Page 1 ROBOTICS Product manual IRBT 4004/6004/7004...
Page 2 Trace back information: Workspace Main version a1 Checked in 2025-03-12 Skribenta version 5.6.018...
Page 3: Product Manual
Product manual IRBT 4004 IRBT 6004 IRBT 7004 IRC5 Document ID: 3HAC028506-001 Revision: AJ © Copyright 2006-2025 ABB. All rights reserved. Specifications subject to change without notice.
Page 4 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, damage to persons or property, fitness for a specific purpose or the like.
Page 5: Table Of Contents
Mounting bolts ..................2.5.3 Hole configuration ................... 2.5.4 Track motion IRBT 4004/6004/7004 overview ..........2.5.5 Assembling the sections of the track motion IRBT 4004/6004/7004 (Longer than 9m) ....................... 2.5.6 Positioning the stand ................2.5.7 Geometric alignment of track motion IRBT 4004/6004/7004 ......
Page 6 2.7.3 Connections ................... 2.7.3.1 Introduction ................2.7.3.2 Assembly of the cable MS2 XS/P41 ..........2.7.3.3 Connectors on the controller ............2.7.3.4 Connectors on Drive Module ............2.7.3.5 Assembly of M12 Ethernet/PROFINET connector ......2.7.3.6 Grounding point ................2.7.4 Routing the robot’s cable harness .............. 2.7.4.1 IRB 6640 inline ................
Page 7 Adjusting the gearbox backlash ................Replacing the motor ..................Changing the track motion motor to Type A ............Replacing the gear racks ..................Replacing the linear guides ................. Replacing the ball elements ................Replacing the mechanical stops ................4.10 Replacing the SMB unit ..................4.11 Repair procedures for cable chain Brevetti .............
Page 9: Overview Of This Manual
ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Product manual scope The manual covers covers all variants and designs of the IRBT 4004/6004/7004. Some variants and designs may have been removed from the business offer and are no longer available for purchase.
Page 10 References Documentation referred to in the manual, is listed in the table below. Document name Document ID Product manual, spare parts - IRBT 4004/6004/7004 3HAC042864-001 Product specification - IRBT 4004/6004/7004 3HEA802965-001 Safety manual for robot - Manipulator and IRC5 or OmniCore con-...
Page 11 • The spare parts are moved from this product manual to a separate manual, Product manual, spare parts - IRBT 4004/6004/7004. • Changed oil to cable grease in section Replacing the cable harness on page 243.
Page 12 Assembling the sections of the track motion IRBT 4004/6004/7004 (Longer than 9m) on page • Some general tightening torques have been changed/added, see updated values in Screw joints on page 299.
Page 13 Inspecting the brush on page 166. • Additional information about alignment of the track is added, see Geometric alignment of track motion IRBT 4004/6004/7004 on page • New section about storing the cable chain is added, see Storing the cable chain on page •...
Page 14 The section is also made valid for IRBT 4004 and some information is added based on assembly instructions in production. Published in release R17.1. The following updates are made in this revi- sion: •...
Page 15 Information about functional ground added throughout the manual. Published in release 20A. The following updates are made in this revision: • Permitted extra maximum load on IRBT 4004 corrected to 50 kg, Maximum load on page • Replaced article number and name of grease, previously 3HAB3537-1.
Page 16 • Changed locking liquid Loctite 243 to Loctite 2400. Published in release 25A. The following updates are made in this revision: • Added Leica laser scanner as example, see section Geometric alignment of track motion IRBT 4004/6004/7004 on page...
Page 17: Product Documentation
Product documentation Categories for user documentation from ABB Robotics The user documentation from ABB Robotics is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.
Page 18 • Examples of how to use the application. Operating manuals The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and troubleshooters.
Page 19: How To Read The Product Manual
How to read the product manual Reading the procedures The procedures contain references to figures, tools, material, and so on. The references are read as described below. References to figures The procedures often include references to components or attachment points located on the manipulator/controller.
Page 21: Safety
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial robot will not cause injury or damage even if all safety instructions are complied with. The information does not cover how to design, install and operate a robot system, nor does it cover all peripheral equipment that can influence the safety of the robot system.
Page 22: Requirements On Personnel
1.1.2 Requirements on personnel General Only personnel with appropriate training are allowed to install, maintain, service, repair, and use the robot. This includes electrical, mechanical, hydraulics, pneumatics, and other hazards identified in the risk assessment. Persons who are under the influence of alcohol, drugs or any other intoxicating substances are not allowed to install, maintain, service, repair, or use the robot.
Page 23: Safety Signals And Symbols
1.2 Safety signals and symbols 1.2.1 Safety signals in the manual Introduction to safety signals This section specifies all safety signals used in the user manuals. Each signal consists of: • A caption specifying the hazard level (DANGER, WARNING, or CAUTION) and the type of hazard.
Page 24 Symbol Designation Significance Signal word used to indicate where to find additional information or how to do an operation in an easier way.
Page 25: Safety Symbols On Manipulator Labels
1.2.2 Safety symbols on manipulator labels Introduction to symbols This section describes safety symbols used on labels (stickers) on the manipulator. Symbols are used in combinations on the labels, describing each specific warning. The descriptions in this section are generic, the labels can contain additional information such as values.
Page 26 Symbol Description See user documentation Read user documentation for details. Which manual to read is defined by the symbol: • No text: Product manual. • EPS: Application manual - Electronic Position Switches. xx0900000813 Before disassembly, see product manual xx0900000816 Do not disassemble Disassembling this part can cause injury.
Page 27 Symbol Description Tip risk when loosening bolts The robot can tip over if the bolts are not securely fastened. xx0900000810 xx1500002402 Crush Risk of crush injuries. xx0900000817...
Page 28 Symbol Description Heat Risk of heat that can cause burns. (Both signs are used) xx0900000818 xx1300001087 Moving robot The robot can move unexpectedly. xx2400000736 xx1500002616 Brake release buttons xx0900000820 xx1000001140...
Page 29 Symbol Description Lifting bolt xx0900000821 Adjustable chain sling with shortener xx1000001242 Lifting of robot xx0900000822 Swivel eye bolt The exclamation mark indicates required usage of swivel eye bolts at the lifting points. Can be used in combination with prohibition if oil is not allowed. xx0900000823 Mechanical stop xx0900000824...
Page 30 Symbol Description Stored energy Warns that this part contains stored energy. Used in combination with Do not disassemble symbol. xx0900000825 Pressure Warns that this part is pressurized. Usually contains additional text with the pressure level. xx0900000826 Shut off with handle Use the power switch on the controller.
Page 31: Robot Stopping Functions
1.3 Robot stopping functions Protective stop and emergency stop The protective stops and emergency stops are described in the product manual for the controller. For more information see: • Product manual - IRC5...
Page 32: Safety During Installation And Commissioning
1.4 Safety during installation and commissioning National or regional regulations The integrator of the robot system is responsible for the safety of the robot system. The integrator is responsible that the robot system is designed and installed in accordance with the safety requirements set forth in the applicable national and regional standards and regulations.
Page 33 Wherever possible, power on/off or rebooting the robot controller shall be performed with all persons outside the safeguarded space. Note Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot. Safety devices The integrator is responsible for that the safety devices necessary to protect people working with the robot system are designed and installed correctly.
Page 34: Safety During Operation
1.5 Safety during operation Automatic operation Verify the application in the operating mode manual reduced speed, before changing mode to automatic and initiating automatic operation. Unexpected movement of robot arm WARNING Hazards due to the use of brake release devices and/or gravity beneath the manipulator shall be considered.
Page 35: Safety During Maintenance And Repair
1.6 Safety during maintenance and repair 1.6.1 Safety during maintenance and repair General Corrective maintenance must only be carried out by personnel trained on the robot. Maintenance or repair must be done with all electrical, pneumatic, and hydraulic power switched off, that is, no remaining hazards. Hazards due to stored mechanical energy in the manipulator for the purpose of counterbalancing axes must be considered before maintenance or repair.
Page 36 Warning Description Elimination/Action When working with lubricants Make sure that protective gear there is a risk of an allergic reac- like goggles and gloves are al- tion. ways worn. Allergic reaction When opening the oil or grease Open the plug carefully and keep plug, there may be pressure away from the opening.
Page 37 Warning Description Elimination/Action For lifetime reasons always drain as much oil as possible from the gearbox. The magnetic oil plugs will gather residual metal chips. Contaminated oil in gearboxes Hazards related to batteries Under rated conditions, the electrode materials and liquid electrolyte in the batteries are sealed and not exposed to the outside.
Page 38: Emergency Release Of The Robot Axes
1.6.2 Emergency release of the robot axes Description In an emergency situation, the brakes on a robot axis can be released manually by pushing a brake release button. How to release the brakes is described in the section: • Releasing the brake on page The robot may be moved manually on smaller robot models, but larger models may require using an overhead crane or similar equipment.
Page 39: Safety During Troubleshooting
The manipulator can move unexpectedly at any time. DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers. A risk assessment must be done to address both robot and robot system specific hazards.
Page 40: Safety During Decommissioning
1.8 Safety during decommissioning General See section Decommissioning on page 289. If the robot is decommissioned for storage, take extra precaution to reset safety devices to delivery status.
Page 41: Installation And Commissioning
2 Installation and commissioning 2.1 Overview of installation and commissioning procedure Installation and commissioning steps Carry out the following steps after delivery, to install and commission the track motion IRBT 4004/6004/7004. Action Reference Unpack the track motion. Compare the delivery check to the identific-...
Page 42: Operating Requirements
2.2 Operating requirements Protection standards Protection type Protection class Standard IP65 Foundry IP65 Explosive environments The track motion must not be located or operated in an explosive environment. Ambient temperature Description Standard/Option Temperature Track motion during Standard +5°C (41°F) to + 50°C (122°F) operation For the controller Standard/Option...
Page 43 Forces Maximum floor loads in relation to the base coordination system and indicated per each stand of the section of the track, see figure below. xx1000000945 Robot Endurance load in operation Max. load at Emergency stop (kN) (kN) IRB 4400 ±...
Page 44 Robot Endurance load in operation Max. load at Emergency stop (kN) (kN) IRBT 6004/IRB 6700-300 ± 4 6.5 ±28 ± 11 6.5 ±55 with pedestal IRB 7600 ± 11 8 ± 24 ± 22 8 ± 51 IRB 7600 with pedestal ±...
Page 45: Zone Division
2.3 Zone division Division of the track The purpose of the zone division is to divide the track into zones. Read about SafeMove in the Product manual - IRC5. Document ID is specified in References on page...
Page 46: Unpacking
Always try to determine if the goods are as ordered, and that the package is not damaged before unpacking. To identify the delivery, check the identification plate and compare it to the delivery note. The identification plates are shown in the figure. xx1100000695 ABB logotype Rating label Calibration label Instruction label Warning sign Warning label...
Page 47: Unpacking
2.4.2 Unpacking Inspection at delivery The track motion IRBT 4004/6004/7004 is wrapped in plastic. Unpack the track and check for any visible transport damage. If the track motion IRBT 4004/6004/7004 is damaged, contact ABB. Contents in delivery As standard the track motion IRBT 4004/6004/7004 includes the following on delivery: •...
Page 48 Cleaning Before transport the track motion IRBT 4004/6004/7004 has been protected against rust by a thin film of oil that has been applied before packing. The figure shows the pre-lubricated areas. xx1100000696 Note Do not clean any of the pre lubricated parts of the track motion IRBT 4004/6004/7004.
Page 49: Storage
2.4.3 Storage 2.4.3.1 Storing the cable chain Two methods for storage There are two methods for storing spare / not in use cable chains. Method 1: folded in half For complete chains with strapping in place and the strapping plates attached to the chains, the chain can only be folded in half.
Page 50 Method 2: rolled up For complete chains with or without strapping in place or strapping in place and the strapping plate not connected to the chain, the chain can be rolled up and stored lying on its side xx1300000885 Moving the cable chain from storage To move the chain from storage to track, see Lifting and fitting the cable chain Murrplastik on page...
Page 51: Moving The Track Motion
WARNING Never attempt to lift the Track Motion IRBT 4004/6004/7004 if the carriage is not in the centered position. Any lifting or moving of the track unit will require a realignment check to be performed.
Page 52: Lifting And Moving Track Motion Irbt 4004/6004/7004
WARNING Never attempt to lift the Track Motion IRBT 4004/6004/7004 if the carriage is not in the centered position. Any lifting or moving of the track unit will require a realignment check to be performed.
Page 53 Lifting zones max 60 ° xx1100000698 WARNING Never place lifting straps wider than a combined angle of max. 60°.
Page 54 3-9 sections lift The illustration shows the eye on the track motion IRBT 4004/6004/7004 where the lifting straps should be placed. 1806 1806 1806 1806 1696 1696 1306 1306 1196 1196 xx1100000699 Track motion length Lifting eye from left Lifting eye from right...
Page 55 Lifting using fork lift Proceed as follows to lift the track motion IRBT 4004/6004/7004 using the fork lift. xx1100000712 Lifting using an overhead crane Proceed as follows to lift the track motion IRBT 4004/6004/7004 using an overhead crane. xx1100000713...
Page 56 Moving the track motion using roller dollies Lift the IRBT 4004/6004/7004 according to lifting instructions, and place roller dollies under the stand’s ground plates. Depending on the length of the track motion, the number of roller dollies varies. See table for information.
Page 57 The type of roller dolly and the placement of the two types is shown in the following illustration and table. xx1400002006 Track motion length Roller dollies with steering Fixed roller dollies 9 sections 4 pcs 2 pcs 8 sections 4 pcs 2 pcs 7 sections 4 pcs...
Page 58: Lifting Weight
Required space for installation of double carriage track (option 1088-2) on page WARNING Never lift the track motion IRBT 4004/6004/7004 in sections longer than 9 meters. Never lift the track motion IRBT 4004/6004/7004 using a overhead crane without first removing the cover plates.
Page 59: Technical Data For The Track Motion
Below is an example of travel length for a 4 m stand with single carriage. xx1000001257 Description IRBT 4004 L=646 mm IRBT 6004/7004 L=841 mm IRBT 4004 Travel length= 2.9 m IRBT 6004/7004 Travel length=2.7 m Double carriage Below is an example of travel length for a 6 m stand with double carriage. xx1000001426...
Page 60 IRBT 4004 L= 646 mm IRBT 6004/7004 L= 461 mm IRBT 4004 L= 1200 mm IRBT 6004/7004 L= 1780 mm IRBT 4004 Travel length= 3700 mm IRBT 6004/7004 Travel length=3300 mm Required space for installation of single carriage track (standard) Note The tables only give the space that the track motion itself requires.
Page 61 The table below shows the required space for installation of single carriage track motions with different travel lengths, when using the cable chain Murrplastik. ii iii Travel length (m) Sections (pcs) Required space for installation (m) IRBT 4004 IRBT 6004/ 7004 Value of N 4.231 5.231 6.231 7.231...
Page 62 The table below shows the required space for installation of double carriage track motions with different travel lengths, when using the cable chain Brevetti. ii iii Travel length (m) Sections (pcs) Required space for installation (m) IRBT 4004 IRBT 6004/ 7004 Value of N 7.800 8.800 9.800 10.800...
Page 63 The table below shows the required space for installation of double carriage track motions with different travel lengths, when using the cable chain Murrplastik. ii iii Travel length (m) Sections (pcs) Required space for installation (m) IRBT 4004 IRBT 6004/ 7004 Value of N 8.300 9.300 10.300 11.300...
Page 64 Valid for track motions with motor type A (the motor is marked with an "A" on its side). Cable chain Brevetti: 1215 mm Cable chain Murrplastik: 1325 mm Cable chain Brevetti: 1238 mm Cable chain Murrplastik: 1350 mm For IRBT 6004/7004: 384.5 mm For IRBT 4004: 374.5 mm...
Page 65 Weight of track with carriage excluding packaging Weight of track with single carriage excluding packaging Travel length (m) Weight (kg) IRBT 4004 IRBT 6004/ 7004 IRBT 4004 IRBT 6004/ 7004 1050 1079...
Page 66 Height: 250 mm 238 kg 230 kg Height: 500 mm 288 kg 330 kg Only available for IRBT 4004 and 6004. Airborne noise level The sound pressure level outside the working space. IR(B)T type Level IRBT 4004 < 77 dB (A) / 1m IRBT 6004 <...
Page 67: Measures Of The Carriage Table
2.4.6 Measures of the carriage table IRBT 4004 Use the hole configuration for the manipulator when designing fixures to be used on the track. The figure below shows the dimensions in mm. Both tables on double track are the same.
Page 68 IRBT 6004 and IRBT 7004 Standard carriage The figure below shows the standard carriage for IRBT 6004/7004. 317.3 354.8 317.3 282.8 184.7 20 ±1 (4x) 18 ±1 (H7)(4x) 12H7 (4x) 0.10 E (2x) 32 ±1 (4x) xx1000000944 Description Drilling allowed within the marked area.
Page 69 Carriage plate The figure below shows the carriage plate that is used as a second added carriage for a double track or as a single carriage as mirrored, for track motions IRBT 6004/7004. 354.8 317.3 282.8 184.7 282.8 317.3 12H7 xx000001281 Description Drilling allowed within the marked area.
Page 70 Description Distance plate (fitted to the carriage at delivery) Adapter for guide pin (fitted to the carriage at delivery)
Page 71: The Unit Is Sensitive To Esd
2.4.7 The unit is sensitive to ESD Description ESD (electrostatic discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges.
Page 72: On-Site Installation
Incline The foundation must be designed so that the track motion IRBT 4004/6004/7004 can be mounted without the incline exceeding 0.5 mm/m in the direction of travel and 0.2 mm/m across this.
Page 73: Mounting Bolts
Mounting bolts Chemical anchor bolts, bolting towards steel foundation, are recommended to secure the track motion IRBT 4004/6004/7004 to the floor. However, the mounting bolts are not supplied since they must be selected on the basis of the material the foundation is made of.
Page 74: Hole Configuration
Cable tray bracket, position for standard (non-mirrored) track motion Cable tray bracket, position for mirrored track motion The table shows the value of N in the previous figure with different travel lengths. Travel length IRBT 4004 / Total length of the stand Quantity N IRBT 6006 and IRBT 7004 1.9 / 1.7 m...
Page 75 Travel length IRBT 4004 / Total length of the stand Quantity N IRBT 6006 and IRBT 7004 etc. Hole configuration The stand’s ground plates have holes for assemble. The hole configuration on the right side (shown in figure) is the same as the hole configuration on the left side.
Page 76: Track Motion Irbt 4004/6004/7004 Overview
2.5.4 Track motion IRBT 4004/6004/7004 overview Track motion content xx1100000714 Gear rack Linear guides Motor Gearbox Carriage Cable chain Cable tray Mechanical stop Protecting plate Attachment plate for cabling The same components are used in standard, doubled and mirrored layout variants.
Page 77 Easily damaged parts on the track motion Do not step on the locations marked in the figure since they are easily damaged. xx1300000797...
Page 78: Assembling The Sections Of The Track Motion Irbt 4004/6004/7004 (Longer Than 9M)
2.5.5 Assembling the sections of the track motion IRBT 4004/6004/7004 (Longer than 9m) Preparation of assembling the track motion The track motion is delivered in one complete unit up to 9 meters. Tracks longer than 9 meters are divided, and delivered in sections as described in...
Page 79 Assembling the track motion Action Note Align the two sections roughly, and remove the covers. Note Make sure that correct section ends are assembled together by checking the labeling. xx1400000826 xx1900001760 Push the two sections together saving a gap of about 10-12 mm between the two sections.
Page 80 Action Note Push the sections tightly together, and secure the guide rail to the oth- er section using two hex socket head cap screws M12x40. Set the screw joint loosely. Repeat on the opposite side of the track with the second guide rail. Note xx1800001273 If the sections are not level with...
Page 81 Action Note Assemble the six locking washers with torx screws M10x20, on both sides of the track. Make sure the mark on the washer is positioned in the upper right corner, see figure. Tightening torque: 45 Nm. xx1400000816 xx1600000972 Tighten the hex socket head cap screws M12x40 for the linear guide rails.
Page 82 Action Note Continue the assembly as described in section Fit the screw covers and screw joints on page Note Do not remove the plastic holder of the bearing until the bearing as been slid onto the guide rail. Fit the screw covers and screw joints Action Note Fit the screw covers in both linear...
Page 83: Positioning The Stand
Mount shims to fill up the gap between the foot and the floor. Note The track motion must be adjusted with Laser leveling tools before use, described in Geometric alignment of track motion IRBT 4004/6004/7004 on page...
Page 84: Geometric Alignment Of Track Motion Irbt 4004/6004/7004
A laser-level system is recommended for the alignment of the track system and can be rented at an industrial equipment company. If renting equipment is not a possibility, ABB refers to these three examples of equipment combinations to be used as leveling systems: 1 Leica laser system, with an accuracy of 0.1 mm.
Page 85 Required equipment Equipment Art. no. Note Laser level Example of a laser scanner from Leica xx2400001426 Track alignment in different directions Directions xx1100000723...
Page 86 Note The origin of coordinates is located in the manipulator’s base zero. Alignment in Y direction The figure shows the possible variation along the Y-axis. The track should be laser aligned between each section. Measure the transitions between the guiderail. The offset in Y-direction must correspond to a tolerance +/- 0.1 mm.
Page 87 Action Note ±0.1 ±0.1 Measure the track position along the X-axis. 1 Start at the third foot from the edge of the ±0.1 ±0.1 track (marked with an X). 2 Measure the tolerance to four different section's feet, according to the figure, two in each direction (0.5 m between the feet).
Page 88 R 15 57,5 ±0,5 115 ±0,5 xx1100000709 The IRBT 4004/6004/7004 is dimensioned to distribute the forces along its total foot area. WARNING The shims used for levelling must be manufactured according to the shim dimensions given in the figure, otherwise warranty can be voided. Incorrectly...
Page 89 Levelling the track with shims Use this procedure to level the track with shims during laser leveling. Action Note Screw the leveling bolts (A) in or out to raise or lower the foot plate in question. xx1100000724 A Leveling bolt B Bolt C Shim Add/remove shim(s) to fill up the...
Page 90 Action Note Remove the leveling bolt from the foot. xx1800001276...
Page 91: Moving The Carriage Manually
24V DC can be connected directly to the motor on axis 7 using an 24V DC converter and a connector cable. CAUTION The motor brakes on the track motion IRBT 4004/6004/7004 are phase dependent. Incorrect polarity can cause damage to vital parts.
Page 92 Release the axis 7 motor brake Action Note Remove the six socket head cap screws that hold the cover plate (A). xx1100000703 A Cover plate B Connector J1.XP7 C External power supply 24V DC Connect the external power supply to the O V DC J1.XP7 contact J1.XP7.
Page 93: Assembling The Pedestal (Option)
288 kg Pedestal IRBT 6004, IRBT 7004 250 mm 230 kg 500 mm 330 kg Assembling the IRBT 4004 pedestal Action Note Fit lifting eyes to the pedestal. Lifting eye, M16 (3 pcs) xx1900001597 Lift the pedestal to the mounting position using...
Page 94 Action Note Lower the pedestal to the track motion and secure with enclosed attachment screws and washers. Tightening torque: 385 Nm ± 10%. A, B xx1900001566 A Hex socket head cap screw: 9ADA183-109 (M20x100 Steel 8.8-A2F, 3 pcs) B Plain washer: 9ADA312-11 (21x37x3 Steel - A3F, 3 pcs) Assembling the IRBT 6004, IRBT 7004 pedestal Action Note...
Page 95 Action Note Lower the pedestal to the track motion and secure with enclosed attachment screws and washers. Tightening torque: 665 Nm ± 10%. Note The robot mounting hole pattern is not equal on all sides of the pedestal. Make sure to orient the pedestal as shown in the figure.
Page 96: Delivery Quick-Guide
2.5.10 Delivery quick-guide The delivery quick-guide is a document that can be found on myABB Business Portal, www.abb.com/myABB. The document is included with the delivery of the track motion and contains information from Product manual - IRBT 4004/6004/7004 (3HAC028506-001).
Page 97: Assembling The Cable Tray And Manipulator
2.6 Assembling the cable tray and manipulator 2.6.1 Assembling the manipulator Assembly position The manipulator should be assembled in one of following two positions: • InLine: Neutral position for axis 1 aligned in line with the Track Motion’s direction of travel. •...
Page 98 Manipulator positions on track motion xx1100000727 1 In line 2 90° Orienting manipulator IRB7600 and pedestal On delivery, the pedestal (if ordered) is mounted in an inline position. If the manipulator shall be turned 90 ° in any direction, the pedestal must also be rotated in the same direction due to the fact that the guide pins only fits the manipulator base according to the illustration.
Page 99: Assembling The Cover And Side Plates
2.6.2 Assembling the cover and side plates Assemble the cover and side plates Use this procedure to assemble the cover and end plates. Action Note Check the both gaskets running on top of the sections. Ensure that they are fastened properly and will not fall off during fitting of the cover plates.
Page 100 Action Note Assemble the connecting plate to the Screws: M10x25 Steel 8.8-A3F (2 pcs). carriage. Washers: DIN 125, 10,5x20x2 Steel-A3F (2 pcs). Note The figures show different designs of the plate as well as different installa- tion locations depending on the design of the plate.
Page 101: Assembling The Cable Tray
2.6.3 Assembling the cable tray Two different designs There are two designs of the cable tray. Use the correct assembling instruction depending on your design. Cable tray for cable chain Murrplastik The cable tray made for the cable chain Murrplastik is made of aluminium profiles, fastened to each other by brackets and thereby forming a tray.
Page 102 Cable tray for cable chain Brevetti The cable tray made for the cable chain Brevetti is a solid tray that is fastened to the track motion with guide plates. xx1300001027 Assembling the cable tray for the cable chain Murrplastik Use extra support if the track is raised If the track is raised between 10 - 50 mm off the ground, M6 machine feet should be added to the cable chain brackets.
Page 103 Action Note Fasten the profiles by securing the clamping pro- files with screws. xx1300001003 Use a spirit level to check that the tray is level. If needed, adjust by inserting M6 leveling bolts or shim the brackets that hold the tray (shown in figure).
Page 104: Electrical Installation
2.7 Electrical installation 2.7.1 Lifting and fitting the cable chain Murrplastik Illustration, cable chain and cable tray made of aluminium profiles The figure shows the cable chain Murrplastik and the cable tray designed for the cable chain. xx1300000926 Cable chain Aluminium profile Cable chain bracket Aluminium profile with cut-out...
Page 105 Required equipment Equipment Art. no. Note Lifting slings, standard Quantity depends on track motion length. Required if using lifting method 1. Lifting sling, extra wide (50 mm) Required if using lifting method 2. Overhead crane Method 1: lifting the cable chain that is folded in half Action Note CAUTION...
Page 106 Action Note With the chain lying on its side, secure the loose end to ensure that the chain can not unroll during the lift. xx1300000888 Lift the chain so that it is standing upright and in- sert a wide lifting sling (50 mm) through the center of the chain.
Page 107: The Cabling From The Controller
2.7.2 The cabling from the controller Cable run Cabling between the control equipment and the track motion contact plate should be run through cable conduits on the floor. Connection points The cable harness that normally connects the control equipment with the manipulator and carriage is connected to the track motion’s standard contact plate and customer contact plate.
Page 108 Connection points, Standard contact plate xx1100000731 Connection points, Customer contact plate xx1100000732...
Page 109: Connections
2.7.3 Connections 2.7.3.1 Introduction Connections The wiring diagrams are described in section Circuit diagrams on page 309.
Page 110: Assembly Of The Cable Ms2 Xs/P41
2.7.3.2 Assembly of the cable MS2 XS/P41 Assembly of the cable The following section describes the assembly of the additional axes SMB connection on IRC5 controller front panels. WARNING Disconnect all electrical supply before installation of the cable. Location of the cable xx1100000710 Connecting the cable Action...
Page 111: Connectors On The Controller
2.7.3.3 Connectors on the controller General The following section describes the connectors on the front panel of the IRC5 controller. CAUTION Always inspect the connector for dirt or damage before connecting it to the controller. Clean or replace any damaged parts. Note It is important that the earth connection point (B) is connected to a ground plane, in order to avoid disturbance.
Page 112 Description Reference on the cir- cuit diagram Robot SMB connection XS.2...
Page 113: Connectors On Drive Module
2.7.3.4 Connectors on Drive Module General The following section describes the connectors on the Drive Module. The Drive Module is detailed in section Installation of additional Drive Module in Product manual - IRC5. Connections The following details the connectors on the front panel of the Drive Module. xx0600002931 Description Power connection to Control Module...
Page 114: Assembly Of M12 Ethernet/Profinet Connector
2.7.3.5 Assembly of M12 Ethernet/PROFINET connector General If the robot is configured with Ethernet/PROFINET, there is an Ethernet cable connected between the manipulator base contact plate and the customer contact plate beneath the track motion. The M12 male Ethernet connector connected to the manipulator base contact plate must be tightened with correct torque and by using proper torque tool.
Page 115 Connector appearance Manufacturer Torque tool Tightening torque Phoenix M12 torque screwdriver and 0.4 Nm M12 assembly tool (bit) Article number: TSD 04 SAC (article number at Phoenix Contact) SAC BIT M12-D15 (article number at Phoenix Contact) xx2200001262 xx2200001285 CAUTION If the M12 Ethernet connector is not tightened correctly, there is a risk that the connector can loosen and the cable shield gets disconnected, which will require retightening with the correct torque tools.
Page 116: Grounding Point
Grounding and bonding point on track motion There is a grounding/bonding point on the track motion. The grounding/bonding point is used for potential equalizing between control cabinet, track motion and any peripheral devices. IRBT 4004 IRBT 6004, IRBT 7004 xx2000001497 xx2000001498...
Page 117 (i.e., screws) on the control cabinet, the customer connection plate-J1 in the middle of the track motion stand, and the connector plate on the manipulator. ABB supplies the ground cable from the track motion connection plate-J1 to the connector plate on the manipulator.
Page 118: Routing The Robot's Cable Harness
2.7.4 Routing the robot’s cable harness General The following information describes how to route the cables in various robot positions. The robot's cable harness fits, regardless of which one of the two possible positions the robot is placed in on the carriage. Note that the routing always starts with the robot power cable.
Page 119: Irb 6640 Inline
2.7.4.1 IRB 6640 inline Illustrations xx1400000623 xx1400000624 xx1400000626 xx1400000625...
Page 120: Irb 6640
2.7.4.2 IRB 6640 90° Illustrations xx1400000627 xx1400000628 xx1400000629...
Page 121: Irb 6640 Pedestal Inline
2.7.4.3 IRB 6640 pedestal inline Illustrations xx1400000634 xx1400000635 xx1400000636...
Page 122: Irb 6640 Pedestal 90
2.7.4.4 IRB 6640 pedestal 90° Illustrations xx1400000630 xx1400000631 xx1400000632 xx1400000633...
Page 123: Irb 7600 Inline
2.7.4.5 IRB 7600 inline Illustrations xx1400000637 xx1400000638 xx1400000639 xx1400000640...
Page 124: Irb 7600
2.7.4.6 IRB 7600 90° Illustrations xx1400000641 xx1400000642 xx1400000643 xx1400000644...
Page 125: Adjustments
2.7.5 Adjustments 2.7.5.1 Adjusting cables and covers Adjustments Use this procedure to adjust cables and covers. Action Note Adjust cables (A) and covers. If the cover is used for the cable chain, make sure there is no risk of collision and that the covers are well tightened.
Page 126 Action Note Check that the cables are attached to the attachment plate with straps (A). Check that the track motion motor cables are placed in the slot located at the end of the plate (B). Check that the motor and resolver cables are bended 90º...
Page 127: Inspection Points Of Cable Chain Murrplastik Prior To Start-Up
2.7.6 Inspection points of cable chain Murrplastik prior to start-up Important inspection points prior to start-up of track Please use the inspection sheet below to check that the installation of the cable chain Murrplastik is complete, before the track is commissioned. Inspection sheet Cable inspection Inspection...
Page 128: Software Installation
2.8 Software installation 2.8.1 Starting the system for the first time General Make sure that all steps of the physical installation is completed, see Overview of installation and commissioning procedure on page How to start the controller for the first time after the physical installation has been completed is described in Operating manual - Getting started, IRC5 and RobotStudio.
Page 129: Creating And Downloading A System
In the Add Additional Options window, click Enter key and browse to the installed track motion mediapool: ...\ABB Industrial IT\Robotics IT\MediaPool\Track.5.xx.xxxx Select, open, and add the generic license file XX-XXXXX_TRACK.kxt. In the Modify Options window, node TRACK, select and modify the options that suits your track motion.
Page 130 Action Download the system and restart the controller. Load the necessary system parameters, system modules, and program modules from the backup and restart the controller. Note Do not restore the old motor configuration file moc.cfg, this will remove the track motion settings.
Page 131 For more detailed instructions on using the Installation Manager, see Operating manual - RobotStudio.
Page 132: Arm Load
2.8.3 Arm load Extra load If the system has an extra load (kg) located on the carriage, for example a pedestal, the weight has to be described for the system in the Arm Load parameters. See Technical reference manual - System parameters.
Page 133: Check Travel Length
2.8.4 Check travel length Checking the traveling length The different travel length working areas are defined on the basis of the calibration mark. The travel length is set to maximum in the parameter file for the ordered travel length. Action Note Jog the carriage X+ direction to the end position approx.
Page 134: Updating The Revolution Counter On The Track Motion
(Non sync speed). Stop the carriage with the machined in- cision (A) with in the syncplate gap. xx1100000741 On the FlexPendant, tap the ABB menu. Tap Calibration, then tap Track 1, then tap A dialog is displayed. Update Revolution Counters.
Page 135: Base Frame Configuration
2.8.6 Base frame configuration 2.8.6.1 Introduction General To ensure that the robot works properly in linear on its track motion, it is necessary that the orientation of the robot relative to the track is properly declared. If the customer installation differs from the default selections available in Installation Manager it might be necessary to change the orientation of the robot relative to the track according to the examples below, see Configuration examples on page...
Page 136: Configuration Examples
2.8.6.2 Configuration examples Standard carriage IRB 0° (in line) in relation to the World coordinate system 0 degrees (in line) WORLD xx1500000928 xx1600000659 • Positive travel direction x in World coordinates Parameter Robot (ROB_1) Track motion (TRACK_1) Base Frame q1 Base Frame q2 Base Frame q3 Base Frame q4...
Page 137 Mirrored carriage IRB in line 0° in relation to the World coordinate system 0 degrees (in line) WORLD xx1600000661 xx1500000927 • Positive travel direction x in World coordinates Parameter Robot (ROB_1) Track motion (TRACK_1) Base Frame q1 Base Frame q2 Base Frame q3 Base Frame q4 Gamma Rotation...
Page 138: Motion Pattern Effects On Expected Component Life
2.8.7 Motion pattern effects on expected component life IRB position during travel It is highly recommended that the center of gravity of the robot arm system is as close to the center of gravity of IRBT carriage, during travel, as possible. Operation with extension of the robot arm system, combined with intense or high load operation, may significantly decrease the expected component life cycle.
Page 139: Automatic Lubrication
2.9 Automatic lubrication Factory settings of pause time and lubrication time Time setting of the lubrication cycle is described in document Operating instructions - Printed circuit board for pump 203 (Lincoln Quicklub) (2.6L-28006-B10). The factory settings at delivery are: • Jumper position with ControlPCP is V11 (see description on page 5 in Operating instructions - Printed circuit board for pump 203 (Lincoln Quicklub)).
Page 140: Test Run After Installation, Maintenance, Or Repair
2.10 Test run after installation, maintenance, or repair Safe handling Use the following procedure after installation, maintenance, or repair, before initiating motion. DANGER Initiating motion without fulfilling the following aspects, may increase the risk for injury or cause damage to the robot. Action Remove all tools and foreign objects from the robot and its working area.
Page 141: Maintenance
Note If the IRBT 4004/6004/7004 is connected to power, always make sure that the IRBT 4004/6004/7004 is connected to protective earth and a residual current device (RCD) before starting any maintenance work.
Page 142: 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 IRBT 4004/6004/7004: • Calendar time: specified in months regardless of whether the system is running or not.
Page 143: Maintenance Schedule
3.2.2 Maintenance schedule General The track motion must be maintained regularly to ensure proper function. The maintenance activities and intervals are specified in the table below. Non-predictable situations also give rise to inspections of the track motion. Any damages must be attended to immediately! The inspection intervals do not specify the life of each component.
Page 144 iv Glide shoes have been introduced to the chains in 2013. These have been provided to simplify and reduce the time associated with changing links. The first glide shoes to wear out will be located at the point where the chain first makes contact with itself during operation.
Page 145: Gearbox Oil
3.2.3 Gearbox oil Where to find information about gearbox oil See Technical reference manual - Lubrication in gearboxes (3HAC042927-001) for information about gearbox oil.
Page 146: Expected Component Life
The expected life strongly depends on the motion pattern, use of pedestal, and the extension of the robot arm system. It is important that the installation requirement stated by ABB is met, otherwise the expected component life can be significantly reduced and warranty be voided.
Page 147 Deviations from this cycle will result in differences in expected life! See the note in the Product specification about warranty, when running the track motion IRBT 4004/6004/7004 in a cold environment (0°C to 5°C).
Page 148: Activities 100 Km
3.3 Activities 100 km 3.3.1 Cleaning and lubricating the ball element Location of ball element The ball element is located as shown in figure. xx1100000742 Ball elements...
Page 149 Required equipment Equipment, etc. Article number Note Longtime lubricant Factory fill (preferred): Total CERAN CA Alternative (mixable with TOTAL CERAN CA): Klueber Microlube GB 0 WARNING The grease used causes seri- ous eye irritation and may cause an allergic skin reac- tion.
Page 150: Cleaning And Lubricating The Gear Racks
3.3.2 Cleaning and lubricating the gear racks Location of gear racks The gear racks are located as shown in figure. xx1100000744 Gear racks Required equipment Equipment, etc. Article number Note Lubricant, standard lubrication Tribol GR 100-2 PD Lubricant, standard lubrication 3HAC042536- Shell Gadus S2 Lubricant, automatic lubrication...
Page 151 Lubricating the gear racks Use this procedure to lubricate the gear racks. Action Note Inspect the gear racks, clean if necessary. Use lint free cloth Use a brush to lubricate the gear rack.
Page 152: Cleaning The Linear Guides
3.3.3 Cleaning the linear guides Location of linear guides The linear guides are located as shown in figure. xx1100000745 Linear guides Required equipment Equipment, etc. Article number Note Lint free cloth Longtime lubricant Factory fill (preferred): Total CERAN CA Alternative (mixable with TOTAL CERAN CA): Klueber Microlube GB 0 WARNING...
Page 153 Action Note Lubricate the linear guides after cleaning. Factory fill (preferred): Total CERAN CA Alternative (mixable with TOTAL CERAN CA): Klueber Microlube GB 0 WARNING The grease used causes serious eye irrita- tion and may cause an allergic skin reac- tion.
Page 154: Activities 1 Month
3.4 Activities 1 month 3.4.1 Inspecting the lubrication system Overview If the track motion is equipped with an automatic lubrication system the level of the lubricant should be checked according to the maintenance schedule (see Activities and intervals, optional equipment on page 144), even if the system should apply the lubricant equally over a longer period.
Page 155 Required equipment Equipment, etc. Art. no. Note Standard toolkit Content is defined in section Standard toolkit on page 303. Other tools and procedures These procedures include may be required. See refer- references to the tools re- ences to these procedures in quired.
Page 156 Checking the performance Use this procedure to check the performance of the lubrication system. Action Note In the case of a blockage in the system, the grease pushes out the red pin at the pres- sure limiting valve, this is a fault indication. xx1800000168 Check that the stirring paddle (B) rotates clockwise during the operating time.
Page 157 Action Note Check if power is applied to the circuit board: LED (1) is lit if OK. Press push button (5) >2 seconds LED (3) is lit if OK. For more information see section Automat- ic lubrication on page 139 Circuit dia- grams on page 309.
Page 158: Testing The Manual Feed
3.4.2 Testing the manual feed Overview If the track motion is equipped with an automatic lubrication system the level of the lubricant should be checked according to the maintenance schedule (see Activities and intervals, optional equipment on page 144), even if the system should apply the lubricant equally over a longer period.
Page 159 Equipment, etc. Art. no. Note Other tools and procedures These procedures include may be required. See refer- references to the tools re- ences to these procedures in quired. the step-by-step instructions below. Testing the manual feed Use this procedure to check the function of the lubrication system. Action Note Press the button "Feed"...
Page 160: Activities 3 Months
3.5 Activities 3 months 3.5.1 Inspecting the cable chain Location of harness The track motion harness is located as shown in figure. xx1100000730 Motor cables Cable chain Customer cables Standard cables Manipulator cables Required equipment Equipment, etc. Art. no. Note Visual inspection Cable ties 21662055-6...
Page 161 Equipment, etc. Art. no. Note Locking liquid Loctite 2400 (or equivalent Loctite 243) Used if loose screws are de- tected. Checking the emergency stop Action Note Allow the track motion to stop. Press in the emergency stop. Try to start the track motion. Inspecting the junction boxes Action Note...
Page 162 Location of the glide shoes The figure shows the location of the glide shoes on the cable chain. xx1300000899 Inspecting the glide shoes Action Note Check the thickness of the glide shoes. If it is less than 1.5 mm the glide shoes must be replaced. Normally only the glide shoes in the area that make first contact when the chain transitions into gliding mode need to be checked.
Page 163 Action Note Ensure that the plastic guide piece located between the aluminum profiles with the cut-out is in place. Check that all clamps holding the tray are secure and in Loctite 2400 (or equivalent place. If some are loose the screws need to have locking Loctite 243) liquid applied and then tightened.
Page 164: Inspecting The Linear Guides
3.5.2 Inspecting the linear guides Location of linear guides The linear guides are located as shown in figure. xx1100000745 Linear guides Required equipment Equipment, etc. Article number Note Visual inspection Inspecting the linear guides Use this procedure to inspect the linear guides. Action Note Inspect the linear guides for contamination...
Page 165 Action Note Check the guide surface of the linear If wear or damage is detected, replace all guides for damages or wear. linear guides and ball elements on the • If visual wear is detected, use a fin- concerned side. Always lubricate new lin- ger to feel the surface in the ball ear guides.
Page 166: Inspecting The Brush
3.5.3 Inspecting the brush Location of brush Oil brush Required equipment Equipment, etc. Art. no. Note Visual inspection Inspecting the brush Use this procedure to inspect the brush. Action Note Inspect the brush for wear. The brush Replacing the oil brush on page 276.
Page 167: Activities 12 Months
3.6 Activities 12 months 3.6.1 Inspecting the cables and connectors Required equipment Equipment, etc. Art. no. Note Visual inspection Inspecting the connectors Use this procedure to check the connectors. Action Note Check that the connectors at the robot base, track motor and interchange to the floor cable are correctly fitted and that there is no risk of loose connections.
Page 168: Inspecting The Mechanical Stops
3.6.2 Inspecting the mechanical stops Location of mechanical stops The mechanical stops are located as shown in figure. xx1100000746 Mechanical stops left Mechanical stops right Required equipment Equipment, etc. Art. no. Note Visual inspection...
Page 169 Inspecting the mechanical stops Use this procedure to inspect the mechanical stops. Action Note Visually inspect the mechanical stops for damage. xx1100000747 A Rubber buffer B Mechanical stop If the mechanical stops are damaged, re- place them.
Page 170: Inspecting The Gearbox, Back Lash
3.6.3 Inspecting the gearbox, back lash Location of gearbox The gearbox is located as shown in figure. xx1100000748 Gearbox Required equipment Equipment, etc. Art. no. Note Standard toolkit Content is defined in section Standard toolkit on page 303. Inspecting the gearbox, back lash Use this procedure to inspect the gearbox, back lash.
Page 171: Adjusting The Leveling
3.6.4 Adjusting the leveling Adjusting the leveling Follow the procedure in Geometric alignment of track motion IRBT 4004/6004/7004 on page 84 to adjust the leveling on the track motion.
Page 172: Activities 36 Months
3.7 Activities 36 months 3.7.1 Replacing the SMB battery pack Note The battery low alert (38213 Battery charge low) is displayed when the battery needs to be replaced. The recommendation to avoid an unsynchronized robot is to keep the power to the controller turned on until the battery is to be replaced. For an SMB board with 3-pole battery contact (RMU101 3HAC044168-001 or RMU102 3HAC043904-001), the lifetime of a new battery is typically 36 months.
Page 173 Location of SMB battery pack The SMB battery pack is located in the SMB box. The box can be located either under the track motion, or on the side of the carriage. The principle for how to replace the battery is the same even if the location varies. xx1100000731...
Page 174 xx1100000749 SMB battery pack Required equipment Note There are different variants of SMB units and batteries. The variant with the 3-pole battery contact has longer lifetime for the battery. It is important that the SMB unit uses the correct battery. Make sure to order the correct spare parts.
Page 175 Action Note Remove the cover and locate the battery. CAUTION Clean cover from metal residues before opening. Metal residues can cause shortage on the boards which can result in hazardous failures. Disconnect the cables and remove the battery. Fit the new battery in the reverse order. Fit the cover.
Page 177: Repair
Repair activities not described in this chapter must only be carried out by ABB. Report replaced units Note When replacing a part on the IRBT 4004/6004/7004, report to your local ABB the serial number, the article number, and the revision of both the replaced unit and the replacement unit.
Page 178: Replacing The Gearbox (Including The Motor) And The Gear Wheel
4.2 Replacing the gearbox (including the motor) and the gear wheel Location of gearbox and gear wheel The gearbox, motor and gear wheel are part of the drive unit and located as shown in figure. xx1100000748 Gearbox TMA 2 and motor Gear wheel (located inside the gear wheel protection) Required equipment Equipment, etc.
Page 179 Removing the drive unit Use this procedure to remove the drive unit from the track motion. Action Note CAUTION Whenever parting/mating motor and gear- box, the gears may be damaged if excess- ive force is used! DANGER Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot and for the track motion.
Page 180 Action Note Remove the cables from the motor. Motor, not type A: xx1100000750 A Cable unit, Motor B BRB option contact Motor, type A (with a bracket): xx1300000058 CAUTION The complete drive unit weighs 90 kg. All lifting accessories used must be sized accordingly! Fit lifting accessories to the drive unit.
Page 181 Action Note Remove the drive unit by removing all 12 screws (A). xx1100000751 A Hex socket head cap screw M12x40, 12 pcs Lift away the drive unit. xx1100000752 A Hex socket head cap screw M12x40, 12 pcs Removing the gear wheel and gearbox Use this procedure to remove the gear wheel and the gearbox from the drive unit.
Page 182 Action Note Remove the lower part of the gear wheel protection (F) by re- moving the four screws (E). Remove the gear wheel (G) and the friction washer (H), by remov- ing the eight screws M10x40 (D). Remove the upper part of the gear wheel protection (C) from the gearbox, if the gearbox is to be replaced.
Page 183 Action Note Fit the upper part of the gear wheel protection (C) to the gear- box with screws M6x10 (J). Use locking liquid. WARNING Do NOT use self-tapping screws! Do not mix the screws for the upper and lower protection shield.
Page 184 Action Note Fit lifting accessories to the complete drive unit and lift it to mounting position. Refit the drive unit to the track motion and secure with the 12 screws. (How to tighten the screws and which tightening torque to use is described in Adjusting the gear- box backlash on page...
Page 185 Action Note Reconnect the cables. Motor, not type A: Ensure the cables are at 90º. xx1100000750 A Cable unit, Motor B BRB option contact Motor, type A (with a bracket): xx1300000058 Clean the guide rails (before moving the carriage). Calibrate the track motion. Use Fine calibration on page 283.
Page 186 Action Note DANGER Make sure all safety requirements are met when performing the first test run. See Test run after install- ation, maintenance, or repair on page 140.
Page 187: Adjusting The Gearbox Backlash
4.3 Adjusting the gearbox backlash Adjusting the gearbox backlash Use this procedure to adjust the gearbox backlash. Action Note Loose all socket head cap screws except screw (A). Socket head cap screw (A) Tightening torque: 40 Nm. (Socket head cap screw (A) is the joint screw).
Page 188 Action Note Tighten the lock screws (B) and (C). Tightening torque: 40 Nm. xx1100000756 B Lock screw C Lock screw Fit the indicator clock as shown in figure. xx1100000757 Push the carriage by hand X+ direction until the gear wheel is in contact with the next cog on the gear rack.
Page 189 Action Note Continue with step 7 step If the gap is OK, then tighten Tightening torque: 80 Nm. the lock screws (B) and (C) in figure. xx1100000756 B Lock screw C Lock screw If the gap is not OK then re- peat step 6 step...
Page 190: Replacing The Motor
4.4 Replacing the motor Changing version of motor There are two versions of the track motion motor. If changing from one version to another, see Changing the track motion motor to Type A on page 202 instead of this replacement procedure. Location of motor The motor is located as shown in the figure.
Page 191 Two versions of the track motion motor The figures show the visual differences between motor Type A and the version that is not Type A. The replacement procedures differ between the two versions of the motor. Version not marked with "A" Type A version, marked with "A"...
Page 192 Removing the motor - version not marked with "A" Use this procedure to remove the motor. Action Note CAUTION Whenever parting/mating motor and gear- box, the gears may be damaged if excess- ive force is used! DANGER Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot and for the track motion.
Page 193 Action Note Remove the motor. xx1100000761 Remove the gasket from the machined contact surface of the motor. xx1100000762 A AC Motor B Machined contact surface C Axle drive bearing Refitting the motor - version not marked with "A" Use this procedure to refit the motor. Action Note CAUTION...
Page 194 Action Note Fit the new gasket on the motors machined contact surfaces. xx1100000762 A AC Motor B Machined contact surface C Axle drive bearing In order to release the brake, connect the Connect to motor connector: 24 VDC power supply. •...
Page 195 Action Note DANGER Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot and for the track motion. Clean the linear guide rails and then Measuring reference values for zero measure reference values for the zero pos- position on page 282.
Page 196 Action Note Remove the plate from the connection box. xx1300000449 Unscrew the attachment screws of the connection box and run the cables carefully out through the motor cable gland as remov- ing the box from the motor. Place the connection box aside. xx1300000221 Remove the adapter plate by removing the two screws.
Page 197 Action Note Remove the four screws that secure the motor. xx1300000230 CAUTION The motor weighs 26 kg. All lifting accessories used must be sized accordingly! Remove the motor. xx1300000060 Type A motor.
Page 198 Refitting the Type A motor - marked with "A" Use this procedure to refit the motor. Action Note CAUTION The motor weighs 26 kg. All lifting accessories used must be sized accordingly! Replace the o-ring. O-ring: 3HAB3772-107 xx1300000061 Unscrew the motor cover screws and re- move the motor cover.
Page 199 Action Note Secure the motor with four screws and Tightening torque: 47 Nm. plain washers. If required, use the extension 300 mm for bits 1/2". xx1300000230 Remove the 24 VDC power supply. Check both gaskets. Replace them if dam- aged. xx1300000222...
Page 200 Action Note Secure the bracket to the motor with the two screws and washers. Do not tighten yet. xx1300000059 Run the motor cables to the inside of the motor and refit the connection box with the attachment screws. Do not tighten yet. xx1300000221 Refit the plate to the connection box.
Page 201 Action Note Snap on the contact block to the push but- ton unit. xx1300000448 Refit the connection box cover and secure with the attachment screws and washers. xx1300000219 Clean the guide rails (before moving the carriage). Calibrate the track motion. Use previously Fine calibration on page 283.
Page 202: Changing The Track Motion Motor To Type A
4.5 Changing the track motion motor to Type A Two versions of the track motion motor The figures show the visual differences between Type 0 of track motion motor and Type A. Type 0 Type A, with a bracket xx1300000056 xx1300000057 Exploded views of Type A motor The figures show exploded views of the Type A version of the track motion motor.
Page 203 xx1300000228 Motor Adapter plate Screws M10x25, 4 pcs O-ring, diameter 102 mm O-ring, diameter 134 mm Contact NO Brake release push button Connection box cover Plate Connection box Cables Gasket, 2 pcs Bracket...
Page 204 Required equipment Equipment Art. no. Note Motor, Type A Spare parts on page 307. Adapter cable kit Spare parts on Required when connecting the page 307. Type A motor to track motion cabling without bayonet cabling Grease 3HAC042536-001 Shell Gadus S2 Used to lubricate the o-rings.
Page 205 Action Note CAUTION The motor weighs 26 kg. All lifting accessories used must be sized accordingly! Remove the motor. xx1100000761 Remove the gasket from the machined contact surface of the motor. xx1100000762 A AC Motor B Machined contact surface C Axle drive bearing Fitting the Type A motor - marked with "A"...
Page 206 Action Note Fit the o-ring to the adapter plate. Lubricate with grease to make it stick to the groove. xx1300000441 Fit the adapter plate to the drive unit and Tightening torque: 47 Nm. secure with screws and washers. xx1300000751...
Page 207 Action Note Fit the o-ring to the adapter plate. Lubricate with grease to make it stick to the groove. xx1300000061 Remove the motor cover. In order to release the brake, connect the Connect to motor connector: 24 VDC power supply. •...
Page 208 Action Note Fit the both gaskets. xx1300000222 Secure the bracket to the motor with the two screws and washers. Note Do not tighten the screws until the connec- tion box and the plate are fitted, as de- scribed in following steps. xx1300000059 Fit the connection box to the motor with the attachment screws.
Page 209 Action Note Fit the plate to the connection box with the attachment screws. xx1300000443 Tighten all the screws. Tightening torque: 10 Nm. Electrical installation Use this procedure to install the motor to track motion cabling without bayonet fitting, using the adapter cable kit. Parts marked with italic are included in the adapter cable kit.
Page 210 Action Note Run the power and signal track motion cables into the connection box. Place the power cabling on the right side of the plate and signal cabling on the left side of the plate. Secure the cabling to the adapter cable plate (D).
Page 211 Action Note Assemble and fit the push button unit to the connection box cover. xx1300000444 xx1300000445 Snap on the contact block to the push but- ton unit. xx1300000448 xx1300000446...
Page 212 Action Note Refit the connection box cover and secure with the attachment screws and washers. xx1300000219 Refit the motor cover with its attachment screws and washers. Clean the guide rails (before moving the carriage). Calibrate the track motion. Use previously Fine calibration on page 283.
Page 213 Action Note Use the SystemBuilder in RobotStudio to upgrade the controller system with the additional option software for the track motion Type A. C-start the system on the controller. Download the upgraded system to the controller Restore the backup. For more information on how to build and modify systems using the SystemBuilder in RobotStudio, see Operating manual - RobotStudio.
Page 214: Replacing The Gear Racks
4.6 Replacing the gear racks Location of gear racks The gear racks are located as shown in the figure. xx1100000744 Gear racks Required equipment Equipment, etc. Art. no. Note Gear rack Spare part number is spe- cified in: • Spare parts on page 307.
Page 215 Removing the gear racks Use this procedure to remove the gear racks. Action Note Remove all ten hex socket head cap screws M10x50 (B) that hold the gear rack (A). xx1100000763 A Gear rack B Hex socket head cap screw M10x50 Refitting the gear racks Use this procedure to refit the gear racks.
Page 216 Action Note Use the meshing gauge (B) to check that the joints on the laid gear rack have a smooth transition. Fit the meshing gauge in the outer holes and tighten it to the gear rack with 70 Nm. If the teeth on the meshing gauge and the gear rack do not mesh, continue with step...
Page 217: Replacing The Linear Guides
4.7 Replacing the linear guides Repair actions at breakdown If a breakdown has occurred on a ball element or linear guide, use this procedure to take proper repair measures. xx1600000893 Ball elements (underneath the bracket), totally 4 pcs Linear guide CAUTION If not all parts are replaced during a breakdown, lifetime will be reduced.
Page 218 Location of linear guides The linear guides are located as shown in the figure. xx1600000971 Linear guides Hex socket head cap screw M12x40 Torx screw M10x20 Cover Locking washer Required equipment Equipment, etc. Article number Note Linear guides Spare part number is spe- cified in: •...
Page 219 Equipment, etc. Article number Note Factory fill (preferred): Total CERAN CA WARNING Alternative (mixable with TOTAL CERAN CA): Klueber The grease used causes seri- Microlube GB 0 ous eye irritation and may cause an allergic skin reac- tion. Other tools and procedures These procedures include may be required.
Page 220 Refitting the linear guides Use this procedure to refit the linear guides. Action Note Attach the first linear guide to the middle of the frame with a hex socket head cap screw M12x40 at each end of the guide, see figure. Note Make sure that the screws are correctly aligned with the center of their respective...
Page 221 Action Note Valid for linear guides from Bosch- Rexroth: Use a ball element to adjust the sections. Tighten the hex socket head cap screws M12x40. Valid for linear guides from INA: Feel with a finger at the section joint that the linear guide sections are in line with each other.
Page 222: Replacing The Ball Elements
4.8 Replacing the ball elements Overview This section contains instructions for replacement of the ball elements, which requires removal of following components: • Bracket for ball element (runner block) • Ball elements (runner block) • Mechanical stops • Gearbox and motor (only required when replacing ball elements on the motor side of the carriage, when an IRB 7600 is mounted in 90º...
Page 223 Position of robot The position of an IRB 7600 that is rotated 90°, prevents removal of the ball element on the carriage motor side, it is therefore always necessary to lift the IRB 7600 to access the hex socket head cap screws. Check lifting instructions in the Installation chapter in Product manual - IRB 7600.
Page 224 Location of ball elements The ball elements are located as shown in the figure. xx1100000768 Ball element position A (getting access to the ball element requires removal of the gearbox and motor, see Getting access to the ball elements on a track motion for IRB 7600, 90°...
Page 225 Illustration of removal of ball elements, IRB 7600, 90° motor side The figure shows details for removal of ball elements on the motor side when an IRB 7600, 90° is mounted. xx1100000769 IRB 7600, 90° Gearbox and motor 12 x Hex socket head cap screw M12x50 Jack >...
Page 226 Getting access to the ball elements Getting access to the ball elements on a track motion for IRB 7600, 90° motor side Use this procedure to get access to the ball elements on the motor side of a track motion for IRB 7600, mounted 90° (position A in figure Location of ball elements on page 224).
Page 227 Action Note Lift the robot according to lift instructions in section Installation and commissioning in Product manual - IRB 7600. xx0700000394 CAUTION The gearbox weighs 90 kg. All lifting accessories used must be sized accordingly! Remove the gearbox and the motor accord- ing to Replacing the gearbox (including the motor) and the gear wheel on page 178...
Page 228 Action Note Remove all the socket head cap screws holding the top covers and the end protec- tions, using standard tools. To move the carriage without power see Releasing the brake with external 24V DC on page xx1100000770 A Socket head cap screw 6X M10 B Top cover for IRBT C End protection Replacing a complete ball element assembly (ball element and bracket)
Page 229 Action Note Remove all the hex socket head cap screws Motor side of track motion for IRB 7600, (A) that hold the bracket to the carriage. mounted 90°: Use a jack (C) to rise the robot and the carriage max. 1 mm, use a feeler (B). WARNING Rising the carriage more than 1 mm can seriously damage the remaining three ball...
Page 230 Action Note Remove all the hex socket head cap screws holding the bracket to the damaged ball element. xx1600000981 Use a screwdriver to separate the bracket from the ball element. xx1600000982 Refitting the ball element assembly Use this procedure to refit the ball element if the ball element bracket has eight access holes (no access hole for the parallel pins).
Page 231 Action Note Fit two parallel pins to the bracket. xx1100000775 A Bracket for ball element B Parallel pins C Ball elements (runner block) Turn the side of the ball element with the difference in level upwards and fit the ball element to the bracket.
Page 232 Action Note Note For easy assemble of the ball elements, always use the plastic gauge. Note Ball elements with Viton sealing (Foundry option), out side mounted only. xx1100000777 A Ball elements (runner block) B Gauge Secure the bracket to the carriage using Without tightening the screw joints! six hex socket head cap screws (A).
Page 233 Action Note After verification of grease supply from the tube is made, connect the lubrication tube to the grease nipple on the ball element. xx1600000906 Refit the gearbox and motor, if removed. Replacing the gearbox (including the motor) and the gear wheel on page 178.
Page 234 Replacing a ball element without removing the bracket Removing the ball element Use this procedure to remove the ball element if the ball element bracket has 10 access holes (including two access holes for the parallel pins). The ball element can be removed from the carriage without removing the ball element bracket from the carriage.
Page 235 Action Note Fit the runner block replacement tool to the Runner block replacement tool: bracket loosely with enclosed screws and 3HAC044740-002. nuts. Hex socket head cap screw: 9ADA183-52 (M10x35 8.8-A3F). Turn the nut beneath the shelf so that the Nuts: 9ADA312-8. shelf makes contact against the bracket.
Page 236 Refitting the ball element Use this procedure to refit the ball element if the ball element bracket has 10 access holes (including two access holes for the parallel pins) and the bracket is already installed on the carriage. Action Note Install a straight grease nipple to the ball element.
Page 237 Action Note Turn the side of the ball element with the difference in level upwards and slide the ball element into mounting position. xx1600000977 xx1600000987 Fit two parallel pins to the bracket and ball element. The threaded end of the pin must be out- wards in order to be able to remove the pin with the extractor tool if removing the ball element in the future.
Page 238 Action Note Verify that the lubrication system is func- tioning properly by supplying grease with the push-button on the automatic lubrica- tion system control unit and checking if grease comes out from the lubrication tube that will be connected to the ball element. After verification of grease supply from the tube is made, connect the lubrication tube to the grease nipple on the ball element.
Page 239: Replacing The Mechanical Stops
4.9 Replacing the mechanical stops Location of mechanical stops The mechanical stops are located as shown in the figure. xx1100000746 Mechanical stops, left Mechanical stops, right Required equipment Equipment, etc. Art. no. Note Mechanical stops Spare part number is spe- cified in: •...
Page 240 Removing the mechanical stops Use this procedure to remove the mechanical stops. Action Note If only the rubber damper (B) is damaged: remove the rubber damper. If the mechanical stops (A) are damaged: remove all four hexagon socket head cap screws MC6S M20x100 (D).
Page 241: Replacing The Smb Unit
4.10 Replacing the SMB unit Location of SMB unit The SMB unit is located as shown in the figure. xx1400000739 SMB unit Attachment screw (4 pcs) Required equipment Equipment, etc. Art. no. Note SMB unit Spare part number is spe- cified in: •...
Page 242 Action Note Measuring reference values for zero position on page 282. DANGER Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot and for the track motion. Unscrew attachment screws, and open cover to serial measurement unit box. CAUTION Clean cover from metal residues before opening.
Page 243: Repair Procedures For Cable Chain Brevetti
4.11 Repair procedures for cable chain Brevetti 4.11.1 Replacing the cable harness Overview This section describes replacement of track motion cable harness including removal and refitting of following components: • Cable chain (Brevetti) • Cable harness Customer • Cable harness Standard •...
Page 244 Required equipment Equipment, etc. Art. no. Note Cables Spare part number is spe- Cables must be designed for cified in: use in continuous flexing op- • Spare parts on eration. page 307. Cable chain parts Spare part number is spe- cified in: •...
Page 245 Illustration, removing the cable chain xx1100000779 Cable harness manipulator Cable harness, track motion IRBT 4004/6004/7004 motor Cover plate Removing the cable chain Use this procedure to remove the cable chain. Action Note Remove all cover plates before turning off all electric power. Without 24V DC the car- riage can not be moved.
Page 246 Action Note DANGER Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot and for the track motion. Disassemble all cables from the robot base Illustration, removing the cable chain cable interface (A). on page 245. Disassemble all cables from the track mo- Illustration, removing the cable chain tion motor (B).
Page 247 Action Note Cut all cable straps using standard tools, and disassemble the screws holding the cable chain. xx1100000781 A Cable straps B Torx pan head screw Lift up the cable chain and straighten it out. Loosen and remove the protection plate for the cable chain.
Page 248 Action Note Before removing damaged cables, measure the length of the damaged cable projecting from the end of the cable chain. This will facilitate refitting. xx1100000785 The placement of all cables is shown in lustration, refitting the cables on page 249.
Page 249 Illustration, refitting the cables Cable layout, material handling - with hydraulic hose xx1200000678 Diameter in mm Description Signal cable IRB Power cable IRB R1.MP Signal cable IRBT Power cable IRBT J1 Media hose Hydraulic hose Cable layout, material handling - without hydraulic hose xx1200000677 Diameter in mm Description...
Page 250 Cable layout, spot welding xx1200000679 Diameter Description in mm Signal cable IRB Power cable IRB R1.MP Signal cable IRBT Power cable IRBT J1 8 axis power cable/M8 Customer cable CP/CS 13.5 Customer cable CP/CS 13.7 Customer cable CP/CS Cable splitbox J1-XS101 Weld power cable Hydraulic hose Media hoses...
Page 251 Action Note Fit the new cables, use the same length projecting from the cable chain as for the damaged cable. Note Correct placement of cables in the cable chain is vital and will prevent unnecessary wear of the cables. Also the following mat- ters must be considered: •...
Page 252 Action Note Fit the distance for the cable tray, use the two torx pan head screws (A). xx1100000790 A Torx pan head screw Fit the protection plate for the cable chain, using the four screws. xx1100000791 A Protection plate for cable chain Fit the cable chain using the four torx pan head screws (B).
Page 253 Action Note Fit all cables to the motor. Motor, not type A: xx1100000780 A Cable inlet Type A motor: xx1300000058...
Page 254 Action Note Fit all cables to the manipulator base. xx1100000779 A Cable harness manipulator B Cable harness, track motion motor Place the track motion motor cables in the slot located at the end of the plate (B). Fasten the cables to the attachment plate with straps (A).
Page 255 Action Note After 50 cycles, check that the cables and hoses are not installed too tight (stretched between carrier bars) or too loose (hanging on the carrier bars). Optimally, aim for the center line of the link of the carrier system, as shown in the figure.
Page 256: Repair Procedures For Cable Chain Murrplastik
4.12 Repair procedures for cable chain Murrplastik 4.12.1 Replacing the cable chain Illustration, cable chain and cable tray made of aluminium profiles The figure shows the cable chain Murrplastik and the cable tray designed for the cable chain. xx1300000926 Cable chain Aluminium profile Cable chain bracket Aluminium profile with cut-out...
Page 257 Equipment, etc. Art. no. Note Customer connection plate J1 3HAC079958-001 Includes connection for func- tional ground cable. Required to be exchanged if installing ground cable for functional ground and the connection is missing in the current plate. Bracket, Profinet 3HAC033751-001 Torx pan head screw (4 pcs) 9ADA618-23 M3x8...
Page 258 Action Note Disconnect the connectors for power, signal and media at the floor end of the cable chain. Note Water may spill out. Make a marking on the moving end of the chain to show its location relative to the connecting plate.
Page 259 Action Note Place the cable chain into the cable tray, in the section without glide bars. If using lifting slings, ensure that these are removed before lowering the chain into the tray so as not to bend the tray. CAUTION Cable chains are easily damaged through improp- er handling.
Page 260 Action Note Align the moving end of the chain by loosening and adjusting the bolts on the connecting plate attached to the carriage. xx1300000930 Check that all cable(s) and/or hose(s) are not in- stalled too tight or too loose inside the carrier system when clamping them into place.
Page 261 Action Note The track is now ready to be powered up to full speed and duty cycle. Check the tightening torque on fastening screws after 500 cycles. Adjust, if needed. The use of serrated lock washers, snap rings and other locking means is not permitted in this part of the track.
Page 262 Action Note Swap places of the profiles. xx1300000935 Move the bracket so that it lines up under the profile divisions. xx1300000936 Refit the profiles to the brackets. xx1300000937 Continue to swap places of the profiles until the correct length is achieved. Refit the black support clip that links the two cut-out profiles.
Page 263: Replacing The Side Links, Glide Shoes And Covers
4.12.2 Replacing the side links, glide shoes and covers Location of the side links The figure shows the location of the side links on the cable chain. xx1300000892 Location of the glide shoes The figure shows the location of the glide shoes on the cable chain. xx1300000899...
Page 264 Required equipment Equipment Art. no. Note Side link Spare part number is specified in: Glide shoes • Spare parts on page 307. Standard toolkit Content is defined in section Standard toolkit on page 303. Opening the covers To replace a side link, the top and bottom cover must first be removed. Action Note Place wooden blocks under the chain to facilitate...
Page 265 Refitting the side link Action Note Position the links so that the two marks on the side line up. Press the links together until they snap together. xx1300000941 Rotate the link to "close" it. xx1300000942 Replacing the glide shoes Action Note Remove the glide shoes by pushing in the clips with a screwdriver and then pulling out the glide...
Page 266 Closing the covers Action Note Fit the cover with the dividers / shelving system to check if the cables are lying in the chain cor- rectly. Press the cover against the chain until they snap together. xx1300000943 Fit the rest of the covers. Ensure correct orientation of the covers.
Page 267: Replacing The Cables
4.12.3 Replacing the cables Required equipment Equipment, etc. Art. no. Note Cables Spare part number is spe- Cables must be designed for cified in: use in continuous flexing op- • Spare parts on eration. page 307. Cable chain parts Spare part number is spe- cified in: •...
Page 268 Action Note Move the carriage to the far end, bend closest to the middle, and loosen the bolts on the fixed end. Unfold the bend so that the chain is flat. Spot welding chains have shelving systems and the cable that requires replacement might be on the bottom.
Page 269 Illustration, refitting cables View seen from movable end. Cable layout, material handling xx1900001106 Diameter Description in mm Outer bend Inner bend Signal cable IRB Power cable IRB R1.MP Power cable IRBT 8 axis power cable 13,7 Customer signal cable Customer power cable CP / CS Parallel Customer power cable CP / CS Ethernet 13,3 Customer power cable CP / CS CANBus...
Page 270 Diameter Description in mm Functional ground Option with 8:th axis. The functional ground cable only exists in cable chains with option CP/CS Ethernet (1014-6) on IRBT 6004 and IRBT 7004. Cable layout, spot welding xx1900001121 Diameter Description in mm Outer bend Inner bend Signal cable IRB Power cable IRB R1.MP...
Page 271 Diameter Description in mm Media hose PROC4 Weld power Cable split box Functional ground Option with 8:th axis. The functional ground cable only exists in cable chains with option CP/CS Ethernet (1014-6) on IRBT 6004 and IRBT 7004.
Page 272 Refitting the cable Action Note Fit the new cable(s), use the same length project- ing from the cable chain as for the damaged cable. Note Correct placement of cables in the cable chain is vital and will prevent unnecessary wear of the cables.
Page 273 Action Note Check that all cable(s) and/or hose(s) are not in- stalled too tight or too loose inside the carrier system when clamping them into place. Optimally, aim for the neutral axis (center line of the link) of the chain as shown in the figure. To ensure that the cables are in the neutral axis, move the carriage to one end and open the links xx1200000518...
Page 274 Action Note After 50 cycles, check that the cables and hoses are not installed too tight (stretched between carrier bars) or too loose (hanging on the carrier bars). Optimally, aim for the center line of the link of the carrier system, as shown in the figure.
Page 275: Addition Of Functional Ground (Cp/Cs Ethernet)
4.12.4 Addition of functional ground (CP/CS Ethernet) Configuration of customer connection plates Only for CP/CS Ethernet and for spare part replacement. The cable chain spare part with option CP/CS Ethernet (1014-6) includes functional ground. If the installed cable chain has not included functional ground previously, or if the functional ground cable is added, the customer connection plate J1 must be replaced.
Page 276: Automatic Lubrication System
4.13 Automatic lubrication system 4.13.1 Replacing the oil brush Location of oil brush The oil brush is located as shown in the figure. xx1100000797 Oil brush Required equipment Equipment, etc. Art. no. Note Oil brush Spare part number is spe- cified in: •...
Page 277 Removing the oil brush Use this procedure to remove the oil brush. Action Note Slightly loosen the one-way flow valve M10x1-Ø6 (A). Loosen the nut (B) and the counter nut (C). Remove the oil brush (D). xx1100000798 A One-way flow valve M10x1-Ø6 B Nut C Nut D Oil brush...
Page 278: Replacing The Hydraulic Hose And Repair Of The Grease Pump
4.13.2 Replacing the hydraulic hose and repair of the grease pump Replacing the hydraulic hoses Location of hydraulic hoses The fixed hydraulic hose runs from the grease container (A) to the track motion contact plate (B), secured on the floor. The flexible hydraulic hose runs from the track motion contact plate (B), in the cable chain, and to the grease distribution block (C).
Page 279 • After pump repair, perform a operational test. Loosen the hydraulic hose at the grease distribution block and check that grease is coming out of the hose when supplying grease with the push-button on the automatic lubrication system control unit. Filling the grease pump reservoir •...
Page 281: Calibration
The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the track motion carefully with standard calibration. The resolver values will change when parts affecting the calibration position are replaced on the track motion, for example motors or parts of the transmission.
Page 282: Measuring Reference Values For Zero Position
5.2 Measuring reference values for zero position Zero position measures for calibration procedure The zero position of each track motion is unique due to possible earlier differences in positioning for calibration. Before replacing parts that effect the calibration position (for example a motor or part of transmission) or rebuilding the track, the zero position of the specific track must be documented by using the calibration tool.
Page 283: Fine Calibration
5.3 Fine calibration General If resolver values are changed, the robot must be re-calibrated using the calibration methods supplied from ABB. In order to perform fine calibration there must be reference values available for the zero position. See Measuring reference values for zero position on page 282.
Page 284 Fitting the calibration tool Use this procedure to fit the calibration tool to the track motion. Action Note WARNING Make sure no persons are on the track motion when the carriage is in motion. Also make sure that the track motion’s cover plates are free from loose objects, other- wise they can get trapped between the carriage and the plates.
Page 285 Action Note Secure the tool with screws M10x35. Ensure that all contact surfaces lie against each other when the calibration tool is fit- ted. xx1200000005 Note The mirrored version only requires one screw. Calibrating Use this procedure to perform fine calibration. Action Note WARNING...
Page 286 282. The carriage is now in calibration position. On the FlexPendant, tap the ABB menu. Tap Calibration, then tap Track, then tap Calibration Parameters. Tap Yes at Fine Calibration. Tap Track and then tap Calibrate.
Page 287: Defining Base Frame
5.4 Defining base frame General To run coordinated axes, the base frame must be defined. See Application manual - Additional axes and standalone controller (Coordinated track motion).
Page 289: Decommissioning
6 Decommissioning 6.1 Introduction to decommissioning Introduction This section contains information to consider when taking a product, robot or controller, out of operation. It deals with how to handle potentially dangerous components and potentially hazardous materials. Note The decommissioning process shall be preceded by a risk assessment. Disposal of materials used in the robot All used grease/oils and dead batteries must be disposed of in accordance with the current legislation of the country in which the robot and the control unit are...
Page 290: Environmental Information
6.2 Environmental information Introduction ABB robots contain components in different materials. During decommissioning, all materials shall be dismantled, recycled, or reused responsibly, according to the relevant laws and industrial standards. Robots or parts that can be reused or upcycled helps to reduce the usage of natural resources.
Page 291 Oil and grease Where possible, arrange for oil and grease to be recycled. Dispose of via an authorized person/contractor in accordance with local regulations. Do not dispose of oil and grease near lakes, ponds, ditches, down drains, or onto soil. Incineration must be carried out under controlled conditions in accordance with local regulations.
Page 293: Lincoln Quicklub
7 LINCOLN QUICKLUB® 7.1 Documentation for LINCOLN QUICKLUB® Where to find the manual The owner manual and operating instructions for LINCOLN QUICKLUB® are not included in this manual, but delivered as separate documents. Document numbers are specified in References on page...
Page 295: Reference Information
8 Reference information 8.1 Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual.
Page 296: Applicable Standards
IEC 60204-1 Safety of machinery - Electrical equipment of machines - Part 1: General requirements Deviations from ISO 10218-1:2011 for IRBT 4004/6004/7004 Deviations from the standard are motivated for IRBT 4004/6004/7004 in the table below. Requirement Deviation for IRBT Motivation 4004/6004/7004 §5.12.1 Limiting the...
Page 297 Other standards used in design Standard Description ISO 9787:2013 Robots and robotic devices -- Coordinate systems and motion nomenclatures IEC 61000-6-2 Electromagnetic compatibility (EMC) – Part 6-2: Generic standards – Immunity standard for industrial environments IEC 61000-6-4 Electromagnetic compatibility (EMC) – Part 6-4: Generic standards –...
Page 298: Unit Conversion
8.3 Unit conversion Converter table Use the following table to convert units used in this manual. Quantity Units Length 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...
Page 299: Screw Joints
8.4 Screw joints General This section describes how to tighten the various types of screw joints on ABB robots. The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.
Page 300 Lubricant Article number Molykote 1000 (molybdenum disulphide grease) 3HAC042472-001 Molykote P1900 (molybdenum disulphide grease) 3HAC070875-001 Tightening torque Before tightening any screw, note the following: • Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the following tables. Any special torques are specified in the repair, maintenance or installation procedure descriptions.
Page 301 Dimension Tightening torque (Nm) Tightening torque (Nm) Tightening torque (Nm) Class 8.8, oil-lubricated Class 10.9, oil-lubric- Class 12.9, oil-lubric- ated ated 1150 Tightening torque for lubricated screws (Molykote, Gleitmo or equivalent) with allen head screws The following table specifies the recommended standard tightening torque for screws lubricated with Molycote 1000, Gleitmo 603 or equivalent with allen head screws.
Page 302: 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 303: Standard Toolkit
8.6 Standard toolkit General All service (repairs, maintenance, and installation) procedures contains lists of tools required to perform the specified activity. All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the standard toolkit and defined in the following table.
Page 304: Special Tools
8.7 Special tools Extra toolkit All service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in the section Standard toolkit on page 303, and of special tools, listed directly in the instructions and also gathered in this section.
Page 305: Lifting Accessories And Lifting Instructions
8.8 Lifting accessories and lifting instructions General Many repair and maintenance activities require different pieces of lifting accessories, which are specified in each procedure. The use of each piece of lifting accessories is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting accessories. The instructions delivered with the lifting accessories should be stored for later reference.
Page 307: Spare Parts
9.1 Spare part lists and illustrations Location Spare parts and exploded views are not included in the manual but delivered as a separate document for registered users on myABB Business Portal, www.abb.com/myABB. All documents can be found via myABB Business Portal, www.abb.com/myABB.
Page 309: Circuit Diagrams
10 Circuit diagrams 10.1 Circuit diagrams Overview The circuit diagrams are not included in this manual, but are available for registered users on myABB Business Portal, www.abb.com/myABB. See the article numbers in the tables below. Controllers Product Article numbers for circuit diagrams...
Page 310 Article numbers for circuit diagrams Circuit diagram - IRBT IRB 6600/7600 3HEA803013-001 Circuit diagram - IRBT IRB 4400/4400F 3HEA803014-001 Circuit diagram - IRBT IRB 4600 3HAC033657-001 Circuit diagram - IRBT 4004/6004/7004 3HAC043574-001 Not valid for motor Type A. Valid for motor Type A.
Page 311: Index
Index Lithium disposal, 290 lock and tag, 32 lubricants, 35 allergenic material, 32 lubrication time aluminum factory settings, 139 disposal, 290 assessment of hazards and risks, 32 automatic lubrication national regulations, 32 factory settings, 139 neodymium grease amount, 139 disposal, 290 nodular iron disposal, 290 base frame, 135...
Page 312 in manual, 23 safety standards, 296 time of lubrication, 139 screw joints, 299 transportation, 289 setting the base frame, 135 troubleshooting shipping, 289 safety, 39 signals safety, 23 upcycling, 290 standards, 296 users ANSI, 296 requirements, 22 CAN, 296 EN IEC, 296 EN ISO, 296 validity and responsibility, 21 steel...
Page 314 SHANGHAI 201315, China Telephone: +86 21 6105 6666 ABB Inc. Robotics & Discrete Automation 1250 Brown Road Auburn Hills, MI 48326 Telephone: +1 248 391 9000 abb.com/robotics © Copyright 2006-2025 ABB. All rights reserved. Specifications subject to change without notice.

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