Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Articulated robot
IRB 6600 - 225/2.55 type B
IRB 6600 - 175/2.8 type B
IRB 6650 - 200/2.75 type B
IRB 6650 - 125/3.2 type B
IRB 6600ID - 185/2.55
IRB 6650ID - 170/2.75
M2000, M2000A, M2004
Product manual
IRB 6600 - 225/2.55 type B
IRB 6600 - 175/2.8 type B
IRB 6650 - 200/2.75 type B
IRB 6650 - 125/3.2 type B
IRB 6600ID - 185/2.55
IRB 6650ID - 170/2.75
M2000
M2000A
M2004
Document ID: 3HAC023082-001
Revision: E
The information in this manual is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind of guarantee or warranty by ABB for losses, damages to persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's written
permission, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
Table of Contents
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 Safety
17
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
43
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.2 Robot transportation precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.3 Securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.4 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Table of Contents
2.6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.3 Mechanically restricting the working range of axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.4 Mechanically restricting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.5 Installation of position switches (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104
105
107
109
111
129
137
139
141
143
146
149
153
158
162
164
166
169
171
173
176
177
182
185
188
191
194
197
200
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Table of Contents
223
4.4.1 Replacement of turning disk, IRB 6600 and IRB 6650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4.4.2 Replacement of complete wrist unit, IRB 6600 and IRB 6650 . . . . . . . . . . . . . . . . . . . . . . . . . . 277
4.4.3 Replacement of complete wrist unit, IRB 6600ID and IRB 6650ID . . . . . . . . . . . . . . . . . . . . . . 282
4.4.4 Replacement of upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
4.4.5 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4.4.6 Replacement of lower arm shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
4.4.7 Securing the lower arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305
4.5 Frame and base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 309
409
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Table of Contents
423
427
429
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Applicable Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 Unit conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.6 Standard toolkit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Spare part / part list
429
430
431
432
435
436
437
440
441
477
10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 Base incl. Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 Frame-Lower arm 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 Frame-Lower arm 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.5 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.6 Wrist complete, IRB 6600 and IRB 6650 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.7 Wrist complete, IRB 6600ID and IRB 6650ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
477
478
479
480
481
482
483
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Table of Contents
11 Circuit Diagram
485
Index
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Table of Contents
3HAC023082-001 Revision: E
Overview
Overview
About this manual
This manual contains instructions for
Usage
This manual should be used during
installation, from lifting the robot to its work site and securing it to the foundation, to
making it ready for operation
maintenance work
repair work
installation personnel
maintenance personnel
repair personnel.
Prerequisites
A maintenance/repair/ installation craftsman working with an ABB Robot must:
be trained by ABB and have the required knowledge of mechanical and electrical
installation/repair/maintenance work.
Organization of chapters
Copyright 2004-2008 ABB. All rights reserved.
Contents
Safety
Maintenance
Repair
Calibration Information
Decommissioning
Overview
Continued
References
Following documents are referred to throughout the manual:
Document name
Document ID
Note
M2004
M2000/M2000A
3HAC021313-001
3HAC021333-001
3HAC022419-001
3HAC16590-1
3HAC16578-1
3HAC022907-001
3HAC7793-1
3HAC025709-001
3HAC17076-1
3HAC021395-001
M2004
3HAC9299-1
M2000/M2000A
3HAC023082-001 Revision: E
Overview
Continued
Revisions
Revision Description
-
First edition
New lubricating oil in the gearboxes, axes 1, 2, 3 and 6. Changes are made in
chapter Maintenance and section Part list.
New robot models, IRB 6600ID and IRB 6650ID, are implemented throughout
the manual.
Additional changes made in the manual:
Changes made in the Part list in the Product manual, reference
information (new article numbers for items 101.2.3, 103.1.30, 109.302).
Attachment holes in the frame moved to different location. New figure in
section Illustration, fitting of extra equipment on frame on page 84.
New procedure for optional equipment: Installation of cooling fan for
motors, axes 1-3 (option) on page 97. Additional cabling also added to
section Robot cabling and connection points on page 122.
Supplementary details about required cabling for position switches are
added to section Installation of position switches (option) on page 111,
together with a procedure for how to install the cabling.
A complete (undivided) cabling from axis 1 to axis 6 is added to the spare
parts in Spare part list on page 443. New procedure: Replacement of
cable harness, axes 1-6 on page 228. Also a new circuit diagram is
added to the manual, due to the new cabling.
New procedure: Replacement of spherical roller bearing, balancing
device on page 317 due to added spare parts in Spare part list on page
443.
The section about SIS (Service Information System) is now only valid for
M2000 robot systems. For information regarding SIS for M2004
systems, see additional manual about SIS. Art. no. for the manual is
specified in section References on page 10.
3HAC023082-001 Revision: E
11
Safety information
Part list
Circuit diagrams
The product manual published as a PDF consists of only one file where the two parts are
presented together, as one Product manual.
The software documentation consists of a wide range of manuals, ranging from manuals for
basic understanding of the operating system to manuals for entering parameters during
operation.
A complete listing of all available software manuals is available from ABB.
Controller hardware option manual
Each hardware option for the controller is supplied with its own documentation. Each
document set contains the types of information specified below:
Installation information
Repair information
Maintenance information
12
3HAC023082-001 Revision: E
Software manuals
Safety information
Part list
Circuit diagrams
The product manual published as a PDF consists of only one file where the two parts are
presented together, as one Product manual.
Technical reference manuals
The following manuals describe the robot software in general and contain relevant reference
information:
RAPID Instructions, Functions and Data types: Description and syntax for all
RAPID instructions, functions and data types.
13
What is included (e.g. cables, I/O boards, RAPID instructions, system parameters, CD
with PC software)
Operating manuals
This group of manuals is aimed at those having first hand operational contact with the robot,
i.e. production cell operators, programmers and trouble shooters. The group of manuals
includes:
Getting started - IRC5 and RobotStudio
RobotStudio
14
3HAC023082-001 Revision: E
8.
Action
Note/Illustration
The table below shows an example of a reference to a list of required equipment, from a step
in a procedure.
3.
Action
Note/Illustration
Safety information
The manual includes a separate safety chapter that must be read through before proceeding
with any service or installation procedures. All procedures also include specific safety
information when dangerous steps are to be performed.
Read more in chapter Safety on page 17.
3HAC023082-001 Revision: E
15
16
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1 Safety
1.1. Introduction
1 Safety
1.1. Introduction
Overview
The safety information in this manual is divided in two categories:
general safety aspects, important to attend to before performing any service work on
the robot. These are applicable for all service work and are found in section General
safety information on page 18.
specific safety information, pointed out in the procedure at the moment of the danger.
How to avoid and eliminate the danger is either detailed directly in the procedure, or
further detailed in separate instructions, found in section Safety related instructions on
page 35.
3HAC023082-001 Revision: E
17
1 Safety
1.2.1. Safety in the robot system
Product Manual
Related information
18
Type of information
Detailed in document
Section
Installation of safety
devices
Changing operating
modes
Start-up
Operating modes
3HAC023082-001 Revision: E
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.
1 Safety
1.2.2.1. Safety risks during installation and service work on robot
The instructions in the Product Manual - Installation and Commissioning must always
be followed.
Emergency stop buttons must be positioned in easily accessible places so that the robot
can be stopped quickly.
Those in charge of operations must make sure that safety instructions are available for
the installation in question.
Those who install the robot must have the appropriate training for the robot system in
question and in any safety matters associated with it.
Safety zones, which have to be crossed before admittance, must be set up in front of
the robot's working space. Light beams or sensitive mats are suitable devices.
Turntables or the like should be used to keep the operator out of the robot's working
space.
The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving robot parts, you run the risk of being crushed by the
parallel arm.
Energy, stored in the robot for the purpose of counterbalancing certain axes, may be
released if the robot, or parts thereof, are dismantled.
Never use the robot as a ladder, i.e. do not climb on the robot motors or other part
during service work. There is a serious risk of slipping because of the high temperature
of the motors or oil spills that can occur on the robot.
The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance with the
applicable standards for the emergency stop function.
Continues on next page
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19
1 Safety
1.2.2.1. Safety risks during installation and service work on robot
Continued
Complete robot
Safety risk
Description
Hot components!
CAUTION!
Motors and gears are HOT after running the robot!
Touching the motors and gears may result in burns!
Removed parts may result in
collapse of robot!
WARNING!
Take any necessary measures to ensure that the robot
does not collapse as parts are removed, e.g. secure the
lower arm with fixtures if removing motor, axis 2.
Cabling
Safety risk
Description
CAUTION!
The cable packs are sensitive to mechanical damage!
They must be handled with care, especially the
connectors, in order to avoid damaging them!
Description
CAUTION!
Whenever parting/mating motor and gearbox, the gears
may be damaged if excessive force is used!
Balancing device
Safety risk
Description
WARNING!
Do not under any circumstances, deal with the balancing
device in any other way than that detailed in the product
documentation! For example, attempting to open the
balancing device is potentially lethal!
20
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1 Safety
1.2.2.2. Safety risks related to tools/workpieces
3HAC023082-001 Revision: E
21
1 Safety
1.2.2.3. Safety risks related to pneumatic/hydraulic systems
Residual energy may be present in these systems. After shutdown, particular care must
be taken.
The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.
Gravity may cause any parts or objects held by these systems to drop.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
Safe design
22
3HAC023082-001 Revision: E
1 Safety
1.2.2.4. Safety risks during operational disturbances
The industrial robot is a flexible tool which can be used in many different industrial
applications.
All work must be carried out professionally and in accordance with the applicable
safety regulations.
Corrective maintenance must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated with its
different parts.
Qualified personnel
Extraordinary risks
If the working process is interrupted, extra care must be taken due to risks other than those
associated with regular operation. Such an interruption may have to be rectified manually.
3HAC023082-001 Revision: E
23
1 Safety
1.2.2.5. Risks associated with live electric parts
Although troubleshooting may, on occasion, have to be carried out while the power
supply is turned on, the robot must be turned off (by setting the mains switch to OFF)
when repairing faults, disconnecting electric leads and disconnecting or connecting
units.
The mains supply to the robot must be connected in such a way that it can be turned
off outside the robots working space.
Units inside the controller, e.g. I/O modules, can be supplied with power from an
external source.
The power supply unit for the computer system (230 VAC)
The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
The power supply unit for tools, or special power supply units for the machining
process.
The external voltage connected to the control cabinet remains live even when the robot
is disconnected from the mains.
Additional connections
Copyright 2004-2008 ABB. All rights reserved.
3HAC023082-001 Revision: E
1 Safety
1.2.2.5. Risks associated with live electric parts
Continued
Voltage related risks, IRC5 controller
A danger of high voltage is associated with for example the following parts:
Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the
controller.
Units such as I/O modules, can be supplied with power from an external source.
The transformers
The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
The power supply unit for additional tools, or special power supply units for the
machining process.
The external voltage connected to the controller remains live even when the robot is
disconnected from the mains.
Additional connections.
The user connections for tools or other parts of the installation (max. 230 VAC, see
chapter Installation and commissioning in the Product manual).
3HAC023082-001 Revision: E
25
1 Safety
1.2.3.1. Safety fence dimensions
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
26
3HAC023082-001 Revision: E
1 Safety
1.2.3.2. Fire extinguishing
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot system
(manipulator or controller)!
3HAC023082-001 Revision: E
27
1 Safety
1.2.3.3. Emergency release of the robots arm
Manually releasing the brakes in the product manual for the robot.
The robot arm may be moved manually on smaller robot models, but larger models may
require using an overhead crane or similar.
Increased injury
Before releasing the brakes, make sure that the weight of the arms does not increase the
pressure on the trapped person, further increasing any injury!
28
3HAC023082-001 Revision: E
1 Safety
1.2.3.4. Brake testing
If the manipulator does not change position as the motors are switched off, then the brake
function is adequate.
3HAC023082-001 Revision: E
29
1 Safety
1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"
Do not change "Transm gear ratio" or other kinematic system parameters from the
FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s".
30
3HAC023082-001 Revision: E
1 Safety
1.2.3.6. Safe use of the FlexPendant
During programming and testing, the enabling device must be released as soon as
there is no need for the robot to move.
The programmer must always bring the FlexPendant with him/her, when entering the
robot's working space. This is to prevent anyone else taking control of the robot
without the programmer knowing.
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31
1 Safety
1.2.3.7. Work inside the manipulator's working range
The robots speed is limited to max. 250 mm/s when the operating mode selector is in
position "manual mode with reduced speed". This should be the normal position when
entering the working space. The position "manual mode with full speed (100%)" may
only be used by trained personnel who are aware of the risks that this entails.
Pay attention to the rotating axes of the manipulator! Keep a distance to the axes in
order not to get entangled with hair or clothing. Also be aware of any danger that may
be caused by rotating tools or other devices mounted on the manipulator or inside the
cell.
Test the motor brake on each axis, according to section Brake testing on page 29.
32
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1 Safety
1.2.3.8. Signal lamp (optional)
Further information about the MOTORS ON/MOTORS OFF mode may be found in the
controller documentation.
3HAC023082-001 Revision: E
33
1 Safety
1.2.3.9. Translate the information on safety and information labels
Translation possibilities
The labels fitted to the product contain space for adding a fourth language underneath the
three standard languages (English, German and French).
Add a local language to the label by:
Using a transparent sticker over the standard label with text added in a fourth
language. Drawings detailing the design (text, figure, dimensions) of the standard
labels can be ordered from ABB. Notice that each label is identified according to the
article number located in the lower corner of the label.
The figure below shows the location of the free space on one of the labels on the robot, where
the fourth language can be added. The figure also shows a transparent sticker, containing the
text in Swedish.
xx0500002517
34
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1 Safety
1.3.1. Safety signals, general
A caption specifying the danger level (DANGER, WARNING or CAUTION) and the
type of danger.
Danger levels
The table below defines the captions specifying the danger levels used throughout this
manual.
Symbol
Designation
Signification
DANGER
WARNING
ELECTRICAL
SHOCK
CAUTION
danger
warning
Electrical shock
caution
35
1 Safety
1.3.1. Safety signals, general
Continued
Symbol
Designation
Signification
Electrostatic discharge
(ESD)
NOTE
TIP
Note
Tip
36
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1 Safety
1.3.2. DANGER - Moving manipulators are potentially lethal!
Action
Note
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37
1 Safety
1.3.3. DANGER - First test run may cause injury or damage!
38
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1 Safety
1.3.4. WARNING - The brake release buttons may be jammed after service work
1.3.4. WARNING - The brake release buttons may be jammed after service work
Description
The brake release unit has push buttons for brake release of each axis motor. When service
work is performed inside the SMB recess that includes removal and refitting of the brake
release unit, the brake release buttons may be jammed after refitting!
In case the power is turned on while a brake release button is jammed in depressed position,
the affected motor brake is released! This may cause serious personal injuries and damage to
the robot!
Elimination
To eliminate the danger after service work has been performed inside the SMB recess, follow
the procedure below:
Action
1. Make sure the power is turned off.
2. Remove the push button guard, if necessary.
3. Check the push buttons of the brake release unit by pressing them down, one by one.
Make sure none of the buttons are jammed in the tube.
4. If a button gets jammed in the depressed position, the alignment of the brake release
unit must be adjusted so that the buttons can move freely in their tubes!
3HAC023082-001 Revision: E
39
1 Safety
1.3.5. WARNING - The unit is sensitive to ESD!
Note
The wrist strap button is located in the top right corner as shown in the illustration below.
xx0500002171
40
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1 Safety
1.3.6. WARNING - Safety risks during work with gearbox oil
Description
Elimination / Action
Hot oil!
When opening the oil plug,
Open oil plug carefully and keep
there may be pressure present away from the opening. Do not
in the gearbox, causing oil to overfill the gearbox when filling.
spray from the opening!
-
Do not overfill!
Specified amount
depends on drained
volume!
3HAC023082-001 Revision: E
The specified amount of oil is After refilling, check the oil level.
based on the total volume of
the gearbox. When changing
the oil, the amount of refilled oil
may differ from the specified
amount, depending on how
much oil has previously been
drained from the gearbox.
41
1 Safety
42
3HAC023082-001 Revision: E
More detailed technical data, such as load diagram, permitted extra loads (equipment) and
location of extra loads (equipment), may be found in the Product Specification for the robot.
3HAC023082-001 Revision: E
43
xx0800000030
Always follow these instructions when transporting an ABB robot according to method 1:
Always place the robot in the ABB recommended transport position, detailed in
section Risk of tipping/stability.
44
3HAC023082-001 Revision: E
Always read and follow the instructions in section Securing the robot
Always place the robot in the ABB recommended transport position for robot with
tool, detailed in sub section Transport position with a transport support.
Always use the recommended transport support detailed in sub section Recommended
transport support.
IRB7600/IRB66XX
xx0800000037
Transport Support
Nut M10
45
IRB6620
xx0800000036
Transport Support
Nut M10
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xx0800000040
47
IRB 6620
xx0800000041
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xx0800000039
49
IRB 6620
xx0800000038
50
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xx0800000062
51
Note
1. Mount the transport support lower end to the Do not tightening the screw.
robot using the recommended screw joint, (A) See attachment point for the specific
in figure.
robot in section Transport position with
a transport support.
2. Jog the robot into a position as near above as
possible to the recommended transport
position for the specific robot. specified in
section Transport position with a transport
CAUTION!
support.
Do not try to jog the robot to the exact
position (max distance 1mm).
3. Use the brake release for axis 3 to reach the See attachment point for the specific
final resting position on the transport support, robot in section Transport position with
see section Manually releasing the brakes .
a transport support
4. Tightening all the attachment screws (A) and
(B) in figure with the brake release for axis 3
still activated starting with the lower end
attachment screw.
CAUTION!
Do not attempt to tightening any
attachment screw without first release
the brakes, this can seriously damage
the robot.
52
3HAC023082-001 Revision: E
2.4 Unpacking
2.4.1. Pre-installation procedure
General
This section is intended for use when unpacking and installing the robot for the first time. It
also contains information useful during later re-installation of the robot.
Checking the pre-requisites for installation
The checklist below details what must be observed before proceeding with the actual
installation of the robot:
1. Make sure only qualified installation personnel conforming to all national and local codes
are allowed to perform the installation.
2. Visually inspect the robot to make sure it is not damaged.
3. Make sure the lifting device used is suitable to handle the weight of the robot as specified
in Weight, robot on page 53.
4. If the robot is not installed directly, it must be stored as described in Storage conditions,
robot on page 54.
5. Make sure the expected operating environment of the robot conforms to the specifications
as described in Operating conditions, robot on page 54.
6. Before taking the robot to its installation site, make sure the site conforms to Loads on
foundation, robot on page 54, Requirements, foundation on page 54 and Protection
classes, robot on page 55.
7. Before moving the robot, please observe Risk of tipping / stability on page 60 regarding
risk of tipping!
8. When these prerequisites are met, the robot may be taken to its installation site as
described in section On-site installation on page 61.
Weight, robot
The table below shows the weights of the different models:
Robot model
Weight
1780 kg *
1780 kg *
1780 kg *
1780 kg *
1880 kg
1880 kg
53
Force xy
10.1 kN
20.7 kN
Force z
18.0 13.8 kN
18.0 22.4 kN
11.0 3.7 kN
Torque xy
27.6 kNm
30.4 kNm*
50.6 kNm
55.7 kNm*
Torque z
7.4 kNm
14.4 kNm
Value
Min. levelity
0.5 mm
Max. tilt
22 Hz
Note
The limit for the maximum load on the robot
is reduced if the robot is tilted.
Contact ABB for further information about
acceptable loads.
Parameter
Value
-25 C
+55 C
+70 C
Value
+5 C
+50 C
3HAC023082-001 Revision: E
The table below shows the allowed storage conditions for the robot:
Robot
IP 67
IP 54
Equipment
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55
xx0200000025
3HAC023082-001 Revision: E
xx0200000026
57
xx0200000338
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xx0200000339
Type of motion
Axis
Type of motion
Range of movement
Note
Rotation motion
+180 to -180
Arm motion
+85 to -65
Arm motion
+70 to -180
Wrist motion
+300 to -300
Bend motion
IRB 6600/6650:
+120 to -120
IRB 6600ID/6650ID:
+100 to -100
Turn motion
IRB 6600/6650:
+360 to -360 (default),
96 revolutions
IRB 6600ID/6650ID:
+300 to -300
300 max 1)
1)
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59
xx0100000103
The robot is likely to be mechanically unstable while not secured to the foundation!
60
3HAC023082-001 Revision: E
WARNING!
The attachment points for the fork lift equipment are shown in the figure below.
xx0400000707
61
Art. no.
Note
Standard toolkit
The fork lift set, 3HAC 0604-1, is fitted to the robot as shown in the figure below.
xx0200000379
Spacer (2 pcs)
3HAC023082-001 Revision: E
Note/Illustration
xx0200000387
4.
CAUTION!
xx0400001068
A: horizontal attachment
screws, 4 pcs, M16 x 60.
Tightening torque: 60 Nm.
B: spacers, 2 pcs.
63
Note/Illustration
xx0400000977
A: securing screw
xx0300000464
CAUTION!
The fork lift pocket weighs 22 kg!
9. Secure the shorter fork lift pocket on the other 4 pcs, M16x60.
side of the robot with the four remaining
Tightening torque: 60 Nm.
horizontal attachment screws.
Make sure the original screws are
always used (or replacements of
equivalent quality: M16, quality 12.9)!
Attachment points on the robot are
shown in the figure Attachment points
on page 61.
3HAC023082-001 Revision: E
Note/Illustration
xx0200000380
CAUTION!
The robot models weigh:
IRB 6600, IRB 6650: 1780 kg!
IRB 6600ID, IRB 6650ID: 1880 kg!
All lifting equipment used must be sized
accordingly!
12. Carefully lift the robot and move it to its installation site.
13.
WARNING!
3HAC023082-001 Revision: E
65
The figure below shows how to attach the roundslings to the robot.
xx0200000282
Roundsling, robot
3HAC023082-001 Revision: E
Qty
Lifting capacity
Length / Note
3 pcs
4 250 kg
0.47 m
0.54 m
0.76 m
Roundsling, robot
3 pcs
2 000 kg
2m
2 pcs
2 000 kg
Note
CAUTION!
The robot models weigh:
IRB 6600, IRB 6650: 1780 kg!
IRB 6600ID, IRB 6650ID: 1880 kg!
All lifting equipment used must be sized accordingly!
3.
WARNING!
3HAC023082-001 Revision: E
67
Note the recommended robot position shown in the figure below and in the instruction!
Attempting to lift a robot in any other position may result in the robot tipping over, causing
severe damage or injury!
xx0200000153
Load hook
Shortening hook
Chain
Hook
3HAC023082-001 Revision: E
Art. no.
Note
3HAC 15607-1
Includes
user instructions (3HAC 15971-2).
Note/Illustration
xx0100000103
3. Fit the lifting device, manipulator to the robot Art. no. is specified in Required
as described in the enclosed instruction!
equipment on page 69
4.
CAUTION!
The robot models weigh:
IRB 6600, IRB 6650: 1780 kg!
IRB 6600ID, IRB 6650ID: 1880 kg!
All lifting equipment used must be sized
accordingly!
5.
WARNING!
Personnel must not, under any circumstances, be present under the suspended
load!
69
Note/Illustration
70
3HAC023082-001 Revision: E
xx0300000044
Internal brake release unit with push buttons. Open the protection cover to access
the buttons.
The procedure below details how to release the holding brakes when the robot is equipped
with an internal brake release unit.
Action
Note/Illustration
DANGER!
When releasing the holding brakes, the robot axes may
move very quickly and sometimes in unexpected ways!
Make sure no personnel is near the robot arm!
3. Release the holding brake on a particular robot axis by
pressing the corresponding button on the internal brake
release panel and keeping it depressed.
The brake will function again as soon as the button is
released.
71
Note/Illustration
1.
DANGER!
Incorrect connections, such as supplying
power to the wrong pin, may cause all
brakes to be released simultaneously!
2. Supply 0V on pin 12 and 24V on pin 11.
xx0300000565
72
3HAC023082-001 Revision: E
Art. no.
Note
3HAC 14457-4
3 pcs
Lifting slings
3 pcs
Length: approx. 2 m
Hole configuration
xx0200000096
Note
1.
CAUTION!
The base plate weighs 353 kg! All lifting equipment
used must be sized accordingly!
2. Fit the lifting eyes in the three lifting holes.
3. Fit the lifting slings to the eyes and to the lifting device.
3HAC023082-001 Revision: E
73
xx0100000105
3HAC023082-001 Revision: E
Continued
xx0400000715
Note1
75
xx0300000045
Equipment
Art. no.
Note
Base plate
3HAC 12937-8
Includes
guide sleeves, 3HAC 12937-3
levelling screws, 9ADA 120-79
attachment screws and
washers for securing the
manipulator to the base plate.
A drawing of the base plate itself may
be ordered from ABB Robotics!
Standard toolkit
3HAC023082-001 Revision: E
Required equipment
Recommendation
Base plate
This section details how to secure the base plate to the foundation.
Action
Note
CAUTION!
5. Use the base plate as a template and drill 16 If possible, observe the recommendaattachment holes as required by the selected tions specified in section Recommendabolt dimension.
tions, quality on page 77. ABB does not
assume any responsibility for other
foundation qualities, due to great
variations in the foundation properties.
6. Fit the base plate and use the levelling bolts to Shown in the figure Base plate, grooves
level the base plate.
and holes on page 76.
7. If required, fit strips of sheet metal underneath
the base plate to fill any gaps.
8. Secure the base plate to the foundation with
screws and sleeves.
9. Recheck the four robot contact surfaces on
Max. allowed deviation: 0.5 mm
the base plate to make sure they are level and
flat.
If they are not, pieces of sheet metal or similar
may be used to bring the base plate to a level
position.
3HAC023082-001 Revision: E
77
Levelling screws
Attachment screws
The table below specifies the type of securing screws and washers to be used for securing the
robot to the base plate/foundation.
Suitable screws, lightly lubricated:
M24 x 140
Quality:
Quality 8.8
Suitable washer:
Thickness: 4 mm
Outer diameter: 44 mm
Inner diameter: 25 mm
Tightening torque:
725 Nm
3HAC023082-001 Revision: E
xx0300000566
Note/Illustration
Detailed in section Lifting robot with
lifting slings on page 68.
The illustration below shows the hole configuration used when securing the robot.
xx0600002628
79
xx0600002629
80
3HAC023082-001 Revision: E
Note! Extra equipment may not be mounted on the lower arm of IRB 6600ID or IRB 6650ID!
xx0200000195
81
xx0300000571
xx0300000572
3HAC023082-001 Revision: E
xx0300000573
xx0200000196
83
The illustration below shows the mounting holes available for fitting extra equipment on the
frame.
xx0500001568
*1
*2
3HAC023082-001 Revision: E
The illustration below shows the mounting holes available for fitting equipment on the
turning disk.
xx0200000197
Turning disk for robot version IRB 6600 - 225/2.55 and - 175/2.8, IRB 6650 - 125/3.2
and - 200/2.75
85
xx0500001580
Turning disk unit for robot versions IRB 6600ID and IRB 6650ID.
When fitting tools on the turning disk (see the figures above), use only screws with quality
12.9. When fitting other equipment, standard screws with quality 8.8 can be used.
86
3HAC023082-001 Revision: E
Fastener quality
The illustration below shows the chip and dust protection mounted on the robot.
xx0400001071
Stop
Shield (4 pcs)
Sliding cover
Required equipment
Equipment
Art. no.
Note
3HAC 020529-008
87
Art. no.
Note
Locking liquid
Loctite 577
Used to secure the attachment
screws of the rear cover at the
end of the balancing device.
Standard toolkit
3HAC 15571-1
Note/Illustration
xx0400001077
A: Bearing unit
B: Lower arm shaft
C: Washer and nut
Also shown in the figure Illustration, equipment
mounted on robot on page 87
3HAC023082-001 Revision: E
Note/Illustration
xx0400001103
xx0400001079
xx0400001098
89
Note/Illustration
xx0400001080
xx0400001099
3HAC023082-001 Revision: E
Note/Illustration
xx0400001082
xx0400001086
91
Note/Illustration
xx0400001085
xx0400001087
J: Bushing
K: Hub
3HAC023082-001 Revision: E
Note/Illustration
xx0400001100
L: Rubber cloth
M: Upper shield
N: Rear bracket
xx0400001088
Removing parts
In case the chip and dust protection must be removed, for example in order to perform certain
repair activities, read and follow the information below. If removing the complete protection,
follow the removal order below. If only removing some parts, follow the actions detailed for
the specific part.
Part to be removed
Action
Sliding cover
1.
2.
3.
4.
Shields
Stop
93
Action
94
3HAC023082-001 Revision: E
xx0500001570
Required equipment
Equipment
Art. no.
Note
Base spacers
3HAC 021899-002
Base plate
3HAC 12937-8
Standard toolkit
95
Art. no.
Note
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Unfasten the robot from the foundation, if
fastened, and lift it away with lifting slings.
Make sure the robot is positioned in the most
stable position; the transport position!
4. Fit the four base spacers and guiding sleeves to Shown in the figure Illustration, instalthe base plate.
lation of base spacers on page 95.
5. Lift the robot with lifting slings and move it to the
prepared base plate.
6. Guide the robot with the guiding sleeves as
lowering it towards the base plate and spacers.
M24 x 240, tightening torque: 775 Nm.
Copyright 2004-2008 ABB. All rights reserved.
DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 38.
96
3HAC023082-001 Revision: E
complete cabling, including connections for both cooling fans and position switches,
at axes 1, 2 and 3. Installation of this complete cabling is detailed in section
Installation of cable harness for position switches and fans on page 118.
separate cabling for axis 1 or 2, including only connections for the cooling fans on
axes 1 or 2. Installation of this cabling is detailed in section Installation, separate fan
cabling axis 1 or 2 on page 101.
If both cooling fans and position switches are installed on the robot, the complete cabling
must be used! It can not be combined with the separate cabling.
Location of cooling fans
The fans are installed on the motors, axes 1-3, as shown in the figure below.
xx0500002157
97
Fanbox
Required equipment
Equipment
Art. no.
Note
Cooling fan
3HAC15374-1
3HAC15390-1
Choose this cabling if equipping the robot
(IRB 6600/6600ID) with both position switches and cooling
fans or with cooling fans on axis 3.
3HAC16659-1
(IRB 6650/6650ID)
3HAC023599-001
3HAC023082-001 Revision: E
xx0500002158
Art. no.
Note
3HAC025778-001
Locking liquid
Standard toolkit
Circuit diagram
xx0500002301
99
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure
supplies to the robot!
For Foundry Prime robots: Do not turn off the air pressure to
motors and SMB.
2. Prepare the fanbox for installation:
Shown in the figure
disassemble the two parts of the box by removing the Cooling fan on page 98.
nine attachment screws
loosen the three tightening screws, to avoid damaging
the surfaces of the motor when fitting the fanbox
turn the connector to the correct position; axis 1:
groove pointing inwards, as shown in the figure
Cooling fan on page 98. Positions for axis 2 and 3 are
shown in the figure Location of cooling fans on page
97.
3. Temporarily lift the motor cabling out of the way of the current
motor to make room for the fanbox.
4. Fit the parts of the fanbox to the motor and reassemble with
the nine attachment screws.
5. Lift the box (axis 1) so that it does not rest directly on the robot
and secure the box with the three tightening screws, using
locking liquid. Tighten them properly so that the box is firmly
attached to the motor.
xx0500002173
Cable bracket
3HAC023082-001 Revision: E
Note/Illustration
Shown in section Calibration
scales and correct axis position on
page 412.
2.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3. Remove the rear cover plate from the robot base. Shown in the figure Location of
cooling fans on page 97.
4. Fit the plate for customer connections, if not
Shown in the figure Plate for
already fitted, to the connection plate of the robot customer connections, at base on
base.
page 99.
Art. no. is specified in Required
equipment on page 98.
xx0500002174
101
Note/Illustration
7. Connect the connector R3.FAN2 to the fan of axis Note! Fans on both axis 1 and 2
1 or 2.
can not be used at the same time!
8. Connect the connector R1.SW2/3 to the base of
the robot. Make sure that the cabling, run through
the frame and base, is not twisted and runs freely
from the robot cabling.
9. Refit the rear cover plate to the robot base.
10. Install additional cabling to and inside the
controller.
Also make adjustments in RobotWare, as
described in the following procedure.
Adjustments in RobotWare
Action
Note
102
3HAC023082-001 Revision: E
2.5.12. Loads
General
Any loads mounted on the robot must be defined correctly and carefully (with regard to the
position of center of gravity and mass moments of inertia) in order to avoid jolting
movements and overloading the motors.
CAUTION!
Incorrect defined loads may result in operational stops or major damage in bearings.
References
Load diagrams, permitted extra loads (equipment) and their positions are specified in the
Product Specification. The loads must also be defined in the software as detailed in User's
Guide(RobotWare 4.0)Operating manual(RobotWare 5.0).
Stop time and braking distances
Robot motor brake performance depends on any loads attached. For further information about
brake performance, please contact ABB.
3HAC023082-001 Revision: E
103
Axis 1, hardware (mechanical stop) and software (signal from adjustable position
switch)
Axis 2, hardware (mechanical stop) and software (signal from adjustable position
switch)
Axis 3, hardware (mechanical stop) and software (signal from adjustable position
switch)
As standard configuration, axis 1 is allowed to move 180. The working range may however
be increased to 220 with option 561-1 "Extended working range axis 1". Notice that this
option also requires installation of a position switch on axis 1.
This section describes how to install hardware that restricts the working range.
Notice that adjustments must also be made in the software. References to software manuals
are given in the following installation procedures.
104
3HAC023082-001 Revision: E
The illustration below shows the mounting position of the stop pin and one of the additional
mechanical stops available for axis 1.
xx0300000049
Stop pin
Required equipment
Equipment, etc.
Art. no.
Note
3HAC 11076-1
3HAC 11076-2
Standard toolkit
105
Art. no.
Note
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2. Fit the additional mechanical stop to the
frame according to the figure Mechanical
stops, axis 1 on page 105.
4.
WARNING!
If the mechanical stop is deformed after a
hard collision, it must be replaced!
106
3HAC023082-001 Revision: E
xx0300000047
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
107
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2. Fit and tighten the additional stops in a row,
starting from the fixed stop.
4.
WARNING!
108
3HAC023082-001 Revision: E
xx0300000048
Required equipment
Equipment, etc.
Art. no.
Note
3HAC 13128-1
Includes:
six stops, one with 80
restriction, 3HAC 12708-3
(use when limitation angle
>=80), and five with 20,
3HAC 12708-1.
attachment screws.
Standard toolkit
109
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off
the air pressure to motors and SMB.
2. Mount and tighten the additional stops in a
row, starting from the fixed stop.
4.
WARNING!
110
3HAC023082-001 Revision: E
Fitted by ABB Robotics on delivery. In this case, the cams must still be fitted and
locked by the user. For axis 1, the cover for the cams must also be fitted.
Required equipment
Art. no.
Note
3HAC 15715-1
3HAC 021885-001
3HAC 16417-2
3HAC 15390-1
3HAC 16659-1
3HAC 025778-001
3HAC 17252-1
3HAC 17253-1
Description
111
xx0100000158
Cam
Protection sheet
Rail
Rail attachment
Copyright 2004-2008 ABB. All rights reserved.
3HAC023082-001 Revision: E
xx0100000159
Cam
Rail
Rail Attachment
113
The illustration below shows the position switch for axis 3. In addition to the shown
components, cabling must also be installed from the switch to the robot base.
xx0100000160
Cam
Rail
Rail attachment
Specifications
Maximum voltage/current for the position switches:
Parameter
Value
Voltage
Max. 50 VDC
Current
Max. 1 A
3HAC023082-001 Revision: E
XT8, screw terminal in the controller cabinet when position switch cables are used.
R1.SW1 at the robot base. Customer connection kit is recommended, art. no. is
specified in Required equipment on page 111!
R1.SW2/3 at the robot base. Customer connection kit is recommended, art. no. is
specified in Required equipment on page 111!
Further information about the cables and connection points, see section Robot cabling and
connection points on page 122.
Installation of position switch, axis 2
In The robot is equipped with a cable protection at the lower arm that must be removed before
fitting the positions switch for axis 2:
Action
1. Remove the cable protection from the lower arm.
2. Fit the rail by pushing it against the support surface on the lower arm and tightening
the two screws.
3. Fit the cam and the position switch unit.
4. Refit the cable protection to the lower arm with two screws.
Action
Note
115
xx0100000113
Adjustable cam
Profile
The illustration below show how to cut the position switch cam.
xx0100000114
3HAC023082-001 Revision: E
xx0500002301
xx0500002305
R1.SW2/3
R3.FAN2
117
R2.SW2
R2.SW3
Note/Illustration
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off
the air pressure to motors and SMB.
3. Remove the rear cover (A) from the robot
base and replace the protection (B) with a
plate for customer connections (if not
already mounted).
xx0500002306
3HAC023082-001 Revision: E
Note/Illustration
xx0500002309
xx0500002312
119
Note/Illustration
xx0500002313
xx0500002314
3HAC023082-001 Revision: E
Note/Illustration
12. Install additional cabling to and inside the Cabling is specified in section:
control cabinet.
Position switch and fan cables,
robot base to controller (option) on
page 123
3HAC023082-001 Revision: E
121
Description
Robot cables
Position switch and fan cables Handles supply to and feedback from any position switches
(option)
and cooling fans on the robot.
Specified in the table Position switch and fan cables, robot
base to controller (option) on page 123.
Customer cables (option)
1)
Robot cables
These cables are included in the standard delivery. They are completely pre-manufactured
and ready to plug in.
Cable sub-category Description
Connection
Connection
point, cabinet point, robot
R1.MP
R1.SMB
XS2
Art. no.
3HAC 11818-1
3HAC023082-001 Revision: E
Art. no.
3HAC 11818-2
3HAC 11818-3
3HAC 11818-4
Cable
Art. no.
3HAC 7998-1
3HAC 7998-2
3HAC 7998-3
3HAC 7998-4
In a M2004 robot system, however, the cables below are only used for position switches.
Cabling for the cooling fans is specified in the table Cabling between robot base and
controller, cooling fans, M2004 on page 124.
Connection point,
robot
Connection
point,
cabinet
Cable
Art. no.
XS8
XS8
XS8
XS8
XS58
XS58
XS58
XS58
123
Art. no.
Connection point
Distributing cable
3HAC 022708-001
Harness - cooling, 7 m
3HAC 022723-001
Harness - cooling, 15 m
3HAC 022723-004
Harness - cooling, 22 m
3HAC 022723-005
Harness - cooling, 30 m
3HAC 022723-006
3HAC 15899-1
XS58
XP57
XS58
XP57
124
Connection
Connection
point 1 inside point 2 inside
cabinet
cabinet
XT8.1 and
XT8.2
XT58.1 and
XT58.2
3HAC 15666-1
XS57
XT31
3HAC 17832-1
XS57
XT31:10
XT31:12
3HAC023082-001 Revision: E
Cable
Never switch off the overpressure in motors and serial measurement compartment
during cooling down of robot after it has been switched off.
When turning off an cleaning cell we recommend that the humid air inside a cell is
ventilated out, to avoid that the humid air is sucked into e.g. gearboxes due to the
raised vacuum when cooled down.
Environmental conditions
Humidity
100%
<9.0
<+2C at 6 bar
<5 microns
Oil content
Pressure to robot
0.2-0.3 bar
125
Note/Illustration
xx0600002794
3HAC023082-001 Revision: E
C
xx0600002792
Recommendations
NOTE!
To reduce the risk for corrosion due to condensation in gearboxes, it is recommendable that
the robot is running with high speed on each axes at least on one occasion each hour. This is
to lubricate the gearbox cavities.
WARNING!
Never switch off the overpressure in motors and serial measurement compartment during
cooling down of robot after it has been switched off.
NOTE!
When turning off an cleaning cell we recommend that the humid air is ventilated out from the
cell, to avoid that the humid air is sucked into e.g gearboxes due to the arised vacuum when
cooled down.
3HAC023082-001 Revision: E
127
128
3HAC023082-001 Revision: E
3 Maintenance
3.1. Introduction
3 Maintenance
3.1. Introduction
Structure of this chapter
This chapter details all maintenance activities recommended for the robot and any external
units of the robot.
It is based on the maintenance schedule, located in the beginning of the chapter. The schedule
contains information about required maintenance activities including intervals and refers to
procedures for the activities.
Each procedure contains all information required to perform the activity, e.g. required tools
and materials.
The procedures are gathered in different sections, divided according to the maintenance
activity.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing the procedures. Read the
chapter Safety on page 17 before performing any service work.
3HAC023082-001 Revision: E
129
3 Maintenance
3.2.1. Specification of maintenance intervals
Operating time: specified in operating hours. More frequent running of the robot
means more frequent maintenance activities.
SIS: specified by the robot's SIS (Service Information System). A typical value is
given for a typical work cycle, but the value will differ depending on how hard each
part is run. The SIS is further detailed in section Service Information System, M2000
on page 214
130
3HAC023082-001 Revision: E
3 Maintenance
3.2.2. Maintenance schedule
The table below specifies the required maintenance activities and intervals:
Maintenance
activity
Equipment
Interval
Cleaning
Robot
Inspection
12 mths
1)
Inspection
12 mths
1)
Inspection
12 mths
1)
Inspection
12 mths
Inspection
12 mths
Inspection
12 mths
Inspection
Balancing device
12 mths
Inspection
Robot harness
12 mths
Inspection
Information labels
12 mths
Inspection, information
labels on page 162
Inspection
12 mths
Inspection
Changing
Changing
Detailed in section
Cleaning, robot on page 212
1)
131
3 Maintenance
3.2.2. Maintenance schedule
Continued
Equipment
Interval
Detailed in section
Changing
Changing
24 000 h
1)
Changing
24 000 h
1)
Changing
Changing
12 000 h 1)
Replacement
Axis 1 gearbox
As specified by
the SIS, or
typically 96 mths
Replacement of gearbox,
axis 1 on page 383
Replacement
Axis 2 gearbox
As specified by
the SIS, or
typically 96 mths
Replacement of gearbox
axis 2 on page 391
Replacement
Axis 3 gearbox
As specified by
the SIS, or
typically 96 mths
Replacement of gearbox,
axis 3 on page 399
Replacement
Axis 4 gearbox 5)
96 mths
2)
Replacement
Axis 5 gearbox 6)
96 mths
2)
Replacement of complete
wrist unit, IRB 6600 and IRB
6650 on page 277
Replacement
Axis 6 gearbox
96 mths1
Replacement
Robot harness
Replacement
36 mths
Lubrication
Balancing device
bearing
12 000 h
Replacement of gearbox,
axis 6 on page 405
3HAC023082-001 Revision: E
Maintenance
activity
3 Maintenance
3.2.2. Maintenance schedule
Continued
1)
2)
3)
4)
5)
6)
It is recommended to replace the complete wrist unit, instead of only replacing the
gearbox.
9)
If the robot is run at ambient temperatures higher than 50C, the equipment may
require maintenance more frequently.
The service time for gearboxes, axes 4 and 5, is not calculated by the SIS, see
expected life in section Expected component life on page 136.
Replace when damage is detected or when approaching life limit as specified in
Expected component life on page 136.
The interval is the same as the interval for changing axis 2 gear oil because of the
similarity of the type and degree of operation. Always lubricate the front eye bearing
after refitting the balancing device shaft!
The table below specifies the required maintenance activities and intervals for common
optional equipment. Maintenance of other external equipment for the robot is detailed in
separate documentation.
Maintenance
activity
Equipment
Inspection
Signal lamp
Inspection
Inspection
Interval
Detailed in section
Inspection, signal lamp on
page 173
12 mths
Inspection, additional
mechanical stops on page
166
Inspection, position switch
axes 1, 2 and 3 on page 171
Interval
Detailed in section
Inspection
Cable harness
6 mths
Inspection
Air hoses
6 mths
Inspection
Balancing device
12 mths
Inspection
Information labels
12 mths
Inspection
12 mths
Inspection
12 mths
133
3 Maintenance
3.2.2. Maintenance schedule
Continued
Interval
Detailed in section
Analysis
3000h or
6 mths 2)
Changing
6000h
Changing
6000h
Changing
6000h
Changing
12000h
Changing
12000h
Changing
3000h or
6 mths1)
Replacement
Cable harness
Replacement
36 mths
Replacement
Axis 1 gearbox
Replacement
Axis 2 gearbox
Replacement
Axis 3 gearbox
Replacement
Axis 4 gearbox 4)
96 mths
Replacement
Axis 5 gearbox 5)
96 mths 3)
Replacement
Axis 6 gearbox
3)
6 mths
6 mths
3HAC023082-001 Revision: E
Maintenance
Equipment
activity
3 Maintenance
3.2.2. Maintenance schedule
Continued
1. If the robot is working in cleanings cells that are not emptied when the robot is
switched off, the oil may be replaced more frequently.
2. Analyse water content in oil in gearbox axis 6 first time after 3000H or 6 mounths.
If the working conditions changes, analyse again after 3000h or 6 mounths.
3.The service time for gearboxes, axes 4 and 5, is not calculated by the SIS, see
expected life in section Expected component life on page 136.
5. It is recommended to replace the complete wrist unit, instead of only replacing the
gearbox.
6. The guarantee does not apply to effects or wear caused by environmental factors.
3HAC023082-001 Revision: E
135
3 Maintenance
3.2.3. Expected component life
Expected life
Note
See note 1)
Balancing device
2,000,000 cycles
See note 2)
Gearbox
40,000h
See note 3)
1)
The expected life can also be affected by assemblage of cabling other than standard options.
The given life is based on a test cycle that for every axis starts from the calibration position
to minimum angle to maximum angle and back to the calibration position. Deviations from
this cycle will result in differences in expected life! The life may also be affected by acid or
alkaline environment.
2)
The given life for the balancing device is based on a test cycle that starts from the initial
position and goes to maximum extension, and back. Deviations from this cycle will result in
differences in expected life!
3)
The robot is dimensioned for a life of 8 years (350,000 cycles per year) in a normal spot
welding application. Depending on the actual application, the life of individual gearboxes
may vary greatly from this specification. The Service Information System (SIS), integrated
in the robot software, keeps track of the gearbox life in each individual case and will notify
the user when a service is due. For Foundry Prime robots, working in 100% humidity, other
service intervalls may be required.
For an M2000 system, the SIS is described in section Service Information System, M2000 on
page 214.
136
3HAC023082-001 Revision: E
The SIS is for an M2004 system described in the Operating manual - Service Information
System. Document number can be found in section References on page 10.
3 Maintenance
3.3.1. Inspection, oil level gearbox axis 1
The axis 1 gearbox is located between the frame and base. The oil plugs are shown in the
figure below.
xx0200000228
Gearbox axis 1
Motor, axis 1
Required equipment
Equipment
Art. no.
Note
Lubricating oil
3HAC032140-001
Standard toolkit
137
3 Maintenance
3.3.1. Inspection, oil level gearbox axis 1
Continued
Equipment
Art. no.
Note
These procedures include
references to the tools required.
Note
1.
WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING - Safety
risks during work with gearbox oil on page 41.
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3. Open the oil plug, inspection.
7.
WARNING!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe
damage to gearbox! on page 42!
138
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3 Maintenance
3.3.2. Inspection, oil level gearbox axis 2
xx0400001066
Gearbox axis 2
Required equipment
Equipment etc.
Art. no.
Note
Lubricating oil
3HAC032140-001
Standard toolkit
139
3 Maintenance
3.3.2. Inspection, oil level gearbox axis 2
Continued
Inspection, oil level gearbox 2
The procedure below details how to inspect the oil level in gearbox axis 2.
Action
Note
1.
WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING - Safety
risks during work with gearbox oil on page 41.
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3. Open the oil plug, filling.
7.
WARNING!
Do not mix the oil types! If wrong oil is refilled,
the gearbox must be rinsed as detailed in
section WARNING - Mixed oils may cause
severe damage to gearbox! on page 42!
140
3HAC023082-001 Revision: E
3 Maintenance
3.3.3. Inspection, oil level gearbox axis 3
xx0200000230
Gearbox axis 3
Required equipment
Equipment, etc.
Art. no.
Note
Lubricating oil
3HAC032140-001
Standard toolkit
141
3 Maintenance
3.3.3. Inspection, oil level gearbox axis 3
Continued
Equipment, etc.
Art. no.
Note
These procedures include
references to the tools required.
Note
1.
WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING - Safety
risks during work with gearbox oil on page 41.
2. Move the robot to the calibration position.
3.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
4. Open the oil plug, filling.
8.
WARNING!
Do not mix the oil types! If wrong oil is refilled,
the gearbox must be rinsed as detailed in
section WARNING - Mixed oils may cause
severe damage to gearbox! on page 42!
142
3HAC023082-001 Revision: E
3 Maintenance
3.3.4. Inspection, oil level gearbox axis 4
xx0200000231
xx0600002962
143
3 Maintenance
3.3.4. Inspection, oil level gearbox axis 4
Continued
Required equipment
Equipment, etc.
Art. no.
Note
Lubricating oil
11712016-604
Standard toolkit
Note
1.
WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING Safety risks during work with gearbox oil on
page 41.
2. Move the robot to the calibration position.
3.
3HAC023082-001 Revision: E
DANGER!
3 Maintenance
3.3.4. Inspection, oil level gearbox axis 4
Continued
Action
Note
8.
WARNING!
3HAC023082-001 Revision: E
145
3 Maintenance
3.3.5. Inspection, oil level, gearbox axis 5
The figure above shows the wrist unit of IRB 6600 and IRB 6650
xx0500002013
The figure above shows the wrist unit of IRB 6600ID and IRB 6650ID
3HAC023082-001 Revision: E
xx0200000232
3 Maintenance
3.3.5. Inspection, oil level, gearbox axis 5
Continued
Required equipment
Equipment etc.
Art. no.
Note
Lubricating oil
11712016-604
Standard toolkit
Note
1.
WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please observe the safety
information in section WARNING - Safety risks
during work with gearbox oil on page 41.
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3. Turn the wrist unit so that the both oil plugs face
upwards.
4. Open the oil plug, filling.
xx0500002222
147
3 Maintenance
3.3.5. Inspection, oil level, gearbox axis 5
Continued
Action
Note
8.
WARNING!
148
3HAC023082-001 Revision: E
3 Maintenance
3.3.6. Inspection, oil level gearbox axis 6
xx0400001092
The figure above shows the wrist unit of IRB 6600 and IRB 6650
Gearbox, axis 6
xx0500002017
The figure above shows the wrist unit of IRB 6600ID and IRB 6650ID
Gearbox, axis 6
149
3 Maintenance
3.3.6. Inspection, oil level gearbox axis 6
Continued
Required equipment
Equipment
Art. no.
Note
Lubricating oil,
IRB 6600/6650
3HAC032140-001
Lubricating oil,
IRB 6600ID/6650ID
11712016-604
Standard toolkit
Note
1.
WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING - Safety
risks during work with gearbox oil on page 41.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3. Make sure the oil plug, filling is facing upwards Shown in the figure Location of
and open it.
gearbox on page 149!
4. Measure the oil level.
Required oil level to the upper edge of the oil
plug hole for filling (a):
55 mm 5 mm (IRB6600/6650)
15 mm (IRB 6600ID/6650ID)
xx0500002222
3HAC023082-001 Revision: E
2.
3 Maintenance
3.3.6. Inspection, oil level gearbox axis 6
Continued
Action
Note
7.
WARNING!
Do not mix the oil types! If wrong oil is refilled,
the gearbox must be rinsed as detailed in
section WARNING - Mixed oils may cause
severe damage to gearbox! on page 42!
Then....
18
6
24
12
30
3000 6000 9000 12000 15000
C
xx0600003155
151
3 Maintenance
3.3.6. Inspection, oil level gearbox axis 6
Continued
If:
2. Less than 2% water in oil,
Then....
normal replacement interval as specified by
SIS or typically 96 months for gearbox axis 6
is required
2%
B
6
12
18
24
30
3000 6000 9000 12000 15000
xx0600003156
152
3HAC023082-001 Revision: E
3 Maintenance
3.3.7. Inspection, balancing device
dissonance
damage
leakage
The balancing device is located at the top rear of the frame as shown in the figure below. The
figure also shows the inspection points, further detailed in the instructions.
xx0300000580
Balancing device
153
3 Maintenance
3.3.7. Inspection, balancing device
Continued
Required equipment
Equipment, etc.
Art. no.
Maintenance kit,
complete
3HAC 021592-001
Includes:
complete kit including the
kit with bearings and
seals
instructions for maintenance.
Maintenance kit,
bearings and seals
3HAC 021593-001
Includes:
kit with bearings, o-rings
and seals only
instructions for maintenance.
Securing screw
Note
Toolkit for
maintenance
3HAC 021984001
4552-2
(Bahco)
Separator
4551-C
(Bahco)
Standard toolkit
If dissonance is detected...
... perform maintenance according to given
instructions in Maintenance kit, bearings and
seals. The replacement of the bearing at the
ear is also detailed in section Replacement
of spherical roller bearing, balancing device
on page 317.
Art. no. for the kit and the documentation are
specified in section Required equipment on
page 154.
3HAC023082-001 Revision: E
3 Maintenance
3.3.7. Inspection, balancing device
Continued
Check for dissonance from...
If dissonance is detected...
2.
3.
2.
If damage is detected...
155
3 Maintenance
3.3.7. Inspection, balancing device
Continued
Check for leakage
The front ear of the balancing device is lubricated with grease. After filling, excessive grease
may normally be forced out between the shaft and the sealing ring in the sealing spacer. This
is normal behaviour and must no be confused with incorrect leaks from the ear.
Leaks at the o-rings, however, are not acceptable and must be attended to immediately in
order to avoid any damage to the bearing!
xx0500002506
Shaft
O-ring
Sealing spacer
Correct way out for excessive grease from inside the front ear
Action
Note
3HAC023082-001 Revision: E
Check the o-rings in the front ear of the balancing device for leaks, as shown and detailed
below.
3 Maintenance
3.3.7. Inspection, balancing device
Continued
Action
Note
3.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
4. Check the o-rings at the front ear for leakage.
Replace the o-rings, if any leaks are detected.
Excessive grease from between the shaft and
the sealing ring is normal and is not considered
as a leak!
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
2. Check that there are no obstacles inside the frame, that could prevent the balancing
device from moving freely. See the figure Inspection points, balancing device on page
153.
Keep the areas around the balancing device clean and free from objects, such as service
tools.
3HAC023082-001 Revision: E
157
3 Maintenance
3.3.8. Inspection, cable harness
xx0200000097
Lower arm
Connectors at base
Required equipment
Equipment, etc.
Art. no.
Note
Standard toolkit
3HAC 15571-1
Circuit diagram
3HAC023082-001 Revision: E
Note! The cable harness is also available without the division point R2.M5/6. Except for the
connectors at the division point, the rest of the inspection points are the same for the harness
that runs undivided from axis 1 to axis 6.
3 Maintenance
3.3.8. Inspection, cable harness
Continued
Inspection, cable harness 1-6
The procedure below details how to inspect the cable harness of axes 1-4.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2. Make an overall visual inspection of the cable
harness, in order to detect wear and damage.
3. Check the connectors at the division point and Shown in the figure Location of cable
at the base.
harness, axes 1-6 on page 158.
4.
note
159
3 Maintenance
3.3.8. Inspection, cable harness
Continued
Location of cabling axes 5-6
The robot cable harness, axes 5-6, is located as shown in the figure below.
Note! The cable harness is also available without the division point R2.M5/6. Except for the
connectors at the division point, the rest of the inspection points are the same for the harness
that runs undivided from axis 1 to axis 6.
xx0200000234
3HAC023082-001 Revision: E
3 Maintenance
3.3.8. Inspection, cable harness
Continued
Inspection, cable harness, axes 5-6
The procedure below details how to inspect the cable harness of axes 5-6.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2. Make an overall visual inspection of the cable
harness, in order to detect wear and damage.
3. Check the attachments at the rear of the
upper arm and in the upper arm tube.
Check the connectors at the cable harness
division. Make sure the attachment plate is
not bent or in other way damaged.
4.
3HAC023082-001 Revision: E
161
3 Maintenance
3.3.9. Inspection, information labels
Warning label, tools are not allowed around the balancing device during operation,
3HAC020611-001
Information labels at gearboxes and at robot base, if gearboxes are filled with
Kyodo Yushi TMO 150
3HAC023082-001 Revision: E
xx0200000236
3 Maintenance
3.3.9. Inspection, information labels
Continued
xx0400000786
Required equipment
Equipment
Art. no.
Note
3HAC8711-1
3HAC021670-002
Inspection, labels
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Check the labels, located as shown in the figures
Location of labels on page 162.
3. Replace any missing or damaged labels.
3HAC023082-001 Revision: E
163
3 Maintenance
3.3.10. Inspection, mechanical stop, axis 1
xx0200000151
Required equipment
Art. no.
Note
Mechanical stop ax 1
3HAC12812-2
Standard toolkit
Equipment, etc.
3HAC023082-001 Revision: E
3 Maintenance
3.3.10. Inspection, mechanical stop, axis 1
Continued
Inspection, mechanical stop
The procedure below details how to inspect the mechanical stop axis 1.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Inspect the mechanical stop, axis 1.
3HAC023082-001 Revision: E
165
3 Maintenance
3.3.11. Inspection, additional mechanical stops
Additional stop
Fixed stop
xx0200000150
3HAC023082-001 Revision: E
3 Maintenance
3.3.11. Inspection, additional mechanical stops
Continued
xx0200000150
Required equipment
Equipment etc.
Art. no.
Note
3HAC11076-1
3HAC11076-2
3HAC020885-1
3HAC13128-1
Standard toolkit
167
3 Maintenance
3.3.11. Inspection, additional mechanical stops
Continued
Inspection, mechanical stops
The procedure below details how to inspect the additional mechanical stops on axes 1,2 and 3.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Check the additional stops on axes 1, 2 and 3for
damage.
168
3HAC023082-001 Revision: E
3 Maintenance
3.3.12. Inspection, damper axes 2-5
The figure below shows the location of all the dampers to be inspected.
xx0300000040
Damper, axis 5 (IRB 6600, IRB 6650: 2 pcs, IRB 6600ID, IRB 6650ID: 4 pcs)
Required equipment
A damper must be replaced if damaged!
Equipment
Damper axis 2
3HAC12991-1
Damper axis 3
3HAC12320-1
Damper axis 4
3HAC13564-1
Damper axis 5
3HAB4337-2
3HAC021325-001
169
3 Maintenance
3.3.12. Inspection, damper axes 2-5
Continued
Equipment
3HAC021675-001
Standard toolkit
3HAC15571-1
Inspection, dampers
The procedure below details how to inspect the dampers, axes 2-5
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Check all dampers for damage, and for cracks or
Shown in the figure Location of
existing impressions larger than 1 mm.
dampers on page 169!
To inspect the damper, axis 4, remove the two covers
on top of the upper arm!
3. Check attachment screws for deformation.
Art. no. is specified in Required
equipment on page 169!
170
3HAC023082-001 Revision: E
3 Maintenance
3.3.13. Inspection, position switch axes 1, 2 and 3
Art. no.
Note
Standard toolkit
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Check the position switch!
Check that the rollers are easy to push in and
that they roll freely.
3. Check the rail!
Check that the rail is firmly attached with the
attachment screws.
4. Check the cams!
Check that the rollers have not caused any
impressions on the cams.
Check that the cams are clean. Wipe them if
necessary!
Check that the set screws holding the cams in
position are firmly attached.
171
3 Maintenance
3.3.13. Inspection, position switch axes 1, 2 and 3
Continued
Action
Note
172
3HAC023082-001 Revision: E
3 Maintenance
3.3.14. Inspection, signal lamp
xx0200000240
Signal lamp
Clamp
173
3 Maintenance
3.3.14. Inspection, signal lamp
Continued
xx0600003071
UL signal lamp
Clamp
Motor, axis 3
Equipment, etc.
Art. no.
Note
Signal lamp
3HAC10830-1
Standard toolkit
3HAC023082-001 Revision: E
Required equipment
3 Maintenance
3.3.14. Inspection, signal lamp
Continued
Inspection, signal lamp
The procedure below details how to inspect the function of the signal lamp.
Action
Note
1. Check that the signal lamp is lit, when the motors are
put in operation ("MOTORS ON").
2.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3HAC023082-001 Revision: E
175
3 Maintenance
3.3.15. Inspection of air hoses (Foundry Prime)
Art. no.
Pressure gauge
Note
Procedure
For this test it is recommended that the air supply to the robot has a pressure gauge and a cutoff valve connected.
Action
1. Apply compressed air to the air
connector on robot base, and raise the
pressure with the knob until the correct
value is shown on the pressure gauge.
Note/Illustration
Recommended pressure:
0.2+0.1/0 bar
xx0600002794
A: Air connection
2. Close the shut-off valve.
176
3HAC023082-001 Revision: E
3 Maintenance
3.4.1. Type of oil in gearboxes
F
C
D
xx0800000247
Axis 1 gearbox
Axis 2 gearbox
Axis 3 gearbox
Axis 4 gearbox
Axis 5 gearbox
Axis 6 gearbox
xx0500002226
177
3 Maintenance
3.4.1. Type of oil in gearboxes
Continued
Type of oil - historically used
The six gearboxes of the robot have historically been filled with different types of oils. Today
only the types of oil specified in the table is recommended.
NOTE!
When there is a change of oil types in the gearbox, it need to be rinsed. See Rinsing gearbox.
CAUTION!
When filling gearbox oil, do not mix different types of oil as this may cause severe damage
to the gearbox! Always use the type of oil specified in the table!
If oils are mixed, the gearbox must be thoroughly rinsed! See Rinsing gearbox.
Type of oil - currently used
The table show which types of oil is used in gearboxes.
Gearbox
Type of oil
Art. no.
Amount
Axis 1
3HAC032140-001
7,300 ml
Axis 2
3HAC032140-001
5,800 ml
Axis 3
3HAC032140-001
2,500 ml
Axis 4
11712016-604
8,100 ml
Axis 5
11712016-604
IRB 6600/6650:
6,700 ml
IRB 6600ID/
6650ID:
5,000 ml
3HAC032140-001
450 ml
Axis 6, IRB
6600ID/6650ID
11712016-604
6,000 ml
Labels located next to oil plugs of each gearbox show which type of oil it contains. All
gearboxes must have the correct label clearly visible.
Kyodo Yushi
TMO 150
3HAC032140-001
3HAC032726-001
xx0800000230
Mobil
Gearlube X320
Shell
Tivela S 150
3HAC021469-001
Optimol, Optigear
RMO 150
11712016-604
3HAC021480-001
3HAC021485-001
3HAC16843-1
xx0800000234
3HAC023082-001 Revision: E
3 Maintenance
3.4.1. Type of oil in gearboxes
Continued
Labels at robot base
Label located at robot base show the types of oil in all gearboxes.
Lifting of robot
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
Warning
UL
3HAC021505-002
xx0500001396
IRB 66X0
Label at robot base. Currently used types of oil.
Lifting of robot
Warning
Axis 1
Axis 2
Axis 3
Axis 4
Axis 5
Axis 6
UL
3HAC025378-001
xx0500002012
IRB 66X0ID
-
179
3 Maintenance
3.4.1. Type of oil in gearboxes
Continued
Mixed types of oil may cause may cause severe damage!
When refilling or replacing oil in a gearbox it is important to first check which type of oil is
recommended to use in the gearbox. See Type of oil - currently used. If the oil used is other
than the one in the list of currently used types of oil, it is recommended to replace the oil.
As Kyodo Yushi TMO 150 (as well as Shell Tivela S 150) is not compatible with mineral oil,
contamination with other types of oil in the gearboxes is not accepted! Equipment used in
handling of Kyodo Yushi (as well as Shell Tivela S 150) must be carefully cleaned before use!
In case of changing the type of oil, the gearbox therefor must be thoroughly rinsed! See
Rinsing gearbox.
NOTE!
When filling gearbox oil, do not mix different types of oil as this may cause severe damage
to the gearbox! Always use the oil recommended by the manufacturer!
Rinsing gearbox
Depending on which types of oil are mixed and which type of oil shall be filled in the gearbox
after rinsing, use the appropiate procedure.
The same applies if the type of oil shall be changed in the gearbox.
NOTE!
What is said about Kyodo Yushi TMO 150, also applies to Shell Tivela S 150.
What is said about Mobilgear 600 XP320, also applies to Mobil Gearlube X320.
Kyodo Yushi TMO 150 mixed with Optimol Optigear RMO 150
Flush the gearbox properly three times with the correct type of oil. Use a service
program when flushing.
Flush the gearbox properly three times with Kyodo Yushi TMO 150. Use a service
program when flushing.
3HAC023082-001 Revision: E
Use this procedure to rinse the contaminated gearbox if the oil types Kyodo Yushi TMO 150
and Optimol Optigear RMO 150 are mixed.
3 Maintenance
3.4.1. Type of oil in gearboxes
Continued
Equipment
Art. no.
Note
Label set
3HAC021745-001
Equipment
3HAC023082-001 Revision: E
181
3 Maintenance
3.4.2. Oil change, gearbox axis 1
Gearbox axis 1
Motor axis 1
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil
3HAC032140-001
7,300 ml
3HAC023082-001 Revision: E
xx0200000228
3 Maintenance
3.4.2. Oil change, gearbox axis 1
Continued
Equipment, etc.
Art. no.
Standard toolkit
Amount
Note
The contents are defined in
section Standard toolkit on page
436.
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2.
WARNING!
Handling gearbox oil involves several safety
risks. Before proceeding, please observe the
safety information in section WARNING Safety risks during work with gearbox oil on
page 41.
3. Remove the rear cover on the base by
unscrewing its attachment screws.
xx0200000237
6. Remove the oil plug, filling, in order to drain the Shown in the figure Location of oil
oil quicker!
plugs on page 182.
7. Open the hose endoil plug, draining and drain Notice! The draining is timethe oil into the vessel.
consuming. Elapsed time depends on
the temperature of the oil.
183
3 Maintenance
3.4.2. Oil change, gearbox axis 1
Continued
Action
Note
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2.
WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please observe the safety
information in section WARNING - Safety risks during
work with gearbox oil on page 41.
3. Open the oil plug, filling.
5.
WARNING!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe damage to
gearbox! on page 42!
6. Refit the oil plug, filling.
184
3HAC023082-001 Revision: E
3 Maintenance
3.4.3. Oil change, gearbox axis 2
xx0400001066
Gearbox axis 2
Required equipment
Equipment, etc. Art. no.
Amount
Note
Lubricating oil
5,800 ml
3HAC032140-001
Oil exchange
equipment
3HAC021745-001
Standard toolkit
185
3 Maintenance
3.4.3. Oil change, gearbox axis 2
Continued
Draining, oil
The procedure below details how to drain the oil in gearbox axis 2.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 185.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2.
WARNING!
Filling, oil
The procedure below details how to fill oil into the gearbox, axis 2.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 185.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3HAC023082-001 Revision: E
3 Maintenance
3.4.3. Oil change, gearbox axis 2
Continued
Action
Note
2.
WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please observe the safety
information in section WARNING - Safety risks
during work with gearbox oil on page 41.
3. Remove the oil plug, filling and the plug from the
vent hole.
5.
WARNING!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe damage
to gearbox! on page 42!
Tightening torque: 24 Nm.
3HAC023082-001 Revision: E
187
3 Maintenance
3.4.4. Oil change, gearbox, axis 3
Gearbox axis 3
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil
3HAC032140-001
2,500 ml
Oil exchange
equipment
3HAC021745-001
3HAC023082-001 Revision: E
xx0200000230
3 Maintenance
3.4.4. Oil change, gearbox, axis 3
Continued
Equipment, etc.
Art. no.
Standard toolkit
Amount
Note
The contents are defined in
section Standard toolkit on page
436.
Draining, oil
The procedure below details how to drain oil from the gearbox, axis 3.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 188.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2.
WARNING!
189
3 Maintenance
3.4.4. Oil change, gearbox, axis 3
Continued
Filling, oil
The procedure below details how to fill oil to the gearbox, axis 3.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 188.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2.
WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please observe the safety
information in section WARNING - Safety risks during
work with gearbox oil on page 41.
3. Remove the oil plug, filling.
190
3HAC023082-001 Revision: E
WARNING!
3 Maintenance
3.4.5. Oil change, gearbox, axis 4
xx0200000231
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil
11712016-604
8,100 ml
3HAC 021745-001
Standard toolkit
191
3 Maintenance
3.4.5. Oil change, gearbox, axis 4
Continued
Draining, oil
The procedure below details how to drain the oil in the gearbox, axis 4.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 191.
Action
Note
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3.
WARNING!
Filling, oil
The procedure below details how to fill the oil in the gearbox, axis 4.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 191.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3HAC023082-001 Revision: E
3 Maintenance
3.4.5. Oil change, gearbox, axis 4
Continued
Action
Note
2.
WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please observe the safety
information in section WARNING - Safety risks
during work with gearbox oil on page 41.
3. Refill the gearbox with lubricating oil through the oil
plug, filling.
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil
level is detailed in section Inspection, oil level
gearbox axis 4 on page 143.
4.
WARNING!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe damage
to gearbox! on page 42!
Tightening torque: 24 Nm.
3HAC023082-001 Revision: E
193
3 Maintenance
3.4.6. Oil change, gearbox, axis 5
xx0200000232
xx0500002013
3HAC023082-001 Revision: E
3 Maintenance
3.4.6. Oil change, gearbox, axis 5
Continued
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil
11712016-604
IRB 6600/6650:
6,700 ml
IRB 6600ID/6650ID:
5,000 ml
Oil exchange
equipment
3HAC021745-001
Standard toolkit
Note
DANGER!
WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please observe the safety
information in section WARNING - Safety risks
during work with gearbox oil on page 41.
4. Drain the oil from the gearbox by opening the oil
plug, draining.
Remove the oil plug, filling in order to drain the oil
quicker!
195
3 Maintenance
3.4.6. Oil change, gearbox, axis 5
Continued
Filling, oil, axis 5
The procedure below details how to change the oil in gearbox, axis 5.
When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.
no. for the kit is specified in Required equipment on page 195.
Action
Note
WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please observe the safety
information in section WARNING - Safety risks
during work with gearbox oil on page 41.
3.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
4. Refill the gearbox with lubricating oil through the
oil plug, filling.
The amount of oil to be refilled depends on the
amount previously being drained. The correct oil
level is detailed in section Inspection, oil level,
gearbox axis 5 on page 146.
WARNING!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe
damage to gearbox! on page 42!
6. Refit the oil plug, filling.
196
3HAC023082-001 Revision: E
5.
3 Maintenance
3.4.7. Oil change, gearbox axis 6
xx0400001092
The figure above shows the wrist unit of IRB 6600 and IRB 6650
Gearbox, axis 6
xx0500002017
The figure above shows the wrist unit of IRB 6600ID and IRB 6650ID
Gearbox, axis 6
197
3 Maintenance
3.4.7. Oil change, gearbox axis 6
Continued
Required equipment
Equipment, etc.
Art. no.
Amount
Note
Lubricating oil,
IRB 6600/6650
3HAC032140-001
450 ml
6,000 ml
Lubricating oil,
11712016-604
IRB 6600ID/6650ID
Oil exchange
equipment
3HAC021745-001
Vessel capacity:
500 ml (IRB 6600/6650)
7,000 ml (IRB 6600ID/6650ID)
Standard toolkit
1. IRB 6600/6650:Run the robot to a position where Shown in the figure Location of
the oil plug, draining of axis 6 gearbox is facing
gearbox on page 197!
downwards and the oil plug, filling, is facing
upwards.
IRB 6600ID/6650ID: Run the robot to a position
where the oil plug, draining is facing downwards.
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3.
WARNING!
Handling gearbox oil involves several safety risks.
Before proceeding, please observe the safety
information in section WARNING - Safety risks
during work with gearbox oil on page 41.
4. Drain the oil from the gearbox into a vessel by
removing the oil plug.
3HAC023082-001 Revision: E
Action
3 Maintenance
3.4.7. Oil change, gearbox axis 6
Continued
Action
5. Refit the oil plug, draining.
Note
Tightening torque: 24 Nm.
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2.
WARNING!
5.
WARNING!
Do not mix the oil types! If wrong oil is refilled, the
gearbox must be rinsed as detailed in section
WARNING - Mixed oils may cause severe damage
to gearbox! on page 42!
6. Note! Dont mix Kyodo Yushi TMO 150 with other oil Detailed in section Oil in
types!
gearboxes on page 176.
7. Refit the oil plug.
3HAC023082-001 Revision: E
199
3 Maintenance
3.4.8. Replacement of SMB battery
Battery cable
Required equipment
Equipment, etc.
Note
Battery pack
3HAC 16831-1
Standard toolkit
Circuit Diagram
Removal, battery
The procedure below details how to remove the SMB battery.
Action
1. Move the robot to its calibration position.
Note
This is done in order to facilitate the
updating of the revolution counter.
3HAC023082-001 Revision: E
xx0200000238
3 Maintenance
3.4.8. Replacement of SMB battery
Continued
Action
Note
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3.
esd
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to ESD!
on page 40
4. Remove the SMB battery cover by unscrewing its Shown in the figure Location of SMB
attachment screws.
battery on page 200.
5. Pull out the battery and disconnect the battery
cable.
Refitting, battery
The procedure below details how to refit the SMB battery.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 40
201
3 Maintenance
3.4.8. Replacement of SMB battery
Continued
Action
Note
3. Reconnect the battery cable to the SMB battery Art. no. is specified in Required
pack and fit it to the frame.
equipment on page 200.
Shown in the figure Location of SMB
battery on page 200.
4. Secure the SMB battery cover with its
attachment screws.
6.
DANGER!
202
3HAC023082-001 Revision: E
3 Maintenance
3.5.1. Lubrication of spherical roller bearing, balancing device
xx0200000109
Sealing spacer
Required equipment
Equipment, etc.
Art. no.
Note
Grease
3HAA 1001-294
Lubrication nipple
M6.
Grease pump
203
3 Maintenance
3.5.1. Lubrication of spherical roller bearing, balancing device
Continued
Lubrication, balancing device bearing
The procedure below details how to lubricate the spherical roller bearing.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2. Replace the securing screw at the front ear
with a lubrication nipple.
M6
204
3HAC023082-001 Revision: E
3 Maintenance
3.5.2. Rust preventive, bearing axis 1 (Foundry Prime)
A
xx0600002866
Required equipment
Equipment
Art. no.
Note
3HAC026621-001
Equivalent:
Mercasol 3106
Brush
Rust preventive
Standard toolkit
205
3 Maintenance
3.5.2. Rust preventive, bearing axis 1 (Foundry Prime)
Continued
Procedure
The following procedure details how to grese the bearing axis 1.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Remove the plastic ring.
A
xx0600002866
A: plastic ring
A
xx0600002867
A: bearing
206
3HAC023082-001 Revision: E
3 Maintenance
3.5.3. Rust preventive, bearing axis 4 (Foundry Prime)
xx0500002869
Plastic cover
Plastic ring
Required equipment
Equipment
Art. no.
Note
3HAC026621-001
Equivalent:
Mercasol 3106
Brush
Rust preventive
Standard toolkit
Procedure
The following procedure details how to grease the bearing axis 1.
Action
Note/Illustration
207
3 Maintenance
3.5.3. Rust preventive, bearing axis 4 (Foundry Prime)
Continued
Action
Note/Illustration
2.
DANGER!
Turn off all electric power, hydraulic
and pneumatic pressure supplies to
the robot!
For Foundry Prime robots: Do not turn
off the air pressure to motors and
SMB.
3. Remove the plastic cover at the rear
end of the upper arm.
xx0600002872
A: plastic cover
B: plastic ring
xx0600002871
A: plastic ring
3HAC023082-001 Revision: E
3 Maintenance
3.5.3. Rust preventive, bearing axis 4 (Foundry Prime)
Continued
Action
Note/Illustration
xx0600002868
A: bearing axis 4
B plastic ring
3HAC023082-001 Revision: E
209
3 Maintenance
3.5.4. Rust preventive, support bearing in wrist (Foundry Prime)
xx0500002863
Bearing
Cable bracket
Cover
Required equipment
Equipment
Art. no.
Note
3HAC026621-001
Equivalent:
Mercasol 3106
Rust preventive
Standard toolkit
Greasing, bearings
The procedure below details how to grease the bearing in the wrist.
Action
Note/Illustration
3HAC023082-001 Revision: E
Brush
3 Maintenance
3.5.4. Rust preventive, support bearing in wrist (Foundry Prime)
Continued
Action
Note/Illustration
2.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3. Dismantle the air hose from motor axis 6.
4. Tighten the hose clamp on motor axis 6, and
remove the air hose.
5. Remove thew cover according to the illustration.
A
xx0600002864
A: cover
3HAC023082-001 Revision: E
211
3 Maintenance
3.6.1. Cleaning, robot
xx0200000239
Inside of base/axis 1
3HAC023082-001 Revision: E
3 Maintenance
3.6.1. Cleaning, robot
Continued
Required equipment
Equipment, etc.
Art. no.
Steam cleaner
Note
Always use cleaning equipment as specified above! Any other cleaning equipment
may shorten the life of paintwork, rust inhibitors, signs, or labels!
Always check that all protective covers are fitted to the robot before cleaning!
Never!
Never point the water jet at bearing seals, contacts, and other seals!
Never remove any covers or other protective devices before cleaning the robot!
Never use any cleaning agents, e.g. compressed air or solvents, other than those
specified above!
Never spray with a high pressure cleaner onto the sealing cup at the bottom of the
motor 6 spiral cable (item A in the figure Special points)!
Although the robot is watertight, avoid spraying connectors and similar items with a
high pressure cleaner!
Foundry versions
In working environments, e.g. foundries, where the robot may be exposed to fluids that dry
to make a crusty surface, e.g. release agents, clean the cable harnesses to prevent the crust
damaging the cables:
Clean the spiral wound cables to motor 6 (item A in the figure Special points on page
212) with water and a cloth!
3HAC023082-001 Revision: E
213
3 Maintenance
3.7.1. Using the SIS system
The section is only valid for M2000 systems. For information regarding M2004 robot
systems, see additional documentation, Operating manual - Service Information System:
Art. no. is specified in section References on page 10.
Basic procedure
Action
Reference
214
3HAC023082-001 Revision: E
1. Determine which of the system functions you These are described in Description of
require.
Service Information System (SIS) on
page 215.
3 Maintenance
3.7.2. Description of Service Information System (SIS)
Gearbox 1 operation time counter, based on percentage of the axis 1 gearbox service
interval
Gearbox 2 operation time counter, based on percentage of the axis 2 gearbox service
interval
Gearbox 3 operation time counter, based on percentage of the axis 3 gearbox service
interval
Gearbox 6 operation time counter, based on percentage of the axis 6 gearbox service
interval
Calendar time
This is a clock within the control system that keeps track of the service interval, based on
calendar time.
When the calendar time limit for maintenance is reached, a message is displayed on the TPU.
How to access this is detailed in section Reading the SIS output logs on page 221.
The following information is available about the calendar time in the service routine.
Prev service
Date when the counter was reset last time, i.e. after the last service.
Elapsed time
Elapsed time since the counter was reset the last time.
Next service
Remaining time
215
3 Maintenance
3.7.2. Description of Service Information System (SIS)
Continued
Operation time
This is a function within the control system that keeps track of the amount of time the
"MOTORS ON" signal is active, i.e. the amount of time the robot is in the operating mode.
When the operation time limit for maintenance is reached, a message is displayed on the TPU.
How to access this is detailed in section Reading the SIS output logs on page 221.
The following information is available about the operation time in the service routine.
Service interval
Elapsed time
Operation time since the service interval was set the last time.
Remaining time
Remaining operation time until the time set in service interval has
expired.
Gearbox
Based on measurements, torque and RPM, for example, the system calculates an expected
service interval for each gearbox. When service is due, a message will be shown on the TPU.
How to access this is detailed in section Reading the SIS output logs on page 221.
The following information is available about the joint service status in the service routine.
Joint x OK
Joint x NOK
The service interval for the axis in question has been reached.
Joint x N/A
Consumed time
Elapsed time
Remaining time
Remaining operation time for axis x until the service time parameter
value has been reached.
Reset values
Counters may be reset at any time by running the service routine.
When resetting, the counter variables are reset. The variables are described in section
Exporting the SIS data on page 222!
Service interval exceeded
When the service time has been exceeded for the selection made, an error message (Service
interval exceeded!) is displayed.
No data available
When no data is available for the selection made, a message (No data available!) is displayed
when trying to display the data.
216
3HAC023082-001 Revision: E
The following information is available for the axis service status in the service routine.
3 Maintenance
3.7.3. SIS system parameters
en0200000049
E.g. by setting the value "20,000", the SIS will save this as the nominal time for activating
the alarm, not counting the percentage described below.
Operation time warning
A percentage of the "Operation time limit" specified above.
E.g. by setting the value "90", the SIS will alert the operator 18,000 hours after an operation
time "Reset" was made the last time.
Calendar time limit (service level)
The number of calendar years selected as service interval.
E.g. by setting the value "2", the SIS will save this as the nominal time for activating the
alarm, not counting the percentage described below.
Calendar time warning
A percentage of the "Calendar time limit" specified above.
E.g. by setting the value "90", the SIS will alert the operator after 90% of two years, i.e. 657
days after a calendar time "Reset" was made the last time.
217
3 Maintenance
3.7.3. SIS system parameters
Continued
Gearbox warning
A percentage of the gearbox service interval as calculated by the system.
E.g. by setting the value "90", the SIS will alert the operator after 90% of the expected service
interval of each gearbox.
The robot system automatically detects and stores all required variables to calculate the
expected service interval of each gearbox. This is done by extrapolating data from earlier
operation into a function of time, using a formula including:
input and output torque
other variables
218
3HAC023082-001 Revision: E
3 Maintenance
3.7.4. Setting the SIS parameters
Note
xx0200000045
en0200000046
219
3 Maintenance
3.7.4. Setting the SIS parameters
Continued
Action
Note
en0200000047
xx0100000200
en0200000048
en0200000049
3HAC023082-001 Revision: E
3 Maintenance
3.7.5. Reading the SIS output logs
Available in:
SIS message in
the log:
Meaning:
Calendar time
Service Message
Service is due!
X calendar days
since last service.
Calendar time
Service Message
X calendar days to
next service.
Operation time
Service Message
Service is due!
X production hours
since last service.
Operation time
Service Message
X production hours
to next service.
Gearbox time
Service Message
Gearbox x requires
service!
Gearbox time
Service Message
X% of the service
interval has expired
for gearbox x!
X percent of gearbox hours remain until the automatically calculated gearbox time limit expires.
How to set the value determining when the
message is to be shown, is detailed in section
Setting the SIS parameters on page 219.
3HAC023082-001 Revision: E
221
3 Maintenance
3.7.6. Exporting the SIS data
222
Signal
Unit
Counter type
Function
sisRestartDate
sec
Calendar time
sisCalendarT
sec
Calendar time
sisTotRunT
sec
Operation time
sisRunT
sec
Operation time
sisL10h_1
hrs
Gearbox time
sisL10h_Time_1
sec
Gearbox time
sisL10h_2
hrs
Gearbox time
sisL10h_Time_2
sec
Gearbox time
sisL10h_3
hrs
Gearbox time
sisL10h_Time_3
sec
Gearbox time
sisL10h_6
hrs
Gearbox time
sisL10h_Time_6
hrs
Gearbox time
3HAC023082-001 Revision: E
The table below defines the names and functions of all software variables available for
communication between the SIS and an external computer.
4 Repair
4.1. Introduction
4 Repair
4.1. Introduction
Structure of this chapter
This chapter details all repair activities recommended for the robot and any external units of
the robot.
It is made up of separate procedures, each detailing a specific repair activity. Each procedure
contains all information required to perform the activity, e.g. spare parts numbers, required
special tools and materials.
The procedures are gathered in sections, divided according to the component location on the
robot.
Required equipment
All equipment required to perform a specific repair activity is listed together with the current
procedure.
The equipment is also gathered in different lists in the Product manual, reference information.
Safety information
Before any service work is commenced, it is extremely important that all safety information
is observed!
There are general safety aspects that must be read through, as well as more specific safety
information that describe danger and safety risks when performing specific steps in a
procedure. Make sure to read through the chapter Safety on page 17 before commencing any
service work.
3HAC023082-001 Revision: E
223
4 Repair
4.2.1. Performing a leak-down test
Art. no.
Leakdown tester
3HAC 0207-1
Note
Procedure
Action
Note
224
3HAC023082-001 Revision: E
4 Repair
4.2.2. Mounting instructions for bearings
Art. no.
Note
Grease
3HAB 3537-1
The bearings must not be completely filled with grease. However, if space is available
beside the bearing fitting, the bearing may be totally filled with grease when mounted,
as excessive grease will be pressed out from the bearing when the robot is started.
During operation, the bearing should be filled to 70-80% of the available volume.
Grooved ball bearings must be filled with grease from both sides.
Tapered roller bearings and axial needle bearings must be greased in the split
condition.
3HAC023082-001 Revision: E
225
4 Repair
4.2.3. Mounting instructions for seals
Art. no.
Note
Grease
3HAB 3537-1
Rotating seals
The procedure below details how to fit rotating seals.
CAUTION!
Please observe the following before commencing any assembly of seals:
Keep the seal in its original wrappings or protect it well before actual mounting.
The fitting of seals and gears must be carried out on clean workbenches.
Use a protective sleeve for the sealing lip during mounting, when sliding over threads,
keyways, etc.
Action
Note
3. Lubricate the seal with grease just before fitting. (Not too
Art. no. is specified in
early as there is a risk of dirt and foreign particles adhering Equipment on page 226.
to the seal.)
Fill the space between the dust tongue and sealing lip to 2/
3 with grease. The rubber coated external diameter must
also be greased, unless otherwise specified.
4. Mount the seal correctly with a mounting tool.
Never hammer directly on the seal as this may result in
leakage.
3HAC023082-001 Revision: E
4 Repair
4.2.3. Mounting instructions for seals
Continued
Action
2. Clean the surfaces properly and in accordance with ABB recommendations.
3. Distribute the sealing compound evenly over the surface, preferably with a brush.
4. Tighten the screws evenly when fastening the flange joint.
O-rings
The procedure below details how to fit o-rings.
Action
Note
3HAC023082-001 Revision: E
227
4 Repair
4.3.1. Replacement of cable harness, axes 1-6
The cable harness of axes 1-6 is run throughout the robot as shown in the figure below.
xx0500002176
Velcro straps
3HAC023082-001 Revision: E
4 Repair
4.3.1. Replacement of cable harness, axes 1-6
Continued
Required equipment
Equipment
3HAC 024385-001
3HAC 024386-001
Note
Brush
Rust preventive
3HAC026621-001
Equivalent:
Mercasol 3106
Gasket
3HAC3537-1
Gasket
3HAC12877-1
motor axis 6
Standard toolkit
Circuit diagram
xx0500002293
Note/Illustration
Axes 2 and 3 may be tilted slightly to
improve access.
229
4 Repair
4.3.1. Replacement of cable harness, axes 1-6
Continued
Action
Note/Illustration
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
3. Remove the cover, wrist unit and the cover,
upper arm tube.
xx0200000214
NOTE!
Axis 5 must be oriented in the correct position
(+90) to allow the motor 6 cover to open!
5. Remove the cover of motor, axis 6 and
disconnect all connectors beneath.
Shown in the figure Cable brackets of
the upper arm on page 229.
xx0200000254
3HAC023082-001 Revision: E
4 Repair
4.3.1. Replacement of cable harness, axes 1-6
Continued
Action
Note/Illustration
Note/Illustration
1. Remove the rear cover plate from the robot by Shown in the figure Location of cable
removing its attachment screws.
harness on page 228.
2. Disconnect the earth cable beneath.
3. Disconnect connectors R1.MP and R1.SMB.
xx0200000118
231
4 Repair
4.3.1. Replacement of cable harness, axes 1-6
Continued
Action
Note/Illustration
xx0300000560
A. Cable gland
B. Attachment screws, cable
gland
C. Attachment plate
D. Velcro strap
9. Remove the cable gland securing the cables
inside the lower arm.
3HAC023082-001 Revision: E
8. Remove
the cable gland (A), by removing the
four attachment screws from inside the
SMB recess (B)
the attachment plate (C), by removing
the attachment screws and the velcro
strap (D).
Note! Different robot versions are fitted with
different versions of the attachment plate.
When replacing the cable harness, make sure
the correct one is used to avoid cable failure.
4 Repair
4.3.1. Replacement of cable harness, axes 1-6
Continued
Action
Note/Illustration
xx0100000143
Action
1.
Note
See Required equipment on page 229.
NOTE!
On Foundry Prime robots:
Apply rust preventive around all dismantled
covers and attachment screws with a brush.
2. Pull the cable and connectors down through
the cable guide in the center of the frame.
3. Reconnect connectors R1.MP and R1.SMB at Shown in the figure Location of cable
the base.
harness on page 228.
Make a note of the correct positions of
the connectors!
4. Reconnect the earth cable.
5. Refit the rear cover plate to the robot with its
attachment screws.
233
4 Repair
4.3.1. Replacement of cable harness, axes 1-6
Continued
Action
Note
NOTE!
3HAC023082-001 Revision: E
4 Repair
4.3.1. Replacement of cable harness, axes 1-6
Continued
Action
Note
xx0300000560
A.
B.
C.
D.
Cable gland
Attachment screws, cable gland
Attachment plate
Velcro strap
235
4 Repair
4.3.1. Replacement of cable harness, axes 1-6
Continued
Action
Note
xx0200000118
WARNING!
Before continuing any service work, please
observe the safety information in section
WARNING - The brake release buttons may
be jammed after service work on page 39!
12. Pull the cable harness through the lower arm.
xx0100000142
3HAC023082-001 Revision: E
4 Repair
4.3.1. Replacement of cable harness, axes 1-6
Continued
Action
Note
xx0100000143
18. Connect the two connectors inside the upper Shown in the figure Cable brackets of
arm tube, R3.FB5 and R3.MP5 and secure the the upper arm on page 229.
cable bracket with the two attachment screws
to the tube.
19. Place the cabling to motor, axis 6, correctly on
the upper arm and gently pull the connectors
through the hole on top of wrist unit to motor,
axis 6.
xx0200000185
237
4 Repair
4.3.1. Replacement of cable harness, axes 1-6
Continued
Action
Note
xx0200000254
xx0200000214
3HAC023082-001 Revision: E
4 Repair
4.3.1. Replacement of cable harness, axes 1-6
Continued
Action
Note
xx0500002320
26. If the connection between the SMB battery and Detailed in section Updating revolution
the SMB unit has been broken, the revolution counters on page 415.
counters must now be updated!
27.
DANGER!
Copyright 2004-2008 ABB. All rights reserved.
3HAC023082-001 Revision: E
239
4 Repair
4.3.2. Replacement of cable harness, axes 1-4
The cable harness for axes 1-4 is run throughout the base, frame and lower arm as shown in
the figure below.
xx0300000561
Connector R1.MP
Connector R1.SMB
3HAC023082-001 Revision: E
4 Repair
4.3.2. Replacement of cable harness, axes 1-4
Continued
F
SMB recess
Connectors at motor 3: R2.FB3 and R2.MP3 (optional signal lamp: R2.H1 and
R2.H2)
Required equipment
Equipment, etc.
Note
3HAC 025503001
3HAC 025504001
Locking liquid
Standard toolkit
Loctite 638
Used to secure the
attachment screws for the
attachment plate inside the
frame.
3HAC 15571-1
Circuit Diagram
241
4 Repair
4.3.2. Replacement of cable harness, axes 1-4
Continued
Removal, cable harness, axes 1-4
The procedure below details how to remove the cable harness, axes 1-4.
Action
Note/Illustration
1. In order to facilitate refitting of cable harness, run the Axes 2 and 3 may be tilted
robot to the specified position:
slightly to improve access.
Axis 1: 0
Axis 2: 0
Axis 3: 0
Axis 4: 0
Axis 5: +90
Axis 6: no significance
2.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3. Remove the rear cover plate from the robot by
removing its attachment screws.
3HAC023082-001 Revision: E
4 Repair
4.3.2. Replacement of cable harness, axes 1-4
Continued
Action
Note/Illustration
xx0200000118.wmf
10. Remove
the cable gland (A), by removing the four
attachment screws from inside the SMB
recess (B)
the attachment plate (C), by removing the
attachment screws and the velcro strap (D).
Note! Different robot versions are fitted with different
versions of the attachment plate. When replacing the
cable harness, make sure the correct one is used to
avoid cable failure.
xx0300000560
A: Cable gland
B: Attachment screws,
cable gland
C: Attachment plate
D: Velcro strap
243
4 Repair
4.3.2. Replacement of cable harness, axes 1-4
Continued
Action
Note/Illustration
xx0100000143.wmf
14. Disconnect connector R2.M5/6 at the cable division Shown in the figure Location of
point.
cable harness on page 240!
15. Disconnect all connectors at motor 3 and motor 4.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. In order to facilitate refitting of cable harness,
move the robot to the specified position:
Axis 1: 0 degrees
Axis 2: 0 degrees
Axis 3: 0 degrees
Axis 4: 0 degrees
Axis 5: +90 degrees
Axis 6: no significance
3HAC023082-001 Revision: E
The procedure below details how to refit the cable harness, axes 1-4.
4 Repair
4.3.2. Replacement of cable harness, axes 1-4
Continued
Action
3. Pull the cable and connectors down through the
cable guide in the center of the frame.
Note/Illustration
Make sure the cables are not
twisted with each other or with
eventual customer harnesses!
Make a note of the correct positions
of the connectors!
4. Reconnect connectors R1.MP and R1.SMB at the Make a note of the correct positions
rear cover plate.
of the connectors!
Attachment point is shown in the
figure Location of cable harness on
page 240.
5. Reconnect the earth cable.
7. Reconnect all connectors at motor 1 and motor 2. Specified and shown in the figure
Location of cable harness on page
240!
245
4 Repair
4.3.2. Replacement of cable harness, axes 1-4
Continued
Action
Note/Illustration
xx0300000560
A: Cable gland
B: Attachment screws, cable
gland
C: Attachment plate
D: Velcro strap
3HAC023082-001 Revision: E
8. Secure the cable gland (A) with four attachment Locking liquid is specified in
screws (B) from inside the SMB recess.
Required equipment on page 241.
Secure the correct attachment plate (C) to the
cable gland with its two attachment screws, using
locking liquid.
Refit the velcro strap (D).
Note! Different robot versions are fitted with
different versions of the attachment plate. Make
sure the correct one is used to avoid cable failure.
4 Repair
4.3.2. Replacement of cable harness, axes 1-4
Continued
Action
Note/Illustration
11.
WARNING!
Before continuing any service work, please
observe the safety information in section
WARNING - The brake release buttons may be
jammed after service work on page 39!
12. Pull the cable harness through the lower arm.
13. Refit the cable gland securing the cables inside
the lower arm.
xx0100000142
xx0100000143
15. Reconnect all connectors at motor 3 and motor 4. Specified and shown in the figure
Location of cable harness on page
240!
16. Reconnect the connector R2.M5/6 gently at the
Shown in the figure Location of
cable division point.
cable harness on page 240!
Be careful not to bend the attachment plate when M6, 2 pcs.
fastening the screws!
17. Secure the cable harness to the upper arm house Shown in the figure Location of
by refitting the velcro strap to the cable bracket at cable harness on page 240!
the upper arm house.
247
4 Repair
4.3.2. Replacement of cable harness, axes 1-4
Continued
Action
18. Fit a cable protection to the lower arm, if not
already mounted, with two securing screws (A),
M6x16.
Secure the cable harness with two velcro straps
(B), with a distance of approximately 180 mm. Fix
the strap by wrapping it two turns around the
largest cable before wrapping around the
complete harness.
Note/Illustration
Both the protection and the strap
are included in the spare part no.,
specified in Required equipment on
page 241.
xx0500002320
20.
DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 38.
248
3HAC023082-001 Revision: E
4 Repair
4.3.3. Replacement of cable harness, axes 5-6
xx0200000213
Required equipment
Equipment, etc.
3HAC 14140-1
Standard toolkit
Note
The contents are defined in section
Standard toolkit on page 436 in part 2
of the Product manual.
249
4 Repair
4.3.3. Replacement of cable harness, axes 5-6
Continued
Equipment, etc.
Note
Circuit Diagram
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
xx0200000214
3.
NOTE!
Axis 5 must be oriented in the correct position
(+90) to allow the motor 6 cover to open!
4. Remove the cover of motor, axis 6 and
disconnect all connectors beneath.
3HAC023082-001 Revision: E
4 Repair
4.3.3. Replacement of cable harness, axes 5-6
Continued
Action
5. Loosen the cable bracket on top of the wrist
unit by undoing the three attachment screws.
Two of the attachment screws are visibly
located at the rear attachment and the third is
located at the bottom of the cable bracket, in
the center.
Note/Illustration
Shown in the figure Location of cable
harness ax 5-6 on page 249!
xx0200000254
Note/Illustration
251
4 Repair
4.3.3. Replacement of cable harness, axes 5-6
Continued
Action
Note/Illustration
xx0200000185
5. Fasten the cable bracket, wrist unit with three Also shown in the figure Location of
attachment screws, two of them visible at the cable harness ax 5-6 on page 249!
rear attachment point and the third located on
the bottom of the cable bracket, in the center.
xx0200000254
xx0200000214
252
3HAC023082-001 Revision: E
4 Repair
4.3.4. Replacement of cable harness, axes 5-6, IRB 6600ID and IRB 6650ID
4.3.4. Replacement of cable harness, axes 5-6, IRB 6600ID and IRB 6650ID
Location of cable harness, axes 5-6
The cable harness of axes 5-6 is run inside the upper arm, as shown in the figure below.
xx0500001896
Required equipment
Equipment
3HAC 024815-001
Cable grease
Art. no.
Note
253
4 Repair
4.3.4. Replacement of cable harness, axes 5-6, IRB 6600ID and IRB 6650ID
Continued
Equipment
Art. no.
Note
Standard toolkit
Note/Illustration
Shown in section Calibration scales and
correct axis position on page 412.
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off
the air pressure to motors and SMB.
3. Remove the process cabling from the
upper arm, if any.
4. Remove the cover from the upper arm tube Shown in the figure Location of cable
and the hood from the upper arm housing. harness, axes 5-6 on page 253.
5. Disconnect all the connectors at the axis 5 The connectors are specified and shown
and 6 motors, and the connector at the
in the figure Location of cable harness,
cable harness division point.
axes 5-6 on page 253.
Copyright 2004-2008 ABB. All rights reserved.
xx0500001903
3HAC023082-001 Revision: E
4 Repair
4.3.4. Replacement of cable harness, axes 5-6, IRB 6600ID and IRB 6650ID
Continued
Action
Note/Illustration
xx0500001905
xx0500001904
10. Pull out the cabling from the wrist unit and
the upper arm tube. Be careful not to
damage the connectors!
255
4 Repair
4.3.4. Replacement of cable harness, axes 5-6, IRB 6600ID and IRB 6650ID
Continued
Cable layout, wrist unit
The figure below shows how to run and attach the cabling inside the wrist unit.
xx0500002014
Location inside the wrist unit where to strap the cabling, next to the axis 5 motor.
Note/Illustration
1.
3HAC023082-001 Revision: E
DANGER!
4 Repair
4.3.4. Replacement of cable harness, axes 5-6, IRB 6600ID and IRB 6650ID
Continued
Action
Note/Illustration
xx0500001904
5. Place the cabling inside the wrist unit according Shown in the figure Location of cable
to the cable layout shown in the figure Cable
harness, axes 5-6 on page 253.
layout, wrist unit on page 256 and fasten it with
velcro straps.
Reconnect the connectors to the axis 5 and 6
motors.
xx0500001909
257
4 Repair
4.3.4. Replacement of cable harness, axes 5-6, IRB 6600ID and IRB 6650ID
Continued
Action
Note/Illustration
11.
DANGER!
258
3HAC023082-001 Revision: E
4 Repair
4.3.5. Replacement of cabling, axis 5 motor
xx0500002294
Required equipment
Equipment
3HAC 14139-1
Note
Standard toolkit
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2. Remove the complete wrist unit.
Detailed in section:
IRB 6600/6650:Removal, wrist
unit on page 278.
IRB 6600ID/6650ID: Removal,
wrist unit on page 283.
259
4 Repair
4.3.5. Replacement of cabling, axis 5 motor
Continued
Action
Note
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2. Reconnect all connectors at motor, axis 5.
3. Refit the cable gland cover at the cable exit
with its two attachment screws.
5. Refit the complete wrist unit.
Detailed in section:
IRB 6600/6650:Refitting, wrist
unit on page 279.
IRB 6600ID/6650ID: Refitting,
wrist unit on page 284.
7.
DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First
test run may cause injury or damage! on page
38.
260
3HAC023082-001 Revision: E
4 Repair
4.3.6. Replacement of complete arm system
xx0200000224
Upper arm
Lower arm
Frame
Gearbox, axis 1
Balancing device
Motor axis 1
261
4 Repair
4.3.6. Replacement of complete arm system
Continued
Required equipment
Equipment, etc.
Art. no.
Note
3HAC15607-1
3HAC022637-001
Hoisting block
Standard toolkit
Note/Illustration
1. Make sure the robot is positioned as shown Release the brakes if necessary, as
in figure to the right. If it is not, position it
detailed in section Manually releasing the
that way.
brakes on page 71.
xx0100000103
3HAC023082-001 Revision: E
4 Repair
4.3.6. Replacement of complete arm system
Continued
Action
Note/Illustration
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off
the air pressure to motors and SMB.
3. Drain the oil from gearbox axis 1.
9. Unfasten the arm system from the base by Shown in the figure Location of arm system
unscrewing its 24attachment screws.
on page 261!
10. Fit the two guide pins in two opposite screw
holes.
11.
CAUTION!
The complete arm system weighs 1250 kg!
All lifting equipment used must be sized
accordingly!
12. Lift the arm system carefully and secure it
in a safe area.
Always move the robot at very low speeds,
making sure it does not tip.
Continue lifting even if the arm system turns
out to be unbalanced despite earlier adjustments! The risk of damaging the interfaces
is bigger if the load is lowered unbalanced!
263
4 Repair
4.3.6. Replacement of complete arm system
Continued
Refitting, arm system
The procedure below details how to lift and refit the complete arm system.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2. Fit the lifting device as detailed in enclosed Art. no. is specified in Required
instruction.
equipment on page 262!
Also fit a hoisting block to the frontchain,
used to adjust the balance of the arm system
in order to lift it completely level!
3.
CAUTION!
The complete arm system weighs 1250 kg!
All lifting equipment used must be sized
accordingly!
xx0300000070
3HAC023082-001 Revision: E
4. Lift the complete arm system and move it at Make sure all the hooks and attachments
very low speed, making sure it does not tip! stay in the correct position while lifting the
Make sure the lift is done completely level. robot!
Adjust the length of the chains as detailed in
enclosed instruction or with a hoisting block!
4 Repair
4.3.6. Replacement of complete arm system
Continued
Action
Note/Illustration
xx0600003093
8. Remove the guide pins and secure the arm Shown in the figure Location of arm
system to the base with its 24attachment
system on page 261!
screws and washers.
M12 x 70, tightening torque: 115 Nm.
Reused screws may be used, providing
they are lubricated as detailed in section
Screw joints on page 432 before fitting.
9. Refit the block for calibrationat the bottom of Shown in the figure Location of arm
the frame.
system on page 261!
10. Refit the motor axis 1.
265
4 Repair
4.3.6. Replacement of complete arm system
Continued
Action
Note/Illustration
15.
DANGER!
266
3HAC023082-001 Revision: E
4 Repair
4.3.7. Replacement of air nipple and hose (Foundry Prime)
xx0500002176
267
4 Repair
4.3.7. Replacement of air nipple and hose (Foundry Prime)
Continued
Hose lenghts
Pos
Length in mm.
1A
40
1B
40
1C
1520
1D
1090
1E
310
1F
35
1G
250
1H
540
1K
4020
1L
195
1M
40
1N
40
1P
1605
1Q
1R
1S
570
Required equipment
Equipment
Art. no.
Pos. in illustration
Elbow fitting
100
Rubber clamp
3HAC026523-001
T-plugg connector
3HAC026515-001
Y-plugg connector
3HAC026514-001
3HAC026513-001
Hose
3HAC026526-001
Cable strap
21662055-3
3HAC023082-001 Revision: E
xx0600003027
4 Repair
4.3.7. Replacement of air nipple and hose (Foundry Prime)
Continued
Procedure
The following procedures details how to replace the Foundry Prime air nipples and hose. The
pos. no. in following procedures correspond to the illustration in Hose lenghts on page 268
and the table in Required equipment on page 268
Action
Note/Illustration
<<
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot.
Localise the damaged hose or air
connector, and Continue to replace the
damaged hose route the hose according to
the following illustrations
Connection at base.
xx0600003042
Axis 1
xx0600003043
269
4 Repair
4.3.7. Replacement of air nipple and hose (Foundry Prime)
Continued
Action
Note/Illustration
Balancing device
xx0600003397
3HAC023082-001 Revision: E
4 Repair
4.3.7. Replacement of air nipple and hose (Foundry Prime)
Continued
Action
Note/Illustration
Axis 1-2
xx0600003044
xx0600003162
xx0600003045
271
4 Repair
4.3.7. Replacement of air nipple and hose (Foundry Prime)
Continued
Action
Note/Illustration
xx0600003046
xx0600003047
xx0600003163
3HAC023082-001 Revision: E
Tube shaft
4 Repair
4.3.7. Replacement of air nipple and hose (Foundry Prime)
Continued
Action
Note/Illustration
Wrist
xx0600003097
3HAC023082-001 Revision: E
273
4 Repair
4.4.1. Replacement of turning disk, IRB 6600 and IRB 6650
xx0200000217
Turning disk
Wrist unit
Equipment, etc.
Note
3HAC 13752-1
O-ring
3HAB 3772-64
(1 pc)
3HAB 3772-61
(12 pcs)
Grease
3HAB 3537-1
Standard toolkit
3HAC023082-001 Revision: E
Required equipment
4 Repair
4.4.1. Replacement of turning disk, IRB 6600 and IRB 6650
Continued
Removal, turning disk
The procedure below details how to remove the turning disk.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Remove any equipment fitted to the turning disk.
3. Run the robot to a position where the oil plug, draining Shown in the figure Location of
of axis 6 gearbox faces downwards.
turning disk on page 274!
4. Drain the oil from gearbox 6.
Note/Illustration
xx0200000218
275
4 Repair
4.4.1. Replacement of turning disk, IRB 6600 and IRB 6650
Continued
Action
2. Secure the turning disk with its attachment
screws.
Note/Illustration
12 pcs, M12 x 30, 12.9 quality
UNBRAKO, tightening torque: 100 Nm.
Reused screws may be used, providing
they are lubricated as detailed in
section Screw joints on page 432
before fitting.
3. Perform a leak-down test of the gearbox axis 6. Detailed in section Performing a leakdown test on page 224.
4. Refill the gearbox 6 with oil.
DANGER!
276
3HAC023082-001 Revision: E
4 Repair
4.4.2. Replacement of complete wrist unit, IRB 6600 and IRB 6650
4.4.2. Replacement of complete wrist unit, IRB 6600 and IRB 6650
Wrist unit for robot models IRB 6600 and IRB 6650
This section is valid for robot models IRB 6600 and IRB 6650. How to replace the wrist of
the models IRB 6600ID and IRB 6650ID is detailed in section Replacement of complete wrist
unit, IRB 6600ID and IRB 6650ID on page 282.
Location of wrist unit
The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.
xx0200000184
Wrist unit
Turning disk
Cable bracket
277
4 Repair
4.4.2. Replacement of complete wrist unit, IRB 6600 and IRB 6650
Continued
Required equipment
Equipment etc.
Wrist, type 2
3HAC 16626-2
3HAC 16626-3
Note
3HAC13056-3
3HAC 13605-1
Standard toolkit
Circuit diagram
Note/Illustration
1.
3HAC023082-001 Revision: E
DANGER!
4 Repair
4.4.2. Replacement of complete wrist unit, IRB 6600 and IRB 6650
Continued
Action
Note/Illustration
12.
CAUTION!
The complete wrist unit weighs 130 kg!All lifting
equipment used must be sized accordingly!
13. Slightly raise the wrist unit to unload the screw
joint, facilitating removing the attachment screws.
15. Pull the wrist unit out, lift it away and place it on a
secure surface.
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2. Fit two guide pins, M12 in the upper arm tube, Art. no. is specified in Required
in two of the holes for the wrist unit attachment equipment on page 278!
screws.
Shown in the figure Location of wrist
unit on page 277!
279
4 Repair
4.4.2. Replacement of complete wrist unit, IRB 6600 and IRB 6650
Continued
Action
3. Fit the lifting tool to the wrist unit.
Note/Illustration
Art. no. is specified Location of wrist
unit on page 277!
4.
CAUTION!
The complete wrist unit weighs 130 kg!All
lifting equipment used must be sized accordingly!
5. Lift the wrist unit and guide it to the upper arm
tube with help of the guide pins.
Make sure the cabling from motor, axis 5 is
safely run into the arm tube and does not get
jammed.
6. Secure the wrist unit with 10 of the 12
attachment screws and washers.
10.
NOTE!
Axis 5 must be oriented in the correct position
(+90) to allow the motor 6 cover to open!
11. Place the cabling to motor, axis 6, correctly on
the upper arm and gently pull the connectors
through the hole on top of wrist unit to motor,
axis 6.
xx0200000185
3HAC023082-001 Revision: E
4 Repair
4.4.2. Replacement of complete wrist unit, IRB 6600 and IRB 6650
Continued
Action
Note/Illustration
xx0200000254
DANGER!
3HAC023082-001 Revision: E
281
4 Repair
4.4.3. Replacement of complete wrist unit, IRB 6600ID and IRB 6650ID
4.4.3. Replacement of complete wrist unit, IRB 6600ID and IRB 6650ID
Wrist unit for robot models IRB 6600ID and IRB 6650ID
This section is only valid for robot models IRB 6600ID and IRB 6650ID. How to replace the
wrist unit on the models IRB 6600 and IRB 6650 is detailed in section Replacement of
complete wrist unit, IRB 6600 and IRB 6650 on page 277.
Location of wrist unit
The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views on page 477 in part 2 of the Product manual.
xx0500001567
Wrist unit
Equipment
Art. no.
Note
Wrist, process
Guide pins M12 x 200
3HAC 024793-001
3HAC13056-3
Lifting slings
Standard toolkit
3HAC023082-001 Revision: E
Required equipment
4 Repair
4.4.3. Replacement of complete wrist unit, IRB 6600ID and IRB 6650ID
Continued
Equipment
Art. no.
Note
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Remove all equipment fitted to the turning disk.
3. Remove the integrated spotpack cabling.
CAUTION!
283
4 Repair
4.4.3. Replacement of complete wrist unit, IRB 6600ID and IRB 6650ID
Continued
Refitting, wrist unit
The procedure below details how to refit the complete wrist unit to the robot.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Fit the two guide pins in the upper arm tube, in two of Art. no. is specified in Required
the attachment holes for the wrist unit.
equipment on page 282.
3.
CAUTION!
The complete wrist unit weighs 187 kg! All lifting
equipment used must be sized accordingly!
4. Attach the lifting slings to the wrist unit and lift it to the
upper arm tube.
5. Insert the cabling and connectors through the wrist
unit and match the wrist against the upper arm tube
with guidance from the guide pins.
Shown in the figure Location of
wrist unit on page 282.
12 pcs; M12 x 50, 12.9 quality
UNBRAKO. Tightening torque:
115 Nm.
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints
on page 432 before fitting.
Calibration is detailed in a
separate calibration manual,
enclosed with the calibration
tools.
General calibration information
is included in section Calibration
information on page 409.
3HAC023082-001 Revision: E
4 Repair
4.4.3. Replacement of complete wrist unit, IRB 6600ID and IRB 6650ID
Continued
Action
Note
11.
DANGER!
3HAC023082-001 Revision: E
285
4 Repair
4.4.4. Replacement of upper arm
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.
3HAC023082-001 Revision: E
4 Repair
4.4.4. Replacement of upper arm
Continued
xx0200000163
Attachment hole for lifting eye, M12 (if wrist unit is mounted)
Attachment for lifting device, upper arm (2 pcs if there is no wrist unit mounted)
Motor, axis 3
Motor, axis 4
Required equipment
Equipment
Art. no.
Note
3HAC 12443-2
3HAC 12703-1
To be replaced if damaged.
3HAC 14628-1
3HAC 14628-2
Power supply
Rotation tool
3HAC 17105-1
3HAC16131-1
3HAC15994-1
3HAC15556-1
Standard toolkit
3HAC 15571-1
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
287
4 Repair
4.4.4. Replacement of upper arm
Continued
Action
Note
6. Fasten the lifting tool (chain) onto the lifting eye, the Art. no. is specified in Required
lifting device and an overhead crane.
equipment on page 287!
7. Drain the oil from gearbox axis 3.
3HAC023082-001 Revision: E
CAUTION!
4 Repair
4.4.4. Replacement of upper arm
Continued
Action
Note
16. Remove the sealing, axis 2/3 from the lower arm.
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
xx0200000166
289
4 Repair
4.4.4. Replacement of upper arm
Continued
Action
4. Upper arm including wrist unit:
Fit one of the pieces included in the lifting
device, upper arm to the front attachment for
the lifting device on the upper arm.
Upper arm without wrist unit:
Fit the lifting device, upper arm to the both
attachments for the lifting device on the upper
arm.
Note/Illustration
Art. no. is specified in Required
equipment on page 287!
Attachment points are shown in the
figure Location of upper arm on page
286!
Notice the different attachment points
depending on whether the wrist unit is
mounted or not!
5. In order to release the brake of the axis 3 motor, Connect to connector R2.MP3
connect the 24 VDC power supply, after
+: pin 2
removing the motor cover.
-: pin 5
6. Fasten the lifting tool (chain) onto the lifting eye, Art. no. is specified in Required
the lifting device and an overhead crane.
equipment on page 287!
7.
CAUTION!
The complete upper arm weighs 380 kg
(IRB6600, IRB 6650) without any additional
equipment fitted! (robot model IRB 66X0ID: 437
kg!) Use a suitable lifting device to avoid injury
to personnel!
8. Lift the upper arm and move to its mounting
position.
Make sure the lift is done completely level!
xx0200000165
3HAC023082-001 Revision: E
4 Repair
4.4.4. Replacement of upper arm
Continued
Action
Note/Illustration
22.
DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First test
run may cause injury or damage! on page 38.
3HAC023082-001 Revision: E
291
4 Repair
4.4.5. Replacement of complete lower arm
Lower arm
The figure (1) shows a cut between the lower arm and the gearbox axis 3. The location
of the sealing axis 2/3 is identical between the lower arm and the axis 2.
The figure (2) shows a cut through the lower arm pivot point in axis 2 (item B in the
figure above!).
3HAC023082-001 Revision: E
xx0200000255
4 Repair
4.4.5. Replacement of complete lower arm
Continued
xx0200000031
Gearbox
Lower arm
Frame
Shaft hole
201
202
Attachment screw
204
Washer
401
Bearing
402
Thrust washer
403
Bushing
404
Retaining ring
405
406
Protection plug
409
Protection washer
Required equipment
Equipment, etc.
Art. no.
Note
Bearing
3HAC 12441-2
3HAC 020123-001
3HAC 020997-1
293
4 Repair
4.4.5. Replacement of complete lower arm
Continued
Equipment, etc.
Art. no.
Note
3HAC14691-1
Rotation tool
3HAC 17105-1
3HAC13086-1
3HAC021563-012
3HAC021563-001
3HAC021600-001
3HAC13527-1
Grease
3HAB 3537-1
Isopropanol
1177 1012-208
Standard toolkit
The procedure below details how to remove the complete lower arm.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Remove the upper arm.
3HAC023082-001 Revision: E
4 Repair
4.4.5. Replacement of complete lower arm
Continued
Action
4. Apply the shackle to the balancing device and
raise to unload the weight of the device.
Note/Illustration
Art. no. is specified in Required
equipment on page 293.
Attachment is shown in the figure
Location of lower arm on page 292.
5. Unload the balancing device in order to make the Detailed in sectionUnloading the
piston rod and front ear adjustable when pulling balancing device on page 331.
the front shaft out.
6. Remove the securing screw from the balancing
device front shaft.
xx0300000056
xx0300000015
12.
CAUTION!
The lower arm weighs 160 kg! All lifting
equipment used must be sized accordingly!
13. Raise the tool to unload the lower arm.
14. Remove the lower arm shaft and all additional
components, as detailed in section Removal,
lower arm shaft on page 301!
295
4 Repair
4.4.5. Replacement of complete lower arm
Continued
Action
Note/Illustration
15. Remove the attachment screws and washers that Shown in the figure Internal
attach the lower arm to the gearbox axis 2.
components, lower arm on page 292!
16. Lift the lower arm and place it on a secure
surface.
17. Remove the bearing and thrust washer from the Shown in the figure Internal
shaft hole in the lower arm.
components, lower arm on page 292!
On reassembly a new bearing must
be used!
18. Remove the sealing, axis 2/3 from the lower arm. Shown in the figure Internal
components, lower arm on page 292!
On reassembly new sealings must
be used!
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
xx0300000548
3HAC023082-001 Revision: E
2. Fit two guidings in the attachment holes of the Art. no. is specified in Required
lower arm.
equipment on page 293!
4 Repair
4.4.5. Replacement of complete lower arm
Continued
Action
Note/Illustration
5.
CAUTION!
The lower arm weighs 160 kg! All lifting
equipment used must be sized accordingly!
6. Lift the lower arm and move it to its mounting
position.
7. In case the hole pattern of the lower arm and
Connect power supply to connector
the gearbox axis 2 does not match, use power R2.MP2
supply to release the motor axis 2 brakes and
+: pin 2
rotate the pinion and gear with the rotational
-: pin 5
tool.
xx0200000165
297
4 Repair
4.4.5. Replacement of complete lower arm
Continued
Action
Note/Illustration
19.
DANGER!
298
3HAC023082-001 Revision: E
4 Repair
4.4.6. Replacement of lower arm shaft
unloading the balancing device and removing the front eye shaft
The figure below shows the components fitted to the lower arm shaft.
xx0300000487
Protection plug
Thrust washer
Bearing
Protection washer
Retaining ring
299
4 Repair
4.4.6. Replacement of lower arm shaft
Continued
Required equipment
Equipment
Art. no.
Note
Bearing
3HAC 12441-2
3HAC021563-001
3HAC021600-001
3HAC13086-1
3HAC021563-012
3HAC13527-1
Isopropanol
1177 1012-208
Grease
3HAB 3537-1
Glycerin
Rust preventive
3HAC026621-001
Equivalent:
Mercasol 3106
The illustration below shows the puller tool used to remove the lower arm shaft (axis 2 shaft).
xx0400001029
3HAC023082-001 Revision: E
4 Repair
4.4.6. Replacement of lower arm shaft
Continued
Press device for refitting of axis 2 shaft
The illustration below shows the press tool used to refit the lower arm shaft (axis 2 shaft).
xx0300000485
Indicator
The procedure below details how to remove the lower arm shaft.
If encountering any problems when removing the shaft, contact ABB Robotics!
Action
Note/Illustration
1.
WARNING!
This procedure is a step in the complete procedure
of removing the lower arm! Make sure all the
preceding steps specified in Prerequisites on page
299 are made before removing the lower arm shaft!
2. Remove the protection plug.
301
4 Repair
4.4.6. Replacement of lower arm shaft
Continued
Action
4. Fit the puller device to the shaft as shown in the
figure to the right.
Note/Illustration
Art. no. is specified in Required
equipment on page 300!
xx0300000010
3HAC023082-001 Revision: E
5. Fit both the hydraulic pump and the glycerin pump to Art. no. is specified in Required
the puller device.
equipment on page 300.
The attachments on the tool are
shown in figure Puller device for
removal of axis 2 shaft on page
300.
4 Repair
4.4.6. Replacement of lower arm shaft
Continued
Refitting, lower arm shaft
The procedure below details how to refit the lower arm shaft.
Action
1. Clean the shaft with isopropanol and lubricate it
with glycerin.
Note/Illustration
Art. no. is specified in Required
equipment on page 300!
A
A
xx0600003137
A: Mercasol on marked
areas.
7. Fit both the hydraulic pump and the glycerin pump Art. no. is specified in Required
to the press device.
equipment on page 300.
The attachments on the tool are
shown in the figure Press device for
refitting of axis 2 shaft on page 301.
8. Set the indicator on the press device to zero.
303
4 Repair
4.4.6. Replacement of lower arm shaft
Continued
Action
Note/Illustration
13. Apply grease to the location of the shaft where the Art. no. is specified in Required
bearing is to be mounted.
equipment on page 300
14. Press in the new bearing with the press tool, axis 2 Always use a new bearing when
bearing.
reassembling!
Art. no. is specified in Required
equipment on page 300.
15. Refit the protection washer and the retaining ring. Shown in the figure Components,
lower arm shaft on page 299.
16. Refit the protection plug.
304
3HAC023082-001 Revision: E
4 Repair
4.4.7. Securing the lower arm
The special equipment used to secure the lower arm is fitted to the attachment points shown
in the figure below.
xx0400000708
305
4 Repair
4.4.7. Securing the lower arm
Continued
Required equipment
Equipment, etc
Art. no.
Note
3HAC020729-001
Standard toolkit
3HAC 15571-1
Locking screw
Adjusters, 2 pcs
Placeholder
3HAC023082-001 Revision: E
4 Repair
4.4.7. Securing the lower arm
Continued
Securing the lower arm
The procedure below details how to secure the lower arm by fitting the fixture to the robot.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Remove any load or equipment fitted to the upper
arm or turning disk.
3. Move the robot to the calibration position. The upper
arm can be directed in three different ways, shown in
the figure to the right.
The lowered position, as in figure A, is
recommended as it gives the least load on the tool.
xx0200000260
307
4 Repair
4.4.7. Securing the lower arm
Continued
Action
7. Fit the fixture, lower arm to the frame and the lower
arm, according to following instruction:
1. Fit the both adjusters in the correct holes and
make sure that they are screwed back (C).
2. Align the fixture with the frame and lower
arm.
3. Make sure the fixture is pressed tightly
against the lower arm before securing with
screws!
4. Fit and tighten the four M16 bolts in the
attachment holes on the inside of the frame
with tightening torque: 220 Nm (A).
5. Screw in the two adjusters until they rest
against the flats on the lower arm. Tighten by
hand.
6. Lock, using the two ring nuts.
7. Fit and tighten the two M12 bolts in the
attachment holes on the lower arm with
tightening torque: 91 Nm (C).
Note/Illustration
Art. no. is specified in Required
equipment on page 306.
Attachment holes on the frame
and on the lower arm are shown in
the figure Attachment points, robot
on page 305!
The adjusters, bolts and ring nuts
are shown in the figure Fixture,
lower arm on page 306.
308
3HAC023082-001 Revision: E
xx0300000610
4 Repair
4.5.1. Replacement of SMB unit
xx0200000203
SMB cover
SMB unit
Pins
Battery cable
Required equipment
Equipment, etc.
SMB unit
3HAC 16014-1
Art. no.
Note
Brush
Rust preventive
3HAC026621-001
Equivalent:
Mercasol 3106
Standard toolkit
Circuit Diagram
309
4 Repair
4.5.1. Replacement of SMB unit
Continued
Removal, SMB unit
The procedure below details how to remove the SMB unit.
Action
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page 40
4. Remove the SMB cover by unscrewing its
attachment screws.
3HAC023082-001 Revision: E
4 Repair
4.5.1. Replacement of SMB unit
Continued
Refitting, SMB unit
The procedure below details how to refit the SMB unit.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the
unit please observe the safety information in
section WARNING - The unit is sensitive to ESD!
on page 40
3. Connect the battery cable to the SMB unit.
4. Connect all connectors to the SMB board and fit Art. no. is specified in Required
the SMB unit onto the pins.
equipment on page 309!
Shown in the figure Location of SMB
unit on page 309!
R1.SMB1-3, R1.SMB4-6 and R2.SMB
5. Secure the SMB unit to the pins with the nuts and
washers.
9.
DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 38.
311
4 Repair
4.5.1. Replacement of SMB unit
Continued
Replacement of SMB unit (Foundry Prime)
Robots working with Foundry Prime and that have the special tightness for this application
require special repair routines to maintain the tightness level.
The repair must be done according to the previous repair procedure with the following
additions.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling the unit
please observe the safety information in section
WARNING - The unit is sensitive to ESD! on page
40
3. Remove the SMB unit according to step 4 - 8 in
Removal, SMB unit on page 310
4. Refit the new SMB unit according to step 3 - 6 in
Refitting, SMB unit on page 311
5.
NOTE!
Copyright 2004-2008 ABB. All rights reserved.
312
3HAC023082-001 Revision: E
4 Repair
4.5.2. Replacement of brake release unit
xx0200000226
Buttons
SMB cover
Required equipment
Equipment, etc.
Art. no.
Note
3HAC 16035-1
Standard toolkit
313
4 Repair
4.5.2. Replacement of brake release unit
Continued
Removal, brake release unit
The procedure below details how to remove the brake release unit.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 40
3. Remove the push button guardfrom the SMB Shown in the figure Location of brake
cover.
release unit on page 313.
The guard must be removed to ensure a
correct refitting of the brake release unit.
4. Open the SMB cover by unscrewing the
attachment screws.
Let the battery stay connected, to avoid the
need of synchronization of the robot!
xx0200000129
A: Connector X8
B: Connector X9
C: Connector X10
D: Push buttons
Location of brake release unit is shown
in the figure Location of brake release
unit on page 313!
3HAC023082-001 Revision: E
4 Repair
4.5.2. Replacement of brake release unit
Continued
Action
Note/Illustration
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2.
esd
WARNING!
The unit is sensitive to ESD, before handling
the unit please observe the safety information
in section WARNING - The unit is sensitive to
ESD! on page 40
xx0200000129
A: Connector X8
B: Connector X9
C: Connector X10
D: Push buttons
315
4 Repair
4.5.2. Replacement of brake release unit
Continued
Action
Note/Illustration
WARNING!
Before continuing any service work, please
observe the safety information in section
WARNING - The brake release buttons may
be jammed after service work on page 39!
8. Refit the push button guardto the SMB cover.
10.
DANGER!
316
3HAC023082-001 Revision: E
4 Repair
4.5.3. Replacement of spherical roller bearing, balancing device
xx0500002249
Sealing ring
O-ring
Sealing spacer
Required equipment
Equipment
Spherical roller
bearing
3HAA 2167-18
Sealing spacer
3HAC 12649-1
2 pcs required.
O-ring
3HAB 3772-75
2 pcs required.
Sealing ring
3HAC 11581-5
Grease
Note
2 pcs required.
3HAB 3537-1
317
4 Repair
4.5.3. Replacement of spherical roller bearing, balancing device
Continued
Equipment
Toolkit
3HAC
021984-001
Note
Includes:
Threaded bar 3HAC15945-1
Dolly 3HAC15948-2
Press tool 3HAC15941-2
Press tool 3HAC15846-2
Hexagon nut M12 9ADA267-9
Plain washer 9ADA312-9
The tools in the set are shown in the
figure Tool set on page 318.
These procedures include
references to the tools required.
Tool set
The parts of the tool set for replacement of the spherical roller bearing are shown in the figure
below.
Threaded bar
Dolly
xx0500002259
3HAC023082-001 Revision: E
4 Repair
4.5.3. Replacement of spherical roller bearing, balancing device
Continued
Removal, bearing
The procedure below details how to remove the bearing from the balancing device front ear.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2. Remove the balancing device from the robot. Detailed in section Removal,
balancing device on page 325.
3. Remove the both sealing spacers with a
screwdriver or any equal tool.
xx0500002255
Refitting, bearing
The procedure below details how to refit the bearing to the balancing device front ear.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2. Grease the inside walls of the front ear.
319
4 Repair
4.5.3. Replacement of spherical roller bearing, balancing device
Continued
Action
Note/Illustration
xx0500002257
xx0500002258
8. Lubricate the spherical roller bearing in the ear. Detailed in section Lubrication of
Note! The balancing device must be mounted spherical roller bearing, balancing
device on page 203.
on the robot when lubrication is performed!
9. Make sure no incorrect leakage occures. It
could indicate damaged o-rings.
3HAC023082-001 Revision: E
4 Repair
4.5.3. Replacement of spherical roller bearing, balancing device
Continued
Action
Note/Illustration
10.
DANGER!
3HAC023082-001 Revision: E
321
4 Repair
4.5.4. Replacement of balancing device
Balancing device
Rear cover
Bearing attachment
xx0200000223
3HAC023082-001 Revision: E
4 Repair
4.5.4. Replacement of balancing device
Continued
Attachment points, balancing device
The attachment points for the lifting tools etc. are located as shown in the figure below.
xx0300000482
Securing screw attachment hole, secures the bearing attachment to the balancing
device (remove the protection plug)
Hole in the frame to access the balancing device shaft with the puller/press tool
Locking screw attachment hole, secures the lower arm to the frame
Required equipment
Equipment
Art. no.
Note
Balancing device
(IRB 6600 and IRB
6600ID)
3HAC 020691-001
IRB 6600
Includes balancing device
3HAC 17117-2!
Includes end cover gasket
3HAC 17188-1.
Balancing device
(IRB 6650 and IRB
6650ID)
3HAC 020692-001
IRB 6650
Includes balancing device
3HAC 17117-3!
Includes end cover gasket
3HAC 17188-1.
323
4 Repair
4.5.4. Replacement of balancing device
Equipment
Art. no.
Note
3HAC 17188-1
To be replaced if damaged!
Locking screw
3HAA1001-266
M16 x 60
For securing the lower arm.
Securing screw
9ADA 183-66
Bearing grease
3HAB 3537-1
Grease
3HAA 1001-294
Rust preventive
3HAC026621-001
Equivalent:
Mercasol 3106
Locking liquid
Loctite 243
To apply to the securing
screw in the shaft.
Grease pump
3HAC13120-5
Shackle, balancing
device
3HAC 020997-1
3HAC15556-1
3HAC020902-001
3HAC12475-1
3HAC17129-1
Hydraulic cylinder
3HAC11731-1
Hydraulic pump, 80
MPa
3HAC13086-1
Standard toolkit
3HAC023082-001 Revision: E
Continued
4 Repair
4.5.4. Replacement of balancing device
Continued
Removal, balancing device
The procedure below details how to remove the balancing device.
Action
Note/Illustration
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3. Secure the lower arm to the frame by inserting Attachment hole for the locking screw
the locking screw into the attachment hole in
is shown in the figure Attachment
the frame.
points, balancing device on page 323.
Art. no. is specified in Required
equipment on page 323!
4.
CAUTION!
7. Remove the securing screw from the balancing Shown in the figure Location of
device shaft.
balancing device on page 322!
8. Apply the puller tool, balancing device shaft to
the shaft through the hole in the frame.
The shaft has a M20 thread diameter, as shown
in the figure to the right.
Pull the shaft out using the puller tool and the
hydraulic pump.
xx0300000056
325
4 Repair
4.5.4. Replacement of balancing device
Continued
Action
9. Restore the balancing device.
10. Secure the two bearing attachments to the
balancing device by replacing the protection
plug on the outside of each attachment, with
securing screws.
The protection plugs must be refitted after
refitting the balancing device, do not loose
them!
Note/Illustration
Detailed in section Restoring the
balancing device on page 334.
Shown in the figure Attachment points,
balancing device on page 323!
Dimensions for the securing screws
are specified in Required equipment
on page 323.
11. Remove the two bearing attachments from the Shown in the figure Location of
frame by unscrewing their four attachment
balancing device on page 322!
screws.
Make sure the parallel pins inside are
not lost!
12. Fit two guide pins through the upper holes of
the bearing attachments, to the frame.
13. Lift the balancing device gently backwards to a Note! Make sure not to burden the
secure area, allowing the bearing attachments guide pins with the weight of the
to slide on the guide pins.
balancing device!
Note
1.
DANGER!
2. Secure the lower arm to the frame by inserting Art. no. is specified in Required
the locking screw into the attachment hole in
equipment on page 323!
the frame.
Attachment hole is shown in the
figure Attachment points, balancing
device on page 323.
3. Secure the bearing attachments to the
balancing device with securing screws.
3HAC023082-001 Revision: E
4 Repair
4.5.4. Replacement of balancing device
Continued
Action
6. Fit the shackle to the balancing device.
Note
Art. no. is specified in Required
equipment on page 323!
Attachments are shown in the figureAttachment points, balancing device
on page 323.
7.
CAUTION!
The balancing device weighs 210 kg! All lifting
equipment used must be sized accordingly!
8. Lift the balancing device and bring it forward, Note! Make sure not to burden the
gliding the bearing attachments on to the guide guide pins with the weight of the
pins.
balancing device!
9. Remove the guide pins.
10. Secure the rear of the balancing device by
fastening the two bearing attachments to the
frame with their four attachment screws.
327
4 Repair
4.5.4. Replacement of balancing device
Continued
Action
Note
19.
DANGER!
The rear cover of the balancing device is a
safety device for the piston rod during
operation! Make sure the cover is properly
secured before commissioning of the robot!
20. Remove the locking screw that secures the
lower arm to the frame.
xx0300000483
21.
DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First test
run may cause injury or damage! on page 38.
3HAC023082-001 Revision: E
4 Repair
4.5.4. Replacement of balancing device
Continued
Replacement of balacing device (Foundry Prime)
Robots working with Foundry Prime and that have the special tightness for this application
require special repair routines to maintain the tightness level.
The repair must be done according to the repair chapter in the Product Manual with the
following additions.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Pull out the sealing spacers out, they shall still
remain on the ear.
Apply rust preventive abundantly in the
gap
press the sealing back in place
wipe off surplus material.
xx0600003131
A: sealing spacers
xx0600003130
329
4 Repair
4.5.4. Replacement of balancing device
Continued
Action
Note/Illustration
4.
DANGER!
330
3HAC023082-001 Revision: E
4 Repair
4.5.5. Unloading the balancing device
The press tool includes two press devices that are used to different models of the balancing
device.
xx0200000174
Press block
Hydraulic cylinder
Press device
Bolt (4 pcs)
331
4 Repair
4.5.5. Unloading the balancing device
Continued
Required equipment
Equipment, etc.
Art. no.
Note
3HAC020902-001
Includes
press device 3HAC 15767-2
press device 3HAC 18100-1
Choose the correct device, depending
on model of balancing device.
Hydraulic cylinder
3HAC11731-1
3HAC13086-1
Standard toolkit
3HAC 15571-1
Press device
xx0300000599
Note/Illustration
1. Fit the moving pin to the current press device. Choose the correct press device,
according to the table Using the correct
press device on page 332.
The moving pin is shown in the figure
Press tool and hydraulic cylinder on
page 331.
2. Fit the correct press device and moving pin to Shown in the figure Press tool and
the press tool. Secure with the bolt, press
hydraulic cylinder on page 331.
device.
Note! Make sure the bolt is secured properly!
3HAC023082-001 Revision: E
xx0300000602
4 Repair
4.5.5. Unloading the balancing device
Continued
Action
Note/Illustration
xx0200000175
9. Turn the fix plate to position "Closed" in order See the figure Press tool and hydraulic
to lock the tool in loaded condition.
cylinder on page 331!
Copyright 2004-2008 ABB. All rights reserved.
3HAC023082-001 Revision: E
333
4 Repair
4.5.6. Restoring the balancing device
Press block
Hydraulic cylinder
Press device
Bolt (4 pcs)
Required equipment
The different designs of the balancing device are sealed in different ways beneath the rear
cover of the balancing device.
Equipment, etc.
Art. no.
Note
Hydraulic cylinder
3HAC11731-1
3HAC13086-1
3HAC023082-001 Revision: E
xx0200000174
4 Repair
4.5.6. Restoring the balancing device
Continued
Equipment, etc.
Art. no.
Note
Locking liquid
Loctite 577
Used to secure the attachment screws
of the rear cover at the end of the
balancing device.
3HAC 17188-1
Standard toolkit
3HAC 15571-1
Note/Illustration
Shown in the figure Press tool and
hydraulic cylinder on page 334!
2. Apply Mercasol 3106 between piston rod and ear. See illustration above.
3. Press with the cylinder and the hydraulic pump
until the fix plate is movable again. Turn the pin
on the fix plate to position "Open".
xx0200000175
335
4 Repair
4.5.6. Restoring the balancing device
Continued
Action
Note/Illustration
9.
DANGER!
336
3HAC023082-001 Revision: E
4 Repair
4.6.1. Replacement of motor, axis 1
4.6 Motors
4.6.1. Replacement of motor, axis 1
Location of motor
The motor axis 1 is located on the left hand side of the robotas shown in the figure below.
xx0200000200
Motor, axis 1
Required equipment
Equipment, etc.
Art. no.
Note
Includes
motor
pinion
o-ring 2152 2012430.
O-ring
2152 2012-430
Sikaflex 251FC
3HAC026620-001
Mercasol 3106
3HAC026621-001
Gasket
3HAC3438-1
337
4 Repair
4.6.1. Replacement of motor, axis 1
Continued
Equipment, etc.
Art. no.
Note
Grease
3HAB 3537-1
3HAC 14631-1
3HAC 14459-1
Power supply
Standard toolkit
Calibration Pendulum
toolkit
3HAC15716-1
Note/Illustration
Copyright 2004-2008 ABB. All rights reserved.
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Remove the cover for connector access on top of
the motor by unscrewing its four attachment screws.
3HAC023082-001 Revision: E
4 Repair
4.6.1. Replacement of motor, axis 1
Continued
Action
Note/Illustration
xx0200000199
6. In order to release the brakes, connect the 24 VDC Connect to connector R2.MP1
power supply.
+: pin 2
-: pin 5
7. Remove the motor by unscrewing its four
attachment screws and plain washers.
8. If required, press the motor out of position by fitting Art. no. is specified in Required
removal tool, motor to the motor attachment screw equipment on page 337!
holes.
Always use the removal tools in
pairs!
9.
CAUTION!
The motor weighs 25 kg! All lifting equipment used
must be sized accordingly!
10. Lift the motor to get the pinion away from the gear
and disconnect the brake release voltage.
11. Remove the motor by gently lifting it straight up.
Note
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Make sure the o-ring on the circumference of the Art no. is specified in Required
motor is seated properly. Lightly lubricate the o-ring equipment on page 337!
with grease.
339
4 Repair
4.6.1. Replacement of motor, axis 1
Continued
Action
Note
3.
CAUTION!
The motor weighs 25 kg! All lifting equipment used
must be sized accordingly!
4. Apply the lifting tool, motor axis 1, 4, 5 to the motor. Art no. is specified in Required
equipment on page 337!
5. In order to release the brake, connect the 24 VDC
power supply.
Calibration is detailed in a
separate calibration manual,
enclosed with the calibration tools.
General calibration information is
included in section Calibration
information on page 409.
13.
DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 38.
3HAC023082-001 Revision: E
4 Repair
4.6.1. Replacement of motor, axis 1
Continued
Replacement of the motor axis 1 (Foundry Prime)
Robots working with Foundry Prime and that have the special tightness for this application
require special repair routines to maintain the tightness level.
The repair must be done according to the repair chapter in the Product Manual with the
following additions.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Remove the cover for connector access on top of
the motor by unscrewing its four attachment
screws.
B
A
C
xx0600002874
A: attachment screw
B: air hose
C: top cover
D: motor unit
3.
note
NOTE!
Keep the old top cover, with the air nipple
mounted.
4. Remove the motor unit, according to step 5 to 12
in Removal, motor axis 1 on page 338.
341
4 Repair
4.6.1. Replacement of motor, axis 1
Continued
Action
Note/Illustration
xx0600002875
A: motor unit
B: Sikaflex in screw
recesses
xx0600002877
A: base frame
B: motor unit
342
3HAC023082-001 Revision: E
4 Repair
4.6.2. Replacement of motor axis 2
xx0400001067
Motor, axis 2
Required equipment
Equipment, etc.
3HAC 021030-001
Art. no.
Note
Includes
motor
pinion
o-ring 2152 2012430
O-ring
2152 2012-430
Sikaflex 251FC
3HAC026620001
343
4 Repair
4.6.2. Replacement of motor axis 2
Equipment, etc.
Art. no.
Note
Gasket
3HAC3438-1
Grease
3HAB 3537-1
Locking screw
3HAC 14631-1
3HAC 15521-2
3HAC 15534-1
3HAC 12342-1
Power supply
24 VDC, 1.5 A
For releasing the brakes.
Rotation tool
3HAC 17105-1
Standard toolkit
Calibration Pendulum
toolkit
3HAC15716-1
Circuit diagram
Removal, motor
The procedure below details how to remove the motor, axis 2.
Action
1. Move the robot to a position close enough to its
calibration position, to allow the lock screw to be
inserted into thehole for lock screw .
Note
Shown in the figure Location of
motor on page 343!
3HAC023082-001 Revision: E
Continued
4 Repair
4.6.2. Replacement of motor axis 2
Continued
Action
Note
2.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3. Lock the lower arm by inserting the lock screw into Art. no. and dimension is specified
the hole.
in Required equipment on page
343!
4. Drain the oil from gearbox, axis 2.
DANGER!
Secure the weight of the lower arm properly before
releasing the brakes of motor, axis 2!
When releasing the holding brakes of the motor,
the lower arm will be movable and may fall down!
9. In order to release the brake, connect the 24 VDC Connect to connector R2.MP2
power supply.
+: pin 2
-: pin 5
10. Remove the motor by unscrewing its four
attachment screws and plain washers.
11. Fit the two guide pins in two of the motor
attachment holes.
12. If required, press the motor out of position by fitting Art. no. is specified in Required
the removal tool, motor to the remaining motor
equipment on page 343!
attachment holes.
Shown in the figure Location of
motor on page 343!
Always use the removal tools in
pairs!
13. Remove the removal tools and fit the lifting tool,
motor axis 2, 3, 4 to the motor.
345
4 Repair
4.6.2. Replacement of motor axis 2
Continued
Action
Note
14.
CAUTION!
The motor weighs 32 kg! All lifting equipment used
must be sized accordingly!
15. Lift the motor to get the pinion away from the gear. Make sure the motor pinion does
not get damaged!
16. Remove the motor by gently lifting it straight out
and place it on a secure surface. Disconnect the
brake release voltage.
Refitting, motor
The procedure below details how to refit the motor axis 2.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2. Make sure the o-ring on the circumference of Art. no. is specified in Required
the motor is seated properly. Lightly lubricate equipment on page 343!
the o-ring with grease.
5. Fit the two guide pins in the two lower motor Art. no. is specified in Required
attachment holes.
equipment on page 343!
Shown in the figure Location of motor on
page 343!
6.
CAUTION!
The motor weighs 32 kg! All lifting equipment
used must be sized accordingly!
7. Lift the motor and guide it on to the guide pins,
as close to the correct position as possible
without pushing the motor pinion into the
gear.
Make sure that the motor is turned the right
direction, i.e. the cables facing downwards.
8. Remove the lifting tool and allow the motor to
rest on the guide pins.
3HAC023082-001 Revision: E
4 Repair
4.6.2. Replacement of motor axis 2
Continued
Action
Note/Illustration
xx0200000165
15. Refit the cover on top of the motor with its four Make sure the cover is tightly sealed!
attachment screws.
16. Remove the lock screw from the hole for lock Shown in the figure Location of motor on
screw.
page 343!
17. Perform a leak down test.
20.
DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First test
run may cause injury or damage! on page 38.
347
4 Repair
4.6.2. Replacement of motor axis 2
Continued
Replacement of the motor axis 2 (Foundry Prime)
Robots working with Foundry Prime and that have the special tightness for this application
require special repair routines to maintain the tightness level.
The repair must be done according to the repair chapter in the Product Manual with the
following additions.
Action
1. Move the robot to a position close enough to its
calibration position, to allow the lock screw to be
inserted into the hole for lock screw.
Note/Illustration
Shown in the figure Location of
motor on page 343!
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Lock the lower arm by inserting the lock screw into Art. no. and dimension is specified
the hole.
in Required equipment on page
343!
4. Drain the oil from gearbox, axis 2.
B
A
C
xx0600002874
A: attachment screw
B: air hose
C: top cover
D: motor unit
note
NOTE!
Keep the old top cover with the air nipple
mounted.
3HAC023082-001 Revision: E
4 Repair
4.6.2. Replacement of motor axis 2
Continued
Action
Note/Illustration
8.
DANGER!
Secure the weight of the lower arm properly
before releasing the brakes of motor, axis 2!
When releasing the holding brakes of the motor,
the lower arm will be movable and may fall down!
9. Continue to remove the motor unit, according to
step 9 to 17 in Removal, motor on page 344.
10. Fill the four screw recesses on the new motor with
Sikaflex. (After hardening, Sikaflex can be formed
with a knife)
xx0600002875
A: motor unit
B: Sikaflex in screw
recesses
3HAC023082-001 Revision: E
349
4 Repair
4.6.3. Replacement of motor, axis 3
xx0200000186
Motor axis 3
xx0600003051
Motor, axis 3
3HAC023082-001 Revision: E
4 Repair
4.6.3. Replacement of motor, axis 3
Continued
Required equipment
Equipment, etc. Spare part no.
Motor including
pinion
Art. no.
3HAC 15885-2
Note
Includes
motor
pinion
o-ring 2152 2012-430
O-ring
2152 2012-430
Sikaflex 251FC
Gasket
3HAC3438-1
Foundry Prime
Removal tool,
motor M12x
Lifting tool, motor
ax 2, 3, 4
3HAC 15534-1
Mech stop ax 3
3HAC 12708-1
Grease
3HAB 3537-1
Removal tool,
motor M12x
3HAC 14631-1
3HAC 15534-1
Mech stop ax 3
3HAC 12708-1
3HAA 1001-186
3HAC 15521-1
3HAC 15521-2
Rotation tool
3HAC 17105-1
Power supply
Standard toolkit
Calibration
Pendulum toolkit
3HAC15716-1
351
4 Repair
4.6.3. Replacement of motor, axis 3
Continued
Equipment, etc. Spare part no.
Art. no.
Note
Circuit Diagram
Removal, motor
The procedure below details how to remove motor, axis 3.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
xx0300000051
3HAC023082-001 Revision: E
4 Repair
4.6.3. Replacement of motor, axis 3
Continued
Action
Note/Illustration
8.
DANGER!
Secure the weight of the upper arm properly before
releasing the brakes of motor, axis 3.
When releasing the holding brakes of the motor, the
upper arm will be movable and may fall down!
9. Release the brake by connecting the 24 VDC power Connect to connector R2.MP3
supply.
+: pin 2
-: pin 5
10. Unscrew the motors four attachment screws and
plain washers .
11. Fit the two guide pins in two of the motor attachment Art. no. is specified in Required
screw holes.
equipment on page 351!
12. Press the motor out of position by fitting removal
Art. no. is specified in Required
tool, motor to the remaining motor attachment screw equipment on page 351!
holes.
Always use the removal tools in
pairs!
13. Apply the lifting tool, motor axis 2 ,3, 4 to the motor. Art. no. is specified in Required
equipment on page 351!
14.
CAUTION!
The motor weighs 27 kg! All lifting equipment used
must be sized accordingly!
15. Lift the motor to get the pinion away from the gear.
16. Remove the motor by gently lifting it straight out and Make sure the motor pinion is not
disconnect the brake release voltage.
damaged!
Refitting, motor
The procedure below details how to refit motor, axis 3.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Make sure the o-ring on the circumference of the Art no. is specified in Required
motor is seated properly. Lightly lubricate it with equipment on page 351!
grease.
3. Fit the lifting tool, motor axis 2, 3, 4 to the motor.
353
4 Repair
4.6.3. Replacement of motor, axis 3
Continued
Action
4. Fit the two guide pins in the two lower motor
attachment holes.
Note/Illustration
Art no. is specified in Required
equipment on page 351!
Shown in the figure Location of
motor on page 350!
5.
CAUTION!
The motor weighs 27 kg! All lifting equipment
used must be sized accordingly!
6. Lift the motor and guide it onto the guide pins, as
close to the correct position as possible without
pushing the motor pinion into the gear.
7. Remove the lifting tool and allow the motor stay on
the guide pins.
8. In order to release the brake, connect the 24 VDC Connect to connector R2.MP3
power supply.
+: pin 2
-: pin 5
Art no. is specified in Required
equipment on page 351!
Make sure the motor pinion does not
get damaged!
Make sure the motor is turned the
right direction, i.e. the cables facing
forwards.
xx0200000165
14. Refit the cable gland cover at the cable exit with Make sure the cover is tightly
its two attachment screws.
sealed!
Shown in the figure Location of
motor on page 350!
3HAC023082-001 Revision: E
4 Repair
4.6.3. Replacement of motor, axis 3
Continued
Action
15. Refit the cover on top of the motor with its four
attachment screws.
Note/Illustration
Make sure the cover is tightly
sealed!
20.
DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 38.
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Remove the motor accordingto step 2 - 4 in
Removal, motor on page 352.
355
4 Repair
4.6.3. Replacement of motor, axis 3
Continued
Action
Note/Illustration
B
A
C
xx0600002874
A: attachment screw
B: air hose
C: top cover
D: motor unit
4.
note
NOTE!
Keep the old top cover with the air nipple
mounted.
5. Continue to remove the motor unit, according to
step 6 to 17 in Removal, motor on page 352.
xx0600002875
A: motor unit
B: sikaflex in screw recesses
356
3HAC023082-001 Revision: E
4 Repair
4.6.4. Replacement of motor, axis 4
xx0200000202
Motor, axis 4
xx0500003050
Motor, axis 4
357
4 Repair
4.6.4. Replacement of motor, axis 4
Continued
Required equipment
Equipment, etc.
Motor including
pinion
3HAC 15889-2
Art. no.
Note
Includes
motor
pinion
o-ring 2152 2012-430
O-ring
2152 2012-430
Sikaflex251FC
3HAC026620-001
Gasket
3HAC3438-1
3HAC 14459-1
Grease
3HAC 3537-1
3HAC 14972-1
3HAC 15520-1
3HAC 15520-2
Rotation tool
3HAC 17105-1
Power supply
Standard toolkit
Calibration
Pendulum toolkit
3HAC15716-1
Circuit Diagram
3HAC023082-001 Revision: E
4 Repair
4.6.4. Replacement of motor, axis 4
Continued
Removal, motor axis 4
The procedure below details how to remove the motor, axis 4.
Action
Note
1. Move the robot to a position where the upper Draining of oil is described in section
arm is pointed straight up.
Draining, oil on page 192.
This position enables the motor to be
replaced without draining the gear oil, which
in turn saves time.
Any other position of the upper arm requires
a draining of oil from the gearbox for axis 4.
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
3. Remove the cable gland cover at the cable
exit of the motor by unscrewing its two
attachment screws.
7. Unscrew the motors four attachment screws Shown in the figure Location of motor on
and plain washers.
page 357!
8. Fit the two guide pins in two of the motor
attachment screw holes.
9. If required, press the motor out of position by Art. no. is specified in Required
fitting removal tool, motor to the motor
equipment on page 358!
attachment screw holes.
Always use the removal tools in pairs!
10. Lift the motor to get the pinion away from the
gear and disconnect the brake release
voltage.
11. Remove the motor by gently lifting it straight Make sure the motor pinion is not
out.
damaged!
359
4 Repair
4.6.4. Replacement of motor, axis 4
Continued
Refitting, motor axis 4
The procedure below details how to refit motor, axis 4.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off
the air pressure to motors and SMB.
Art. no. is specified in Required
equipment on page 358!
3HAC023082-001 Revision: E
4 Repair
4.6.4. Replacement of motor, axis 4
Continued
Action
7. Use the rotation tool in order to rotate the
motor pinion when mating it to the gear!
Fit the motor, making sure the motor pinion
is properly mated to the gear, axis 4.
Note/Illustration
Art. no. is specified in Required
equipment on page 358!
Make sure the motor pinion does not get
damaged!
Make sure the motor is turned the right
direction, i.e. the cables facing forwards.
xx0200000165
13. Refit the cable gland cover at the cable exit Shown in the figure Location of motor on
with its two attachment screws.
page 357!
14. Perform a leak-down test if gearbox has
been drained.
17.
DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First
test run may cause injury or damage! on
page 38.
361
4 Repair
4.6.4. Replacement of motor, axis 4
Continued
Replacement of the motor axis 4 (Foundry Prime)
Robots working with Foundry Prime and that have the special tightness for this application
require special repair routines to maintain the tightness level.
The repair must be done according to the repair chapter in the Product Manual with the
following additions.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Remove the cover for connector access on top of
the motor by unscrewing its four attachment
screws.
B
A
C
A: attachment screw
B: air hose
C: top cover
D: motor unit
3.
note
NOTE!
Keep the old top cover with the air nipple
mounted.
4. Remove the motor unit, according to step 4 to 12
in Removal, motor axis 4 on page 359.
3HAC023082-001 Revision: E
xx0600002874
4 Repair
4.6.4. Replacement of motor, axis 4
Continued
Action
Note/Illustration
xx0600002875
A: motor unit
B: sikaflex in screw recesses
3HAC023082-001 Revision: E
363
4 Repair
4.6.5. Replacement of motor, axis 5, IRB 6600 and IRB 6650
Motor, axis 5
Wrist unit
Required equipment
Equipment, etc.
Art. no.
Note
3HAC026982-001
(Foundry Prime)
3HAC027319-001
(Foundry Prime)
Motor
3HAC 17484-10
3HAC023082-001 Revision: E
xx0200000204
4 Repair
4.6.5. Replacement of motor, axis 5, IRB 6600 and IRB 6650
Continued
Equipment, etc.
Art. no.
Note
O-ring
2152 2012-430
Sikaflex 251FC
Mercasol 3106
Gasket
3HAC3438-1
Grease
3HAC 3537-1
Isopropanol
1177 1012-208
Mineral oil
CS 320
3HAC 14972-1
Measuring tool
6896134-GN
3HAC 15520-1
3HAC 15520-2
Power supply
24 VDC, 1.5 A
For releasing the brakes.
Standard toolkit
365
4 Repair
4.6.5. Replacement of motor, axis 5, IRB 6600 and IRB 6650
Continued
Removal, motor, axis 5
The procedure below details how to remove motor, axis 5.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Drain the oil from gearbox axis 5.
12. Lift the motor to get the pinion away from the gear Make sure the motor pinion is not
and disconnect the brake release voltage.
damaged!
13. Remove the motor by gently lifting it straight out. Keep track of the shims between the
motor flange and the wrist housing.
14. Measure the distance between the motor flange, Art. no. is specified in Required
included eventual shims, and the outer surface of equipment on page 364!
the pinion, with measuring tool.
Make a note of the distance.
3HAC023082-001 Revision: E
4 Repair
4.6.5. Replacement of motor, axis 5, IRB 6600 and IRB 6650
Continued
Action
Note
Note
1.
DANGER!
5. Place the motor and pinion in the press fixture. Art. no. is specified in Required
equipment on page 364!
6. Press the pinion onto the new motor and check
the pressing force.
For an axis diameter of 15.5 mm, use min.
pressing force: 18.5 kN and max. pressing
force: 39.5 kN.
367
4 Repair
4.6.5. Replacement of motor, axis 5, IRB 6600 and IRB 6650
Continued
Action
Note
Connect to either:
- connector R4.MP5 (in the motor):
+: pin 2
-: pin 5
- connector R3.MP5 (on the separate
cable, if not removed):
+: pin C
- : pin D
20.
DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First test
run may cause injury or damage! on page 38.
3HAC023082-001 Revision: E
15. Refit the cover on top of the motor with its four Make sure the cover is tightly sealed!
attachment screws.
4 Repair
4.6.5. Replacement of motor, axis 5, IRB 6600 and IRB 6650
Continued
Replacement of the motor axis 5 (Foundry Prime)
Robots working with Foundry Prime and that have the special tightness for this application
require special repair routines to maintain the tightness level.
The repair must be done according to the previous repair procedures with the following
additions.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2. Perform step 2 - 4 in Removal, motor, axis 5
on page 366
xx0600002904
A: attachment screw
B: air hose
C: top cover
D: motor unit
4.
note
NOTE!
Keep the old top cover with air nipple
mounted.
5. Disconnect all connectors beneath the motor
cover and remove the separate cable of the
axis 5 motor.
369
4 Repair
4.6.5. Replacement of motor, axis 5, IRB 6600 and IRB 6650
Continued
Action
Note/Illustration
xx0600002880
A: air hose
B: motor unit
C: sikaflex in screw recesses
xx0600002879
A: wrist unit
B: attachment screw (4 pcs)
C: surface to protect with
Mercasol
D: motor unit
370
3HAC023082-001 Revision: E
4 Repair
4.6.6. Replacement of motor, axis 5, IRB 6600ID and IRB 6650ID
xx0500001573
Motor, axis 5
Required equipment
Equipment
3HAC 023745-003
Art. no.
Note
Includes o-ring 3HAB 377222.
Grease
Power supply
24 VDC, 1.5A
For releasing the brakes.
Standard toolkit
371
4 Repair
4.6.6. Replacement of motor, axis 5, IRB 6600ID and IRB 6650ID
Continued
Removal tools, motor attachment screws
The figure below shows the required dimensions of the tools, in order to access the
attachment screws of the motor.
xx0500002271
Allen key, 6 mm
Socket, 12 mm
Torque wrench
Note
Connect to connector
R3.MP5:
+ : pin C
- : pin D
3HAC023082-001 Revision: E
DANGER!
4 Repair
4.6.6. Replacement of motor, axis 5, IRB 6600ID and IRB 6650ID
Continued
Refitting, motor axis 5
The procedure below details how to refit the motor, axis 5.
Action
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Make sure the o-ring on the circumference of the Article numbers are specified in
motor is seated properly. Replace it if damaged. Required equipment on page 371.
Lightly lubricate the o-ring with grease.
3. In order to release the brakes, connect the 24
VDC power supply to the motor.
6. Disconnect the brake release and reconnect the Shown in the figure Location of
motor connectors.
motor, axis 5 on page 371.
7. Perform a leak-down test.
10.
DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 38.
3HAC023082-001 Revision: E
373
4 Repair
4.6.7. Replacement of motor, axis 6, IRB 6600 and IRB 6650
xx0200000222
Wrist unit
Motor, axis 6
Required equipment
Equipment, etc.
3HAC 15991-4
Art. no.
Note
Includes:
motor
pinion
o-ring 2152 2012430
3HAC023082-001 Revision: E
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.
4 Repair
4.6.7. Replacement of motor, axis 6, IRB 6600 and IRB 6650
Continued
Equipment, etc.
O-ring
Art. no.
Note
2152 2012-430
Merkasol 3106
3HAC026621-001
Sikaflex
3HAC026620-001
3HAC12877-1
Loctite 574
Loctite 480
Gasket
Removal tool, motor
M10x
3HAC 14972-1
3HAC 15520-1
3HAC 15520-2
Power supply
24 VDC, 1.5 A
For releasing the brakes.
Grease
3HAB 3537-1
Standard toolkit
Calibration Pendulum
toolkit
3HAC15716-1
Circuit Diagram
Removal, motor
The procedure below details how to remove the motor, axis 6.
Action
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
375
4 Repair
4.6.7. Replacement of motor, axis 6, IRB 6600 and IRB 6650
Continued
Action
Note
A: Tilthouse
B: Motor, axis 6
C: Attachment screws (4
pcs)
7. If required, press the motor out of position by fitting Art. no. is specified in Required
removal tool, motor to the motor attachment screw equipment on page 374!
holes.
Always use the removal tools in
pairs!
8. Lift the motor carefully to get the pinion away from Make sure the motor pinion is not
the gear and disconnect the brake release voltage. damaged!
9. Remove the motor by gently lifting it straight out.
Refitting, motor
The procedure below details how to refit motor, axis 6.
Action
Note
1.
DANGER!
2. Make sure the o-ring on the circumference of the Art. no. is specified in Required
motor is seated properly. Lightly lubricate the o- equipment on page 374!
ring with grease.
3. In order to release the brake, connect the 24
VDC power supply.
3HAC023082-001 Revision: E
4 Repair
4.6.7. Replacement of motor, axis 6, IRB 6600 and IRB 6650
Continued
Action
Note
11.
NOTE!
On Foundry Prime robots:
When changing motor, keep the cover from the
old motor.
12. Recalibrate the robot.
13.
DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 38.
The repair must be done according to the previous repair procedure with the following
additions.
Action
Note/Illustration
377
4 Repair
4.6.7. Replacement of motor, axis 6, IRB 6600 and IRB 6650
Continued
Action
Note/Illustration
3.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
4. In horizontal position: drain the oil from the axis Detailed in section: Draining, oil, axis 6
6 gearbox.
on page 198.
5. Remove the rear motor cover by unscrewing
the five attachment screws.
xx0600002885
7.
note
NOTE!
Keep the old rear motor cover with the air
nipple,
3HAC023082-001 Revision: E
4 Repair
4.6.7. Replacement of motor, axis 6, IRB 6600 and IRB 6650
Continued
Action
Note/Illustration
xx0600002884
A: mercasol
B: motor unit
C: attachment screw (4pcs)
D: sikaflex in screw recesses
E: loctite 570
F: tilt house
3HAC023082-001 Revision: E
379
4 Repair
4.6.8. Replacement of motor, axis 6, IRB 6600ID and IRB 6650ID
xx0500001574
Motor, axis 6
Required equipment
Spare part no.
3HAC 023746-003
Art. no.
Note
Includes o-ring 3HAB 3772-22.
Grease
Power supply
24 VDC, 1.5 A
For releasing the brakes.
Standard toolkit
3HAC023082-001 Revision: E
Equipment
4 Repair
4.6.8. Replacement of motor, axis 6, IRB 6600ID and IRB 6650ID
Continued
Equipment
Circuit diagram
Art. no.
Note
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3. Disconnect the motor connectors.
Connect to connector
R3.MP6:
+ : pin C
- : pin D
5. Unfasten the motor by unscrewing its three attachment Dimensions of the tools are
screws and washers.
specified in the figure
Removal tools, motor
attachment screws on page
372.
Note
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Make sure the o-ring on the circumference of
the motor is seated properly. Ligthly lubricate
with grease.
381
4 Repair
4.6.8. Replacement of motor, axis 6, IRB 6600ID and IRB 6650ID
Continued
Action
3. In order to release the brakes, connect the 24
VDC power supply to the motor.
Note
Connect to connector R3.MP6:
+ : pin C
- : pin D
11.
DANGER!
382
3HAC023082-001 Revision: E
4 Repair
4.7.1. Replacement of gearbox, axis 1
4.7 Gearboxes
4.7.1. Replacement of gearbox, axis 1
Location of gearbox
The axis 1 gearbox is located between the frame and base as shown in the figure below.
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.
xx0300000015
Gearbox, axis 1
Frame
Base
Required equipment
Equipment, etc.
Note
Gearbox
3HAC 10828-8
Includes:
gearbox
all o-rings and sealing
rings
O-ring
3HAB 3772-54
383
4 Repair
4.7.1. Replacement of gearbox, axis 1
Continued
Equipment, etc.
Note
O-ring
3HAB 3772-55
Sealing ring
3HAC 11581-4
Grease
3HAC 3537-1
Rust preventive
3HAC026621001
Support, base
3HAC15535-1
3HAC15560-1
3HAC15556-1
Standard toolkit
Note/Illustration
xx0300000022
2.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off
the air pressure to motors and SMB.
3. Drain the oil from gearbox 1.
3HAC023082-001 Revision: E
4 Repair
4.7.1. Replacement of gearbox, axis 1
Continued
Action
Note/Illustration
9.
CAUTION!
The base and gearbox weighs 423 kg
together! All lifting equipment must be used
accordingly!
10. Lift the robot base to allow fitting the
Art. no. is specified in Required
support, base and gear 1 on each sides of equipment on page 383!
the base.
11. Fit the support, base.
Make sure the base remains in a stable
position before performing any work
underneath the base!
xx0300000612
A: Bottom plate
B: Rear connector plate
C: Attachment screw
D: Groove
385
4 Repair
4.7.1. Replacement of gearbox, axis 1
Continued
Action
Note/Illustration
xx0200000227
xx0200000256
CAUTION!
The gearbox weighs 160 kg! All lifting
equipment used must be sized accordingly!
16. Lift the gearbox away with the already
mounted lifting tools.
Note/Illustration
1. If the base is not supported with support, base Mounting of the support, base and gear
and gear 1, this should be done first.
1 is detailed in section Removal,
gearbox axis 1 on page 384.
3HAC023082-001 Revision: E
15.
4 Repair
4.7.1. Replacement of gearbox, axis 1
Continued
Action
Note/Illustration
2. Make sure the two o-rings (C, D) on the cirArt no. is specified in Required
cumference of the gearbox are seated
equipment on page 383!
properly in their grooves respectively.
Lubricate them with grease .
Make sure the small o-ring around the oil hole
is fitted properly!
xx0200000055
A: Guide pin
C: O-ring 3HAB 3772-54
D: O-ring 3HAB 3772-55
E: Sealing ring 3HAC 11581-4
xx0200000256
5.
CAUTION!
The gearbox weighs 160 kg! All lifting
equipment used must be sized accordingly!
6. Lift the gearbox to its mounting position in the
center of the base.
7. Make sure the guide pin in the bottom face of Shown in the figure xx0200000055
the gearbox is properly aligned with the base. above!
387
4 Repair
4.7.1. Replacement of gearbox, axis 1
Continued
Action
Note/Illustration
xx0200000227
A: Bottom plate
B: Rear connector plate
C: Attachment screw
D: Groove
10.
CAUTION!
The base and gearbox weighs 423 kg
together! All lifting equipment must be used
accordingly!
11. Lift the robot base and gearbox 1 to allow
removing the support, base and gear.
12. Secure the base to the mounting site.
3HAC023082-001 Revision: E
xx0300000612
4 Repair
4.7.1. Replacement of gearbox, axis 1
Continued
Action
13. Refit the complete arm system.
Note/Illustration
Detailed in section Refitting, arm
system on page 264.
This is a complex task to be performed
with utmost care in order to avoid injury
or damage!
18.
DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First test
run may cause injury or damage! on page 38.
The repair must be done according to the repair chapter in the Product Manual with the
following additions.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
389
4 Repair
4.7.1. Replacement of gearbox, axis 1
Continued
Action
Note/Illustration
xx0600003132
3.
DANGER!
390
3HAC023082-001 Revision: E
4 Repair
4.7.2. Replacement of gearbox axis 2
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.
xx0400001065
Balancing device
Motor axis 2
Cover, axis 2
391
4 Repair
4.7.2. Replacement of gearbox axis 2
Continued
Required equipment
Spare part no.
Gearbox axis 2
3HAC 021541-001
Art. no.
Note
Includes
gearbox
o-ring.
Does not include "Sealing,
axis 2/3"!
O-ring
3HAB 3772-77
O-ring
3HAB 3772-73
Rust preventive
3HAC026621-001
Sealing, axis 2
Grease
3HAB 3537-1
3HAC020729-001
3HAC020386-001
3HAC13056-2
3HAC13056-3
3HAC020902-001
Hydraulic cylinder
3HAC11731-1
Hydraulic pump, 80
MPa
3HAC13086-1
3HAC14627-2
3HAC14627-3
3HAC020999-001
Standard toolkit
3HAC023082-001 Revision: E
Equipment
4 Repair
4.7.2. Replacement of gearbox axis 2
Continued
Removal, gearbox axis 2
The procedure below details how to remove the gearbox, axis 2.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Secure the lower arm with the special fixture
equipment according to section Securing the lower
arm on page 305.
3. Unload the balancing device shaft by using the press Art. no. is specified in Required
tool, balancing device, according to section
equipment on page 392!
Unloading the balancing device on page 331!
4. Drain the gearbox, axis 2.
xx0300000550
A: Front attachment
screws, gearbox (32 pcs)
B: M12 holes for pressing
the gearbox out
9. Fit two guide pins in 180 relation to each other in the Art. no. is specified in Required
empty holes of the front gearbox attachment screws. equipment on page 392!
10. If required, apply two M12 screws to the holes,
shown in the figure above, to press it free.
393
4 Repair
4.7.2. Replacement of gearbox axis 2
Continued
Action
Note/Illustration
12.
CAUTION!
The gearbox weighs 100 kg! All lifting equipment
used must be sized accordingly!
13. Remove the gearbox axis 2 using an overhead crane
or similar, with guidance from the mounted guide
pins.
14. Remove the sealing from the lower arm.
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
xx0300000551
3HAC023082-001 Revision: E
2. Make sure the o-ring is fitted to the gearbox as Art. no. is specified in Required
shown in the figure to the right. Lightly lubricate equipment on page 392!
it with grease.
4 Repair
4.7.2. Replacement of gearbox axis 2
Continued
Action
Note/Illustration
xx0300000552
6. Fit two guide pins, M12 in 180 relation to each Art. no. is specified in Required
other in the frame, in the screw holes for the
equipment on page 392!
gearboxes front attachment screws.
7.
CAUTION!
The gearbox weighs 100 kg! All lifting
equipment used must be sized accordingly!
8. Lift the gearbox to its mounting position and
slide it onto the guiding pins attached in the
frame, through the front attachment screw
holes.
9. Align the gearbox attachment screw holes to
the hole patterns in the lower arm, with help
from the guide pins, sealing axis 2/3.
If necessary, use a gearbox crank to turn the
gear!
Use the gearbox crank with caution! The
gearbox may be damaged if the crank is
inserted too far into the gear!
395
4 Repair
4.7.2. Replacement of gearbox axis 2
Continued
Action
Note/Illustration
12. Insert and secure 30 of the 32 front attachment 32 pcs: M12 x 60, tightening torque:
screws, gearbox.
115 Nm.
Remove the guide pins, M12 and refit the two
remaining screws.
13. Lubricate the o-ring at the sealing surface of
the cover, axis 2. Replace it if damaged.
15. Insert and secure 16 of the 18rear attachment Shown in the figure Location of
screws, gearbox on the inside of the lower arm. gearbox on page 391!
18 pcs: M16 x 50, tightening torque:
300 Nm.
Reused screws may be used,
providing they are lubricated as
detailed in section Screw joints on
page 432 before fitting.
16. Remove the guide pins, sealing axis 2/3, and
tighten the two remaining screws as detailed
above.
17. Refit the motor.
26.
DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First test
run may cause injury or damage! on page 38.
3HAC023082-001 Revision: E
4 Repair
4.7.2. Replacement of gearbox axis 2
Continued
Refitting, gearbox axis 2 (Foundry Prime)
Robots working with Foundry Prime and that have the special tightness for this application
require special repair routines to maintain the tightness level.
The repair must be done according to the repair chapter in the Product Manual with the
following additions.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
2. Lift the protection ring and apply Mercasol
3106. between gear and protection ring.
A
B
xx0600003135
A: protection ring
B: Mercasol on surface
xx0600003134
397
4 Repair
4.7.2. Replacement of gearbox axis 2
Continued
Action
Note/Illustration
xx0600003135
5.
DANGER!
398
3HAC023082-001 Revision: E
4 Repair
4.7.3. Replacement of gearbox, axis 3
A more detailed view of the component and its position may be found in chapter Exploded
views in the Product manual, reference information.
xx0200000194
Gearbox, axis 3
Motor, axis 3
Upper arm
Required equipment
Equipment, etc.
Gearbox
3HAC 021127-001
O-ring
Art. no.
Note
Includes
gearbox
o-ring.
Does not include the
sealing, axis 2/3!
3HAB 3772-68
1 pc on the gearbox.
399
4 Repair
4.7.3. Replacement of gearbox, axis 3
Equipment, etc.
Art. no.
Note
Grease
3HAB 3537-1
Rust preventive
3HAC026621001
3HAC 17212-1
Mech stop ax 3
3HAC 12708-1
3HAA 1001-186
3HAC14457-3
3HAC13056-3
3HAC13056-4
3HAC14628-1
3HAC14628-2
Standard toolkit
Calibration Pendulum
toolkit
3HAC15716-1
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
3HAC023082-001 Revision: E
Continued
4 Repair
4.7.3. Replacement of gearbox, axis 3
Continued
Action
2. Secure the upper arm in a horizontal position
using a mechanical stop.
Fit the mechanical stop to the third and final
attachment hole (A), below the fixed mechanical
stop (B) in the upper arm, shown in the figure to
the right.
Tightening torqure: 115 Nm.
Note/Illustration
Art. no. is specified in Required
equipment on page 399.
xx0300000051
xx0200000201
401
4 Repair
4.7.3. Replacement of gearbox, axis 3
Continued
Action
Note/Illustration
10.
CAUTION!
The gearbox weighs 60 kg! All lifting equipment
used must be sized accordingly!
11. Remove the gearbox, with guidance from the
guide pins, using an overhead crane or similar.
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the air
pressure to motors and SMB.
2. Turn the upper arm in such a position that the
gear mating surface faces upwards.
3. Fit two guide pins in 180 relation to each other in Art. no. is specified in Required
the holes in the upper arm, used for the gearbox equipment on page 399!
attachment screws.
4.
CAUTION!
3HAC023082-001 Revision: E
4 Repair
4.7.3. Replacement of gearbox, axis 3
Continued
Action
Note/Illustration
xx0200000173
12. Refit the upper arm with a new sealing, axis 2/3 . Art. no. is specified in Required
equipment on page 399.
Detailed in section Refitting, upper
arm on page 289.
13. Refit the motor.
403
4 Repair
4.7.3. Replacement of gearbox, axis 3
Continued
Action
Note/Illustration
16.
DANGER!
Make sure all safety requirements are met when
performing the first test run. These are further
detailed in section DANGER - First test run may
cause injury or damage! on page 38.
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
xx0600003138
3.
DANGER!
Make sure all safety requirements are met
when performing the first test run. These are
further detailed in section DANGER - First test
run may cause injury or damage! on page 38.
404
3HAC023082-001 Revision: E
4 Repair
4.7.4. Replacement of gearbox, axis 6
xx0200000219
Gearbox, axis 6
Required equipment
Equipment, etc.
Gearbox
3HAC 10828-13
Art. no.
Note
Includes o-ring 3HAB 377257.
Washers
3HAA 1001-172
O-ring
3HAB 3772-58
Grease
3HAB3537-1
Rust preventive
3HAC026621-001
405
4 Repair
4.7.4. Replacement of gearbox, axis 6
Continued
Equipment, etc.
Art. no.
Note
Standard toolkit
Calibration
Pendulum toolkit
3HAC15716-1
Removal, gearbox
The procedure below details how to remove gearbox, axis 6.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off the
air pressure to motors and SMB.
Detailed in section Oil change, gearbox
axis 6 on page 197.
xx0200000220
3HAC023082-001 Revision: E
4 Repair
4.7.4. Replacement of gearbox, axis 6
Continued
Action
6. Remove the gearbox axis 6 by lifting it out
carefully.
Note/Illustration
Be careful not to damage the motor
pinion!
Refitting, gearbox
The procedure below details how to refit gearbox, axis 6.
Action
Note/Illustration
1.
DANGER!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
For Foundry Prime robots: Do not turn off
the air pressure to motors and SMB.
2. Make sure the o-ring is fitted to the rear of Art. no. is specified in Required equipment
the gearbox. Lubricate the o-ring with
on page 405!
grease.
xx0100000132
3. Insert the gearbox, axis 6 into the wrist unit. Art. no. is specified in Required equipment
on page 405.
Shown in the figure Location of gearbox on
page 405.
Make sure the gears of the gearbox mate
with those of the motor!
4. Secure the gearbox with the attachment
screws and washers.
407
4 Repair
4.7.4. Replacement of gearbox, axis 6
Continued
Action
Note/Illustration
xx0600003143
10.
DANGER!
408
3HAC023082-001 Revision: E
5 Calibration information
5.1. Introduction
5 Calibration information
5.1. Introduction
General
This chapter includes general information about different calibration methods and also details
procedures that do not require specific calibration equipment.
When the robot system must be recalibrated, it is done according to documentation enclosed
with the calibration tools.
When to calibrate
The system must be calibrated if any of the below occurs.
The resolver values are changed
If resolver values are changed, the robot must be recalibrated using the calibration methods
supplied from ABB. Calibrate the robot carefully with standard calibration. The different
methods are briefly described in section Calibration methods on page 410, and further
detailed in separate Calibration manuals.
If the robot has Absolute Accuracy calibration, it is also recommended but not always needed
to be calibrated for new Absolute Accuracy.
The resolver values will change when parts affecting the calibration position are replaced on
the robot, e.g. motors, wrist or part of transmission.
Contents of the revolution counter memory are lost
If the contents of the revolution counter memory are lost, the counters must be updated as
detailed in section Updating revolution counters on page 415. This will occur when:
The revolution counters must also be updated after the robot and controller are connected at
the first installation.
The robot is rebuilt
If the robot has been rebuilt, e.g. after a crash or when the robot has been changed for other
reachability, it needs to be recalibrated for new resolver values.
If the robot has Abslolute Accuracy calibration, it needs to be calibrated for new Absolute
Accuracy.
3HAC023082-001 Revision: E
409
5 Calibration information
5.2. Calibration methods
Type of calibration
Description
Calibration method
Standard
calibration
Calibration Pendulum
(standard method)
or
Levelmeter calibration
(alternative method)
Absolute Accuracy
calibration
(optional)
xx0400001197
3HAC023082-001 Revision: E
Types of calibration
5 Calibration information
5.2. Calibration methods
Continued
Calibration methods
Each calibration method is detailed in a separate manual. Below is a brief description of the
methods available.
Calibration Pendulum - standard method
Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB
6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the
standard type of calibration. It is the recommended method in order to achieve proper
performance.
Two different routines are available for the Calibration Pendulum method:
Calibration Pendulum II
Reference Calibration.
3HAC023082-001 Revision: E
411
5 Calibration information
5.3. Calibration scales and correct axis position
A1
A2
B1
B2
C1
C2
3HAC023082-001 Revision: E
xx0200000176
5 Calibration information
5.3. Calibration scales and correct axis position
Continued
Calibration scales/ marks, IRB 6600ID and IRB 6650ID
The illustration below shows the location of the calibration scales on specific plates and the
calibration marks directly in the casting at axes 2 and 3.
xx0500002016
3HAC023082-001 Revision: E
413
5 Calibration information
5.4. Calibration movement directions for all axes
Note! The figure shows an IRB 7600, but the positive direction is the same for all 6-axis
robots, except the positive direction of axis 3 for IRB 6400R which is in the opposite
direction!
xx0200000089
414
3HAC023082-001 Revision: E
5 Calibration information
5.5. Updating revolution counters
Note
Detailed in section:
Step 2 - Storing the revolution counter
setting with the TPU on page 416
(RobotWare 4.0).
Step 2 - Storing the revolution counter
setting with the FlexPendant on page 417
(RobotWare 5.0).
When running the robot to calibration position, it is extremely important to make sure that
axes 4 and 6 of the below mentioned robots are positioned correctly. The axes can be
calibrated at the wrong turn, resulting in wrong calibrated robot.
Make sure the axes are positioned according to the correct calibration values, not only
according to the calibration marks. The correct values are found on a label, located either on
the lower arm or underneath the flange plate on the base.
At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before
the revolution counters are updated.
If one of the below mentioned axes are rotated one or more turns from its calibration position
before updating the revolution counter, the correct calibration position will be lost due to
uneven gear ratio. This affects the following robots:
Robot variant
Axis 4
Axis 6
IRB6600-175/2.55
Yes
No
IRB6600/6650 / others
Yes
Yes
IRB6600ID/6650ID
Yes
No
If the calibration marks seem to be wrong (even if the motor calibration data is correct), try
to rotate the axis one turn, update the revolution counter and check the calibration marks
again (try both directions, if needed).
415
5 Calibration information
5.5. Updating revolution counters
Continued
Step 2 - Storing the revolution counter setting with the TPU
This section details the second step when updating the revolution counter; storing the
revolution counter setting with the TPU (RobotWare 4.0).
Action
Note
xx0100000194
xx0100000201
3. Select the desired unit and choose Rev Counter Update from the
Calib menu.
The Revolution Counter Update window appears.
xx0100000202
4. Select the desired axis and press Incl to include it (it will be marked
with an x) or press All to select all axes.
5. Press OK when all axes that are to be updated are marked with an x.
CANCEL returns to the Calibration window.
6. Press OK again to confirm and start the update.
CANCEL returns to the Revolution Counter Update window.
7. At this point, it is recommended that the revolution counter values are
saved to a diskette.
Not required.
3HAC023082-001 Revision: E
5 Calibration information
5.5. Updating revolution counters
Continued
Action
Note
8.
CAUTION!
If a revolution counter is incorrectly updated, it will cause incorrect robot
positioning, which in turn may cause damage or injury!
Check the calibration position very carefully after each update.
How to perform the check is detailed in section Checking the calibration
position on page 419.
en0400000771
417
5 Calibration information
5.5. Updating revolution counters
Continued
Action
4. Select the axis to have its revolution counter updated by:
Ticking in the box to the left
Tapping Select all to update all axes.
Then tap Update.
5. A dialog box is displayed, warning that the updating operation cannot be undone:
Tap Update to proceed with updating the revolution counters.
Tap Cancel to cancel updating the revolution counters.
Tapping Update updates the ticked revolution counters and removes the tick from the
list of axes.
6.
CAUTION!
418
3HAC023082-001 Revision: E
5 Calibration information
5.6. Checking the calibration position
Note
This section describes how to create a program, which runs all the robot axes to their zero
position.
Action
Note
419
5 Calibration information
5.6. Checking the calibration position
Continued
Using the Jogging window on the TPU, S4Cplus
This section describes how to jog the robot to all axes zero position.
Action
Illustration/Note
xx0100000195
xx0100000196
Note
420
3HAC023082-001 Revision: E
5 Calibration information
5.7. Additional calibration instruction, IRB4400
xx0600003124
Upper arm
hose clamp
3HAC023082-001 Revision: E
421
5 Calibration information
422
3HAC023082-001 Revision: E
6 Decommissioning
6.1. Environmental information
6 Decommissioning
6.1. Environmental information
Hazardous material
The table specifies some of the materials in the manipulator and their respective use
throughout the product.
Dispose the components properly to prevent health or environmental hazards.
Material
Example application
Copper
Cables, motors
Steel
Neodymium
Brakes, motors
Oil, grease
Gearboxes
Aluminium
3HAC023082-001 Revision: E
423
6 Decommissioning
6.2. Decommissioning of balancing device
Art. no.
Note
Standard toolkit
Cutting torch
DANGER!
Do not under any circumstances, deal with the balancing device in any other way than that
detailed in the product documentation! For example, attempting to open the balancing device
is potentially lethal!
Action on field, decommissioning
The procedure below details the actions to perform on field, when the balancing device is to
be decommissioned.
Note
1. Remove the balancing device from the robot. Detailed in section Removal, balancing
device on page 325.
2. Send the device to a decommissioning
company.
3HAC023082-001 Revision: E
Action
6 Decommissioning
6.2. Decommissioning of balancing device
Continued
Decommissioning at decommissioning company, balancing device
The instruction below details how to decommission the balancing device. Contact ABB
Robotics for further consultation.
Action
Note/Illustration
1.
DANGER!
There is stored energy built up by high
tensioned compression springs inside the
balancing device! The device also contains
some grease!
2. Place the device on a workbench or
similar. Make sure it is clamped in position
with a vice or similar.
3. Open a hole in the side of the housing as
shown in the figure.
xx0400000700
4. Cut the coils of the three springs inside the Use a cutting torch.
housing as specified below:
Outer spring: cut at least five coils!
Middle spring: cut at least four coils!
Inner spring: cut at least four coils!
5. Double-check the number of coils cut and
make sure all the tension in the springs is
removed.
3HAC023082-001 Revision: E
425
6 Decommissioning
426
3HAC023082-001 Revision: E
7 Robot description
7.1. Type A and type B of IRB 6600/6650
7 Robot description
7.1. Type A and type B of IRB 6600/6650
Type B - enlarged gear
Type B robots of IRB 6600/6650 have an enlarged gear on axis 2. As a result of this
enlargement, following main parts on the robot differ from type A:
frame
lower arm
motor, axis 2
Those robots with the enlarged gear are named IRB 6600 Type B / IRB 6650 Type B.
3HAC023082-001 Revision: E
427
7 Robot description
428
3HAC023082-001 Revision: E
8 Reference information
8.1. Introduction
8 Reference information
8.1. Introduction
General
This chapter includes general information, complementing the more specific information in
the Product manual (part 1 of 2), procedures.
3HAC023082-001 Revision: E
429
8 Reference information
8.2. Applicable Safety Standards
EN ISO 10218-1:2006 - Robots for industrial environments - Safety requirements Part 1 Robot.
430
EN 811 - Safety distances to prevent danger zones being reached by the lower limbs.
EN 294 - Safety distances to prevent danger zones being reached by the upper limbs.
3HAC023082-001 Revision: E
The following standards are applicable when the robot is part of a robot cell:
8 Reference information
8.3. Unit conversion
Length
1m
3.28 ft
Weight
1 kg
2.21 lb
Pressure
1 bar
100 kPa
Force
1N
0.738 lbf
Moment
1 Nm
0.738 lbf-tn
Volume
1L
0.264 US gal
39.37 in
14.5 psi
Quantity
3HAC023082-001 Revision: E
431
8 Reference information
8.4. Screw joints
3. Tighten to the torque specified in section Tightening torque below. Screw dimensions
of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or
smaller may be tightened without a torque wrench if this is done by trained and
qualified personnel.
Lubricant
Art. no.
1171 2016-618
3HAC023082-001 Revision: E
8 Reference information
8.4. Screw joints
Continued
Tightening torque
Before tightening any screw, note the following:
Use the correct tightening torque for each type of screw joint.
Always tighten the joint by hand, and never use pneumatical tools.
Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow,
flowing motion.
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.
Tightening torque (Nm)
Class 4.8, oil-lubricated
M2.5
0.25
M3
0.5
M4
1.2
M5
2.5
M6
5.0
Dimension
433
8 Reference information
8.4. Screw joints
Continued
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.
Dimension
Tightening torque
(Nm)
Class 8.8, oil-lubricated
Tightening torque
(Nm)
Class 10.9, oil-lubricated
Tightening torque
(Nm)
Class 12.9, oil-lubricated
M5
M6
10
M8
24
34
40
M10
47
67
80
M12
82
115
140
M16
200
290
340
M24
725
960
1150
The table below specifies the recommended standard tightening torque for Molycotelubricated screws with Allen head screws.
Dimension
M8
28
34
M10
55
66
M12
96
115
M16
235
280
M24
790
950
434
Dimension
Tightening torque
Nm - Nominal
Tightening torque
Nm - Min.
Tightening torque
Nm - Max.
1/8
12
15
1/4
15
10
20
3/8
20
15
25
1/2
40
30
50
3/4
70
55
90
3HAC023082-001 Revision: E
The table below specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of brass.
8 Reference information
8.5. Weight specifications
Note
CAUTION!
3HAC023082-001 Revision: E
435
8 Reference information
8.6. Standard toolkit
Rem.
To be shortened to 12 mm
Qty
436
3HAC023082-001 Revision: E
8 Reference information
8.7. Special tools
Qty
Art. no.
3HAB 3409-86
3HAC 15520-1
3HAC 15520-2
3HAC 15521-1
3HAC 15521-2
3HAC 14459-1
3HAC 15534-1
Mech stop ax 3
3HAC 12708-1
3HAC 14972-1
Fits motors, axes 4, 5 and 6.
3HAC 14631-1
Fits motors axes 1, 2 and 3.
Rotation tool
3HAC 17105-1
3HAC 15571-1
3HAA 1001-186
Special tools
The table below specifies the special tools required during several of the service procedures.
The tools may be ordered separately and are also specified directly in concerned instructions
in the Product manual, procedures.
Description
Qty
Art. no.
3HAC020729-001
3HAC020999-001
3HAC022637-001
3HAC13056-2
3HAC13056-3
3HAC13056-4
437
8 Reference information
8.7. Special tools
Continued
Description
Qty
Art. no.
3HAC13120-5
3HAC14628-2
3HAC14628-1
Hydraulic cylinder
3HAC11731-1
3HAC13086-1
3HAC021563-012
3HAC15560-1
3HAC15607-1
3HAC15994-1
3HAC16131-1
3HAC14457-4
3HAC15556-1
3HAC020386-001
Measuring tool
6896134-GN
3HAC021883-001
3HAC021590-001
3HAC13527-1
3HAC021563-001
3HAC021600-001
3HAC020902-001
3HAC17129-1
3HAC12475-1
3HAC020997-1
Support, base
3HAC15535-1
3HAC021984-001
The table below specifies the tools that may be rented from ABB in order to perform certain
service procedures as described in the Product manual.
The special tools are also listed directly in the instructions.
Description
Art. no.
Note
3HAC14691-1
Includes
guidings, 3HAC14446-1
Art. no.
Angel bracket
68080011-LP
Calibration bracket
3HAC 13908-9
3HAC 13908-4
Note
3HAC023082-001 Revision: E
8 Reference information
8.7. Special tools
Continued
Description
Art. no.
Note
6369901-347
Measuring pin
3HAC 13908-5
Sensor fixture
68080011-GM
Sensor plate
3HAC 0392-1
Sync. adapter
3HAC 13908-1
3HAC 68080011-GU
Art. no.
Note
3HAC15716-1
Note
3HAC 021745-001
Includes
vacuum pump with
regulator, hose and coupling
couplings and adapters
pump (manual) with hose
and coupling
graduated measuring glass
oil gun
user instructions.
Description
3HAC023082-001 Revision: E
439
8 Reference information
8.8. Lifting equipment and lifting instructions
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
440
3HAC023082-001 Revision: E
This chapter specifies all spare parts and replacement articles of the robot.
3HAC023082-001 Revision: E
441
This section specifies all articles considered spare parts of the robot. The spare parts are also
specified as required equipment directly in the repair instruction of the current spare part.
442
3HAC023082-001 Revision: E
The figure below shows the spare parts of the IRB 6600 and IRB 6650.
xx0400001022
443
The figure below shows the spare parts of the IRB 6600ID and IRB 6650ID.
xx0500001796
3HAC023082-001 Revision: E
The table below specifies all the recommended spare parts for the robot.
Item
Description
Note
3HAC 15879-2
3HAC 15879-3
Axis 1
Foundry Prime
Gearbox
3HAC 10828-8
Axis 1
3HAC 021030-001
Axis 2
3HAC026975-001
Foundry Prime
Gearbox axis 2
3HAC 021541-001
Axis 2
3HAC 15885-2
Axis 3
3HAC026976-001
Foundry Prime
Gearbox
3HAC 021127-001
Axis 3
3HAC 15889-2
Axis 4
3HAC026977-001
Foundry Prime
SMB unit
3HAC 16014-1
Battery pack
3HAC 16831-1
Wrist, type 2
3HAC 16626-2
(IRB 6650 -125/3.2, -200/2.75, IRB 6600
-175/2.8, -225/2.55)
Wrist, type 2
3HAC026879-001
Foundry Prime
Wrist, process
(IRB 6600ID and IRB 6650ID)
3HAC 024793-001
3HAC025571-001
3HAC 13752-1
3HAC 020691-001
3HAC 020692-001
3HAC 023745-003
Axis 5
3HAC 023746-003
Axis 6
3HAC 024815-001
3HAC 024810-001
Foundry Prime
445
Description
Note
3HAC 021325-001
Axis 5
3HAC 021675-001
Axis 5
Hood
3HAC 021222-001
3HAC 025899-001
Cable cover
(IRB 6600 and IRB 6650)
3HAC 022172-003
3HAC 025503-001
3HAC 025504-001
3HAC026981-001
3HAC 024385-001
3HAC 024386-001
3HAC 14139-1
Motor
3HAC 17484-10
3HAC026982-001
Axis 5
Foundry Prime
Gearbox
3HAC 10828-13
Axis 6
3HAC 15991-4
3HAC026983-001
Axis 6
Foundry Prime
3HAC 14140-1
3HAA 2167-18
Sealing spacer
3HAC 12649-1
O-ring
3HAB 3772-75
Sealing ring
3HAC 11581-5
3HAC 021592-001
3HAC023082-001 Revision: E
Foundry Prime
25-3
30-1
33-1
37-1
Base plate
87-1
88-1
89-1
159-1
184-1
213-1
Safety lamp
536-1
Chip protection
571-1
Base spacers
430-1
Option no.
3HAC023082-001 Revision: E
447
448
3HAC023082-001 Revision: E
Part
IRB 6600-
Item no
and type
Frame / typeA
101.2.1
101.2.1
3HAC 10141-1
105
3HAC 13940-1
105
105
105
105
105
3HAB3409-84
Screw M16x50
18X
18X
108.202
3HAA1001-186
Washer 7x25x3
18X
18X
108.204
3HAC16926-1
3HAC16331-1
Harness ax.1-4
X
X
X
X
108.201
108.235
X
108.235
108.211
108.211
106
106
108.201
106
X
106
3HAC9760-3
111.501
Standard
3HAC15859-2
111.501
Standard
and Foundry
3HAC9760-7
2X
111.501
Standard
3HAC15859-3
2X
111.501
Standard
and Foundry
3HAB7700-69
Screw M12x50
12X
12X
24X 111.503
12X
449
Art. no.
Part
IRB 6600-
Item no
and type
Washer 13x19x1,5
12X
12X
12X
24X 111.504
9ABA107-56
2X
9ADA618-56
Screw M6x16
4X
6X
6X
12X 111.507
3HAC9760-9
Cover 250mm
111.506
111.506
Cover 450mm
3HAC15879-2
Motor axis 1
3HAC15882-2
Motor axis 2
3HAC15885-2
109.307
109.307
Bracket
3HAC15882-2
Motor axis 3
3HAC15885-2
2X
111.506
109.306
109.307
109.301
109.301
109.302
X
109.302
109.336
109.336
109.336
109.338
Motor axis 3
102.3.5
3HAB3409-71
Screw M12x50
8X
8X
8X
8X
8X
8X
8X
109.304
3HAA1001-134
Washer 13x19x1.5
8X
8X
8X
8X
8X
8X
8X
109.305
3HAB3772-69
O-ring / typeA
3HAB3772-73
O-ring / typeB
3HAC15887-2
Motor axis 4
3HAC15889-2
Motor axis 4
102.3.5
X
X
3HAC11427-1
3HAC16627-3
Wrist, type 1
3HAC16626-2
Wrist, type 2
450
102.4
104
X
X
104
109.318
102.4
109.318
104
110.410
110.410
103
103
3HAC023082-001 Revision: E
111.505
Part list
Item Qty
Art. number
Description
Note / Dimension
3HAC 17358-1
Mechanical stop ax 1,
assembly
101
102
3HAC 10746-1
Axis 3-4
102
3HAC 10746-4
103
3HAC 8114-3
Wrist, type 2
103
3HAC026578-001
103
3HAC 8114-5
103
3HAC 8114-8
103
104
3HAC 17117-2
104
3HAC 17117-3
105
105
106
3HAC 14940-1
106
3HAC 16331-1
106
106
3HAC024386-001
451
Art. number
Description
Note / Dimension
108
3HAC 13263-1
109
3HAC 13264-1
110
3HAC 13265-1
111
3HAC 12311-4
111
3HAC 12311-5
112
2 or 1 3HAC 12129-1
Cover plate
t=1,5 mm
112
113
8 or 4 9ADA 618-56
M6 x 16
114
3HAC 13416-1
Protection cover
Shell size 16
115
3HAC 18281-1
Cover
3HAC026188-001
452
3HAC023082-001 Revision: E
Description
Note / Dimension
101.1
3HAC 17224-4
Base, machining
101.1
3HAC026572-001
101.2
3HAC 020858-001
101.3
3HAC 11732-2
Washer
T=3
101.4
18
3HAB 7700-5
101.5
3HAC 11529-1
101.6
3HAC 14453-1
101.7
3HAC 14453-2
Plug
101.8
3HAC 4428-2
Hose Clip
D=23-27
101.9
9ADA 618-56
M6 x 16
D=28
Base, machining
Item
Description
101.1.1 1
3HAC 17224-2
Base, casting
101.1.2 5
3HAC 4836-7
Protection plug
101.1.3 1
3HAC 1383-2
101.1.4 1
3HAC 14024-1
Protection screw
Dimension
16 x 12.3 x 9 x 7
Item
Description
Dimension
101.2.1 1
3HAC 020136-004
Frame machining
101.2.1 1
3HAC026573-001
Frame machinning
(Foundry Prime)
101.2.2 1
3HAC 10828-8
RV 320C-224,26 assembly
101.2.3 24
3HAB 3409-73
101.2.4 24
3HAA 1001-134
Washer
3HAC023082-001 Revision: E
13 x 19 x 1.5
453
Description
Note
102.1
3HAC 13350-1
Material set ax 4
102.2
3HAC 020049-001
102.3
3HAC 13351-1
Axis 3
102.4
3HAC 14752-1
Art. number
Description
Dimension / Note
102.1.1
3HAC 12261-1
Gear Z4 /4
102.1.3
9ADA 183-37
M8 x 25
102.1.4
9ADA 312-7
Plain washer
8.4 x 16 x 1.6
102.1.5
3HAC 12259-1
102.1.6
3HAA 1001-99
Wedge
102.1.7
3HAC 12560-1
Stud bolt
M8 x 65
102.1.8
12
9ADA 334-7
8.4 x 18 x 2
102.1.9
9ADA 267-7
Hexagon nut
M8
102.1.10 3
3HAB 3409-63
M10 x 110
102.1.11 3
9ADA 334-8
10.5 x 23 x 2.5
102.1.12 1
3HAC 13564-1
Damper axis 4
102.1.13 1
3HAA 1001-17
102.1.14 1
3HAC 11925-1
102.1.15 2
3HAB 3409-81
M16 x 35
102.1.16 1
3HAA 1001-98
Gasket
T=1
102.1.17 1
3HAC 12149-4
102.1.17 1
3HAC026309-001
102.1.18 14
9ADA 618-56
102.1.20 1
3HAC 17218-1
Set of shims
102.1.21 1
3HAC 17219-2
Thrust washer
102.1.22 1
9ABA 135-45
M6 x 16
170
3HAC023082-001 Revision: E
Item
Qty
Art. number
Description
Dimension / Note
102.1.23 2
2213 253-5
Ball bearing
170 x 215 x 22
102.1.24 1
2216 261-18
Sealing
170 x 200 x 15
102.1.25 1
2216 0086-4
Sealing (Nilos)
180 x 215 x 4
102.1.26 1
3HAB 4317-1
Sealing
102.1.27 1
3HAC 022620-001
Spacer ring
102.1.28 1
21522012-535
O-ring
169.3 x 5.7
102.1.29 1
9ABA 107-56
Parallel pin
10 x 20
Lubricating oil:
Mobilgear 600 XP320
102.1.31 30 g
3HAB 3537-1
Bearing grease
102.1.32 1 ml
3HAB 7116-1
Locking liquid
102.1.33 1 ml
3HAB 7116-2
Locking liquid
102.1.34 1
3HAC 16721-1
Magnetic plug
R 1/2
Qty
Art. number
Description
Dimenstion / Note
102.1.5.1 1
3HAC 11742-1
102.1.5.2 1
3HAC 12259-2
102.1.5.3 1
2126 2851-104
Lock nut
M20 X 1
102.1.5.4 1
2213 3802-11
40 x 68 x 19
102.1.5.5 1
3HAA 1001-129
102.1.5.6 1 ml
3HAB 7116-2
Locking liquid
Qty
Art. number
Description
102.1.5.2.0
3HAC 12259-3
Pinion Z3 /4
102.1.5.2.0
3HAC 12259-4
Gear Z2 /4
Item
Qty
Art. number
Description
102.1.12.2
3HAC 13564-2
Dimension
Qty
Art. number
Description
Dimension
102.1.17.1
3HAC 12149-3
102.1.17.2
3HAA 1001-628
Sealing
Qty
Art. number
Description
102.2.1
3HAC 10139-2
Note
455
Qty
Art. number
Description
Note
102.2.2
3HAC 1383-2
Qty
Art. number
Description
Dimension
102.2.2.1 1
9ADA 624-69
M8 x 20
102.2.2.2 1
3HAB 3772-66
O-ring
8x2
102.2.2.3 1
3HAC 1383-1
Protection Cover
102.2.2.4 1
3HAC 1383-3
Gasket
Art. number
Description
102.3.1
3HAC 10133-1
Axis 4 housing
102.3.1
3HAC026577-001
Axis 4 housing
(Foundry Prime)
102.3.2
102.3.3
24
3HAB 3409-71
M12 x 60
102.3.4
24
3HAA 1001-134
Washer
13 x 19 x 1.5
102.3.5
3HAC 14750-1
102.3.6
3HAB 3409-50
M10 x 40
102.3.7
3HAB 4233-1
Washer
102.3.8
3HAC 16721-1
Magnetic plug
102.3.9
102.3.9
102.3.10
10 x 30
9ABA 142-92
Dimension / Note
R 1/2
Qty
Art. number
Description
Dimension
102.3.2.1 1
3HAC 10828-11
RV 410F, i=270,176
102.3.2.2 1
3HAB 3772-68
O-ring
276 x 3.53
Qty
Art. number
Description
Dimension
102.3.5.1
3HAC 17484-9
Rotational ac motor M9
102.3.5.2
3HAC 10122-15
Input gear
3HAC023082-001 Revision: E
Item
Qty
Art. number
Description
Dimension
102.3.5.3
2152 2012-430
O-ring
89.5 x 3
102.3.5.4
9ADA 183-444
M8 x 130
102.3.5.5
3 ml
3HAB 7116-1
Locking liquid
Art. number
Description
102.4.1
3HAC 17484-10
102.4.2
3HAC 12260-1
Pinion Z1 /4
102.4.3
2152 2012-430
O-ring
Dimension
89,5x3
Item
3HAC023082-001 Revision: E
457
Qty
Art. number
Description
Note
102.1
3HAC 13350-1
Material set ax 4
102.2
102.3
3HAC 13351-1
Axis 3
102.4
3HAC 14752-1
458
3HAC023082-001 Revision: E
Art. number
Description
102.1
3HAC 13350-1
Material set ax 4
102.2
102.3
3HAC 13351-1
Axis 3
102.4
3HAC 14753-1
102.4
3HAC 14752-1
Note
Item
3HAC023082-001 Revision: E
459
Qty
Art. number
Description
Dimension / Note
103.1
3HAC 8114-4
Material set
103.2
3HAC 7941-30
103.3
10
3HAB 3409-89
M16 x 80
103.4
3HAC 13890-1
Axis 6 complete
103.5
3HAC 020566001
Label
Item
Qty
Art. number
Description
103.1.1
3HAC 7956-1
103.1.2
3HAC 7941-28
103.1.3
3HAC 7941-19
103.1.4
9ADA 183-37
103.1.5
9ADA 312-7
Plain washer
8.4 x 16 x 1.6
103.1.6
3HAA 2166-11
VK-Cover
D=80 B=10
103.1.7
3HAC 4334-3
50 x 90 x 20
103.1.8
3HAC 12560-1
Stud bolt
M8 x 65
103.1.9
1 ml
3HAB 7116-2
Locking liquid
103.1.10 16
9ADA 334-7
8.4 x 18 x 2
103.1.11 4
9ADA 267-7
Hexagon nut
M8
103.1.12 4
3HAA 1001-99
Wedge
103.1.13 1
3HAB 7299-1
Sealing
103.1.14 1
3HAA 2166-23
VK-Cover
D=120, B=12
103.1.15 1
3HAC 7941-32
103.1.16 6
9ADA 183-39
103.1.17 2
3HAB 4337-2
Damper axis 5
103.1.18 1
3HAC 9953-1
T=1.5
103.1.19 1
3HAC 16721-1
Magnetic plug
R 1/2
103.1.21 27
9ADA 618-56
M6 x 16
103.1.22 2
9ADA 334-6
Plain washer
6.4 x 14 x 1.5
103.1.23 1 ml
3HAB 7116-1
Locking liquid
103.1.24 1
3HAC 14139-1
Manip. Harness ax 5
Lubricating oil:
Mobilgear 600 XP320
3HAC023082-001 Revision: E
Dimension / Note
Qty
Art. number
Description
Dimension / Note
103.1.26 1
3HAC 7941-6
103.1.27 1
3HAC 022695001
Screw
103.1.28 1
3HAC 7941-21
103.1.29 1
3HAC 8081-8
103.1.30 1
3HAC 022172001
Cable cover
103.1.31 1
3HAC 14140-1
103.1.32 2
2166 2055-3
4.8 x 208
103.1.33 5
3HAA 1001-106
Washer
103.1.34 5 ml
1171 2016-618
Lubricant, paste
Qty
Art. number
Description
Dimension
103.1.15.1
3HAC 14731-1
Shaft
103.1.15.2
3HAB 3643-11
130 x 165 x 18
103.1.15.3
9ADA 618-56
M6 x 16
103.1.15.4
1 ml
3HAB 7116-1
Locking liquid
Qty
Art. number
Description
Dimension / Note
103.1.26.1
3HAC 7946-1
103.1.26.2
3HAA 1001-130
103.1.26.3
3HAC 7941-12
103.1.26.4
3HAC 13142-1
Washer
17 x 30 x 6
103.1.26.5
3HAC 7941-11
Locking Nut
103.1.26.6
1 ml
3HAB 7116-2
Locking liquid
Description
103.1.26.3.1
3HAC 7941-7
103.1.26.3.2
3HAC 7941-5
Dimension
Qty
Art. number
Description
Dimension
103.1.28.1
3HAC 7941-8
103.1.28.2
3HAB 4271-1
103.1.28.3
3HAB 6686-1
Support ring
461
Qty
Art. number
Description
103.1.28.4
1 ml
3HAB 7116-2
Locking liquid
Dimension
Qty
Art. number
Description
Dimension
103.2.1
3HAC 17484-10
103.2.2
3HAC 7941-1
103.2.3
2152 2012-430
O-ring
89.5 x 3
Qty
Art. number
Description
Dimension / Note
103.4.1
3HAC 13752-1
Turning disk
103.4.2
3HAC 10828-13
RV 70F-125,8 assembly
103.4.3
3HAC 11522-2
103.4.3
3HAC 16009-1
103.4.4
3HAC 14754-1
103.4.5
9ADA 312-7
Plain washer
8.4 x 16 x 1.6
103.4.6
9ADA 183-37
M8 x 25
103.4.7
18
3HAA 1001-172
Washer
8.4 x 13 x 1.5
103.4.8
2522 122-1
Magnetic plug
R1/4
103.4.9
103.4.9
103.4.10
2 ml
3HAB 7116-1
Locking liquid
103.4.11
3HAB 3772-64
O-ring
150.0 x 2.0
103.4.12
12
3HAB 3772-61
O-ring
13.1 x 1.6
103.4.13
3HAC 16862-1
Syncplate 175 kg
103.4.14
12
3HAB 7700-65
M12 x 30
103.4.15
18
3HAB 7700-55
M8 x 40
103.4.18
9ADA 618-32
M4 x 8
103.4.20
3HAC 14263-1
Protection Cover
103.4.21
9ADA 624-69
Qty
Art. number
Description
103.4.2.1
3HAC 10828-14
RV 70F, i=125,8
103.4.2.2
3HAB 3772-57
O-ring
Dimension
164.69 x 3.53
3HAC023082-001 Revision: E
Art. number
Description
Dimension
103.4.4.1
3HAC 17484-8
Rotational ac motor M8
103.4.4.2
3HAC 11173-3
Pinion RV 70F.125,8
103.4.4.3
2152 2012-430
O-ring
89.5 x 3
103.4.4.4
9ADA 183-415
M5 x 55
103.4.4.5
2 ml
3HAB 7116-1
Locking liquid
103.4.4.6
3HAC 12877-1
Gasket
Item
3HAC023082-001 Revision: E
463
Qty
Art. no.
Description
Note/Dimension
103.1
103.2
103.3
103.4
103.5
103.6
103.7
103.8
3HAC13406-7
103.9
103.10
3HAC18172-3
103.11
19
3HAC11409-6
Shoulder Screw
103.12
19
3HAC11409-6
Shoulder Screw
103.13
103.14
103.15
3HAB3701-30
103.16
3 ml
12690014-413
Locking liquid
103.17
3 ml
12690014-413
Locking liquid
103.18
103.19
103.20
3HAC16721-1
Magnetic plug
103.21
3HAC16721-1
Magnetic plug
103.22
3HAC18146-1
Bearing screw
103.23
3HAC18146-1
Bearing screw
103.24
11
9ADA624-56
Steel 8.8-A2F
M6x16
103.25
9ADA624-56
Steel 8.8-A2F
M6x16
103.26
3HAB3409-51
103.27
5,000ml 11712016-604
Lubricating oil
Mobilgear 600 XP320
103.28
6,000ml 11712016-604
Lubricating oil
Mobilgear 600 XP320
103.29
3HAC021675-001 Damper 2, ax 5
103.30
103.31
3 ml
3HAB7116-1
Locking liquid
103.32
3 ml
3HAB7116-1
Locking liquid
103.33
9ADA618-56
Steel 8.8-A2F
M6x16
3HAC023082-001 Revision: E
Gear z5/6
Qty
Art. no.
Description
Note/Dimension
103.34
9ADA312-6
Plain washer
6,4x12x1,6
103.35
9ADA183-37
103.36
9ADA183-37
103.37
9ADA312-7
Plain washer M8
103.38
9ADA312-7
Plain washer M8
103.39
18
3HAB3409-88
103.40
3HAB3772-85
O-ring
103.41
3HAC13142-1
Washer
103.42
3HAA1001-99
Wedge
103.43
3HAA1001-99
Wedge
103.44
3HAC12560-1
Stud bolt
103.45
3HAC12560-1
Stud bolt
103.46
16
9ADA334-7
Spring washer,conical
103.47
16
9ADA334-7
Spring washer,conical
103.48
9ADA267-7
Hexagon nut M8
103.49
9ADA267-7
Hexagon nut M8
103.50
3HAC022695-001 Screw
103.51
3HAC18246-1
103.52
3HAC021177-001 Screw
103.53
3HAB3701-38
103.54
2 ml
11712016-618
Lubricant, paste
103.55
2 ml
11712016-618
Lubricant, paste
103.56
Washer
3HAC023082-001 Revision: E
465
Qty
Art. number
Description
Dimension
103.1
3HAC 8114-4
Material set
103.2
3HAC 7941-30
103.3
10
3HAB 3409-89
103.4
3HAC 13890-2
103.5
3HAC 020566001
Label
466
3HAC023082-001 Revision: E
Description
Note/Dimension
103.1
3HAC 8114-4
Material set
103.2
3HAC 7941-30
103.3
10
3HAB 3409-89
103.4
3HAC 025176001
Ax 6, insulated
103.5
3HAC 020566001
Label
103.6
3HAC 025177001
Qty
Art. no.
Description
103.4.1
3HAC 17196-1
Axis 6 insulated
103.4.2
3HAC 14754-1
103.4.3
9ADA 312-7
Plain washer
M8
103.4.4
9ADA 183-37
103.4.5
450
ml
3HAC 032140001
103.4.5
450
ml
3HAC 16843-1
103.4.6
2 ml
3HAB 7116-1
Locking liquid
103.4.7
3HAC 16862-1
Syncplate 225 kg
103.4.8
9ADA 618-32
103.4.9
3HAC 14263-1
Protection cover
9ADA 624-69
103.4.10 1
Note/Dimension
Qty
Art. no.
Description
103.4.2.1
3HAC 17484-8
Rotational ac motor M8
103.4.2.2
3HAC 11173-3
Pinion RV70F-125,8
103.4.2.3
21522012-430
O-ring
103.4.2.4
9ADA 183-415
103.4.2.5
2 ml
3HAB 7116-1
Locking liquid
103.4.2.6
3HAC 12877-1
Gasket
3HAC023082-001 Revision: E
Note
467
Art. number
Description
Dimension
103.1
3HAC 8114-4
Material set
103.2
3HAC 7941-30
103.3
10
3HAB 3409-89
103.4
3HAC 13890-2
103.5
3HAC 020566001
Label
Item
468
3HAC023082-001 Revision: E
Description
Dimension /
Note
108.201 1
3HAC 020123-001
Axis 2
108.201 1
3HAC 17212-1
Axis 3
108.202 18
3HAB 3409-84
M16 x 50
108.202 33
3HAB 7700-69
M12 x 50
108.203 3
3HAC 12703-1
Washer, axis 3
108.204 18
3HAA 1001-186
Washer
17 x 25 x 3
108.206 12
3HAB 7700-69
M12 x 50
108.207 12
3HAA 1001-134
Washer
13 x 19 x 1.5
108.210 1
3HAC 14300-1
Cable protector
108.211 1
3HAC020507-001
108.211 1
3HAC 16926-1
108.212 1
3HAC 11771-1
108.213 1
3HAC 13960-1
108.214 2
3HAC 12320-1
Damper, axis 3
108.215 2
3HAC 12991-1
Damper, axis 2
108.216 2
9ADA 624-65
M6 x 60
108.217 2
9ADA 334-7
8.4 x 18 x 2
108.218 2
9ADA 618-57
M6 x 20
108.220 2
3HAC 9953-1
T=1.5
108.222 1
3HAC 12719-1
T=1.5
108.223 2
9ADA 183-48
M10 x 16
108.224 1
3HAC 12844-1
Cable cover
108.224 1
3HAC026340-003
Cable cover
Foundry Prime
108.225 21
9ADA 618-56
M6 x 16
108.228 1
3HAC 3261-1
Cover
108.229 1
3HAC 15431-1
Cable protection
108.230 1
3HAC 14880-1
108.231 1
21520441-1
Washer
108.232 6
3HAC 16721-1
Magnetic plug
R 1/2
108.233 1
2522122-1
Magnetic plug
G 1/4"
108.234 3
9ADA 618-56
M6 x 16
108.235 1
3HAC 021071-001
Item
3HAC023082-001 Revision: E
Qty
t = 4 mm
t=3
469
Item
Qty
Art. number
Description
Dimension / Note
109.301
3HAC 021541-001
Reduction gear
109.302
3HAC 022812-003
Cover, axis 2
109.304
32
3HAB 3409-71
M12 x 60
109.305
32
3HAA 1001-134
Washer
13 x 19 x 1.5
109.306
3HAC 14749-1
109.307
3HAC020219-001
109.308
3HAB 3409-50
M10 x 40
109.309
3HAB 4233-1
Washer
109.310
3HAC 12252-1
Bottom plate
T=3
109.310
3HAC026052-001
Bottom plate
(Foundry Prime)
T=2
109.311
3HAC 14131-1
t=3 mm
109.311
3HAC026186-001
t=3 mm
109.312
3HAC 11774-3
Adapter, complete
109.313
3HAC 11769-1
109.315
14
9ADA 183-39
M8 x 35
109.316
14
9ADA 312-7
Plain washer
8.4 x 16 x 1.6
109.318
3HAB 3772-73
O-ring
410 x 4
109.320
3HAC 021287-001
Sync plate
109.320
3HAC026185-001
Sync plate
109.321
3HAC 12671-6
109.322
3HAC 14024-1
Protection screw
109.324
24
9ADA 618-56
M6 x 16
109.325
9ADA 618-57
M6 x 20
109.326
3HAC 16014-1
109.327
109.328
3HAC 16831-1
Battery pack
109.329
3HAC 13151-1
Cable battery/SMB
L=350 20
109.330
3HAC 11526-1
Stud screw
M6 x 150
Foundry Prime
3HAC023082-001 Revision: E
Overview
Continued
Item
Qty
Art. number
Description
Dimension / Note
109.332
3HAC 14791-3
109.322
3HAC026190-001
109.334
9ADA 618-53
M6 x 8
109.336
3HAC 020745-001
Attachment plate
IRB 6600
109.336
3HAC 020122-001
Attachment plate
IRB 6650
109.337
3HAC 12625-1
Strap, Velcro
25 x 450
109.338
3HAC 14792-1
Bracket
T=3
109.339
3HAC 15619-1
109.340
1 ml
12690014-413
Locking liquid
109.341
7,300 3HAC16843-1
ml
109.341
109.342
109.342
109.344
1 ml
3HAB 7116-1
Locking liquid
109.345
9ADA 267-6
Hexagon nut
109.346
3HAC 16035-1
109.347
3HAC 6499-1
109.348
9ADA 629-56
109.349
9ADA 618-58
109.350
3HAC 4813-1
109.350
3HAC026331-001
109.351
10
9ADA 618-44
109.352
3HAC 14024-1
Protection screw
109.353
3HAC 17423-1
Washer
109.354
9ADA 269-4
Hexagon nut
109.360
3HAB 3558-14
Lock washer
Art. number
Description
M6 x 25
M5 x 12
M8
Reduction gear
Item
Qty
109.301.1 1
109.301.2 1
3HAB 3772-77
Dimension
O-ring
345 x 3.1
Qty
Art. number
Description
Dimension
109.306.1 1
3HAC 17484-6
Rotational ac motor M6
109.306.2 1
3HAC 11350-1
471
Qty
109.306.3 1
Art. number
Description
Dimension
2152 2012-430
O-ring
89.5 x 3
Qty
Art. number
Description
Dimension
109.307.1 1
109.307.2 1
109.307.3 1
9ADA 183-446
M8 x 150
109.307.4 1
2152 2012-430
O-ring
89.5 x 3
109.307.5 1 ml
3HAB 7116-1
Locking liquid
Art. number
Description
109.312.1 1
3HAC 11774-1
Adapter, machined
109.312.2 2
2152 2012-428
O-ring
109.312.3 1 ml
1234 0011-125
Acrylate adhesive
Qty
Dimension
79.5 x 3
Qty
Art. number
Description
Dimension
109.322.1 1
3HAC 13582-1
Protection screw
109.322.2 1
3HAB 3772-32
O-ring
17 x 3
Item
Art. number
Description
Dimension
109.327.1 1
3HAC 14692-1
Cover
109.327.2 1
3HAC 14692-2
Gasket
109.327.3 1
3HAC 14692-4
Rubber cloth
Art. number
Description
Dimension
109.332.1 1
3HAC 14791-1
Cover
T=4
109.332.2 1
3HAC 14791-2
Gasket
T=3
109.332.3 1
3HAC 16977-1
Qty
472
Qty
3HAC023082-001 Revision: E
Qty
Art. number
Description
Dimension
110.401
3HAC 12441-2
65 x 120 x 38
110.402
3HAC 12481-1
Thrust washer
110.403
3HAC 12627-1
Bushing
110.404
9ABA 135-31
110.405
3HAC 12480-1
Shaft
110.406
3HAC 4836-7
Protection plug
16 x 12.3 x 9 x 7
110.407
3HAB 7700-5
M16 x 70
110.408
9ABA 107-56
Parallel pin
10 x 20
110.409
3HAC 12548-1
Protection washer
T=1
110.410
3HAC 12534-1
110.411
3HAA 1001-186
Washer
110.412
50 ml 3HAA 1001-294
Grease
110.413
3HAC 4836-1
Protection plug
110.414
9ADA 183-490
M16 x 180
110.415
9ADA 312-10
Plain washer
17 x 30 x 3
65
17 x 25 x 3
3HAC023082-001 Revision: E
473
Qty
Art. number
Description
Dimension
111.501
3HAC 9760-3
111.501
3HAC 15859-2
111.503
12
3HAB 7700-69
M12 x 50
111.504
12
3HAA 1001-134
Washer
13 x 19 x 1.5
111.505
9ABA 107-56
Parallel pin
10 x 20
111.506
3HAC 9760-9
111.507
9ADA 618-56
M6 x 16
474
3HAC023082-001 Revision: E
Qty
Art. number
Description
Dimension
111.501
3HAC 9760-7
111.501
3HAC 15859-3
111.503
12
3HAB 7700-69
M12 x 50
111.504
12
3HAA 1001-134
Washer
13 x 19 x 1.5
111.505
9ABA 107-56
Parallel pin
10 x 20
111.506
3HAC 9760-10
111.507
9ADA 618-56
M6 x 16
3HAC023082-001 Revision: E
475
476
3HAC023082-001 Revision: E
10 Exploded views
10.1. Introduction
10 Exploded views
10.1. Introduction
Definitions
This chapter contains detailed views of the components on the manipulator.
The numbered details are specified with item numbers in the Part List.
The exploded views are divided into:
Base, incl. frame
Frame-Lower arm 1
Frame-Lower arm 2
Upper arm
Wrist complete
3HAC023082-001 Revision: E
477
10 Exploded views
10.2. Base incl. Frame
Exploded view
xx0200000329
478
3HAC023082-001 Revision: E
10 Exploded views
10.3. Frame-Lower arm 1
Exploded view
xx0500002513
3HAC023082-001 Revision: E
479
10 Exploded views
10.4. Frame-Lower arm 2
Exploded view
xx0200000335
480
3HAC023082-001 Revision: E
10 Exploded views
10.5. Upper arm
Exploded view
xx0200000337
3HAC023082-001 Revision: E
481
10 Exploded views
10.6. Wrist complete, IRB 6600 and IRB 6650
Exploded view
xx0200000336
482
3HAC023082-001 Revision: E
10 Exploded views
10.7. Wrist complete, IRB 6600ID and IRB 6650ID
Exploded view
xx0500002407
3HAC023082-001 Revision: E
483
10 Exploded views
484
3HAC023082-001 Revision: E
11 Circuit Diagram
11.1. Introduction
11 Circuit Diagram
11.1. Introduction
Overview
This chapter includes the circuit diagram for the robot.
Use the correct circuit diagram (IRB 6600, IRB 6650 and IRB 6650S)
The cable harness of the robot is available in two different designs. Either the cabling is
divided between the upper and lower arm, or not. Accordingly there are also two different
versions of the circuit diagram. Determine which circuit diagram that is valid for the robot,
by checking the article number for the cable harness.
3HAC023082-001 Revision: E
485
11 Circuit Diagram
11.2.1. Validity of circuit diagram 3HAC 025744-1
Action
WebConfig
486
3HAC023082-001 Revision: E
The information in this document is subject to change without notice and should not be construed as a
commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document.
Except as may be expressly stated anywhere in this document, nothing herein shall be construed as any
kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a
specific purpose or the like.
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
In no event shall ABB be liable for incidental or consequential damages arising from use of this document.
This document and parts thereof must not be reproduced or copied without ABB's written permission,
and contents therof must not be imparted to a third party nor be used for any unauthorized purpose.
Contravention will be prosecuted.
Additional copies of this document may be obtained from ABB at its then current charge.
Lab/Office:
Latest revision:
Status:
2007-04-20
APPROVED
Prepared by, date:
COPYRIGHT page
Title page/cover sheet
Document no.
=
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 1
Next 2
Total 21
3HAC025744-001
02
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
Table of contents
Page
Page description
ABB Contents1
Comment
COPYRIGHT page
Valid For
IRB 6660
Legend
10
20
30
Axis 1
40
Axis 2
50
Axis 3
60
Axis 4
70
Axis 5
IRB 7600
80
Axis 5
IRB 66XX
90
Axis 5
IRB 66XX ID
100
Axis 6
IRB 7600
110
Axis 6
IRB 66XX
120
Axis 6
IRB 66XX ID
130
140
150
Lab/Office:
Latest revision:
Status:
2007-04-20
APPROVED
Prepared by, date:
Document no.
=
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 2
Next 3
Total 21
3HAC025744-001
02
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
Valid For:
This circuit diagram is valid for the following cable harness assemblies:
3HAC 024385-001 Manipulator harness axis 1-6 (IRB 6600 / 6640)
3HAC 024386-001 Manipulator harness axis 1-6 (IRB 6640 / 6650 / 6650S)
3HAC14940-1 rev 3 and later. Manipulator harness axis 1-4 (IRB 6600 ID / 6640 ID / 7600)
3HAC16331-1 rev 1 and later. Manipulator harness axis 1-4 (IRB 6640 ID / 6650 ID)
3HAC14139-1 Manipulator harness axis 5 (IRB 6600 / 6640 / 6650 / 6650S)
3HAC11440-1 Manipulator harness axis 5-6 (IRB 7600)
3HAC023717-001 Manipulator harness axis 5-6 (IRB 6600 ID / 6640 ID / 6650 ID)
3HAC15930-1 UL signal lamp (IRB 6600 / 6640 / 6650 / 6600 ID / 6640 ID / 6650 ID / 6650S / 7600)
3HAC12498-1 Pos SW 3 functions (IRB 6600 / 6640 / 6650 / 6600 ID / 6640 ID / 6650 ID / 6650S / 7600)
3HAC12587-1 Pos SW 2 functions (IRB 6600 / 6650 / 6600 ID / 6650 ID / 6650S / 7600)
3HAC15374-1 Fan (IRB 6600 / 6640 / 6650 / 6600 ID / 6640 ID / 6650 ID / 6650S /6660 / 7600)
3HAC15390-1 Pos Sw/ Fan cable harness (IRB 6600 / 6600 ID / 7600)
3HAC16659-1 Pos Sw/ Fan cable harness (IRB 6650 / 6650 ID / 6650S)
3HAC023599-001 Fan cable harness (IRB 6600 / 6640 / 6650 / 6600 ID / 6640 ID / 6650 ID / 6650S /6660 / 7600)
3HAC026733-001 Manipulator harness axis 1-6 (IRB 6660)
3HAC028206-001 UL signal lamp (IRB 6660)
See circuit diagram 3HAC13347-1 in the following cases:
- If IRB6600, 6650 or 6650S with 3HAC14940-1, 3HAC16331-1
- If cable harness 3HAC14940-1 rev 2 or earlier
- If cable harness 3HAC16331-1 rev 0
Lab/Office:
Latest revision:
Status:
2007-04-20
APPROVED
Prepared by, date:
Valid For
Text view
Document no.
=
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 3
Next 4
Total 21
3HAC025744-001
02
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
R1.MP
R2.M5/6
(On IRB7600, 6600 ID,
6640 ID, 6650 ID)
1 10 17 24
2
3
12 11 10 9
6
R2.MP4
R2.FB4
8
2
7
B
1
4
5
R2.SW3
12 11 10 9
R3.FAN3
R2.FB3
R2.MP3
R2.H1
R2.H2
26
27
13 20 28
29
14 21
7
1
12 19
7
C
5
6
25
11 18
30
15 22
31
16 23 32
R2.MP1
R2.FB1
R1.MP
R1.SMB
R1.SW1
R1.SW2/3
Lab/Office:
Latest revision:
Status:
2005-10-17
APPROVED
Document no.
= 6600/6640-50/7600
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 4
Next 5
Total 21
3HAC025744-001
02
R3.MP6
R3.FB6
R3.MP5
R3.FB5
R2.CP/CS
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
R2.MP4
R2.FB4
R2.MP3
R2.FB3
R2.H1
R2.H2
R2.MP2
R2.FB2
R2.MP1
R2.FB1
R1.SMB1-3
R1.SMB4-6
R2.SMB
X8
X9
X10
R1.MP
R1.SMB
R1.CP/CS
Lab/Office:
Latest revision:
Status:
APPROVED
Document no.
IRB 6660
= IRB6660
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 5
Next 9
Total 21
3HAC025744-001
02
Motor
Protective Earth
PTC
Brake
Twisted wires
Screened wires
Resolver
XX
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
Battery Pack
BU
FB
Feedback unit
SMB
FAN
Fan
SW
Keypin
Position switch
Lab/Office:
Latest revision:
Status:
Legend
2005-10-17
APPROVED
Document no.
= IRB66XX/7600
Plant:
+ Manipulator
Location:
Sublocation: +
Rev. Ind Page 9
Next 10
Total 21
3HAC025744-001
02
Brake Release
-X8
-X8
1
2
-X10
A
11
Brake PB
12
0V
-X10
R1.MP
R1.MP
R1.MP
R1.MP
R1.MP
10
R1.MP
4
A
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
Key Pin
-BU 0V M6 / =7600+Axis 6/100;2
=66XX+Axis 6/110;2
-X9
A
-X9
10
10
Key Pin
Lab/Office:
Latest revision:
Brake Release
Status:
2005-10-17
APPROVED
Document no.
= 66XX/7600
Plant:
+ BU
Location:
Sublocation: +
Rev. Ind Page 10
Next 20
Total 21
3HAC025744-001
02
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
SMB
R2.SMB
R2.SMB
SDI
BK
SDI-N
WHBK
SDO
BN
SDO-N
WHBN
0V
RD
24V
WHRD
OG
L
M
KEYPIN
R2.G
+
-+
-+
R1.G(X3)
R1.G(X3)
0V
Lab/Office:
Latest revision:
Status:
2005-10-17
APPROVED
Document no.
= 66XX/7600
Plant:
+ SMB
Location:
Sublocation: +
Rev. Ind Page 20
Next 30
Total 21
3HAC025744-001
02
MU1
R1.MP
-R2.MP1
-R2.MP1
17
M1R
RD
24
M1R
RD
R (U)
PE
M
~
T (W)
3
18
M1S
WH
25
M1S
WH
19
M1T
BK
26
M1T
10
10
BK
PE
GNYE
GNYE
PE
GNYE
12
12
GNYE
BU M1
BU +
BU 0V M1
10
BU -
PTC M
PTC M2
11
11
+BU/10;7 / -BU M1
S (V)
Brake
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
+BU/10;2 / -BU 0V M1
27
SMB
-PTC1
FB1
R1.SMB1-3
R1.SMB1-3
BK
X1
14
14
WHBK
0V X1
-R2.FB1
-R2.FB1
RD
BK
Resolver
BN
Y1
BU
15
15
WHBN
0V Y1
YE
RD
0V EXC1
WHBK (WHYE)
18
18
WHRD
EXC1
WHRD
Lab/Office:
Latest revision:
Status:
Axis 1
2005-10-17
APPROVED
Document no.
= 66XX/7600
Plant:
+ Axis 1
Location:
Sublocation: +
Rev. Ind Page 30
Next 40
Total 21
3HAC025744-001
02
MU2
R1.MP
-R2.MP2
-R2.MP2
23
M2R
RD
32
M2R
RD
22
M2S
WH
R (U)
PE
M
~
T (W)
3
31
M2S
WH
21
M2T
BK
30
M2T
10
10
BK
PE
GNYE
GNYE
PE
GNYE
12
12
GNYE
BU M2
BU +
BU 0V M2
10
BU -
PTC M2
BU
PTC M3
11
11
BK
+BU/10;7 / -BU M2
S (V)
Brake
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
+BU/10;2 / -BU 0V M2
SMB
-PTC2
FB2
R1.SMB1-3
R1.SMB1-3
BK
X2
16
16
WHBK
0V X2
-R2.FB2
-R2.FB2
RD
BK
Resolver
BN
Y2
BU
17
17
WHBN
0V Y2
YE
RD
0V EXC1
WHBK (WHYE)
19
19
WHRD
EXC1
WHRD
Lab/Office:
Latest revision:
Status:
Axis 2
2005-10-17
APPROVED
Document no.
= 66XX/7600
Plant:
+ Axis 2
Location:
Sublocation: +
Rev. Ind Page 40
Next 50
Total 21
3HAC025744-001
02
MU3
R1.MP
-R2.MP3
-R2.MP3
M3R
RD
M3R
RD
R (U)
PE
M
~
T (W)
3
5
M3S
WH
M3S
WH
M3T
BK
14
M3T
10
10
BK
PE
GNYE
GNYE
PE
GNYE
12
12
GNYE
BU M3
BU +
BU 0V M3
10
BU -
PTC M3
BU
PTC M4
11
11
BK
+BU/10;7 / -BU M3
S (V)
Brake
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disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
+BU/10;2 / -BU 0V M3
-PTC3
B
A
KEYPIN
KEYPIN
OG
R2.H1
R2.H1
R2.H2
R2.H2
2
SMB
FB3
R1.SMB1-3
R1.SMB1-3
BK
X3
21
21
WHBK
0V X3
-R2.FB3
-R2.FB3
RD
BK
Resolver
10
10
BN
Y3
BU
22
22
WHBN
0V Y3
YE
RD
0V EXC1
WHBK (WHYE)
20
20
WHRD
EXC1
WHRD
Lab/Office:
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3HAC025744-001
02
MU4
R1.MP
-R2.MP4M4R
-R2.MP4-
RD
R (U)
PE
M
~
T (W)
3
2
M4S
WH
10
M4T
BK
PE
GNYE
GNYE
BU M4
BU +
BU 0V M4
BU -
PTC M4
BU
=7600+Axis 5/70;2
=66XX+Axis 5/80;2
=66XX ID+Axis 5/90;2 / -PTC M5
PTC M5
11
11
BK
+BU/10;7 / -BU M4
S (V)
Brake
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disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
+BU/10;2 / -BU 0V M4
1 -PTC4
A Keypin
Keypin B
SMB
FB4
R1.SMB4-6
R1.SMB4-6
BK
X4
14
14
WHBK
0V X4
-R2.FB4
-R2.FB4-
RD
BK
Resolver
BN
Y4
BU
15
15
WHBN
0V Y4
YE
RD
0V EXC2
WHBK (WHYE)
18
18
WHRD
EXC2
WHRD
Lab/Office:
Latest revision:
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2005-10-17
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Rev. Ind Page 60
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3HAC025744-001
02
MU5
R1.MP
R2.M5/6
M5R
20
C1
-R3.MP5
M5R
C1
-R3.MP5-
RD
R (U)
PE
M
~
T (W)
3
28
M5S
C2
C2
M5S
WH
29
M5T
C3
C3
M5T
BK
PE
GNYE
GND
PE
GNYE
GNYE
BU M5
B9
B9
BU M5
BU +
BU 0V M5
B1
B1
BU 0V M5
BU -
PTC M5
B7
B7
PTC M5
BU
B8
PTC M6
11
11
BK
=66XX/7600+BU/10;7 / -BU M5
GND
S (V)
Brake
=66XX/7600+BU/10;2 / -BU 0V M5
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
15
1 -PTC5
SMB
FB5
R1.SMB4-6
R1.SMB4-6
R2.M5/6
BK
X5
A1
A1
BK
X5
16
16
WHBK
0V X5
A7
A7
WHBK
0V X5
-R3.FB5-
-R3.FB5-
RD
BK
Resolver
BN
Y5
A2
A2
BN
Y5
BU
17
17
WHBN
0V Y5
A8
A8
WHBN
0V Y5
YE
RD
0V EXC2
A3
A3
RD
0V EXC2
WHBK (WHYE)
19
19
WHRD
EXC2
A9
A9
WHRD
EXC2
WHRD
Lab/Office:
Latest revision:
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2005-10-17
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Rev. Ind Page 70
Next 80
Total 21
3HAC025744-001
02
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
MU5
R1.MP
R3.MP5
M5R
20
-R4.MP5M5R
-R4.MP5-
RD
R (U)
PE
M
~
T (W)
3
28
M5S
M5S
WH
29
M5T
M5T
BK
PE
GNYE
GND
PE
GNYE
GNYE
BU M5
BU M5
BU +
BU 0V M5
BU 0V M5
BU -
PTC M5
PTC M5
BU
PTC M6
PTC M6
11
11
BK
=66XX/7600+BU/10;7 / -BU M5
GND
S (V)
Brake
=66XX/7600+BU/10;2 / -BU 0V M5
1 -PTC5
A Keypin
SMB
FB5
R1.SMB4-6
R1.SMB4-6
R3.FB5
BK
X5
BK
X5
16
16
WHBK
0V X5
WHBK
0V X5
-R4.FB5- -R4.FB56
6 RD
1
BK
Resolver
BN
Y5
BN
Y5
BU
17
17
WHBN
0V Y5
WHBN
0V Y5
YE
RD
0V EXC2
RD
0V EXC2
WHBK (WHYE)
19
19
WHRD
EXC2
WHRD
EXC2
WHRD
Lab/Office:
Latest revision:
Status:
Axis 5
2005-10-17
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Plant:
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Rev. Ind Page 80
Next 90
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3HAC025744-001
02
MU5
R1.MP
R2.M5/6
M5R
20
C1
C1
-R3.MP5
M5R
-R3.MP5-
RD
R (U)
PE
M
~
T (W)
3
28
M5S
C2
C2
M5S
WH
29
M5T
C3
C3
M5T
BK
PE
GNYE
GND
PE
GNYE
PE
GNYE
BU M5
B9
B9
BU M5
BU +
BU 0V M5
B1
B1
BU 0V M5
11
BU -
PTC M5
B7
B7
PTC M5
BU
BK
=66XX/7600+BU/10;7 / -BU M5
GND
PE
S (V)
Brake
=66XX/7600+BU/10;2 / -BU 0V M5
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
BU
PTC 0V 5
-PTC 0V.1 / +Axis 6/120;3
15
PTC M6
BU
1 -PTC5
SMB
FB5
R1.SMB4-6
R1.SMB4-6
R2.M5/6
BK
X5
A1
A1
BN
X5
16
16
WHBK
0V X5
A7
A7
WHBN
0V X5
-R3.FB5-
-R3.FB5-
RD
BK
Resolver
BN
Y5
A2
A2
RD
Y5
BU
17
17
WHBN
0V Y5
A8
A8
WHRD
0V Y5
YE
RD
0V EXC2
A3
A3
OG
0V EXC2
WHBK (WHYE)
19
19
WHRD
EXC2
A9
A9
WHOG
EXC2
WHRD
Lab/Office:
Latest revision:
Status:
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2005-10-17
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IRB 66XX ID
= 66XX ID
Plant:
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Rev. Ind Page 90
Next 100
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3HAC025744-001
02
R1.MP
9
MU6
-R3.MP6 -R3.MP6
-R2.M5/6M6R
C4
C4
M6R
RD
R (U)
PE
M
~
T (W)
3
8
M6S
C5
C5
M6S
WH
16
M6T
C6
C6
M6T
BK
PE
GNYE
GND
GND
PE
GNYE
GNYE
BU M6
B11
B11
BU M6
BU +
BU 0V M6
B12
B12
BU 0V M6
BU -
BU
11
11
BK
=66XX/7600+BU/10;7 / -BU M6
S (V)
Brake
=66XX/7600+BU/10;2 / -BU 0V M6
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
B10
B10
PTC 0V
PTC M6
SMB
1 -PTC6
FB6
R1.SMB4-6
R1.SMB4-6
R2.M5/6
BK
X6
21
21
WHBK
0V X6
A4
A4
BK
X6
A10
A10
WHBK
0V X6
-R3.FB6
-R3.FB6
RD
BK
Resolver
10
10
BN
Y6
22
22
WHBN
0V Y6
RD
0V EXC2
20
20
WHRD
EXC2
A5
A5
BN
Y6
BU
A11
A11
WHBN
0V Y6
YE
A6
A6
RD
0V EXC2
WHBK (WHYE)
A12
A12
WHRD
EXC2
WHRD
Lab/Office:
Latest revision:
Status:
Axis 6
2005-10-17
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Document no.
IRB 7600
= 7600
Plant:
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Location:
Sublocation: +
Rev. Ind Page 100
Next 110
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3HAC025744-001
02
MU6
-R3.MP6- -R3.MP6-
R1.MP
M6R
RD
R (U)
PE
M
~
T (W)
3
8
M6S
WH
16
M6T
BK
PE
GNYE
GNYE
BU M6
BU +
BU 0V M6
BU -
=66XX/7600+BU/10;7 / -BU M6
S (V)
Brake
=66XX/7600+BU/10;2 / -BU 0V M6
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
PTC M6
BU
PTC 0V
11
11
BK
SMB
1 -PTC6
FB6
R1.SMB4-6
R1.SMB4-6
BK
X6
21
21
WHBK
0V X6
-R3.FB6
-R3.FB6
RD
BK
Resolver
10
10
BN
Y6
BU
22
22
WHBN
0V Y6
YE
RD
0V EXC2
WHBK (WHYE)
20
20
WHRD
EXC2
WHRD
Lab/Office:
Latest revision:
Status:
Axis 6
2005-10-17
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Plant:
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Rev. Ind Page 110
Next 120
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3HAC025744-001
02
R1.MP
9
MU6
-R3.MP6 -R3.MP6
-R2.M5/6M6R
C4
M6R
C4
RD
R (U)
PE
M
~
T (W)
3
8
M6S
C5
C5
M6S
WH
16
M6T
C6
C6
M6T
BK
PE
GNYE
GND
GND
PE
GNYE
GNYE
BU M6
B11
B11
BU M6
BU +
BU 0V M6
BU -
PTC M6
BU
PTC 0V
11
11
BK
=66XX/7600+BU/10;7 / -BU M6
S (V)
Brake
+Axis 5/90;5 / -BU 0V M6.1
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
B10
B10
SMB
1 -PTC6
FB6
R1.SMB4-6
R1.SMB4-6
R2.M5/6
BK
X6
21
21
WHBK
0V X6
A4
A4
BK
X6
A10
A10
WHBK
0V X6
-R3.FB6
-R3.FB6
RD
BK
Resolver
10
10
BN
Y6
22
22
WHBN
0V Y6
RD
0V EXC2
20
20
WHRD
EXC2
A5
A5
BN
Y6
BU
A11
A11
WHBN
0V Y6
YE
A6
A6
RD
0V EXC2
WHBK (WHYE)
A12
A12
WHRD
EXC2
WHRD
Lab/Office:
Latest revision:
Status:
Axis 6
2005-10-17
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IRB 66XX ID
= 66XX ID
Plant:
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Location:
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Rev. Ind Page 120
Next 130
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3HAC025744-001
02
-SW1.1
A
Power 1.1.1
21
22
Power 1.1.2
13
14
Signal 1.1.2
Signal 1.1.1
SW1.6
-SW1.2
E
Power 1.2.1
21
22
Power 1.2.2
13
14
Signal 1.2.2
Signal 1.2.1
SW1.5
SW1.4
SW1.3
-SW1.3
We reserve all rights in this document and in the information contained therein.Reproduction, use or
disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
SW1.2
J
Power 1.3.1
21
22
Power 1.3.2
10
13
14
Signal 1.3.2
12
Signal 1.3.1
11
-SW1.4
Power 1.4.1
13
21
22
Power 1.4.2
14
13
14
Signal 1.4.2
16
Signal 1.4.1
15
SW1.1
Position switches
Axis 1
-SW1.5
T
Power 1.5.1
17
21
22
Power 1.5.2
18
13
14
Signal 1.5.2
20
Signal 1.5.1
19
-SW1.6
Power 1.6.1
21
21
22
Power 1.6.2
22
13
14
Signal 1.6.2
24
Signal 1.6.1
23
Lab/Office:
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3HAC025744-001
02
Power 2.1.1
21
22
Power 2.1.2
Power 2.1.2
13
14
Signal 2.1.2
Signal 2.1.2
Signal 2.1.1
Signal 2.1.1
SW2.1
Power 2.1.1
SW2.2
SW2.4
R2.SW2
SW2.3
-SW2.1
R1.SW2/3
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disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
-SW2.2
E
Power 2.2.1
Power 2.2.1
21
22
Power 2.2.2
Power 2.2.2
13
14
Signal 2.2.2
Signal 2.2.2
Signal 2.2.1
Signal 2.2.1
Position switches
Axis 2
-SW2.3
J
Power 2.3.1
Power 2.3.1
21
22
Power 2.3.2
10
Power 2.3.2
10
13
14
Signal 2.3.2
12
Signal 2.3.2
12
Signal 2.3.1
11
Signal 2.3.1
11
13
24V FAN
+
15
ALARM FAN
-FAN
Fan axis 1 or 2
M
-
14
0V FAN
Lab/Office:
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Rev. Ind Page 140
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3HAC025744-001
02
-SW3.1
Power 3.1.1
Power 3.1.1
21
22
Power 3.1.2
Power 3.1.2
13
14
Signal 3.1.2
Signal 3.1.2
Signal 3.1.1
Signal 3.1.1
SW3.4
SW3.1
R2.SW3
SW3.2
R1.SW2/3
SW3.3
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disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
-SW3.2
X
Power 3.2.1
Power 3.2.1
21
22
Power 3.2.2
Power 3.2.2
13
14
Signal 3.2.2
Signal 3.2.2
Signal 3.2.1
Signal 3.2.1
Position switches
Axis 3
-SW3.3
b
Power 3.3.1
Power 3.3.1
21
22
Power 3.3.2
10
Power 3.3.2
10
13
14
Signal 3.3.2
12
Signal 3.3.2
12
Signal 3.3.1
11
Signal 3.3.1
11
13
24V FAN
+
15
ALARM FAN
-FAN
Fan axis 3
M
-
14
0V FAN
Lab/Office:
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Rev. Ind Page 150
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3HAC025744-001
02
11 Circuit Diagram
11.3.1. Validity of circuit diagram 3HAC 13347-1
Action
WebConfig
This circuit diagram is valid for the following cable harness assemblies:
Robot
Cable harness
Revision
IRB 6600
3HAC 14940-1
all
3HAC 16331-1
all
IRB 7600
3HAC 14940-1
revision 0-2
For remaining cable harness assemblies, see section Circuit diagram 3HAC 025744-001 on
page 486.
3HAC023082-001 Revision: E
487
Sheet
Contents ........................................................................................................................101
Connection Point Location ...........................................................................................102
Legend ..........................................................................................................................103
Brake Release Unit .......................................................................................................104
Serial Measurement Board ...........................................................................................105
Axis 1............................................................................................................................106
Axis 2............................................................................................................................107
Axis 3............................................................................................................................108
Axis 4............................................................................................................................109
Axis 5 (IRB 7600) ........................................................................................................110
Axis 6............................................................................................................................111
Switches axis 1 .............................................................................................................113
Switches/Fan axis 2 ......................................................................................................114
Switches/Fan axis 3 ......................................................................................................115
Axis 5 (IRB 6600) ........................................................................................................901
Design changes, note 1.1 ..............................................................................................905
Design changes, note 2.1-2.7 ........................................................................................906
sheet
Contents
101
02
Revision
sheet
Revision
sheet
Legend
103
02
Revision
sheet
02
Revision
sheet
Revision
sheet
Axis 1
106
02
Revision
sheet
Axis 2
107
02
Revision
sheet
Axis 3
108
02
Revision
Axis 4
109
sheet
02
Revision
sheet
02
Revision
sheet
Axis 6
111
02
Revision
sheet
Switches axis 1
113
02
Revision
sheet
Switches/Fan axis 2
114
02
Revision
sheet
Switches/Fan axis 3
115
02
Revision
901
02
sheet
905
02
sheet
906
02
sheet
11 Circuit Diagram
488
3HAC023082-001 Revision: E
Index
A
Absolute Accuracy, calibration 411
requirements 54
D
direction of axes 414
E
enlarged gear 427
ESD
damage elimination 40
sensitive equipment 40
wrist strap connection point 40
explanation, safety symbols 35
I
identification 427
installation
mechanical stop axis 1 105
mechanical stop axis 2 107
mechanical stop axis 3 109
installing
position switches 111
L
Levelmeter calibration 411
lifting of robot
with lifting slings 68
lifting robot
with fork lift 61
lifting slings, robot 68
lifting upper arm
attachment points for lifting device 286
loads on foundation 54
lower arm shaft, replacement 299
lower arm, replacement 292
M
mechanical stop
axis 1 105
axis 2 107
axis 3 109
motion of axes 59
motor axis 1, replacement
motor axis 2, replacement
motor axis 3, replacement
motor axis 4, replacement
motor axis 5, replacement
motor axis 6, replacement
MoveAbsJ instruction
FlexPendant 419
TPU 419
337
343
350
357
364
374
N
negative directions, axes 414
O
oil change
safety risks 41
operating conditions, robot 54
FlexPendant
jogging to calibration position 420
MoveAbsJ instruction 419
updating revolution counters 417
fork lift 61
foundation
loads 54
position switches
cabling on robot 111
installing 111
position, robot 412
positive directions, axes 414
protection classes 55
3HAC023082-001 Revision: E
383
391
399
405
489
Index
range of movement 59
replacement
balancing device 322
bearing, balancing device 317
brake release unit 313
cable harness axes 1-4 240
cable harness axes 1-6 228
cabling axis 5 259
complete arm system 261
gearbox axis 1 383
gearbox axis 2 391
gearbox axis 3 399
gearbox axis 6 405
lower arm 292
lower arm shaft 299
motor axis 1 337
motor axis 2 343
motor axis 3 350
motor axis 4 357
motor axis 5 364
motor axis 6 374
turning disk 274
upper arm 286
wrist unit 277
requirements on foundation 54
restricting
working range axis 2 107
working range axis 3 109
revolution counters
storing on FlexPendant 417
storing on TPU 416
updating 415
risk of tipping 60
robot
operating conditions 54
protection class 55
storage conditions 54
weight 53
robot position 412
robot types 427
S
safety equipment
mechanical stop 105
mechanical stop axis 2 107
mechanical stop axis 3 109
position switches 111
signal lamp 173
Safety, service 18
safety, symbols 35
scales on robot 412
securing the robot to foundation, attachment screws 78
securing, base plate 74
securing, lower arm 305
securing, robot 78
securing, upper arm 352
serial measurement board unit, replacement 309
special tools 437
stability 60
490
T
testing, brakes 29
tightening torque
mechanical stop axis 1 106
mechanical stop axis 2 108
tool set, balancing device bearing replacement 318
tools
calibration equipment, Levelmeter 438
Calibration Pendulum equipment 439
for service 437
oil exchange equipment 439
TPU
jogging to calibration position 420
MoveAbsJ instruction 419
updating revolution counters 416
turning disk replacement 274
type A 427
type B 427
type of motion 59
U
updating revolution counters 415
upper arm, replacement 286
V
Validity and responsibility 18
W
weight
balancing device 325, 327
base plate 73, 77
complete arm system 263, 264
gearbox 386, 387, 394, 395, 402
lower arm 295, 297
motor 339, 340, 353, 354
robot 65, 67, 69
upper arm 288, 290
wrist unit 279, 280, 283, 284
weight, robot 53
working range 56
restricting axis 1
restricting
working range axis 1 105
restricting axis 2 107
restricting axis 3 109
wrist unit, replacement 277
3HAC023082-001 Revision: E
3HAC023082-001, Revision E, en
ABB AB
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