Post on 01-Jun-2018
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Product manual (part 1 of 2), procedures
IRB 7600 - 500/2.3
IRB 7600 - 400/2.55
IRB 7600 - 340/2.8
IRB 7600 - 150/3.5
M2000
M2000A
M2004
Document ID: 3HAC 022033-001
Revision: B
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The information in this manual is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construed as any kind 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 fromuse of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABBs writtenpermission, and contents thereof must not be imparted to a third party nor be used forany unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
Copyright 2004 ABB All right reserved.
ABB Automation Technologies ABRobotics
SE-721 68 Vsters
Sweden
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Table of Contents
33HAC 022033-001 Revision: B
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Product documentation, M2000/M2000A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1 Safety 11
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
1.2.2 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.2.1 Safety, service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2.2.2 Limitation of Liability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2.3 Related information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.3 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.3.1 Safety risks during service work on robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.3.2 Safety risks related to gripper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.3.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191.2.3.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.3.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.3.6 Safety risks during installation and service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.3.7 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.4 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.4.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.4.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.4.3 Emergency release of the robots arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.4.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2.4.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.2.4.7 Work inside the manipulators working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301.3 Safety related instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3.3 WARNING - The brake release buttons may be jammed after service work . . . . . . . . . . . . . . . . 34
1.3.4 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
1.3.5 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3.6 WARNING - Mixed oils may cause severe damage to gearbox! . . . . . . . . . . . . . . . . . . . . . . . . . 38
2 Installation and commissioning 39
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.2.1 Pre-installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402.2.2 Working range, IRB 7600 - 150/3.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.2.3 Working range, IRB 7600 - 340/2.8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.2.4 Working range, IRB 7600 - 400/2.55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.2.5 Working range, IRB 7600 - 500/2.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.2.6 Risk of tipping / stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.3 On-site Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3.1 Lifting robot with fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3.2 Lifting robot with lifting slings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.3.3 Lifting manipulator with roundslings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
2.3.4 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
2.3.5 Manually releasing the brakes, external brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.3.6 Lifting the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 672.3.7 Securing the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
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2.3.8 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2.3.9 Fitting equipment on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
2.3.10 Installation of chip and dust protection (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
2.3.11 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
2.4.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
2.4.3 Mechanically restricting the working range of axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
2.4.4 Mechanically restricting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
2.4.5 Position switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
2.5.1 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
3 Maintenance 103
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.2 Maintenance schedule and expected life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1043.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.3.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
3.3.2 Inspection, oil level gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
3.3.3 Inspection, oil level gearbox axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.3.4 Inspection, oil level gearbox axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
3.3.5 Inspection, oil level, gearbox axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
3.3.6 Inspection, oil level gearbox axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.3.7 Inspection, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.3.8 Inspection, cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1323.3.9 Inspection, mechanical stop, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
3.3.10 Inspection, mechanical stop, axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.3.11 Inspection, damper axes 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
3.3.12 Inspection, position switch axes 1, 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
3.3.13 Inspection, information labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
3.3.14 Inspection, UL-lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.4 Changing/replacement activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.4.1 Oil in gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
3.4.2 Oil change, gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3.4.3 Oil change, gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
3.4.4 Oil change, gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.4.5 Oil change, gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
3.4.6 Oil change, gearbox, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.4.7 Oil change, gearbox axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
3.5 Lubrication activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.5.1 Lubrication, balancing device bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
3.6 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.6.1 Flushing a contaminated gearbox. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.6.2 Cleaning, manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
3.7 Service Information System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.7.1 Using the SIS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
3.7.2 Description of Service Information System (SIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
3.7.3 SIS system parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
3.7.4 Setting the SIS parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1873.7.5 Reading the SIS output logs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
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3.7.6 Exporting the SIS data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
4 Repair 193
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.3 Complete manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4.3.1 Replacement of cable harness, axes 1-4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
4.3.2 Replacement of cable harness, axes 5-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
4.3.3 Removal of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
4.3.4 Refitting of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.4 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
4.4.1 Removal of turning disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
4.4.2 Refitting of turning disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2224.4.3 Removal of complete wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
4.4.4 Refitting of complete wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
4.4.5 Removal of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
4.4.6 Refitting of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
4.5 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4.5.1 Removal of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
4.5.2 Refitting of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
4.6 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
4.6.1 Removal of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
4.6.2 Refitting of SMB related equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
4.6.3 Removal of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
4.6.4 Refitting of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2614.6.5 Removal of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
4.6.6 Refitting of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
4.6.7 Unloading the balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
4.6.8 Restoring the balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
4.7 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
4.7.1 Removal of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
4.7.2 Refitting of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283
4.7.3 Removal of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
4.7.4 Refitting of motor, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
4.7.5 Removal of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 293
4.7.6 Refitting of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
4.7.7 Removal of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3004.7.8 Refitting of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303
4.7.9 Removal of motor, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
4.7.10 Refitting of motor, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
4.7.11 Removal of motor, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
4.7.12 Refitting of motor, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
4.8 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
4.8.1 Replacement of gearbox, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
4.8.2 Removal of gearbox, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
4.8.3 Refitting of gearbox, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
4.8.4 Removal of gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
4.8.5 Refitting of gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
4.8.6 Removal of gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3444.8.7 Refitting of gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
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Table of Contents
3HAC 022033-001 Revision: B6
4.8.8 Removal of gearbox, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
4.8.9 Refitting of gearbox, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
4.8.10 Removal of gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
4.8.11 Refitting of gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
5 Calibration information 365
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
5.4 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369
5.5 Updating revolution counters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
5.6 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374
6 Decommissioning 377
6.1 Environmental information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 378
6.2 Decommissioning of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 379
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Overview
73HAC 022033-001 Revision: B
Overview
About this manual
This manual contains instructions for
installing the manipulator, mechanically as well as electrically
maintenance of the manipulator
mechanical and electrical repair of the manipulator.
Usage
This manual should be used during
installation, from lifting the manipulator to its work site and securing it to the
foundation to making it ready for operation
maintenance work repair work.
Who should read this manual?
This manual is intended for:
installation personnel
maintenance personnel
repair personnel.
Prerequisites
The reader should...
be a trained maintenance/repair craftsman
have the required knowledge of mechanical and electrical installation/repair/
maintenance work.
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Overview
3HAC 022033-001 Revision: B8
Organization of chapters
The manual is organized in the following chapters:
Revisions
Chapter Contents
Safety, service Safety information
Installation and
commissioning
Information about installation of the manipulator, including working
ranges, lifting instructions, on-site installation, fitting of extraequipment, etc.
Maintenance Information about maintenance work, including maintenance
schedules.
Repair Information about repair work. Each procedure include necessary
spare parts, tools, etc.
Calibration information Procedures that do not require specific calibration equipment.
General information about calibration.
Decommissioning Environmental information about the manipulator.
Revision Description
- First edition.
Replaces previous manuals:
Installation and Commissioning Manual
Maintenance Manual
Repair Manual, part 1
Repair Manual, part 2.Changes made in the material from the previous manuals:
Model M2004 implemented.
Various corrections due to technical revisions, changes in the toolkitsetc.
A Chapter Calibrationreplaced with chapter Calibration information.
Following corrections are made:
In chapter 3: Maintenancein section Exporting the SIS data, the unitsecondsfor different SIS parameters is replaced by the unit hours. The
change is only valid for RobotWare release 5.0.
Following updates are made:
In chapter 4: Repair, the sections Removal of complete lower armand
Refitting of complete lower armare completed with more detailedinformation about how to use the glycerin pump.
B New lubricating oil in the gearboxes. Changes made in the chapterMaintenance.
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Product documentation, M2000/M2000A
93HAC 022033-001 Revision: B
Product documentation, M2000/M2000A
General
The complete product documentation kit for the M2000 robot system, including controller,
robot and any hardware option, consists of the manuals listed below:
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manualwhich
is divided into two parts:
Product manual, procedures
Safety information
Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
Repair (descriptions of all recommended repair procedures including spare parts)
Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards)
Part list
Foldouts or exploded views
Circuit diagrams
Software manuals
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
In addition, spare part information is supplied for the entire option.
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Product documentation, M2004
3HAC 022033-001 Revision: B10
Product documentation, M2004
General
The robot documentation may be divided into a number of categories. This listing is based on
the type of information contained within the documents, regardless of whether the products
are standard or optional. This means that any given delivery of robot products will not contain
alldocuments listed, only the ones pertaining to the equipment delivered.
However, all documents listed may be ordered from ABB. The documents listed are valid for
M2004 robot systems.
Hardware manuals
All hardware, robots and controller cabinets, will be delivered with a Product manualwhich
is divided into two parts:
Product manual, procedures
Safety information
Installation and commissioning (descriptions of mechanical installation, electrical
connections and loading system software)
Maintenance (descriptions of all required preventive maintenance procedures
including intervals)
Repair (descriptions of all recommended repair procedures including spare parts)
Additional procedures, if any (calibration, decommissioning)
Product manual, reference information
Reference information (article numbers for documentation referred to in Productmanual, procedures, lists of tools, safety standards)
Part list
Foldouts or exploded views
Circuit diagrams
RobotWare manuals
The following manuals describe the robot software in general and contain relevant reference
information:
RAPID Overview: An overview of the RAPID programming language.
RAPID reference manual part 1: Description of all RAPID instructions.
RAPID reference manual part 2: Description of all RAPID functions and data types.
Technical reference manual - System parameters: Description of system
parameters and configuration workflows.
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Product documentation, M2004
113HAC 022033-001 Revision: B
Application manuals
Specific applications (e.g. software or hardware options) are described in Application
manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
The purpose of the application (what it does and when it is useful)
What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)
How to use the application
Examples of how to use the application
Operators 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
include: Operators manual - IRC5 with FlexPendant
Operators manual - RobotStudio Online
Trouble shooting manualfor the controller and robot
Miscellaneous
A number of manuals provide generic descriptions of the robot and robot system. These
include:
Robot fundamentals(describing the fundamental aspects, functions, concept and
similar, of a robot system to provide a basic understanding of the robot system)
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How to read the product manual
3HAC 022033-001 Revision: B12
How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material etc. The references are read as
described below.
References to figures
The procedures often include references to components or attachment points located on the
robot/controller. The components or attachment points are marked with italic textin the
procedures and completed with a reference to the figure where the current component or
attachment point is shown.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in an procedure.
References to required equipment
The procedures often include references to equipment (spare parts, tools etc.) required for the
different actions in the procedure. The equipment is marked with italic textin the procedures
and completed with a reference to the section where the equipment is listed with further
information, i.e. article number, dimension.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced list.
The table below shows an example of a reference to a list of required equipment, from a step
in an procedure.
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 Safetyon page
13.
Step Action Note/Illustration
8. Remove the rear attachment screws, gearbox. Shown in the figure Location ofgearbox on page xx.
Step Action Note/Illustration
3. Fit a new sealing, axis 2to the gearbox. Art. no. is specified in Requiredequipment on page xx.
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1 Safety
1.1. Introduction
133HAC 022033-001 Revision: B
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 informationon page 14.
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 instructionson
page 33.
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1 Safety
1.2.1. Introduction
3HAC 022033-001 Revision: B14
1.2 General safety information
1.2.1. Introduction
Definitions
This section details general safety information for service personnel i.e. personnel performing
installation, repair and maintenance work.
Sections
The general safety information is divided into the following sections:
1. General information contains lists of:
Safety, service
Limitation of liability
Referenced documents
2. Safety risks lists dangers relevant when servicing the robot system. The dangers are split
into different categories:
Safety risks during service work on robot
Safety risks related to gripper/end effector
Safety risks related to tools/workpieces
Safety risks related to pneumatic/hydraulic systems
Safety risks during operational disturbances
Safety risks during installation and service
Risks associated with live electric parts
3. Safety actions details actions which may be taken to remedy or avoid dangers.
Safety fence dimensions
Fire extinguishing
Emergency release of the manipulators arm
Brake testing
Risk of disabling function "Reduced speed 250 mm/s"
Safe use of the Teach Pendant Unit enabling device
Work inside the manipulators working range Signal lamp (optional)
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1 Safety
1.2.2.1. Safety, service
153HAC 022033-001 Revision: B
1.2.2. General information
1.2.2.1. Safety, service
Validity and responsibility
The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment, which can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the robot
is installed.
The users of ABB industrial robots are responsible for ensuring that the applicable safety laws
and regulations in the country concerned are observed and that the safety devices necessary
to protect people working with the robot system have been designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of theindustrial robot, described in the applicable documents, e.g. Users Guide and Product
Manual.
Connection of external safety devices
Apart from the built-in safety functions, the robot is also supplied with an interface for the
connection of external safety devices. Via this interface, an external safety function can
interact with other machines and peripheral equipment. This means that control signals can
act on safety signals received from the peripheral equipment as well as from the robot.
In the Product Manual - Installation and Commissioning, instructions are provided for
connecting safety devices between the robot and the peripheral equipment.
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1 Safety
1.2.2.2. Limitation of Liability
3HAC 022033-001 Revision: B16
1.2.2.2. Limitation of Liability
General
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
have been complied with.
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1 Safety
1.2.2.3. Related information
173HAC 022033-001 Revision: B
1.2.2.3. Related information
General
The list below specifies documents which contain useful information:
Documents
Type of information Detailed in document Section
Installation of safety devices Product manual for the
manipulator
Installation and commissioning
Changing robot modes Users Guide Start-up
Restricting the working space Product manual for themanipulator
Installation and commissioning
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1 Safety
1.2.3.1. Safety risks during service work on robot
3HAC 022033-001 Revision: B18
1.2.3. Safety risks
1.2.3.1. Safety risks during service work on robot
Overview
This section includes information of general safety risks to be considered when performing
service work on the robot.
Complete robot
Cabling
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 robotdoes not collapse as parts are removed, e.g. secure the
lower arm with fixtures if removing motor, axis 2.
Safety risk Description
Cable packs are sensitive to
mechanical damage!
Caution!
The cable packs are sensitive to mechanical damage!They must be handled with care, especially theconnectors, in order to avoid damaging them!
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1 Safety
1.2.3.1. Safety risks during service work on robot
193HAC 022033-001 Revision: B
Gearboxes and motors
Balancing device
Safety risk Description
Gears may be damaged if
excessive force is used!
Caution!
Whenever parting/mating motor and gearbox, the gears
may be damaged if excessive force is used!
Safety risk DescriptionDangerous balancing device!
Warning!
Do not under any circumstances, deal with the balancing
device in any other way than that detailed in the productdocumentation! For example, attempting to open thebalancing device is potentially lethal!
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1 Safety
1.2.3.2. Safety risks related to gripper
3HAC 022033-001 Revision: B20
1.2.3.2. Safety risks related to gripper
CAUTION!
Ensure that a gripper is prevented from dropping a workpiece, if such is used.
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1 Safety
1.2.3.3. Safety risks related to tools/workpieces
213HAC 022033-001 Revision: B
1.2.3.3. Safety risks related to tools/workpieces
Safe handling
It must be possible to turn off tools, such as milling cutters, etc., safely. Make sure that guards
remain closed until the cutters stop rotating.
It should be possible to release parts by manual operation (valves).
Safe design
Grippers/end effectors must be designed so that they retain workpieces in the event of a power
failure or a disturbance of the controller.
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1 Safety
1.2.3.4. Safety risks related to pneumatic/hydraulic systems
3HAC 022033-001 Revision: B22
1.2.3.4. Safety risks related to pneumatic/hydraulic systems
General
Special safety regulations apply to pneumatic and hydraulic systems.
Residual energy
Residual energy may be present in these systems so, after shutdown, particular care
must be taken.
The pressure in pneumatic and hydraulic systems must be released before starting to
repair them.
Safe design
Gravity may cause any parts or objects held by these systems to drop.
Dump valves should be used in case of emergency.
Shot bolts should be used to prevent tools, etc., from falling due to gravity.
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1 Safety
1.2.3.5. Safety risks during operational disturbances
233HAC 022033-001 Revision: B
1.2.3.5. Safety risks during operational disturbances
General
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.
Care must be taken at all times.
Qualified personnel
Remedial action 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.
Extraordinary risksIf 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.
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1 Safety
1.2.3.6. Safety risks during installation and service
3HAC 022033-001 Revision: B24
1.2.3.6. Safety risks during installation and service
General risks during installation and service
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.
Nation/region specific regulations
To prevent injuries and damage during the installation of the robot system, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be complied
with.
Non-voltage related risks
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, is dismantled.
When dismantling/assembling mechanical units, watch out for falling objects.
Be aware of stored heat energy in the controller.
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.
To be observed by the supplier of the complete system
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.
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1.2.3.7. Risks associated with live electric parts
253HAC 022033-001 Revision: B
1.2.3.7. Risks associated with live electric parts
Voltage related risks, general
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 robot's working space.
Voltage related risks, controller
A danger of high voltage is associated with the following parts:
Be aware of stored electrical energy (DC link) in the controller.
Units inside the controller, e.g. I/O modules, can be supplied with power from an
external source.
The mains supply/mains switch
The power unit
The power supply unit for the computer system (230 VAC)
The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
The drive unit (700 VDC)
The service outlets (115/230 VAC)
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
Voltage related risks, robot
A danger of high voltage is associated with the robot in:
The power supply for the motors (up to 800 VDC)
The user connections for tools or other parts of the installation (max. 230 VAC, see
Installation and Commissioning Manual)
Voltage related risks, tools, material handling devices, etc
Tools, material handling devices, etc., may be live even if the robot system is in the OFF
position. Power supply cables which are in motion during the working process may be
damaged.
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1.2.4.1. Safety fence dimensions
3HAC 022033-001 Revision: B26
1.2.4. Safety actions
1.2.4.1. Safety fence dimensions
General
Install a safety cell around the robot to ensure safe robot installation and operation.
Dimensioning
Dimension the fence or enclosure to enable it to withstand the force created if the load being
handled by the robot is dropped or released at maximum speed. Determine the maximum
speed from the maximum velocities of the robot axes and from the position at which the robot
is working in the work cell (see Product Specification - Description, Robot Motion).
Also consider the maximum possible impact caused by a breaking or malfunctioning rotating
tool or other device fitted to the manipulator.
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1.2.4.2. Fire extinguishing
273HAC 022033-001 Revision: B
1.2.4.2. Fire extinguishing
NOTE!
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulatoror controller)!
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1.2.4.3. Emergency release of the robots arm
3HAC 022033-001 Revision: B28
1.2.4.3. Emergency release of the robots arm
Description
In an emergency situation, any of the robots axes may be released manually by pushing the
brake release buttons on the robot or on an optional external brake release unit.
How to release the brakes is detailed in section:
Manually releasing the brakeson page 63.
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!
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1.2.4.4. Brake testing
293HAC 022033-001 Revision: B
1.2.4.4. Brake testing
When to test
During operation the holding brakes of each axis motor wear normally. A test may be
performed to determine whether the brake can still perform its function.
How to test
The function of each axis motor holding brakes may be checked as detailed below:
1. Run each manipulator axis to a position where the combined weight of the manipulator
arm and any load is maximized (max. static load).
2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the
controller.
3. Check that the axis maintains its position.
If the manipulator does not change position as the motors are switched off, then the brake
function is adequate.
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1 Safety
1.2.4.5. Risk of disabling function "Reduced speed 250 mm/s"
3HAC 022033-001 Revision: B30
1.2.4.5. Risk of disabling function "Reduced speed 250 mm/s"
NOTE!
Do not change "Transm gear ratio" or other kinematic parameters from the Teach PendantUnit or a PC. This will affect the safety function Reduced speed 250 mm/s.
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1 Safety
1.2.4.6. Safe use of the Teach Pendant Unit
313HAC 022033-001 Revision: B
1.2.4.6. Safe use of the Teach Pendant Unit
NOTE!
The enabling device is a push button located on the side of the Teach Pendant Unit (TPU)which, when pressed halfway in, takes the system to MOTORS ON. When the enabling
device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.
To ensure safe use of the Teach Pendant Unit, the following must be implemented:
The enabling device must never be rendered inoperative in any way.
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 Teach Pendant Unit with him/her, when
entering the robot's working space. This is to prevent anyone else taking control over
the robot without the programmer knowing.
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1.2.4.7. Work inside the manipulators working range
3HAC 022033-001 Revision: B32
1.2.4.7. Work inside the manipulators working range
WARNING!
If work must be carried out within the robots work envelope, the following points must beobserved:
The operating mode selector on the controller must be in the manual mode position to
render the enabling device operative and to block operation from a computer link or
remote control panel.
The robot's speed is limited to max. 250 mm/s when the operating mode selector is in
position < 250 mm/s. This should be the normal position when entering the working
space. The position 100% "full speed" 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 maybe caused by rotating tools or other devices mounted on the manipulator or inside the
cell.
Test the motor brake on each axis, according to sectionBrake testingon page 29.
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1.3.1. Safety signals, general
333HAC 022033-001 Revision: B
1.3 Safety related instructions
1.3.1. Safety signals, general
General
This section specifies all dangers that may arise from performing the work detailed in the
manual. Each danger is detailed in its own section consisting of:
A caption specifying the danger level (DANGER, WARNING or CAUTION) and the
type of danger.
A brief description of what will happen if the operator/service personnel does not
eliminate the danger.
An instruction of how to eliminate the danger to facilitate performing the activity at
hand.
Danger levels
The table below defines the captions specifying the danger levels used throughout this
manual.
Symbol Designation Signification
danger
DANGER Warns that an accident willoccur if the instructions
are not followed, resulting in a serious or fatal injuryand/or severe damage to the product. It applies towarnings that apply to danger with, for example,
contact with high voltage electrical units, explosionor fire risk, risk of poisonous gases, risk of crushing,impact, fall from height etc.
warning
WARNING Warns that an accident mayoccur if the instructions
are not followed, that can lead to serious injury,possibly fatal, and/or great damage to the product. Itapplies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
explosion or fire risk, risk of poisonous gases, risk ofcrushing, impact, fall from height etc.
Electrical shock
ELECTRICAL
SHOCK
The electrocution or electrical shock symbol
indicates electrical hazards which could result insevere personal injury or death.
caution
CAUTION Warns that an accident may occur if the instructions
are not followed, that can result in injury and/ordamage to the product. It also applies to warnings ofrisks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping,
impact, fall from height etc. Furthermore, it applies towarnings that include function requirements whenfitting and removing equipment, where there is a risk
of damaging the product or causing a breakdown.
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1 Safety
1.3.1. Safety signals, general
3HAC 022033-001 Revision: B34
Electrostatic discharge(ESD)
ELECTROSTATICDISCHARGE (ESD)
The electrostatic discharge (ESD) symbol indicateselectrostatic hazards which could result in severe
damage to the product.
Note
NOTE Note symbols alert you to important facts and
conditions.
Tip
TIP Tip symbols direct you to specific instructions, whereto find additional information or how to perform a
certain operation in an easier way.
Symbol Designation Signification
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1 Safety
1.3.2. DANGER - Moving manipulators are potentially lethal!
353HAC 022033-001 Revision: B
1.3.2. DANGER - Moving manipulators are potentially lethal!
Description
Any moving manipulator is a potentially lethal machine.
When running the manipulator, it may perform unexpected and sometimes irrational
movements. However, all movements are performed with great force and may seriously
injure any personnel and/or damage any piece of equipment located within the manipulator
working range.
Elimination
Step Action Info/Illustration
1. Before attempting to run the manipulator,
make sure all emergency stop equipmenthas been correctly installed and connected.
Emergency stop equipment such as
gates, tread mats, light curtains, etc.
2. If possible, use the hold-to-run buttonwhenever possible.
The hold-to-run button is used in manualmode, not in automatic mode.
How to use the hold-to-run control inRobotWare 5.0 is detailed in sectionHow to use the hold-to-run switchinthe Operators Manual, IRC5.
How to use the hold-to-run control inRobotWare 4.0 is detailed in sectionThe Teach Pendant unitin the Users
Guide.
3. Make sure no personnel is present within
the manipulator working range beforepressing the start button.
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1 Safety
1.3.3. WARNING - The brake release buttons may be jammed after service work
3HAC 022033-001 Revision: B36
1.3.3. 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:
Step 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 byone.
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!
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1 Safety
1.3.4. WARNING - The unit is sensitive to ESD!
373HAC 022033-001 Revision: B
1.3.4. WARNING - The unit is sensitive to ESD!
Description
ESD (electro static discharge) is the transfer of electrical static charge between two bodies at
different potentials, either through direct contact or through an induced electrical field. When
handling parts or their containers, personnel not connected to ground potential may transfer
high static charges. This discharge may destroy sensitive electronics.
Elimination
Step Action Note/Illustration
1. Use a wrist strap Wrist straps must be tested frequently toensure that they are not damaged and areoperating correctly.
2. Use an ESD protective floor mat. The mat must be grounded through a current-limiting resistor.
3. Use a dissipative table mat. The mat should provide a controlled dischargeof static voltages and must be grounded.
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1.3.5. WARNING - Safety risks during work with gearbox oil
3HAC 022033-001 Revision: B38
1.3.5. WARNING - Safety risks during work with gearbox oil
Description
When handling the gearbox oil, there are several dangers to both personal injuries and product
damages! Following safety information must be regarded before performing any work with
the oil in the gearboxes!
Warnings and elimination
Warning Description Elimination / Action
-
Hot oil!
Changing and draininggearbox oil may require
handling hot oil of up to 90 C!
Make sure that protective gearlike goggles and gloves are
always worn during this activity.
-
Possible pressure build
up in gearbox!
When opening the oil plug,
there may be pressure presentin the gearbox, causing oil tospray from the opening!
Open oil plug carefully and keep
away from the opening. Do notoverfill the gearbox when filling.
-
Do not overfill!
Overfilling of gearbox oil can
lead to internal over-pressureinside the gearbox which in
turn may:
damage seals and
gaskets
completely press outseals and gaskets
prevent the manipulatorfrom moving freely.
Make sure not to overfill the
gearbox when filling with oil!After filling, check the correct oillevel.
-
Do not mix types of oil!
Mixing types of oil may causesevere damage to thegearbox!
When filling gearbox oil, do notmix different types of oil unlessspecified in the instruction.
Always use the type of oil
specified by the manufacturer!
-
Heat up the oil!
Warm oil drains quicker thancold oil.
When changing gearbox oil, firstrun the robot for a time to heatup the oil.
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1 Safety
1.3.5. WARNING - Safety risks during work with gearbox oil
393HAC 022033-001 Revision: B
-
Specified amount
depends on drained
volume!
The specified amount of oil isbased on the total volume of
the gearbox. When changingthe oil, the amount of refilled oilmay differ from the specified
amount, depending on howmuch oil has previously beendrained from the gearbox.
After refilling, check the oil level.
Warning Description Elimination / Action
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1 Safety
1.3.6. WARNING - Mixed oils may cause severe damage to gearbox!
3HAC 022033-001 Revision: B40
1.3.6. WARNING - Mixed oils may cause severe damage to gearbox!
Description
The six gearboxes of the robot are historically filled with different types of oil. When refilling
a gearbox it is extremely important to fill with exactly the same type of oil that is currently
used! In case the gearbox oil is contaminated with an other type of oil, the gearbox may be
severely damaged and must therefor be rinsed.
Shell Tivela S 150 mixed with Optimol Optigear RMO 150
The procedure below details how to rinse the contaminated gearbox if the oil types Shell
Tivela S 150 and Optimol Optigear RMO 150 are mixed.
Shell Tivela S 150 mixed with Mobil Gearlube X320
The procedure below details how to rinse the contaminated gearbox if the oil types Shell
Tivela S 150 and Mobil Gearlube X320 are mixed.
Step Action Note
1. Flush the gearbox properly three times with the correct typeof oil. Use a service program when flushing.
2. Refill the gearbox with the correct type of oil.
Step Action Note
1. If the gearbox should contain Tivela S 150 and is
contaminated with Gearlube X320:
Flush the gearbox properly three times with Tivela S150. Use a service program when flushing.
Refill the gearbox with Tivela S 150.
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2 Installation and commissioning
2.1. Introduction
413HAC 022033-001 Revision: B
2 Installation and commissioning
2.1. Introduction
General
This chapter contains information for installing the robot to the working site.
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.
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2 Installation and commissioning
2.2.1. Pre-installation procedure
3HAC 022033-001 Revision: B42
2.2 Unpacking
2.2.1. Pre-installation procedure
General
This instruction is primarily intended for use when unpacking and installing the manipulator
(mechanical robot) for the first time. It also contains information useful during later re-
installation of the manipulator.
Checking the pre-requisites for installation
The checklist below details what must be observed before proceeding with the actual
installation of the manipulator:
Step Action Info/Illustration1. Make sure only qualified installation personnel
conforming to all national and local codes are allowedto perform the installation.
2. Make sure the manipulator has not been damaged,by visually inspecting the manipulator and controlcabinet exterior.
3. Make sure the lifting device used is dimensioned tohandle the weight of the manipulator.
Specified in Weight,manipulatoron page 43.
4. If the manipulator is not to be installed directly, it mustbe stored.
Specified in Storage
conditions, manipulatoronpage 44.
5. Make sure the appointed operating environment ofthe manipulator conforms to the specifications.
Specified in Operatingconditions, manipulatoron
page 44.
6. Before taking the manipulator to its installation site,
make sure the site conforms to the demands.Specified in Loads onfoundation, manipulatoronpage 43, Requirements onfoundation, manipulatoron
page 43and Protection
classes, manipulatoronpage 44Protection classes,
manipulatoron page 44
respectively.
7. Before moving the manipulator, please observe therisk of tipping!
Described in Risk of tipping /stabilityon page 49.
8. When these prerequisites have been met, themanipulator may be taken to its installation site.
Specified in Lifting robot withfork lifton page 50.
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2 Installation and commissioning
2.2.1. Pre-installation procedure
433HAC 022033-001 Revision: B
Weight, manipulator
The table below shows the weights of the different models (without DressPack):
Loads on foundation, manipulator
The table below shows the different forces and torques working on the manipulator during
different kinds of operation.
NOTE! These forces and torques are extreme values that are rarely encountered during
operation. The values also never reach their maximum simultaneously!
Requirements on foundation, manipulatorThe table below shows the requirements for the foundation where the manipulator is to be
fitted:
Manipulator model Weight
IRB 7600 - 500/2.3 2400 kg
IRB 7600 - 400/2.55 2400 kg
IRB 7600 - 340/2.8 2450 kg
IRB 7600 - 150/3.5 2450 kg
Force Endurance load (operation) Max. load (emergency stop)
Force xy 14000 N 31000 N
Force z 32000 10000 N 39000 16000 N
Torque xy 42000 Nm 72000 Nm
Torque z 11000 Nm 19500 Nm
Requirement Value Note
Min. levelness 0.5 mm
Max. tilt 5 The limit for the maximum payload on the
manipulator is reduced if the manipulator istilted from 0.
Contact ABB for further information about
acceptable payload.Min. resonancefrequency
22 Hz
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2 Installation and commissioning
2.2.1. Pre-installation procedure
3HAC 022033-001 Revision: B44
Storage conditions, manipulator
The table below shows the allowed storage conditions for the manipulator:
Operating conditions, manipulator
The table below shows the allowed operating conditions for the manipulator:
Protection classes, manipulator
The table below shows the protection class of the manipulator:
Parameter Value
Min. ambient temperature -25 C
Max. ambient temperature +55C
Max. ambient temperature (less than 24 h) +70C
Max. ambient humidity Max. 95% at constant temperature
Parameter Value
Min. ambient temperature +5 C
Max. ambient temperature +50C
Max. ambient humidity Max. 95% at constant temperature
Equipment Protection class
Manipulator, IRB 7600 IP 67
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2 Installation and commissioning
2.2.2. Working range, IRB 7600 - 150/3.5
453HAC 022033-001 Revision: B
2.2.2. Working range, IRB 7600 - 150/3.5
Illustration
The illustration below shows the unrestricted working range of IRB 7600 - 150/3.5:
xx0100000101
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2 Installation and commissioning
2.2.3. Working range, IRB 7600 - 340/2.8
3HAC 022033-001 Revision: B46
2.2.3. Working range, IRB 7600 - 340/2.8
Illustration
The illustration below shows the unrestricted working range of IRB 7600 - 340/2.8:
xx0300000296
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2 Installation and commissioning
2.2.4. Working range, IRB 7600 - 400/2.55
473HAC 022033-001 Revision: B
2.2.4. Working range, IRB 7600 - 400/2.55
Illustration
The illustration below shows the unrestricted working range of IRB 7600 - 400/2.55:
xx0100000100
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2 Installation and commissioning
2.2.5. Working range, IRB 7600 - 500/2.3
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2.2.5. Working range, IRB 7600 - 500/2.3
Illustration
The illustration below shows the unrestricted working range of IRB 7600 - 500/2.3:
en0100000099
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2 Installation and commissioning
2.2.6. Risk of tipping / stability
493HAC 022033-001 Revision: B
2.2.6. Risk of tipping / stability
Risk of tipping
When the robot is not fastened to the foundation and standing still, the robot is not stable in
the whole working area. Moving the arms will displace the center of gravity, which may cause
the robot to tip over. Do notchange the robot position before securing it to the foundation.
Stabililty
The figure below shows the robot in its shipping position, which also is its most stable
position.
xx0100000103
WARNING!
The robot is likely to be mechanically unstable while not secured to the foundation!
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2 Installation and commissioning
2.3.1. Lifting robot with fork lift
3HAC 022033-001 Revision: B50
2.3 On-site Installation
2.3.1. Lifting robot with fork lift
General
The robot may be moved using a fork lift, provided that available special aids are used.
This section describes how to attach the fork lift equipment to the robot.
Different designs
There are two different versions of the fork lift that fit one design of the frame respectevily.
The different designs of the frame and of the fork lift attachments are shown in the figure
below. Determine which fork lift set fits the current robot.
Note!The distance between the attachment holes for the fork lift pockets, shown in the figure
below, are different depending on the design of the frame. This means that the fork lift sets
are unique for one type of frame and not compatible!
Except for the shorter distance between the attachment holes, the later design of the frame
also includes an extra oil plug, located as shown in the figure below.
xx0200000386
1 Frame version withoutan oil plug, use the fork lift set: 3HAC 0604-2
2 Frame version withan oil plug (C), use the fork lift set: 3HAC 0604-1
A Attachment holes, fork lift 3HAC 0604-2
B Attachment holes, fork lift 3HAC 0604-1
C Oil plug
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2.3.1. Lifting robot with fork lift
513HAC 022033-001 Revision: B
Attachment points
The attachment points for the fork lift equipment are shown in the figure below.
xx0400000707
Required equipment
To determine which fork lift set to use, see the sectionDifferent designson page 50.
A Attachment points, spacer and horizontal attachment screws
B Attachment points, horizontal attachment screws
C Attachment points, vertical attachment screws
D Attachment points, horizontal attachment screws
Equipment, etc. Art. no. Note
Fork lift set, incl. all required
hardware
3HAC 0604-2 See the figure Fork lift set, 3HAC 0604-2
on page 52.
Fork lift set, incl. all required
hardware
3HAC 0604-1 See the figure Fork lift set, 3HAC 0604-1
on page 53.
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2.3.1. Lifting robot with fork lift
3HAC 022033-001 Revision: B52
Fork lift set, 3HAC 0604-2
The fork lift set, 3HAC 0604-2, is fitted to the robot as shown in the figure below.
xx0100000102
Standard toolkit 3HAC 1557-1 The contents are defined in sectionStandard toolkitin the Product manual,
reference information!
Equipment, etc. Art. no. Note
A Vertical attachment screws (4 pcs / fork lift pocket)
B Fork lift pockets (2 pcs)
C Spacer (2 pcs)
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Fork lift set, 3HAC 0604-1
The fork lift set, 3HAC 0604-1, is fitted to the robot as shown in the figure below.
xx0200000379
A Fork lift pocket (2 pcs, different from each other)
B Spacer (2 pcs)
C Horizontal attachment screws (4 pcs / fork li ft pocket)
D Vertical attachment screws (2 pcs)
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Lifting the robot with fork lift
The section below details how to secure the fork lift set to the robot in order to lift and move
the robot using the fork lift ONLY!
Step Action Info/Illustration
1. If a cooling fan for the axis 1 motor is used,it must be removed in order to use the fork
lift device!
2. Position the robot as shown in the figure to
the right!
Note!No load is permitted on the robot ifthe fork lift set 3HAC 0604-2 is used!
Release the brakes if required as
detailed in section Manually releasingthe brakeson page 63.
xx0200000079
When using fork lift set 3HAC 0604-2,
no load is permitted on the robot!
xx0200000387
3. Fit the two spacersto the robot and
secure.
Attachment points on the robot are
shown in the figure Attachment pointson page 51.
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4.
Caution!
Caution!
The fork lift pocket weighs 60 kg!
5. Secure the longer fork lift pocketto thespacers with four of the horizontalattachment screwsand washers.
Note!The vertically and the horizontally
attached screws are identical, buttightened with different torques!
Make sure the original screws arealways used (or replacements of
equivalent quality: M16, quality 12.9)!
Attachment points on the robot are
shown in the figure Attachment pointson page 51.
xx0400001068
A: horizontal attachmentscrews, 4 pcs, M16 x 60.
Tightening torque: 60 Nm.
B: spacers, 2 pcs.
6. Make sure the securing screw is removedfrom the fork lift pocket!
It is only used for robot model IRB 6650S.
xx0400000977
A: securing screw
Step Action Info/Illustration
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7. Secure the fork lift pocket to the robot withthe two vertical attachment screwsand
washers.(only valid for the fork lift set 3HAC 0604-1)
Note!The vertically and the horizontally
attached screws are identical, buttightened with different torques!
xx0300000464
A: vertical attachment screws, 2
pcs, M16x60; tightening torque:270 Nm.
Make sure the original screws arealways used (or replacements of
equivalent quality: M16, quality 12.9)!
Attachment points on the robot are
shown in the figure Attachment pointson page 51.
8.
Caution!
Caution!The fork lift pocket weighs 22 kg!
9. Secure the shorter fork lift pocket on the
other side of the robot with the fourremaining horizontal attachment screws.
4 pcs, M16x60; tightening torque: 60
Nm.
Make sure the original screws are
always used (or replacements ofequivalent quality: M16, quality 12.9)!
Attachment points on the robot are
shown in the figure Attachment pointson page 51.
10. Double-check that the pockets are
properly secured to the robot! Insert the
fork lift forks into the pockets.
xx0200000380
Reposition the harness, if any, before
using a fork lift!
Step Action Info/Illustration
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11.
Caution!
Caution!
The robot weighs 2550 kg! All lifting
equipment used must be dimensionedaccordingly!
12. Carefully lift the robot and move it to itsinstallation site.
13.
Warning!
WARNING!
Personnel must not, under any
circumstances, be present under thesuspended load!
Step Action Info/Illustration
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2.3.2. Lifting robot with lifting slings
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2.3.2. Lifting robot with lifting slings
General
This section contains a general overview of how to lift the complete robot using special lifting
equipment. More detailed instructions are included with the equipment.
Illustration, lifting slings
The figure below shows how to lift the complete robot with lifting slings.
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
A Load hook
B Swivelling lifting eyes, 4 pcs
C Shortening hook
D Chain
E M12 lifting eye
F Lifting devices eye
I Lifting slings, 4 pcsL Hook
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Required equipment
Slings attached directly onto robot
The section below details how to lift and move the robot using lifting slings when these are
attached directly onto the robot frame.
Equipment Art. no. NoteLifting device, manipulator 3HAC 15607-1 Includes
user instructions (3HAC 15971-2).
Step Action Note
1. Run the overhead crane to a positionabove the robot.
2. Make sure the robot is positioned asshown in the figure on the right. If it isnot, position it that way.
Release the brakes if required as detailedin section Manually releasing the brakeson page 63.
xx0100000103
3. Fit the lifting device, manipulator to therobot as described in the enclosed
instruction!
Art. no. is specified in Requiredequipmenton page 59!
4.
Caution!
Caution!
The robot weighs 2550 kg! All lifting
equipment used must be dimensionedaccordingly!
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5.
Warning!
WARNING!
Personnel must not, under anycircumstances, be present under the
suspended load!
6. Raise the overhead crane to lift the
robot.
Make sure all hooks and attachments
maintain their correct positions whilelifting the robot!
Always move the robot at very lowspeeds, making sure it does not tip.
Step Action Note
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2.3.3. Lifting manipulator with roundslings
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2.3.3. Lifting manipulator with roundslings
General
The figure below shows how to lift the complete manipulator with roundslings.
Note the recommended manipulator position shown in the figure below!
Roundslings attached to the manipulator
xx0200000315
Required equipment
A Chain sling with shortener, 4250 kg, 3 pcs (0.5 m, 0.5 m, 0.265 m)
B Roundsling, 1000 kg, 2 pcs
C Roundsling, 2000 kg, 3 pcs (4 m)
Equipment Note
Chain sling with shortener, 4250 kg, 3 pcs Lengths: 0.5 m (2 pcs), 0.265 m (1 pc).
Roundslings, 1000 kg, 2 pcs
Roundslings, 2000 kg, 3 pcs Lengths: 4 m (3 pcs).
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Safety information
Read the safety information before lifting the manipulator!
CAUTION!
The manipulator weighs 2550 kg! All lifting equipment used must be dimensioned
accordingly!
Slings attached directly on to manipulator
The section below details how to attach roundslings to the manipulator in order to lift the
complete robot.
Step Action Note
1.
Caution!
Attempting to lift a manipulator in any other
position than the recommended may result inthe manipulator tipping over and causing
severe damage or injury!
Recommended manipulatorposition is described in section
Risk of tipping / stabilityon page49.
2. Run the overhead crane to a position above the
manipulator.
3. Attach the threechain slings with shortenersto
the overhead crane hook.
Shown in the figure Roundslingsattached to the manipulatoronpage 61!
Lengths are specified in Required
equipmenton page 61!
4. Fit the threeroundslings, 2000 kg to the robot.Attach the roundslings to the chain slingshanging from the overhead crane.
Shown in the figure Roundslings
attached to the manipulatoronpage 61!
Lengths are specified in Re