 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 187 Lubricate the o-ring of the turning disk with Art. no. is specified in Required equip- grease and fit it to the turning disk. ment on page 185. xx1000001285 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 188 Refill the axis 6 gearbox with oil. See section: • Changing oil, gearbox axis 6 on page 135 Refit any equipment removed during disas- sembly to the turning disk. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 189 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 190: Replacing The Tilthouse Unit
• Refitting lock nuts and the remaining parts on page 207 Location of tilthouse unit The tilthouse unit is located as shown in the figure. xx1000001418 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 191 (axis 2) and the parallel arm (axis 3). These two sides of the robot will be referred to in the replacing procedures. xx1000001427 Axis 2 side (See marking on lower arm) Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 192 4 Repair 4.4.2 Replacing the tilthouse unit Continued xx1000001428 Axis 3 side (See marking on parallel arm) Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 193 VK cover VK 90x8 (2 pcs) VK cover VK 19x6 (2 pcs) Screw M6x10 quality 8.8-A2F (4 pcs) + Washers (4 pcs) Retaining ring, bore Steel 80 (2 pcs) Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 194 See references to ences to the tools required. these procedures in the step-by- step instructions below. Circuit diagram For art. no. see chapter Circuit diagrams on page 357. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 195 Threaded bar Stop nut Hydraulic cylinder (must be ordered separately) Distance (and screws M6x14, 2 pcs) Press housing (3HAC039277-004) Press washer (3HAC039277-005) Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 196 Hydraulic cylinder (201 kN, 80 MPa), Nike CHF 184 Adapter Press housing Support housing (3HAC039277-003) Torsion bar M20 L=650 mm (fitting) Torsion bar M20 L=900 mm (removal) Shims T=2 mm Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 197 • air pressure supply to the robot, before entering the robot working area. Secure the tilthouse with a roundsling in an overhead crane or similar. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 199 Put a hand with some paper over the VK cover in order to catch it. CAUTION Only a very low air pressure is needed! xx1000001072 Parts: A Screw M6x10 quality steel 8.8- B Washer Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 200 6 by following the steps below. Note A longer threaded bar M16 is needed when re- moving the shaft than the one specified when fitting. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 201 Remove the shaft on the axis 3 side in the same Follow steps above. way. CAUTION The robot tilt house weighs 85 kg. All lifting accessories used must be sized ac- cordingly! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 202 The tilthouse unit weighs 85 kg. All lifting equipment must be sized accordingly! Lift the tilthouse unit to a workbench or similar with a roundsling in an overhead crane. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 203 Apply grease on the inner diameter of the Shown in the figure Cut away view of sealing ring with dustlip. the assembly of the tilthouse unit on page 193. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 204 Before starting this procedure, prepare the tilthouse as described in: • Premounting the outer races of the bearings and other parts, axis 2 side on page 202 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 205 194. Shown in the figure Location of axes Note 2 and 3 sides of the robot on page 191. Fit axis 3 side first. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 206 6 from the outside of the tilt- equipment on page 194. house. Secure the parts with the stop nut. Shown in the figure Press tool as- sembly/disassembly axis 6 on page 196. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 207 Tightening torque: • 90 Nm Note Flat side of the lock nut facing inwards! Fit the lock nut on the axis 3 side in the same way. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 208 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 209: Replacing The Upper Arm
4.4.3 Replacing the upper arm 4.4.3 Replacing the upper arm Location of the upper arm The upper arm is located as shown in the figure. xx1100000016 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 210 Bearing grease Optimol Longtime PD 2 O-ring D119x3 (1 + 1 pc) Sealing (1 + 1) Sealing ring (1 + 1 pc) Oil plug (1 + 1 pcs) Bushing Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 211 Release the brake of axis 3 so that the balan- cing weight really rests on the pallets. Move the lower arm forward to get a better mounting position in the continued removal procedure. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 212 Remove the lock nut securing the shaft. Shown in the figure: • Cut away view of the assembly of the upper arm components on page 210 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 213 Remove the upper arm. Refitting the upper arm shafts Use this procedure to refit the upper arm shafts. Note Start refitting the shaft on the axis 3 side! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 214 Make sure that the upper arm is placed correctly in a way that the shafts can be inserted without being damaged! Note Refit the shaft on the axis 3 side first! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 215 Cut away view of the assembly of the upper arm components on page 210 Note Refit the shaft on the axis 2 side, by following the steps 9-16, above. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 216 • A: Shaft axis 3 • C: Tapered roller bearing • D: Sealing • E: Sealing ring, with o-ring • F: Lock nut + Loctite 243 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 217 Put the shims between the upper and lower arms on the axis 3 side. xx1100000030 • A: T=2.5 mm Press the parts together using the shaft fit- ting/removing tool. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 219 Refit the parallel rod. See section: • Replacing the parallel rod on page 244 Refit the tilthouse unit. See section: • Replacing the tilthouse unit on page 190 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 220 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 221: Replacing Linkage - Upper Link Arm
Replacement of linkage - link on page 235 Location of upper link arm The upper link arm is located as shown in the figure. xx1000001083 Upper link arm Link Lower link arm Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 222 CAUTION In order to avoid accidents, also secure the tilthouse unit in an overhead crane or similar. xx1000001132 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 223 (1+1 pc) that secure the upper link arm. Use a KM10 socket. xx1000001080 CAUTION The link weighs 23 kg. All lifting accessories used must be sized accordingly! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 224 Use this procedure to refit the upper link arm of the linkage system. Action Note If needed, replace the bearings in the upper link arm. Note The bearings are sensitive for pushes. Make sure they are not damaged! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 225 Required equipment on page 222 spacer rings complete will be fitted. xx1000001086 Refit the spacer rings complete on the shaft ends of the link and tilthouse. xx1000001263 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 226 All lifting accessories used must be sized accordingly! Place the upper link arm on the shafts as shown in the figure. Note The link arm must be pushed in completely. xx1000001088 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 227 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 228: Replacing The Linkage - Lower Link Arm
Replacement of linkage - link on page 235 Location of lower link arm The lower link arm is located as shown in the figure below. xx1000001083 Upper link arm Link Lower link arm Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 229 Note DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 231 If needed, replace the bearings. Spare part no. is specified in Required equipment on page 229. Note The bearings are sensitive for pushes. Make sure they are not damaged! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 232 229. be fitted. xx1000001086 Refit the sealing/spacer rings to the shaft ends on the link and frame. xx1000001258 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 233 Place the lower link arm on the shaft ends of the link and frame. Note Check that the lower link arm is pushed completely in. xx1000001260 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 234 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 235: Replacement Of Linkage - Link
Replacing linkage - upper link arm on page 221. • Replacing the linkage - lower link arm on page 228. Location of link The link is located as shown in the figure. xx1000001083 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 236 VK cover D=120 mm, T=12 mm Small VK cover Lock nut Locking liquid (Loctite 243) Bearing, outer races (2 pcs) Bearing, inner races (2 pcs) Bearing grease Link Support ring Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 237 Note DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 238 221 Detailed in section Replacing the linkage - lower link arm on page 228 Remove screw and washer in the hole for filling grease. xx1000001266 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 239 All lifting accessories used must be sized accordingly! Use a bearing puller to remove the link. Remove the link. Remove the support ring with the radial seal. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 240 Bearing, outer race (2 pcs) Mandrel, bearing and seal Guide (2 pcs) Link Pressring, bearing Distance Hydraulic cylinder Connecting rod Stop nut M16 D=80 mm, T=20 mm Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 241 Radial sealing with dust lip D=120/140 mm, T=13 mm Tapered roller bearing (2 pcs) Auxiliary shaft Press housing Distance, fitted on hydraulic cylinder with M6x15 screws (2 pcs) Connection rod Hydraulic cylinder Stop nut Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 242 Apply the pressing tool and secure the link. Art.no. is specified in Required equipment on page 237 Apply locking liquid on the lock nut. Loctite 243 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 243 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 244: Replacing The Parallel Rod
• Spare parts on page 355. Mounting/Demounting tool 3HAC5021-1 Locking liquid 3HAB7116-1 Loctite 243 Standard toolkit Content is defined in section Standard tools on page 351. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 245 CAUTION Secure the upper arm with a roundsling in an overhead crane or similar, in order to avoid accidents. xx1100000088 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 246 A Shaft B Cover washer C Parallel rod D Sealed spherical bearing E Bearing grease F Thrust washer Remove the thrust washer (F). See figure above! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 247 Use this procedure to refit the parallel rod. The procedure is the same in both ends of the parallel rod. Action Note Start by refitting the lower end. Verify that the bearings are in correct posi- tion in the parallel rod. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 248 D Sealed spherical bearing E Bearing grease F Thrust washer Put the cover washer (B) on the axis 3 side See figure above! of the parallel rod. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 249 Lift the parallel rod up into position for fitting the upper end. xx1000001352 Refit the upper end of the parallel rod in the same way as the lower end. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 250 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 251: Replacing The Complete Lower Arm
Guide sleeves 3HAC14446-1 Used to keep the axes 2/3 sealing in place during refitting of lower arm. Crank 3HAC023132-001 Lock screw M16x55 Roundsling Lifting capacity: 500 kg. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 252 Replacing the balancing weight on page 274. Remove the balancing device. Replacing the balancing device on page 265 Remove the parallel rod. Replacing the parallel rod on page 244. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 253 251. overhead crane or similar. xx1000001361 Remove the lock screw that secures the lower arm system. xx1000001101 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 254 CAUTION The parallel arm system weighs 125 kg. All lifting accessories used must be sized accord- ingly! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 255 Remove the complete lower arm (including the parallel arm). xx1000001358 How to replace the parallel arm is detailed in section Replacement of parallel arm on page 259. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 256 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 251. See figure. xx1000001368 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 257 Remove the guide sleeves and secure two screws more. Change the position of the lower arm in order to reach the remaining attachment holes, and fit the remaining screws. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 258 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 259: Replacement Of Parallel Arm
Spare parts on page 355. VK cover 3HAA2166-23 D=120 mm, T=12 mm VK cover 3HAA2166-18 D=35 mm, T=8 mm Bearing grease 3HAB9408-1 Pressing tool, lower arm 3HAC023092-001 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 260 251. Put the complete lower arm on a workbench as shown in the figure. Removal of the parallel arm is best performed on a workbench. xx1000001024 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 261 259. CAUTION The parallel arm system weighs 125 kg. All lifting accessories used must be sized accord- ingly! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 262 Apply some grease on the spacing sleeves on the Specified in Required equipment surfaces that face the parallel arm. on page 259 Refit a spacing sleeve on each shaft. xx1000001376 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 263 Apply some grease in the holes in the lower arm (thick blue arrows). Note Do not put grease on the surfaces for the VK covers (thin red arrow)! xx1000001380 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 264 Make sure all safety requirements are met when performing the first test run. These are further de- tailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 265: Frame And Base
For spare part num- ber, see Spare parts on page 355. Spacer ring (complete) 3HAC037262-001 Replace if damaged. Lock screw M16 x 55 For securing the lower arm. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 266 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 267 It should now be possible to easily rotate the balancing device. Attach a lifting accessories to the balancing device. Use the hole in the lifting ear. xx1000001112 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 268 The ball bearing puller must be applied around the spacer ring. See figure! xx1000001115 CAUTION The balancing device weighs 100 kg. All lifting accessories used must be sized ac- cordingly! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 269 Remove residual grease and sealing compound. Refitting, balancing device use this procedure to refit the balancing device. Action Note Check the bearings. Replace if needed. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 270 CAUTION The balancing device weighs 100 kg. All lifting accessories used must be sized ac- cordingly! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 271 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 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 272 Check play (min. 0.1 mm) between support washers and bearing seat at both bearings. Remove the M12x50 screws from the balancing device to restore the springforce. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 273 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 274: Replacing The Balancing Weight
Equipment etc. Art. no. Note Balancing weight For art. no. see: • Spare parts on page 355 Lifting lugs (2 pcs) Locking liquid 3HAB7116-1 Loctite 243 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 275 The balancing weight weighs 350 kg. All lifting accessories used must be sized accordingly! Secure the balancing weight with round- slings (using the lifting lugs) in an overhead crane or similar. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 276 Note Fit two lifting lugs (M16) in the balancing weight. xx1000001298 CAUTION The balancing weight weighs 350 kg. All lifting accessories used must be sized accordingly! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 277 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 278: Motors
For spare part number, Includes: see: • motor • Spare parts on • pinion page 355 • o-ring (The old o-ring must be replaced when replacing the motor) Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 281 Note The o-ring must be replaced when re- placing the motor. CAUTION The motor weighs 29 kg. All lifting accessories used must be sized ac- cordingly! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 282 Refit the cable gland cover at the cable exit with its attachment screws. Note Make sure the cover is tightly sealed! Replace gasket if damaged. xx1000001094 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 283 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 284: Replacing Motors, Axes 2 And 3 ................................................................. Replacing Motor, Axis
Includes • Spare parts on • motor page 355 chapter • pinion • o-ring (the o-ring must be re- placed when the motor is re- placed) Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 285 Run the robot to a position close enough to its calibration position, to allow the lock screw to be inserted into the hole for lock screw. xx1000001101 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 286 Drain the oil from gearbox. See section: • Changing oil, gearbox axes 2 and 3 on page 132. Remove the motor cover. xx1000001102 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 287 VDC power supply. • + : pin 2 • - : pin 5 Unscrew attachment screws and washers of the motor. Use the bits extension. xx1000001104 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 288 Required motor axes 2-3 to the motor. equipment on page 284. CAUTION The motor weighs 32 kg. All lifting accessories used must be sized ac- cordingly! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 289 Note Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the o-ring with grease. xx1000001096 Parts: A Circumference B O-ring Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 290 Make sure the motor is turned the right way, that is connections for the cables facing down- wards. xx1000001185 Remove the lifting tool and allow the motor to rest on the guide pins. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 291 M10 x 40 quality 12.9 Gleitmo Tightening torque: • 50 Nm Disconnect the brake release voltage. Reconnect all connectors beneath the motor Connect in accordance with markings cover. on connectors. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 292 See section Performing a leak-down gearbox. test on page 148. Refill the gearbox with oil. See section Changing oil, gearbox axes 2 and 3 on page 132. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 293 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 294 355 • pinion • o-ring (the o-ring must be replaced when the motor is replaced) Bits extension 3HAC023760-001 Used to reach attachment screws for motor. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 295 Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Remove motor cover. xx1000001106 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 296 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 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 297 In order to release the brake, connect the 24 Connect to connector R2.MP6 VDC power supply. • + : pin 2 • - : pin 5 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 298 Reconnect all connectors in motor axis 6. Connect in accordance with markings on connectors. Refit the connections to the UL lamp, if the ro- bot is equipped with one. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 299 Make sure the gasket is not damaged! Replace if damaged. Refit the cover, motor axis 6 with its attachment screws and washers. Note Make sure the cover is tightly sealed! xx1000001106 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 300 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 301: Gearboxes
Gearbox For spare part no. see: Includes: • Spare parts on • gearbox page 355. • all o-rings and sealing rings O-ring 3HAB3772-54 Replace if damaged! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 302 DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 303 Art. no. is specified in Required equip- gearbox to allow the base and gear 1 sup- ment on page 301. port be fitted on each sides of the base. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 304 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 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 305 CAUTION The gearbox weighs 200 kg. All lifting accessories used must be sized accordingly! Lift the gearbox away with the already mounted lifting tools. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 306 Art no. is specified in Required equip- ence of the gearbox are seated properly in ment on page 301. their respective groove. Lubricate them with grease. xx1000001390 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 307 Required equipment on holes in the gearbox, parallel to each other. page 301. CAUTION The gearbox weighs 200 kg. All lifting accessories used must be sized ac- cordingly! Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 308 Lift gearbox axis 1 onto the guide pins and Always use guide pins in pairs! lower it carefully to its mounting position. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 309 Screw joints on page 347 before fit- ting. xx1000001394 Refit the cable guide in the center of gearbox 1 with its attachment screws. xx1000001393 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 310 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 311: Replacing The Gearbox, Axes
Screw M12x100 2 pcs, must have full thread. Use to press the gearbox free from the frame. Guide pins M12 Use guide pins in pairs. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 312 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°. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 313 Run axis 2 to 0°. Fit the lock screw in the lower arm to secure axis 2. CAUTION Tighten by hand! xx1000001101 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 314 Remove the axis-2 or axis-3 motor, depend- Detailed in section Replacing motors, axes ing on which gearbox is being removed. 2 and 3 on page 284 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 315 Always use guide pins in pairs! Remove the remaining attachment screws. Fit the lifting accessory to the gearbox. Art. no. is specified in Required equipment on page 311. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 316 Be aware of this and re- move the gearbox carefully! Remove the gearbox axis 2-3 using an overhead crane or similar, with guidance from the fitted guide pins. xx1000001401 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 317 Specified in Required equipment on page 311. Fit two guide pins in the frame. Use two of the attachment holes for the screws that hold the gearbox. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 318 Lubricate necessary surfaces of the gear- Specified in Required equipment on box with grease in order to make it easier page 311. to insert the gearbox into the frame. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 319 Tightening torque: 120 Nm. Clean the gearbox of residual grease. Apply locking liquid in the attachment holes Loctite 243. for the gearbox cover. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 320 Perform a leakdown test. Performing a leak-down test on page 148. Refill the gearbox axes 2-3 with oil. Filling, axes 2 and 3 on page 134 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 321 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 322: Replacing Gearbox Axis
3HAB3772-57 Must be replaced when reas- sembling gearbox. 150.0x2.0 3HAB3772-64 Must be replaced when reas- sembling gearbox. 13.1x1.6 3HAB3772-61 Must be replaced when reas- sembling gearbox. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 323 Changing oil, gearbox axis 6 on page 135 Remove the turning disk. See section: • Replacing the turning disk on page 185 Remove the calibration plate axis 6. xx1000001410 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 324 If required apply two M8 screws in the holes shown in the figure, and press out the gearbox. xx0200000220 A: M8 holes for pressing out the gearbox Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 325 Note DANGER Turn off all: • electric power supply • hydraulic pressure supply • air pressure supply to the robot, before entering the robot working area. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 326 Release the brakes of the axis 6 motor See section: manually. • Manually releasing the brakes on page 73 Check that the pinion is undamaged on the axis 6 motor. xx1000001413 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 327 See section Performing a leak- down test on page 148. Refill the gearbox with oil. See section: • Changing oil, gearbox axis 6 on page 135 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 328 Make sure all safety requirements are met when performing the first test run. These are further detailed in the section DANGER - First test run may cause injury or damage! on page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 329: Calibration Information
The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration. The different methods are briefly described in the section Calibration methods on page 330 , and further detailed in separate calibration manuals.
Page 330: Calibration Methods
To regain 100% absolute accuracy perform- ance, the robot must be recalibrated for abso- lute accuracy! xx0400001197 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 331 Calibration Pendulum - standard method Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H, and IRB 4400S) and is also the most accurate method for the standard type of calibration. It is the recommended method in order to achieve proper performance.
Page 332: Calibration Scale And Correct Axis Position
Introduction This section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration scales / marks, IRB 760 The illustration shows calibration scale positions on IRB 760. xx1000001146 Calibration plate, axis 1 Calibration tab on robot...
Page 334: Calibration Movement Directions For All Axes
This is normally handled by the robot calibration software. Calibration movement directions, 4 axes Note! The graphic shows an IRB 260. The positive direction is the same for all 4-axis robots xx0500001927 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 335: Updating Revolution Counters
Use this procedure to store the revolution counter setting with the FlexPendant (IRC5). Action On the ABB menu, tap Calibration. All mechanical units connected to the system are shown with their calibration status. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 336 If a revolution counter is incorrectly updated, it will cause incorrect manipulator posi- tioning, which in turn may cause damage or injury! Check the calibration position very carefully after each update. See Checking the calibration position on page 337. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 337: Checking The Calibration Position
Check that the calibration marks for the Calibration scale and correct axis pos- axes align correctly. If they do not, update ition on page 332, and Updating revolution the revolution counters! counters on page 335. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
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Page 339: Decommissioning
Also note that: • Spills can form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired. • Spillage can penetrate the soil causing ground water contamination. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 340: Decommissioning Of Balancing Device
The following procedure contains useful information about decommissioning. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 341 Cut a hole in the housing as shown in the Use a cutting torch with a long shaft. figure. xx1100000098 * Minimum measure, in millimeters. ** Maximum measure, in millimeters. Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 342 Inner spring: cut at least eight coils! Double-check the number of coils cut and make sure all the tension in the springs is removed. Cut more coils if there is still tension in the springs. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 343: Reference Information
7 Reference information 7.1 Introduction 7 Reference information 7.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 344: Applicable Safety Standards
Safety of machinery - General requirements for the design and construction of fixed and movable guards Other standards Standard Description ANSI/RIA R15.06 Safety requirements for industrial robots and robot systems Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 345 7.2 Applicable safety standards Continued Standard Description ANSI/UL 1740 Safety standard for robots and robotic equipment (option 429-1) CAN/CSA Z 434-03 Industrial robots and robot Systems - General safety require- ments (option 429-1) 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 346: Unit Conversion
3.28 ft. 39.37 in Weight 1 kg 2.21 lb. Weight 0.035 ounces Pressure 1 bar 100 kPa 14.5 psi Force 0.225 lbf Moment 1 Nm 0.738 lbf-ft Volume 0.264 US gal 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 347: Screw Joints
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.
Page 348 Molycote 1000, Gleitmo 603 or equivalent with allen head screws. Dimension Tightening torque (Nm) Tightening torque (Nm) Class 10.9, lubricated Class 12.9, lubricated Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 349 The following table specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass. Dimension Tightening torque Nm - Tightening torque Nm - Tightening torque Nm - Nominal Min. Max. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 350: Weight Specifications
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.
Page 351: Standard Tools
Hex bit socket head cap no. 6 socket 40 mm L=145 mm Hex bit socket head cap no. 6 socket 40mm bit L=220 mm Slide caliper Width=400 mm Feeler gage, 0.4 mm Bearing puller, three legs Level 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 352: Special Tools
Press tool link (bearing and shaft) 3HAC039304-002 Assembly tool, linkage 3HAC039305-001 KM10 socket Standard Press tool link (bearing and sealing) 3HAC039302-002 Press tool, lower arm 3HAC023092-001 Fitting/Removing tool (Parallel rod) 3HAC5021-1 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 353 3HAC5281-1 Lubrication tool, spherical roller bearing 3HAC039296-001 Lubrication tool, conical roller bearing 3HAC039571-002 Pinion crank RV 450E 3HAC023132-001 Bits extension 3HAC023760-001 Support base 3HAC15535-1 Lock screw M16x55 Guide sleeves 3HAC14446-1 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 354: Lifting Accessories And Lifting Instructions
The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories. This implies that the instructions delivered with the lifting accessories should be stored for later reference. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 355: Spare Parts
8 Spare parts 8.1 Spare part lists and illustrations Location Spare parts and exploded views are not included in the manual but delivered as a separate document on the documentation DVD. 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
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Page 357: Circuit Diagrams
Circuit diagram - IRB 6600 type B 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6620 3HAC025090-001 Circuit diagram - IRB 6620 / IRB 6620LX 3HAC025090-001 Circuit diagram - IRB 6640 3HAC025744-001 Continues on next page 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 358 9.1 About circuit diagrams Continued Product Article numbers for circuit diagrams Circuit diagram - IRB 6650S 3HAC13347-1 3HAC025744-001 Circuit diagram - IRB 6660 3HAC025744-001 3HAC029940-001 Circuit diagram - IRB 7600 3HAC13347-1 3HAC025744-001 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 359: Index
339 axis 6, 135 guide ring, piston rod, 111 cleaning robot, 145 connecting the robot and controller, cabling, 97 hazardous material, 339 connection hold-to-run, 32 external safety devices, 17 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 360 339 symbols on manipulator, 39 test run, 45 working range, 33 wrist strap, 48 disposal, 339 safety equipment oil change mechanical stop, 93 axis 1, 129 signal lamp, 125 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 361 270, 275–276, 280–281, 288, 290, 303, 305, 307, CAN, 344 310, 316, 350 EN, 344 upper arm, 213–214 EN IEC, 344 working range, 57 EN ISO, 344 restricting axis 1, 93 3HAC039838-001 Revision: C © Copyright 2013 ABB. All rights reserved.
Page 364 Telephone +46 (0) 21 344 400 ABB AS, Robotics Discrete Automation and Motion Box 265 N-4349 BRYNE, Norway Telephone: +47 51489000 ABB Engineering (Shanghai) Ltd. 5 Lane 369, ChuangYe Road KangQiao Town, PuDong District SHANGHAI 201319, China Telephone: +86 21 6105 6666 ABB Inc.

ABB IRB 760 Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration Information

6 Decommissioning

7 Reference Information

8 Spare Parts

9 Circuit Diagrams

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