Product manual

Articulated robot

IRB 260
M2004
 Product manual
IRB 260
M2004

Document ID: 3HAC026048-001

Revision: A
© Copyright 2006-2008 ABB. All rights reserved.
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 gurantee 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.

© Copyright 2006-2008 ABB. All rights reserved.

© Copyright 2006-2008 ABB All rights reserved.

ABB AB
Robotics Products
SE-721 68 Västerås
Sweden
 Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Safety 13
1.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1.2.2 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.1 Safety risks during installation and service work on robot . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2.2.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.2.3 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
1.2.2.4 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.2.5 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.3 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.3.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.3.6 Safe use of the Teach Pendant Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.3.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.3.8 Translate the information on safety and information labels . . . . . . . . . . . . . . . . . . . . . . . 28
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
1.3.2 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.3.3 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.3.4 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
1.3.5 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2 Installation and commissioning 37

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.2 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
2.2.2 Working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
© Copyright 2006-2008 ABB. All rights reserved.

2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

2.3.1 Lifting of robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.3.3 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.3.4 Fitting equipment on the robot and robot dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.3.5 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
2.3.6 Load diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
2.3.7 Installation of signal lamp (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
2.4.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.4.3 Installation of position switch, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.4.4 Mechanically restricting the working range of axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
2.4.5 Mechanically restricting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.5.1 Connectors on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.5.2 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

3HAC026048-001 Revision: A 3
Table of Contents

3 Maintenance 75
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
3.2 Maintenace schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.3.1 Inspection of information labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.4 Changing activites . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.4.1 Oil in gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.4.2 Oil change, gearbox axis 6 (wrist unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
3.4.3 Replacement of SMB battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4 Repair 85
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
4.3 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.3.1 Replacement of cable unit, axes 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
4.3.2 Replacement of cable unit, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
4.4 Upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.4.1 Replacement of shaft and bearings, tilthouse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
4.4.2 Replacement of turning disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
4.4.3 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
4.4.4 Replacement of linkage - upper rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
4.4.5 Replacement of linkage - lower rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
4.4.6 Replacement of linkage - link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.5 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4.5.1 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
4.5.2 Replacement of parallel bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4.6 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
4.6.1 Replacement of SMB unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

© Copyright 2006-2008 ABB. All rights reserved.

4.6.2 Replacement of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
4.6.3 Replacement of parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
4.7 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4.7.1 Replacement of motor, axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
4.7.2 Replacement of motor, axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
4.7.3 Replacement of motor, axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
4.7.4 Replacement of motor, axis 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
4.8 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.8.1 Replacement of gearbox, axis 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
4.8.2 Replacement of gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

5 Calibration information 175

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
5.4 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

4 3HAC026048-001 Revision: A
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6 Reference information 183

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
6.2 Applicable safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
6.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
6.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
6.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
6.6 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
6.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
6.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

7 Spare part lists and exploded views 201

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
7.2 Spare parts - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
7.3 Spare parts - cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
7.4 Spare parts - robot IRB 260 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
7.5 Spare parts - axes 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
7.6 Spare parts - upper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
7.7 Spare parts - tilthouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
7.8 Spare parts - linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
7.9 Spare parts - material set cabling axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

8 Circuit diagram 223

8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Index 225
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 5
6
Table of Contents

3HAC026048-001 Revision: A
© Copyright 2006-2008 ABB. All rights reserved.
 Overview

Overview

About this manual

This manual contains instructions for:
• mechanical and electrical installation of the robot
• maintenance of the robot
• mechanical and electrical repair of the robot.

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.

Who should read this manual?

This manual is intended for:
• 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
The manual is organized in the following chapters:
© Copyright 2006-2008 ABB. All rights reserved.

Chapter Contents
Safety Safety information that must be read through before performing
any installation or service work on robot. Contains general safety
aspects as well as more specific information about how to avoid
personal injuries and damage to the product.
Installation and commis- Required information about lifting and installation of the robot.
sioning
Maintenance Step-by-step procedures that describe how to perform
maintenance of the robot. Based on a maintenance schedule
that may be used in the work of planning periodical maintenance.
Repair Step-by-step procedures that describe how to perform repair
activities of the robot. Based on available spare parts.
Calibration information Procedures that does not require specific calibration equipment.
Decommissioning Environmental information about the robot and its components.

Continues on next page

3HAC026048-001 Revision: A 7
Overview

Continued

References
Procedures in this product manual contain references to the following manuals:

Product specification

Document name Document ID

Product specification - IRB 260 3HAC025046-001

Product manual

Document name Document ID

Product manual IRC5 3HAC021313-001

Operating manual

Document name Document ID

IRC5 with FlexPendant 3HAC16590-1
Calibration Pendulum 3HAC16578-1
Service Information System - IRC5 3HAC025709-001

Application manual

Document name Document ID

Additional axes and stand alone controller 3HAC021395-001

Technical reference manual

Document name Document ID

System parameters 3HAC17076-1

Revisions

Revision Description

© Copyright 2006-2008 ABB. All rights reserved.

- First edition
A Changes made in:
• Prerequisites in section Overview

8 3HAC026048-001 Revision: A
 Product documentation, M2004

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
all documents 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.

Product manuals
All hardware, robots and controller cabinets, will be delivered with a Product manual which
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
The product manual published as a PDF consists of only one file where the two parts are
© Copyright 2006-2008 ABB. All rights reserved.

presented together, as one Product manual.

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 : Description of all RAPID instructions.
• Technical reference manual - System parameters: Description of system
parameters and configuration workflows.

Continues on next page

3HAC026048-001 Revision: A 9
Product documentation, M2004

Continued

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

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 Online
• Operator’s manual - IRC5 with FlexPendant
• Operator’s manual - RobotStudio Online
• Trouble shooting manual for the controller and robot

© Copyright 2006-2008 ABB. All rights reserved.

10 3HAC026048-001 Revision: A
 How to read the product manual

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 text in the
procedures and completed with a reference to the figure where the current component or
attachment point is shown.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a procedure.

Action Note/Illustration
8. Remove the rear attachment screws, gearbox. Shown in the figure Location of
gearbox on page xx.

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 text in 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 a procedure.

Action Note/Illustration
© Copyright 2006-2008 ABB. All rights reserved.

3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required
equipment on page xx.

Safety information
The manual includes a separate safety chapter that must be read through before proceeding
with any service or installation procedures. All procedures also include specific safety
information when dangerous steps are to be performed.
Read more in chapter Safety on page 13.

3HAC026048-001 Revision: A 11
How to read the product manual

© Copyright 2006-2008 ABB. All rights reserved.

12 3HAC026048-001 Revision: A
 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 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 instructions on
page 29.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 13
1 Safety
1.2.1. Safety in the robot system

1.2 General safety information

1.2.1. Safety in the robot system

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 are designed and installed correctly.
Personnel working with robots must be familiar with the operation and handling of the
industrial robot, described in the applicable documents, e.g. User's 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.

Limitation of liability
Any information given in this manual regarding safety, must not be construed as a warranty
by ABB that the industrial robot will not cause injury or damage even if all safety instructions
are complied with.

Related information

Type of information Detailed in document Section

Installation of safety devices Product manual for the robot Installation and com- © Copyright 2006-2008 ABB. All rights reserved.
missioning
Changing robot modes Operators manual (RobotWare 5.0) Operating modes
Restricting the working space Product manual for the robot Installation and com-
missioning

14 3HAC026048-001 Revision: A
 1 Safety
1.2.2.1. Safety risks during installation and service work on robot

1.2.2. Safety risks

1.2.2.1. Safety risks during installation and service work on robot

Overview
This section includes information of general safety risks to be considered when performing
installation and service work on the robot.

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
© Copyright 2006-2008 ABB. All rights reserved.

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.
• 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.
Continues on next page
3HAC026048-001 Revision: A 15
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

Cable packs are sensitive to
mechanical damage!

Caution!

The cable packs are sensitive to mechanical damage!

They must be handled with care, especially the
connectors, in order to avoid damaging them!

Gearboxes and motors

Safety risk Description

© Copyright 2006-2008 ABB. All rights reserved.
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!

16 3HAC026048-001 Revision: A
 1 Safety
1.2.2.2. Safety risks related to tools/workpieces

1.2.2.2. Safety risks related to tools/workpieces

Safe handling
It must be possible to safely turn off tools, such as milling cutters, etc. 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.
CAUTION!
Ensure that a gripper is prevented from dropping a workpiece, if such is used.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 17
1 Safety
1.2.2.3. Safety risks related to pneumatic/hydraulic systems

1.2.2.3. 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. 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.

© Copyright 2006-2008 ABB. All rights reserved.

18 3HAC026048-001 Revision: A
 1 Safety
1.2.2.4. Safety risks during operational disturbances

1.2.2.4. 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
• 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.

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.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 19
1 Safety
1.2.2.5. Risks associated with live electric parts

1.2.2.5. 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 IRC5

A danger of high voltage is associated with the following parts:
• Be aware of stored electrical energy (DC link, Ultra Cap unit) 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 transformers
• The power unit
• The control power supply (230 VAC)
• The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)
• The drive unit (700 VDC)
• The drive system power supply (230 VAC)
• The service outlets (115/230 VAC)
• The customer power supply (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

© Copyright 2006-2008 ABB. All rights reserved.

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
chapter Installation and commissioning in the Product 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.

20 3HAC026048-001 Revision: A
 1 Safety
1.2.3.1. Safety fence dimensions

1.2.3. Safety actions

1.2.3.1. 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.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 21
1 Safety
1.2.3.2. Fire extinguishing

1.2.3.2. Fire extinguishing

NOTE!
Use a CARBON DIOXIDE (CO2) extinguisher in the event of a fire in the robot (manipulator
or controller)!

© Copyright 2006-2008 ABB. All rights reserved.

22 3HAC026048-001 Revision: A
 1 Safety
1.2.3.3. Emergency release of the robot’s arm

1.2.3.3. Emergency release of the robot’s arm

Description
In an emergency situation, any of the robot's axes may be released manually by pushing the
brake release buttons on the robot.
How to release the brakes is detailed in section:
• Manually releasing the brakes on page 45.
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!
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 23
1 Safety
1.2.3.4. Brake testing

1.2.3.4. 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.

© Copyright 2006-2008 ABB. All rights reserved.

24 3HAC026048-001 Revision: A
 1 Safety
1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"

1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s"

NOTE!
Do not change "Transm gear ratio" or other kinematic parameters from the Teach Pendant
Unit or a PC. This will affect the safety function Reduced speed 250 mm/s.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 25
1 Safety
1.2.3.6. Safe use of the Teach Pendant Unit

1.2.3.6. 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 of
the robot without the programmer knowing.

© Copyright 2006-2008 ABB. All rights reserved.

26 3HAC026048-001 Revision: A
 1 Safety
1.2.3.7. Work inside the manipulator's working range

1.2.3.7. Work inside the manipulator's working range

WARNING!
If work must be carried out within the robot’s work envelope, the following points must be
observed:
• 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 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 24.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 27
1 Safety
1.2.3.8. Translate the information on safety and information labels

1.2.3.8. Translate the information on safety and information labels

Labels on the product

Both the robot and the controller are marked with several safety and information labels,
containing important information about the product. The information is useful for all
personnel handling the robot system, eg. during installation, service or operation.
The labels are identified and located on the product as shown in section:
• Inspection of information labels on page 78

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.

Example of transparent sticker

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.

© Copyright 2006-2008 ABB. All rights reserved.

xx0500002517

A Free space for adding a fourth language

28 3HAC026048-001 Revision: A
 1 Safety
1.3.1. Safety signals, general

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 do 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 Warns that an accident will occur if the instructions
are not followed, resulting in a serious or fatal injury
and/or severe damage to the product. It applies to
warnings that apply to danger with, for example,
contact with high voltage electrical units, explosion
or fire risk, risk of poisonous gases, risk of crushing,
danger impact, fall from height etc.
WARNING Warns that an accident may occur if the instructions
are not followed, that can lead to serious injury,
possibly fatal, and/or great damage to the product. It
applies to warnings that apply to danger with, for
example, contact with high voltage electrical units,
explosion or fire risk, risk of poisonous gases, risk of
© Copyright 2006-2008 ABB. All rights reserved.

warning crushing, impact, fall from height etc.

ELECTRICAL The electrocution or electrical shock symbol
SHOCK indicates electrical hazards which could result in
severe personal injury or death.

Electrical shock

CAUTION Warns that an accident may occur if the instructions

are not followed, that can result in injury and/or
damage to the product. It also applies to warnings of
risks that include burns, eye injury, skin injury,
hearing damage, crushing or slipping, tripping,
impact, fall from height etc. Furthermore, it applies to
caution warnings that include function requirements when
fitting and removing equipment, where there is a risk
of damaging the product or causing a breakdown.

Continues on next page

3HAC026048-001 Revision: A 29
1 Safety
1.3.1. Safety signals, general

Continued

Symbol Designation Signification

ELECTROSTATIC The electrostatic discharge (ESD) symbol indicates
DISCHARGE (ESD) electrostatic hazards which could result in severe
damage to the product.

Electrostatic discharge
(ESD)

NOTE Note symbols alert you to important facts and

conditions.

Note

TIP Tip symbols direct you to specific instructions, where

to find additional information or how to perform a
certain operation in an easier way.

Tip

© Copyright 2006-2008 ABB. All rights reserved.

30 3HAC026048-001 Revision: A
 1 Safety
1.3.2. DANGER - Moving manipulators are potentially lethal!

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

Action Note/Illustration
1. Before attempting to run the manipulator, Emergency stop equipment such as gates,
make sure all emergency stop equipment is tread mats, light curtains, etc.
correctly installed and connected.
2. If possible, use the hold-to-run button How to use the hold-to-run control in
whenever possible. RobotWare 5.0 is detailed in section How
The hold-to-run button is used in manual to use the hold-to-run function in the
mode, not in automatic mode. Operating manual - IRC5 with Flex-
Pendant.
3. Make sure no personnel are present within
the manipulator working range before
pressing the start button.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 31
1 Safety
1.3.3. DANGER - First test run may cause injury or damage!

1.3.3. DANGER - First test run may cause injury or damage!

Description
Since performing a service activity often requires disassembly of the robot there are several
safety risks to take into consideration before the first test run.

Elimination
Follow the procedure below when performing the first test run after a service activity (repair,
installation or maintenance):

Action
1. Remove all service tools and foreign objects from the robot and its working area!
2. Install all safety equipment properly!
3. Make sure all personnel are standing at a safe distance from the robot, i.e. out of its
reach behind safety fences, etc!
4. Pay special attention to the function of the part previously serviced!

© Copyright 2006-2008 ABB. All rights reserved.

32 3HAC026048-001 Revision: A
 1 Safety
1.3.4. WARNING - The unit is sensitive to ESD!

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 grounded may potentially transfer high
static charges. This discharge may destroy sensitive electronics.

Elimination

Action Note
1. Use a wrist strap Wrist straps must be tested frequently to ensure
that they are not damaged and are operating
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 discharge of
static voltages and must be grounded.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 33
1 Safety
1.3.5. WARNING - Safety risks during work with gearbox oil

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

Changing and draining Make sure that protective gear
gearbox oil may require like goggles and gloves are
handling hot oil of up to 90 °C! always worn during this activity.

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!
-

Possible pressure build

up in gearbox!
Overfilling of gearbox oil can Make sure not to overfill the
lead to internal over-pressure gearbox when filling with oil!
inside the gearbox which in After filling, check the correct oil
turn may: level.
-
• damage seals and
gaskets
Do not overfill!
• completely press out
seals and gaskets
• prevent the manipulator
from moving freely.

© Copyright 2006-2008 ABB. All rights reserved.

Mixing types of oil may cause When filling gearbox oil, do not
severe damage to the mix different types of oil unless
gearbox! specified in the instruction.
Always use the type of oil
specified by the manufacturer!
-

Do not mix types of oil!

Warm oil drains quicker than When changing gearbox oil, first
cold oil. run the robot for a time to heat
up the oil.

Heat up the oil!

Continues on next page

34 3HAC026048-001 Revision: A
 1 Safety
1.3.5. WARNING - Safety risks during work with gearbox oil

Continued

Warning Description Elimination / Action

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
Specified amount much oil has previously been
depends on drained drained from the gearbox.
volume!
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 35
1 Safety
1.3.5. WARNING - Safety risks during work with gearbox oil

© Copyright 2006-2008 ABB. All rights reserved.

36 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.1. Introduction

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.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 37
2 Installation and commissioning
2.2.1. Pre-installation procedure

2.2 Unpacking

2.2.1. Pre-installation procedure

General
These instructions are to be used when unpacking and installing the robot for the first time.
They also contain information useful later during re-installation of the robot.

Checking the pre-requisites for installation

The check-list 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. Make sure the robot is not damaged, by visually inspecting it.
3. Make sure the lifting device to be used is fit to handle the weight of the robot as specified
in Weight, robot on page 38.
4. If the robot is not to be installed directly, it must be stored according to the specifications
in Storage conditions on page 39.
5. Make sure the appointed operating environment of the robot conforms to the
specifications outlined in Operating conditions on page 39.
6. Before taking the robot to the installation site, make sure the site conforms to Loads on
foundation on page 38, Requirements on foundation on page 39 and Protection classes on
page 39.
7. When these prerequisites are met, the robot may be taken to its installation site as
described in Lifting of robot on page 42.

Weight, robot

Robot model Weight

© Copyright 2006-2008 ABB. All rights reserved.

IRB 260 340 kg

Loads on foundation
The table below shows the different forces and torques working on the robot during various
kinds of operation.
Note! These forces and torques are extreme values that are rarely encountered during
operation. The values also never simultaneously reach their maximum!

IRB 260

Endurance load Max. load (emergency

Forces and torques
(operation) stop)
Force xy ± 1400 N ± 2900 N
Force z + 3500 N ± 1100 N + 3500 N ± 2300 N
Torque Mxy ± 2100 Nm ± 3900 Nm
Torque Mz ± 700 Nm ± 950 Nm

Continues on next page

38 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.2.1. Pre-installation procedure

Continued

Requirements on foundation
The table below shows the requirements of the foundation where the robot is to be fitted:
Requirement Value
Min. levelity 0.5 mm
Max. tilt 5°
Min. resonance frequency 30 Hz

Storage conditions
The table below shows the allowed storage conditions for the robot:
Parameter Value
Min. ambient temperature, storage -25° C
Max. ambient temperature, storage +55° C
Max. ambient temperature, storage (less than 24 hrs) +70° C
Max. ambient humidity, storage Max. 95% at constant temperature

Operating conditions
The table below shows the allowed operating conditions for the robot and controller:
Parameter Value
Min. ambient temperature +5° C
Max. ambient temperature +45° C
Max. ambient humidity Max. 95% at constant temperature

Protection classes
The table below shows the protection class of the main parts of the robot system:
Equipment Protection class
Robot IRB 260 IP 67
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 39
2 Installation and commissioning
2.2.2. Working range

2.2.2. Working range

Working range
This section specifies the working areas of the robot models.

IRB 260
The extreme positions of the robot are specified at the tool flange center (dimensions in mm).

© Copyright 2006-2008 ABB. All rights reserved.

xx0500001926

A Position at mechanical stop

B Position at maximum working range, axis 2
C Tool flange center

Positions in the working range

The table below specifies the positions inside the working range, shown in the figure above.
Position in figure Position (mm) Angles (º)

X Z Axis 2 Axis 3
1 870 1139 0 0
2 510 1246 -28 -17
3 446 722 -28 31
4 515 218 60 119
5 607 -73 85 119
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40 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.2.2. Working range

Continued

Position in figure Position (mm) Angles (º)

X Z Axis 2 Axis 3
6 1506 210 85 26
7 1313 1148 42 -17

Type of motion

Axis Type of motion Range of movement

1 Rotation motion +180º to -180º
2 Arm motion +85º to -28º
3 Arm motion +119º to -17º
6 Turn motion +300º to -300º (default)
+150 revolutions to -150 revolutions max.1

1
The default working range for axis 6 can be extended by changing parameter values in the
software (option Advanced Motion is required).
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 41
2 Installation and commissioning
2.3.1. Lifting of robot

2.3 On-site installation

2.3.1. Lifting of robot

Methods for lifting

The robot can be lifted with:
• lifting slings, or
• lifting chains.

Required equipment

Equipment Specification
Overhead crane Lifting capacity: 500 kg.
Lifting slings -
Lifting chains, 3 pcs Lengths:
• axis 2: 950 mm
• axis 3: 920 mm
• upper arm: 680 mm

Liftings slings - attachment and axis position

The lifting slings are attached to the robot as shown in the figure below. The axis positions
are specified below the figure.

© Copyright 2006-2008 ABB. All rights reserved.

xx0500002140

Axis 2 position: -10º

Axis 3 position: +35º

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42 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.3.1. Lifting of robot

Continued

Lifting chains - attachment and axis position

The lifting chains are attached to the robot as shown in the figure below. The axis positions
are specified below the figure.
© Copyright 2006-2008 ABB. All rights reserved.

xx0500002141

Axis 2 position: -28º

Axis 3 position: +17º
A Lifting chain, axis 2
B Lifting chain, axis 3
C Lifting chain, upper arm

Continues on next page

3HAC026048-001 Revision: A 43
2 Installation and commissioning
2.3.1. Lifting of robot

Continued

Lifting of robot
The procedure below details how to lift the complete robot.

Action Note
1. Move the robot to the correct lifting Depending on the method of lifting, the
position. correct axis positions are shown in:
If necessary, release the brakes of • Liftings slings - attachment and
affected axis, according to section axis position on page 42
Manually releasing the brakes on page 45. • Lifting chains - attachment and axis
position on page 43.
2.

CAUTION!
The robot weighs 340 kg! All lifting
equipment used must be sized accord-
ingly!
3. Attach the lifting equipment to the robot as
shown in the previous figures and lift the
robot.

© Copyright 2006-2008 ABB. All rights reserved.

44 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.3.2. Manually releasing the brakes

2.3.2. Manually releasing the brakes

General
The holding brakes of each axis’ motor are of an electromechanical type and are released
when voltage is applied. This section details how to release the brakes, using the internal
brake release unit, in order to enable the axes to move manually.
The brake of each motor can also be released by connecting an external voltage supply
directly on the motor connector, see the circuit diagram or the repair procedures for each
motor (section Motors on page 151).

Releasing the brakes using the brake release unit

The procedure below details how to release the holding brakes using the internal brake release
unit.

Action Note/Illustration
1.

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!
2. If the robot is not connected to the controller, Detailed in section Supplying power
power must be supplied to the connector to connector R1.MP on page 46.
R1.MP.
3. The internal brake release unit is located at the
base of the robot and equipped with buttons
for controlling the holding brakes for each axis
separately. The buttons are numbered
according to the numbers of the axes.
© Copyright 2006-2008 ABB. All rights reserved.

To release the brake on a particular robot axis,

push the corresponding button on the internal
brake release panel and keep it depressed.
The brake will function again as soon as the
button is released.

xx0500001930

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3HAC026048-001 Revision: A 45
2 Installation and commissioning
2.3.2. Manually releasing the brakes

Continued

Supplying power to connector R1.MP

If the robot is not connected to the controller, power must be supplied to connector R1.MP in
the robot base in order to enable the brake release unit on the robot.

Action Note/Illustration
1.

Caution!
Be careful not to interchange the 24 VDC and 0V
pins! If they are mixed up, damage can be caused
to a resistor diode and to the system board.
2. Connect an external power supply to connector
R1.MP, at the robot base.
Supply:
• +24 V on pin B8
• 0 V on pin C10

xx0200000167

3. Release the brakes with the brake release unit as © Copyright 2006-2008 ABB. All rights reserved.
detailed in the previous procedure.

46 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.3.3. Orienting and securing the robot

2.3.3. Orienting and securing the robot

General
This section details how to orient and secure the robot to the foundation in order to safely run
the robot. The requirements for the foundations are shown in the tables and figures below.

Bolting requirements
When bolting a base plate or the base to a concrete floor, follow the general instructions for
expansion-shell bolts. The screw joint must be able to withstand the stress loads defined in
section Loads on foundation on page 38.

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: M16 x 50

Quality Quality 8.8
Suitable washer: Thickness: 3 mm
Outer diameter: 30 mm
Inner diameter: 17 mm
Tightening torque: 190 Nm

Hole configuration
The figure below shows the hole configuration of the robot base, used when securing the
robot. Cross section is shown in the following figure.
© Copyright 2006-2008 ABB. All rights reserved.

xx0200000181

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3HAC026048-001 Revision: A 47
2 Installation and commissioning
2.3.3. Orienting and securing the robot

Continued

Cross section, guide sleeve hole

The figure below shows the cross section of the guide sleeve holes (from previous figure):

xx0200000182

Guide sleeves
Two guide sleeves can be fitted to the two rear bolt holes to allow the same robot to be
remounted without re-adjusting the program.

Equipment Art. no.

Guide sleeves 2151 0024-169

© Copyright 2006-2008 ABB. All rights reserved.

48 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.3.4. Fitting equipment on the robot and robot dimensions

2.3.4. Fitting equipment on the robot and robot dimensions

General
This section shows the dimensions and available mounting holes on the robot.

Main dimensions
© Copyright 2006-2008 ABB. All rights reserved.

xx0500001928

A At maximum working range axis 3

B Mounting hole for safety lamp
C Mounting hole for external air hose

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3HAC026048-001 Revision: A 49
2 Installation and commissioning
2.3.4. Fitting equipment on the robot and robot dimensions

Continued

Fitting equipment on the robot

xx0500002102

© Copyright 2006-2008 ABB. All rights reserved.

A M8 (3x) Depth 16 mm, R=77
B M8 (3x) Depth 16 mm, R=92
C Max. 35 kg total
D The rear side of the robot

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50 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.3.4. Fitting equipment on the robot and robot dimensions

Continued

Turning radius, axis 2

xx0500001929
© Copyright 2006-2008 ABB. All rights reserved.

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3HAC026048-001 Revision: A 51
2 Installation and commissioning
2.3.4. Fitting equipment on the robot and robot dimensions

Continued

Turning disk, dimensions

The figure below shows the mounting holes available for fitting equipment on the turning
disk.

© Copyright 2006-2008 ABB. All rights reserved.

xx0500001932

52 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.3.5. Loads

2.3.5. Loads

General
Any loads mounted on the robot must be defined correctly and carefully (with regard to the
position of center of gravity and inertia factor) 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), or 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.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 53
2 Installation and commissioning
2.3.6. Load diagram

2.3.6. Load diagram

Load diagram, IRB 260-30/1.5

The figure below shows the maximum permitted load mounted on the robot tool flange at
different positions (center of gravity).

© Copyright 2006-2008 ABB. All rights reserved.

xx0500002100

54 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.3.7. Installation of signal lamp (option)

2.3.7. Installation of signal lamp (option)

General
As an option, a signal lamp can be installed on the robot. The lamp is activated when the
controller is in the MOTORS ON state.

Signal lamp on robot

The signal lamp is installed on the upper arm, as shown in the figure below.
© Copyright 2006-2008 ABB. All rights reserved.

xx0500002125

A Indicator lamp
B Lamp holder
C O-ring
D Cable gland
E Bracket
F Attachment screws, 2 pcs
G Cabling for the signal lamp (included in the robot cabling for axis 6)

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3HAC026048-001 Revision: A 55
2 Installation and commissioning
2.3.7. Installation of signal lamp (option)

Continued

Required equipment

Equipment Spare part no. Note

Signal lamp 3HAC025254-001 Includes all components shown in the
previous figure.
Standard toolkit - The contents are defined in section Standard
toolkit on page 190, in part 2 of the Product
manual.

Installation, signal lamp

The procedure below details how to install the signal lamp on the robot.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Connect the two cables to the signal lamp. Run the cables from inside the upper
arm, as shown in the figure Signal lamp
on robot on page 55.
Connectors R3.H1 and R3.H2.
3. Fit the signal lamp to the upper arm by 2 pcs; M6x16.
securing the bracket with two attachment Shown in the figure Signal lamp on robot
screws. on page 55.
4. Make sure that the lamp is lit when the
controller is in MOTORS ON mode.

© Copyright 2006-2008 ABB. All rights reserved.

56 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.4.1. Introduction

2.4 Restricting the working range

2.4.1. Introduction

General
When installing the robot, make sure that it can move freely within its entire working space.
If there is a risk that it may collide with other objects, its working space should be limited.
The working range of the following axes may be restricted:
• Axis 1, hardware (mechanical stop and position switch)
• Axis 2, hardware (mechanical stop). Note! The axis 2 stop is a fixed stop that must be
installed during operation of robot!
• Axis 3, hardware (mechanical stop). Note! The axis 3 stop is a fixed stop that must be
installed during operation of robot!
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 following installation procedures.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 57
2 Installation and commissioning
2.4.2. Mechanically restricting the working range of axis 1

2.4.2. Mechanically restricting the working range of axis 1

Restrictions in the working range

The working range of axis 1 can be restricted within the area from 50º to 140º as shown in the
figure below. The restrictions are made by fitting two extra stops to the robot base.

xx0500002105

Location of the mechanical stop, axis 1

The extra mechanical stop is fitted to the robot base as shown in the figure below.
Note! The stop must only be mounted in the direction shown below!

© Copyright 2006-2008 ABB. All rights reserved.

xx0200000205

1 Stop, axis 1, removable

2 Plain washer
3 Hex socket head cap screw

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58 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.4.2. Mechanically restricting the working range of axis 1

Continued

Required equipment

Equipment Art. no. Note

Stop, axis 1 3HAB 7298-1 Includes:
• removable stop (2 pcs)
• plain washers (4 pcs)
• hex socket head cap screw (4
pcs, M12x30)
• drill template (1 pc)
Technical reference manual - System - Art. no. is specified in section
parameters (RobotWare 5.0) References on page 8.

Fitting, mechanical stop axis 1

The procedure below details how to fit a mechanical stop to the robot base.

Action Note
1. Decide where to fit the extra mechanical stops,
according to the figure Location of where to drill
holes for extra stops on page 60.
2. Make a copy of the drill template, enclosed with The template is also shown in the
the mechanical stop. figure Drill template on page 62 in
scale 1:1.
3. Use the template to mark the center of the two Place the template edge edge with
holes on each stop. the robot base, as shown in the figure
Location of where to drill holes for
extra stops on page 60.
4. Drill the holes through, Ø 10.2. Cut threads,
M12.
5. Fit the stops to the robot base, but without Note! The stops must be mounted in
tightening the screws. correct direction, as shown in the
figure Location of where to drill holes
for extra stops on page 60.
6. Turn axis 1 manually and check the working If necessary; correct the angle of
© Copyright 2006-2008 ABB. All rights reserved.

range between the stops. impact.

7. Tighten the screws.
8. The software working range limitations must be How to define the range of movement
re-defined to correspond to the changes in the in RobotWare 5.0 is detailed in the
mechanical limitations of the working range. Technical reference manual - System
parameters- chapter Motion.
9.

Warning!
If the mechanical stop is deformed after a hard
collision, it must be replaced!

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2 Installation and commissioning
2.4.2. Mechanically restricting the working range of axis 1

Continued

Location of where to drill holes for extra stops

The figure below shows the drill pattern used when drilling for mechanical stops on axis 1.

© Copyright 2006-2008 ABB. All rights reserved.

xx0200000206

A Maximum working range, axis 1

B Minimum working range, axis 1
C Drilling pattern enclosed with the mechanical stop.
D This mounting direction only
* The minimum and maximum measurement between the mechanical stops. The
difference between the measurement and the minimum and maximum working
range is 2 x 4º, which corresponds to the width of the stop pin (at the frame).

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60 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.4.2. Mechanically restricting the working range of axis 1

Continued

Hidden stiffening ribs and forbidden drilling sector

© Copyright 2006-2008 ABB. All rights reserved.

xx0600002647

C Drilling not allowed inside this sector!

D Center lines for the hidden stiffening ribs

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3HAC026048-001 Revision: A 61
2 Installation and commissioning
2.4.2. Mechanically restricting the working range of axis 1

Continued

Drill template

© Copyright 2006-2008 ABB. All rights reserved.

xx0200000207

62 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.4.3. Installation of position switch, axis 1

2.4.3. Installation of position switch, axis 1

General
This section details how to install the position switch to axis 1.

Location of position switch, axis 1

The position switch is installed between the frame and the base, as shown in the figure below.
© Copyright 2006-2008 ABB. All rights reserved.

xx0600002676

A Position switch
B Attachment screws, position switch (2 pcs for each switch) M4 x 16
C Holder ring
D Attachment screws, holder ring, 6 pcs: M8 x 12
E Cam
F Attachment screws, cam, (8 pcs for each cam) M6 x 12
G Attachment plate

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2 Installation and commissioning
2.4.3. Installation of position switch, axis 1

Continued

H Attachment screws, attachment plate (2 pcs) M6 x 16

I Shims
K Bracket
L Attachment screws, bracket (2 pcs) M6 x 30
M Mechanical stop
N Cable straps
O Attachment screw, clamp
P Clamp

Required equipment
All parts are included in the delivery of the kits specified below. An instruction of how to cut
the cams is also enclosed in the kit.

Equipment Art. no. Note

Position switch axis 1 3HAC12062-1 Includes one switch.
Position switch axis 1 3HAC12062-2 Includes two switches.
Position switch axis 1 3HAC12062-3 Includes three switches.

Installation, position switch axis 1

The procedure below details how to install the position switch to the robot.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Fit the two holder rings underneath the Shown in the figure Location of position
© Copyright 2006-2008 ABB. All rights reserved.
frame with the six attachment screws. switch, axis 1 on page 63.
6 pcs, M8 x 12.
3. Cut the cams according to instructions,
enclosed with the position switch kit.
4. Fit the cams to the holder ring with the Shown in the figure Location of position
attachment screws. switch, axis 1 on page 63.
M6 x 12.
5. Fit the complete bracket to the base of the Shown in the figure Location of position
robot with the two attachment screws. switch, axis 1 on page 63.
6. Fit the attachment plate to the base of the 2 pcs, M6 x 16.
robot with the two attachment screws. Shown in the figure Location of position
Fit the switches to the attachment plate. switch, axis 1 on page 63.
Adjust the height of the switches with
shims until each roller aligns with corre-
sponding cam.
Note! Make sure the cabling has
clearance to the mechanical stop at the
base!

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64 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.4.3. Installation of position switch, axis 1

Continued

Action Note
7. Secure the cabling with straps and Shown in the figure Location of position
clamps. switch, axis 1 on page 63.
8. Connect the position switch cabling. The cabling and connection points are
specified in section Position switch cables,
robot base to control cabinet (option) on
page 73.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 65
2 Installation and commissioning
2.4.4. Mechanically restricting the working range of axis 2

2.4.4. Mechanically restricting the working range of axis 2

General
The stops are installed as standard, not movable and must always be installed during
operation of the robot!

Restrictions in working range

The mechanical stops are not movable or optional! They function as solid stops and must be
installed during robot operation. The working range of axis 2 cannot be restricted further.

Location of mechanical stops

xx0500002036

A Mechanical stop (spacer), long

B Mechanical stop (spacer), short
C Fixed stops
© Copyright 2006-2008 ABB. All rights reserved.
Required equipment

Equipment Art. no. Note

Spacer, axis 2 3HAC025740-001 Long.
Spacer, axis 2 3HAC025741-001 Short.
Technical reference manual - System - Art. no. is specified in section
parameters (RobotWare 5.0) References on page 8.
Standard toolkit - The contents are defined in
section Standard toolkit on
page 190, in part 2 of the
Product manual.

Continues on next page

66 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.4.4. Mechanically restricting the working range of axis 2

Continued

Installation, mechanical stops axis 2

The procedure below details how to fit the mechanical stops to the axis 2.

Action Note
1. Move the robot to its calibration position. Shown in section Calibration scales and
correct axis position on page 178.
2.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3.

Danger!
The two mechanical stops must be
installed correctly on axis 2! The robot
may never be run without the stops fitted!
4. Fit the two spacers directly next to the 2 + 4 pcs: M8x25. Tightening torque: 17 Nm.
fixed stops of axis 2, with attachment
screws.
© Copyright 2006-2008 ABB. All rights reserved.

xx0500002037

• A: Attachment holes for the short

stop (spacer)
• B: Attachment holes for the long stop
(spacer)
5. Fit the dampers to the mechanical stops.
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3HAC026048-001 Revision: A 67
2 Installation and commissioning
2.4.4. Mechanically restricting the working range of axis 2

Continued

Action Note
6. The software working range limitations How to define the range of movement in
must be re-defined to correspond to the RobotWare 5.0 is detailed in the Technical
changes in the mechanical limitations of reference manual - System parameters-
the working range. chapter Motion.
7.

Warning!
If the mechanical stop is deformed after a
hard collision, it must be replaced!

© Copyright 2006-2008 ABB. All rights reserved.

68 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.4.5. Mechanically restricting the working range of axis 3

2.4.5. Mechanically restricting the working range of axis 3

General
The stop of axis 3 is installed as standard, not movable and must always be installed during
operation of robot!

Restrictions in working range

The mechanical stop is not movable or optional! It functions as a solid stop and must be
installed during robot operation. The working range of axis 3 cannot be restricted further.

Location of mechanical stop

The figure below shows the location of the mechanical stop on axis 3.
© Copyright 2006-2008 ABB. All rights reserved.

xx0500002039

A Mechanical stop, axis 3

Required equipment

Equipment Art. no. Note

Mechanical stop, axis 3 3HAC024253-001
Locking liquid - Loctite 243
Technical reference manual - System - Art. no. is specified in section
parameters (RobotWare 5.0) References on page 8.
Standard toolkit - The contents are defined in
section Standard toolkit on
page 190, in part 2 of the
Product manual.

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2 Installation and commissioning
2.4.5. Mechanically restricting the working range of axis 3

Continued

Installation, mechanical stop

The procedure below details how to fit the mechanical stop to the robot.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Fit the mechanical stop to the parallel bar Shown in the figure Location of
with the three attachment screws. Use mechanical stop on page 69.
locking liquid. 3 pcs; M6x16. Tightening torque: 11 Nm.
Locking liquid is specified in Required
equipment on page 69.
3. The software working range limitations must How to define the range of movement in
be re-defined to correspond to the changes RobotWare 5.0 is detailed in the
in the mechanical limitations of the working Technical reference manual - System
range. parameters- chapter Motion.
4.

Warning!
If the mechanical stop is deformed after a
hard collision, it must be replaced!

© Copyright 2006-2008 ABB. All rights reserved.

70 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.5.1. Connectors on robot

2.5 Electrical connections

2.5.1. Connectors on robot

Connectors on the robot

The figure below shows all connections of the robot cabling, including the customer
connections.

xx0500002434
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 71
2 Installation and commissioning
2.5.2. Robot cabling and connection points

2.5.2. Robot cabling and connection points

General
Connect the robot and controller to each other after securing them to the foundation. The lists
below specify which cables to use for each respective application.

Main cable categories

All cables between the robot and control cabinet are divided into the following categories:
Cable category Description
Robot cables Handles power supply to and control of the robot's motors as
well as feedback from the serial measurement board.
Specified in the table Robot cables on page 72.
Position switch cables Handles supply to and feedback from any position switches
(option) on the robot.
Specified in the table Position switch cables, robot base to
control cabinet (option) on page 73.
Customer cables (option) Handles communication with equipment fitted on the robot
by the customer, low voltage signals and high voltage power
supply + protective ground.
See the product manual for the controller 1).
External axes cables (option) Handles power supply to and control of the external axes'
motors as well as feedback from the servo system.
See the product manual for external axes 1).

1)
Art. no. is specified in section References on page 8.

The cable categories are divided into sub-categories, specified below:

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 © Copyright 2006-2008 ABB. All rights reserved.
point, cabinet point, robot
Robot cable, power Transfers drive power from the XS1 R1.MP
drive units in the control cabinet
to the robot motors.
Robot cable, signals Transfers resolver data from XS2 R1.SMB
and power supply to the serial
measurement board.

Robot cable, power

Cable Art. no.

Robot cable, power, 7 m 3HAC 9038-1
Robot cable, power, 15 m 3HAC 9038-2
Robot cable, power, 22 m 3HAC 9038-3
Robot cable, power, 30 m 3HAC 9038-4

Continues on next page

72 3HAC026048-001 Revision: A
 2 Installation and commissioning
2.5.2. Robot cabling and connection points

Continued

Robot cable, signals

Cable Art. no.

Robot cable, signal, shielded, 7 m 3HAC 7998-1
Robot cable, signal, shielded, 15 m 3HAC 7998-2
Robot cable, signal, shielded, 22 m 3HAC 7998-3
Robot cable, signal, shielded, 30 m 3HAC 7998-4

Position switch cables, robot base to control cabinet (option)

These cables are not included in the standard delivery, but are included in the delivery if the
position switch option is ordered. The position switches can also be ordered without cables.
The cables are completely pre-manufactured and ready to plug in.

Cabling between robot base and control cabinet

Connec- Connec-
Cable Art. no. tion point, tion point,
robot cabinet
Position switch cable, axis 1, 7 m 3HAC 7997-1 R1.SW XS8
Position switch cable, axis 1, 15 m 3HAC 7997-2 R1.SW XS8
Position switch cable, axis 1, 22 m 3HAC 7997-3 R1.SW XS8
Position switch cable, axis 1, 30 m 3HAC 7997-4 R1.SW XS8

Customer cables (option)

The customer cables specified below are connected between robot and controller.

Customer cables

Connection
Cable Art. no.
point, robot
Customer cable, power-signal, 7 m 3HAC 8183-1 R1.CP/CS
Customer cable, power-signal, 15 m 3HAC 8183-2 R1.CP/CS
© Copyright 2006-2008 ABB. All rights reserved.

Customer cable, power-signal, 22 m 3HAC 8183-3 R1.CP/CS

Customer cable, power-signal, 30 m 3HAC 8183-4 R1.CP/CS

3HAC026048-001 Revision: A 73
2 Installation and commissioning
2.5.2. Robot cabling and connection points

© Copyright 2006-2008 ABB. All rights reserved.

74 3HAC026048-001 Revision: A
 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 13 before performing any service work.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 75
3 Maintenance
3.2.1. Specification of maintenance intervals

3.2 Maintenace schedule

3.2.1. Specification of maintenance intervals

Description
The intervals may be specified in different ways depending on the type of maintenance
activity to be carried out and the working conditions of the robot:
• Calendar time: specified in months regardless of whether the robot system is run or not
• Operating time: specified in operating hours. More frequent running of the robot
means more frequent maintenance activities.

© Copyright 2006-2008 ABB. All rights reserved.

76 3HAC026048-001 Revision: A
 3 Maintenance
3.2.2. Maintenance schedule

3.2.2. Maintenance schedule

General
The robot must be maintained regularly to ensure proper function. The maintenance activities
and intervals are specified in the table below.
Non-predictable situations also give rise to inspections of the robot. Any damages must be
attended to immediately!
The inspection intervals do not specify the life of each component.

Activities and intervals, standard equipment

The table below specifies the required maintenance activities and intervals and also refers to
the section where performing the activity is detailed.
Maintenance activity Interval Note Detailed in section:
Oil change in gearboxes, 40,000 h Lubricated for life.
axes 1,2, 3 Maintenance free units.
Oil change in wrist unit - No preventive Oil change, gearbox
maintenance in terms axis 6 (wrist unit) on
of changing the gear oil page 81.
is needed when
gearbox is lubricated
with Shell Tivela S 150.
Replacement of back-up 12-36 mths 1 Replacement of SMB
battery for SMB unit battery on page 83.
Inspection of all signal 36 mths Replace if required.
cabling in lower and
upper arm
Replacement of 60 mths Replace if bent.
mechanical stop axis 1

1. The battery is used as a back-up when the robot system is switched off. Therefore, the
life of a lithium battery depends on how frequently the power to the system is switched
off and also if the environment temperature is higher than recommended operating
© Copyright 2006-2008 ABB. All rights reserved.

temperature. The life varies from 12 - 36 mths, depending on current conditions. An

alert is given on the TPU or the FlexPendant when the battery is nearly discharged and
it must then be replaced within a month.

3HAC026048-001 Revision: A 77
3 Maintenance
3.3.1. Inspection of information labels

3.3 Inspection activities

3.3.1. Inspection of information labels

Location of labels
The labels are located on the robot as shown in the figure below.

xx0600002622

A, B Instruction plate. Specified further in the following table.

C Rating label (silver coloured)
D Calibration label. Specified further in the following table.
E Label with maximum air pressure.

© Copyright 2006-2008 ABB. All rights reserved.

F Warning sign. Specified further in the following table.
G UL label
H Instruction plate. Specified further in the following table.

List of labels

Equipment Spare part no. Note

Instruction plate 3HAC2814-2 Item A in the figure.
Warning of brake release.
Instruction plate 2945 4489-16 Item B in the figure.
Calibration label 3HAC024307-001 Item D in the figure.
Instruction plate 3HAC025469-001 Item H in the figure.
Lifting of robot.
Warning sign 3HAC1589-1 Item F in the figure.
Lightning flash.

Continues on next page

78 3HAC026048-001 Revision: A
 3 Maintenance
3.3.1. Inspection of information labels

Continued

Inspection, labels

Action Note
1.

Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Inspect that all labels are fitted to the robot. Replace Shown in the figure Location of
them if damaged or missing. labels on page 78.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 79
3 Maintenance
3.4.1. Oil in gearboxes

3.4 Changing activites

3.4.1. Oil in gearboxes

Location of gearboxes
The figure below shows the location of all the gearboxes.

© Copyright 2006-2008 ABB. All rights reserved.

xx0500001950

A Gearbox, axis 1
B Gearbox, axis 2
C Gearbox, axis 3
D Gearbox, axis 6

Type and amount of oil in the gearboxes

Gearbox Type of oil Art. no. Amount

Axis 1 Mobilgear 600 XP320 11712016-604 6,400 ml
Axis 2 Mobilgear 600 XP320 11712016-604 4,500 ml
Axis 3 Mobilgear 600 XP320 11712016-604 3,800 ml
Axis 6 Shell Tivela S 150 3HAC 021469-001 70 ml

80 3HAC026048-001 Revision: A
 3 Maintenance
3.4.2. Oil change, gearbox axis 6 (wrist unit)

3.4.2. Oil change, gearbox axis 6 (wrist unit)

Location of oil plugs, gearbox

The gearbox is located in the frontmost part of the upper arm. Oil plugs are located as shown
in the figure below.

xx0500001949

A Oil plug, draining

B Oil plug, filling

Required equipment

Equipment Art. no. Volume Note

Lubricating oil 3HAC 021469-001 70 ml Shell Tivela S 150
Oil collecting vessel - Capacity: 150 ml.
Standard toolkit - The contents are defined in section
Standard toolkit on page 190, in
© Copyright 2006-2008 ABB. All rights reserved.

part 2 of the Product manual.

Draining oil, gearbox axis 6

The procedure below details how to drain the oil from the gearbox, axis 6.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!

Continues on next page

3HAC026048-001 Revision: A 81
3 Maintenance
3.4.2. Oil change, gearbox axis 6 (wrist unit)

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 34.
3. Place the oil collecting vessel underneath the
gearbox of axis 6.
4. Remove the both oil plugs to drain the gearbox. Shown in the figure Location of oil
plugs, gearbox on page 81.
5. Refit the oil plug, draining.

Filling oil, gearbox axis 6

The procedure below details how to refill the gearbox, axis 6, with lubricating oil.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

© Copyright 2006-2008 ABB. All rights reserved.

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 34.
3. Fill lubricating oil to the wrist unit until the oil Art. no. and volume are specified in
reaches to the hole for the oil plug, filling. Required equipment on page 81.
Oil plugs are shown in the figure Location
of oil plugs, gearbox on page 81.
4. Refit the oil plug.

82 3HAC026048-001 Revision: A
 3 Maintenance
3.4.3. Replacement of SMB battery

3.4.3. Replacement of SMB battery

Location of SMB battery

The SMB battery is located inside the robot base, as shown in the figure below.

xx0300000067

A SMB battery
B SMB battery cable

Required equipment

Equipment Spare part no. Note

Battery pack 3HAC16831-1 Lithium battery.
© Copyright 2006-2008 ABB. All rights reserved.

Gasket, cover 3HAC3200-1 Always replace with a new one!

Standard toolkit The contents are defined in section
Standard toolkit on page 190, in part
2 of the Product manual.
Other tools and procedures may These procedures include
be required. See references to references to the tools required.
these procedures in the step-by-
step instructions below.

Continues on next page

3HAC026048-001 Revision: A 83
3 Maintenance
3.4.3. Replacement of SMB battery

Continued

Replacement, SMB battery

The procedure below details how to replace the SMB battery.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

Warning!

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 33
3. Remove the rear cover plate (A) on the robot
by unscrewing its attachment screws (B).

xx0200000399

4. Remove the battery terminals from the serial

measuring board and cut the clasp that keeps
the battery unit in place.
5. Fit the new battery with a clasp and connect Shown in the figure Location of SMB

© Copyright 2006-2008 ABB. All rights reserved.

the terminals to the serial measuring board. battery on page 83.
6. Refit the cover to the robot base, together with Always replace a removed gasket with
a new gasket. a new!
Spare part no. is specified in Required
equipment on page 83.
7. Update the revolution counters! Detailed in section Updating revolution
counters on page 180.

84 3HAC026048-001 Revision: A
 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 13 before commencing any
service work.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 85
4 Repair
4.2.1. Performing a leak-down test

4.2 General procedures

4.2.1. Performing a leak-down test

General
After refitting any motor and any gearbox, the integrity of all seals enclosing the gearbox oil
must be tested. This is done in a leak-down test.

Required equipment

Equipment, etc. Art. no. Note

Leakdown tester 3HAC 0207-1
Leak detection spray -

Procedure

Action Note
1. Finish the refitting procedure of the motor or gear in
question.
2. Remove the topmost oil plug on the gear in question, Art. no. is specified above!
and replace it with the leakdown tester.
Adapters may be required, which are included in the
leakdown tester kit.
3. Apply compressed air, and raise the pressure with the Recommended value:
knob until the correct value is shown on the 0.2 - 0.25 bar (20 - 25 kPa)
manometer.
4. Disconnect the compressed air supply.
5. Wait for approx. 8-10 minutes. No pressure loss must If the compressed air is signifi-
be detected. cantly colder or warmer than the
gearbox to be tested, a slight
pressure increase or decrease
respectively may occur. This is
quite normal.
6. Was any pressure drop evident? © Copyright 2006-2008 ABB. All rights reserved.
Localize the leak as detailed below.
Remove the leakdown tester, and refit the oil plug.
The test is complete.
7. Spray suspected leak areas with leak detection spray.
Bubbles indicate a leak.
8. When the leak has been localized: take the necessary
measures to correct the leak.

86 3HAC026048-001 Revision: A
 4 Repair
4.2.2. Mounting instructions for bearings

4.2.2. Mounting instructions for bearings

General
This section details how to mount and grease different types of bearings on the robot.

Equipment

Equipment, etc. Art. no. Note

Grease 3HAB 3537-1 Used to grease the bearings, if not
specified otherwise.

Assembly of all bearings

Follow the instructions below when mounting a bearing on the robot.
1. To avoid contamination, let a new bearing remain in its wrapping until it is time for fitting.
2. Ensure that all parts included in the bearing fitting are free from burrs, grinding waste and
other contamination. Cast components must be free from foundry sand.
3. Bearing rings, inner rings and roller elements must under no circumstances be subjected
to direct impact. Furthermore, the roller elements must not be exposed to any stresses
during the assembly work.

Assembly of tapered bearings

Follow the previous instructions for assembly of all bearings, when mounting a tapered
bearing on the robot.
In addition to those instructions, the procedure below must be carried out to enable the roller
elements to adjust to the correct position against the race flange.
1. Tension the bearing gradually until the recommended pre-tension is achieved.
Note! The roller elements must be rotated a specified number of turns before pre-
tensioning is carried out and also rotated during the pre-tensioning sequence.
© Copyright 2006-2008 ABB. All rights reserved.

2. Make sure the bearing is properly aligned, as this will directly affect the lifespan of the
bearing.

Greasing of bearings
The bearings must be greased after assembly, according to instructions below:
• 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.
• Ensure that grease is handled and stored properly, to avoid contamination.
Grease the different types of bearings as detailed below:
• 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.

3HAC026048-001 Revision: A 87
4 Repair
4.2.3. Mounting instructions for seals

4.2.3. Mounting instructions for seals

General
This sections details how to mount different types of seals to the robot.

Equipment

Equipment, etc. Art. no. Note

Grease 3HAB 3537-1 Used to lubricate the seals.

Rotating seals
The procedure below details how to fit rotating seals.
CAUTION!
Please observe the following before commencing any assembly of seals:
• Protect the sealing surfaces during transport and mounting.
• 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
1. Check the seal to ensure that:
• the seal is of the correct type (provided with cutting
edge).
• there is no damage to the sealing edge (feel with a
fingernail).
2. Inspect the sealing surface before mounting. If scratches or
damage are found, the seal must be replaced, as it may
result in future leakage.
3. Lubricate the seal with grease just before fitting. (Not too Art. no. is specified in
© Copyright 2006-2008 ABB. All rights reserved.
early as there is a risk of dirt and foreign particles adhering Equipment on page 88.
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.

Flange seals and static seals

The procedure below details how to fit flange seals and static seals.

Action
1. Check the flange surfaces. They must be even and free from pores.
It is easy to check flatness using a gauge on the fastened joint (without sealing
compound).
If the flange surfaces are defective, the parts may not be used because leakage could
occur.
Continues on next page
88 3HAC026048-001 Revision: A
 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
1. Ensure that the correct o-ring size is used.
2. Check the o-ring for surface defects, burrs, shape accuracy, etc. Defective o-rings may
not be used.
3. Check the o-ring grooves. Defective o-rings may
The grooves must be geometrically correct and free from pores not be used.
and contamination.
4. Lubricate the o-ring with grease.
5. Tighten the screws evenly when assembling.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 89
4 Repair
4.3.1. Replacement of cable unit, axes 1-3

4.3 Complete robot

4.3.1. Replacement of cable unit, axes 1-3

Location of cabling
The cable unit of axes 1-3 is run from the base of the robot to the motors, axes 1, 2 and 3, as
shown in the figure below.
A more detailed view of the component and its position may be found in section Axes 1-3,
spare part view 3 on page 213.

xx0200000396

A Connectors behind the cover plate at the robot base; R1.MP1-3 and R2.BU1-3. At the
serial measurement board; R2.G (battery), R2.FB1-3.
B Connectors at motor 2; R3.MP2 and R3.FB2 © Copyright 2006-2008 ABB. All rights reserved.
C Connectors at motor 3; R3.MP3, R3.FB3,R3.LS1 and R3.LS2
D Connectors at motor 1; R3.MP1, R3.FB1
E Upper bracket
F Cable guide in the middle of the frame

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Cable unit, axes 1-3 3HAC025725-001 Includes:
• cabling
• motor covers
• attachment screws
• gaskets, motor 1-3
Sealing 3HAC4113-1 Sealing in the base for the
cables. Always use a new
sealing.
Continues on next page
90 3HAC026048-001 Revision: A
 4 Repair
4.3.1. Replacement of cable unit, axes 1-3

Continued

Equipment, etc. Spare part no. Art. no. Note

Gasket, cover 3HAC3200-1
Cable straps, outdoor 2166 2055-3
Flange sealing 1234 0011-116 Loctite 574
Circuit diagram See chapter Circuit diagram
in the Product manual,
reference information.
Standard toolkit The contents are defined in
section Standard toolkit on
page 190, in part 2 of the
Product manual.
Other tools and These procedures include
procedures may be references to the tools
required. See references required.
to these procedures in the
step-by-step instructions
below.

Removal, cable unit, axes 1-3

The procedure below details how to remove the cabling of axes 1-3.

Action Note/Illustration
1. In order to facilitate refitting of the cable Axes 2 and 3 may be tilted slightly to
harness, move the robot to the specified improve access.
position:
• Axis 1: 0°
• Axis 2: 0°
• Axis 3: 0°
• Axis 6: no significance
2.
© Copyright 2006-2008 ABB. All rights reserved.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Remove the rear cover plate (A) on the
robot by unscrewing its attachment screws
(B).

xx0200000399

4. Disconnect the connectors R1.MP1-3 and

R2.BU1-3 inside the base.
5. Disconnect all the earth cables on the
R1.M1-3 cable from the back of the cover.

Continues on next page

3HAC026048-001 Revision: A 91
4 Repair
4.3.1. Replacement of cable unit, axes 1-3

Continued

Action Note/Illustration
6. Loosen the nuts (D) and remove the SMB
unit carefully from the bracket.
The cable (A) between the battery (B) and
the SMB unit (C) may stay connected, in
order to avoid recalibration of the robot. Be
careful not to let the weight of the SMB unit
strain the cable!
In order to remove the SMB unit
completely, the connector R2.G must be
disconnected! This causes a necessary
recalibration of the robot!

xx0200000398

7. Disconnect the connector R2.FB 1-3 from

the connection R2.SMB1-4 (C) on the SMB
unit.

xx0200000400

A. R2.SMB
B. R2.SMB3-6
C. R2.SMB1-4
8. Unscrew the four screws securing the This releases the cable harness from the
cable gland. frame.
9. Remove the cable guide in the middle of © Copyright 2006-2008 ABB. All rights reserved.
the frame by removing the attachment
screws of the holder (A).
Remove the cables from the guide.

xx0200000404

Note! Different robot versions are fitted

with different versions of the holder. Make
sure the correct one is used to avoid cable
failure.
10. Remove the upper bracket securing the Note! Do not remove or loosen any of the
cables to the arm house by unscrewing its cable brackets from the new harness, the
two attachment screws. angle of the brackets is factory optimized.
11. Remove the cover of the motors 1-3.

Continues on next page

92 3HAC026048-001 Revision: A
 4 Repair
4.3.1. Replacement of cable unit, axes 1-3

Continued

Action Note/Illustration
12. Disconnect all the connectors at the motors
of axes 1, 2 and 3.

xx0200000401

A. R3.MP1-3
B. R3.FB1-3
C. Connection box
13. Remove the three screws of the connection
box for the motors of axes 1, 2 and 3.
14. Gently pull the cable harness out.

Refitting, cable unit, axes 1-3

The procedure below details how to refit the cabling of axes 1-3 to the robot.

Action Note/Illustration
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Gently pull down the cable harness through
the center hole of axis 1.
3. Fit a new gasket and fit the connection box on The gasket is included in the spare part
© Copyright 2006-2008 ABB. All rights reserved.

motor 1, 2 and 3, using the three attachment of the cable unit, spare part no. is
screws. specified in Required equipment on
page 90.
4. Reconnect all the connectors at motors 1, 2
and 3.

xx0200000401

A. R3.MP1-3
B. R3.FB1-3
C. Connection box
5. Refit the cover of the motors, axes 1, 2 and 3,
with the five attachment screws.

Continues on next page

3HAC026048-001 Revision: A 93
4 Repair
4.3.1. Replacement of cable unit, axes 1-3

Continued

Action Note/Illustration
6. Refit the upper bracket securing the cables to
the arm house, using the two attachment
screws.
7. Fit the cable guide to the harness and secure
the holder to the frame with its two
attachment screws (A).

xx0200000404

Note! Different robot versions are fitted

with different versions of the holder.
Make sure the correct one is used to
avoid cable failure.
8. Secure the cabling inside the base.
Insert the cables in the sealing:
A. Power cable
B. Power cable
C. Power cable
D. Customer cable
E. Signal cable
F. Signal cable
Note! Make sure that each cable is fitted in
the same position as the old one, otherwise
the conduit entry will not be watertight. Use
six cable straps.
Note! Always use a new sealing, combined
with a flange sealing (Loctite 574).

xx0200000402

© Copyright 2006-2008 ABB. All rights reserved.

Art. numbers are specified in Required
equipment on page 90.
9. Connect the connectors R2.FB 1-3 to the
connection R2.SMB1-4 (C) on the SMB unit.

xx0200000400

A. R2.SMB
B. R2.SMB3-6
C. R2.SMB1-4

Continues on next page

94 3HAC026048-001 Revision: A
 4 Repair
4.3.1. Replacement of cable unit, axes 1-3

Continued

Action Note/Illustration
10. Refit the SMB unit to the bracket with the nuts
(D). Be careful not to let the weight of the
SMB-unit strain the cable! (A).

xx0200000398

Note! The cable (A) between the battery

(B) and the SMB-unit (C) may stay
connected, in order to avoid
recalibration of the robot.
11. Connect all the earth cables on the R1.M1-3
cable to the back of the cover.

xx0200000403

12. Connect the connectors R1.MP1-3 and

R2.BU1-3 inside the base.
13. Refit the rear cover plate (A) on the robot with
its attachment screws (B), together with a
new gasket.
© Copyright 2006-2008 ABB. All rights reserved.

xx0200000399

Spare part no. is specified in Required

equipment on page 90.
14. If the battery has been disconnected from the Detailed in section Updating revolution
SMB unit, the revolution counters must be counters on page 180.
updated!
15.

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 32.

3HAC026048-001 Revision: A 95
4 Repair
4.3.2. Replacement of cable unit, axis 6

4.3.2. Replacement of cable unit, axis 6

Location of cable unit, axis 6

The cabling of axis 6 is run throughout the robot, from the base to the wrist unit. Besides the
power and signal cable, the cable unit also includes a customer cable, an UL lamp cable and
an air hose.

xx0500002540

A Cable bracket inside the base

B Cable attachment inside the frame (view from above)
C Cable bracket inside the lower arm (view from above) © Copyright 2006-2008 ABB. All rights reserved.
D Cable bracket inside the upper arm
E Cable guide in the middle of the frame (view from above)
F Connectors at the base: Power cable: R1.MP4-6, signal cable: R2.FB4-6, brake release:
R2.BU4-6, UL-lamp: R1.H1, Customer cable: R1.CP and R1.CS, air hose: R1.CAIR
G Connector at motor axis 6: R3.FB6 (signal)
H Connector at motor axis 6: R3.MP6 (power)
K Connector at UL lamp: R3.H1 and R3.H2.
L Customer connectors / air hose are located on the opposite side of the wrist unit: R2.CS,
R2.CP and R2.CAIR
1 Power cable
2 Signal cable
3 Customer cable
4 Air hose

Continues on next page

96 3HAC026048-001 Revision: A
 4 Repair
4.3.2. Replacement of cable unit, axis 6

Continued

Required equipment

Equipment Spare part no. Note

Cable unit axis 6 3HAC024115-001
Standard toolkit - The contents are defined in section Standard
toolkit on page 190, in part 2 of the Product
manual.
Circuit diagram - See chapter Circuit diagram in the Product
manual, reference information.

Removal, cable unit axis 6

The procedure below details how to remove the cable unit of axis 6 from the robot.

Action Note/Illustration
1. In order to facilitate removal of the cable
unit, move the robot to positions:
• Axis 1: 0º
• Axis 2: 45º
• Axis 3 (upper arm): horizontal
• Axis 6: no significance
2.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
3. Remove the rear cover plate (A) from the
base of the robot by unscrewing the
attachment screws (B).
© Copyright 2006-2008 ABB. All rights reserved.

xx0200000399

4. Disconnect the connectors R1.MP4-6 and Specified in the figure Location of cable
R2.BU4-6 from the base. Also disconnect unit, axis 6 on page 96.
the customer cables and the air hose.
5. Disconnect all earth cables.

Continues on next page

3HAC026048-001 Revision: A 97
4 Repair
4.3.2. Replacement of cable unit, axis 6

Continued

Action Note/Illustration
6. Loosen the nuts (D) and remove the SMB-
unit from the bracket carefully.
Leaving the cable (A) between the battery
(B) and the SMB-unit (C) connected
avoids recalibration of the robot. But be
careful not to let the weight of the SMB-unit
strain the cable!
In order to remove the SMB-unit
completely, the connector R2.G must be
disconnected, which causes a necessary
recalibration of the robot!

xx0200000398

7. Disconnect the connector R2.FB4-6 from

the SMB-unit, connector R2.SMB3-6 (B).

xx0200000400

A. R2.SMB
B. R2.SMB3-6
C. R2.SMB1-4
8. Loosen the cable brackets by removing Shown in the figure Location of cable unit,
their attachment screws: axis 6 on page 96. © Copyright 2006-2008 ABB. All rights reserved.
• inside the base
• inside the frame
• inside the lower arm
• inside the upper arm.
9. Loosen the cables from the cable guide in Shown in the figure Location of cable unit,
the middle of the frame, by unscrewing the axis 6 on page 96.
holder and assembling the guide.
10. Gently pull up the cable harness from
inside the base.
11. Disconnect the connectors at the upper
arm:
• at the UL lamp
• at motor, axis 6 (R3.MP6 and
R3.FB6)
• at customer connections (R2.CS,
R2.CP and R2.CAIR).

Continues on next page

98 3HAC026048-001 Revision: A
 4 Repair
4.3.2. Replacement of cable unit, axis 6

Continued

Action Note/Illustration
12. Gently pull down the cable harness
through the lower arm and remove it from
the robot.

Refitting, cable unit axis 6

The procedure below details how to refit the cable unit of axis 6 to the robot.

Action Note/Illustration
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Insert the lower part of the cable unit through
the frame, into the base.
3. Connect the connectors R1.MP4-6 and
R2.BU4-6 to the base. Also connect the
customer cables and the air hose.
4. Connect the earth cables.
5. Connect the connector R2.FB4-6 to the
SMB-unit, connector R2.SMB3-6 (B).
© Copyright 2006-2008 ABB. All rights reserved.

xx0200000400

A. R2.SMB
B. R2.SMB3-6
C. R2.SMB1-4

Continues on next page

3HAC026048-001 Revision: A 99
4 Repair
4.3.2. Replacement of cable unit, axis 6

Continued

Action Note/Illustration
6. Refit the SMB unit to the bracket by
tightening the nuts (D).
Reconnect the battery cable (A), if discon-
nected.

xx0200000398

7. Secure the cable bracket inside the base. Shown in the figure Location of cable unit,
axis 6 on page 96.
8. Insert the cabling through the cable guide in Shown in the figure Location of cable unit,
the middle of the frame and secure the guide axis 6 on page 96.
with the holder and its attachment screws.
9. Secure the cable attachment inside the Shown in the figure Location of cable unit,
frame with its attachment screws. axis 6 on page 96.
10. Pull the cabling up through the lower arm Shown in the figure Location of cable unit,
and secure the cable bracket inside the axis 6 on page 96.
lower arm with its attachment screws.
Note! Run the cabling in front of the upper
arm attachment, as shown in the figure!
11. Run the cabling through the upper arm and Shown in the figure Location of cable unit,
secure the cable bracket inside the upper axis 6 on page 96.
arm.
12. Connect all the connectors at the upper arm:
• at the UL lamp

© Copyright 2006-2008 ABB. All rights reserved.

• at motor, axis 6 (R3.MP6 and
R3.FB6)
• at customer connections (R2.CS,
R2.CP and R2.CAIR).
13. Refit the rear cover plate (A) to the base with
its attachment screws (B).

xx0200000399

14. If the battery has been disconnected from Detailed in section Updating revolution
the SMB unit, the revolution counters must counters on page 180.
be updated!

Continues on next page

100 3HAC026048-001 Revision: A
 4 Repair
4.3.2. Replacement of cable unit, axis 6

Continued

Action Note/Illustration
15.

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 32.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 101

4 Repair
4.4.1. Replacement of shaft and bearings, tilthouse

4.4 Upper arm

4.4.1. Replacement of shaft and bearings, tilthouse

Location of shaft and bearings

The tilthouse is located in the front part of the upper arm, linked to the upper arm with a shaft,
as shown in the figure below.
A more detailed view of the component and its position may be found in section Upper arm,
exploded view on page 217 in part 2 of the Product manual.

© Copyright 2006-2008 ABB. All rights reserved.

xx0500002583

A Shaft, tilthouse
B Tilthouse
C Sealing ring
D Taper roller bearing (2 pcs)
E Sealing ring with dust lip
F Lock nut (2 pcs)
G Protection hood (2 pcs)
H VK cover (2 pcs)
I M6 screws, including washers (4 pcs)

Continues on next page

102 3HAC026048-001 Revision: A
 4 Repair
4.4.1. Replacement of shaft and bearings, tilthouse

Continued

Required equipment

Equipment Spare part no. Art. no. Note

Shaft 3HAC024867-001
Taper roller bearing 3HAA2103-14 2 pcs.
Sealing ring with dust lip 3HAB3701-25 Always replace with a new
one!
Sealing ring 3HAC7877-2 Always replace with a new
one!
VK-cover 3HAA2166-15 2 pcs. Always replace with
a new one!
Washer 3HAC020537-001 4 pcs. To the lubrication
holes for the bearings.
Protection hood 25222101-17 2 pcs. Must be replaced if
damaged!
Bearing grease 3HAB3537-1 To fill the bearings at the
shaft (2 x 25 ml).
Also for lubricating the
mounting surfaces in the
upper arm.
Locking liquid - Loctite 243
Toolkit for service 3HAC023963- Required tools for
026 removal/refitting are
assembled from the loose
parts in the kit.
The contents are defined
in section Content, toolkit
for service, 3HAC023963-
026 on page 191 in part 2
of the Product manual.
Hydraulic pump, 80 Mpa 3HAC13086-1
Standard toolkit - The contents are defined
in section Standard toolkit
on page 190, in part 2 of
© Copyright 2006-2008 ABB. All rights reserved.

the Product manual.

Calibration Pendulum 3HAC15716-1 Complete kit that also
toolkit includes operating
manual.
Other tools and These procedures include
procedures may be references to the tools
required. See references required.
to these procedures in
the step-by-step instruc-
tions below.

Continues on next page

3HAC026048-001 Revision: A 103
4 Repair
4.4.1. Replacement of shaft and bearings, tilthouse

Continued

Dismounting tool, tilthouse shaft

The tool for removing the tilthouse shaft from the tilthouse is assembled with the parts shown
in the figure below (included in the toolkit for service).
Note! The parts cannot be ordered separately, but are included in the complete toolkit! The
article numbers are only given for identification.

xx0600002589

A Hydraulic cylinder, 3HAC11731-1

B Press washer, 3HAC023963-007
C Hex socket head cap screw, 9ADA183-25, 2 pcs, M6 x 25
D Connection rod, M16, length= 400 mm
E Nut, 3HAC5507-1
F Sleeve, 3HAC023963-027
G Nut, 3HAC023963-028
J Pad, 3HAC023963-029

© Copyright 2006-2008 ABB. All rights reserved.

Continues on next page

104 3HAC026048-001 Revision: A
 4 Repair
4.4.1. Replacement of shaft and bearings, tilthouse

Continued

Dismounting tool, bearing race, upper arm

The tool for removing the bearing race from the upper arm is assembled with the parts shown
in the figure below (included in the toolkit for service).
Note! The parts cannot be ordered separately, but are included in the complete toolkit! The
article numbers are given only for identification.

xx0600002656

A Hydraulic cylinder, 3HAC11731-1

B Press washer, 3HAC023963-007
C Hex socket head cap screw, 9ADA183-25, 2 pcs, M6 x 25
E Nut, 3HAC5507-1
F Sleeve, 3HAC023963-027
G Nut, 3HAC023963-028
H Press sleeve, 3HAC023963-038
I Connection rod, 3HAC025192-006

Dismounting tool, bearing race, tilthouse shaft

The tool for removing the bearing race from the tilthouse shaft is assembled with the parts
shown in the figure below (included in the toolkit for service).
© Copyright 2006-2008 ABB. All rights reserved.

Note! The parts cannot be ordered separately, but are included in the complete toolkit! The
article numbers are given only for identification.

xx0600002657

A Hydraulic cylinder, 3HAC11731-1

Continues on next page

3HAC026048-001 Revision: A 105
4 Repair
4.4.1. Replacement of shaft and bearings, tilthouse

Continued

B Press washer, 3HAC023963-007

C Hex socket head cap screw, 9ADA183-25, 2 pcs, M6 x 25
D Connection rod, M16, length= 400 mm
E Nut, 3HAC5507-1
G Nut, 3HAC023963-028
M Sleeve, 3HAC023963-037

Mounting tool, tilthouse shaft

The tool for fitting the tilthouse shaft to the tilthouse is assembled with the parts shown in the
figure below (included in the toolkit for service).
Note! The parts cannot be ordered separately, but are included in the complete toolkit! The
article numbers are given only for identification.

xx0500002581

A Hydraulic cylinder, 3HAC11731-1

B Press washer, 3HAC023963-007
C Hex socket head cap screw, 9ADA183-25, 2 pcs, M6 x 25

© Copyright 2006-2008 ABB. All rights reserved.

D Connection rod, M16, length= 400 mm
E Nut, 3HAC5507-1
J Pad, 3HAC023963-029
K Press washer, 3HAC023963-014

Continues on next page

106 3HAC026048-001 Revision: A
 4 Repair
4.4.1. Replacement of shaft and bearings, tilthouse

Continued

Mounting tool, bearing race and sealing, upper arm

The tool for fitting the bearing race and sealing to the upper arm is assembled with the parts
shown in the figure below (included in the toolkit for service).
Note! The parts cannot be ordered separately, but are included in the complete toolkit! The
article numbers are given only for identification.

xx0500002582

A Hydraulic cylinder, 3HAC11731-1

B Press washer, 3HAC023963-007
C Hex socket head cap screw, 9ADA183-25, 2 pcs, M6 x 25
E Nut, 3HAC5507-1
I Connection rod, 3HAC025192-006
L Press head, 3HAC023963-039
N Press sleeve, 3HAC023963-015

Mounting tool, bearing race, tilthouse shaft

The tool for fitting a bearing race to the tilthouse shaft is assembled with the parts shown in
the figure below (included in the toolkit for service).
© Copyright 2006-2008 ABB. All rights reserved.

Note! The parts cannot be ordered separately, but are included in the complete toolkit! The
article numbers are given only for identification.

xx0600002658

A Hydraulic cylinder, 3HAC11731-1

Continues on next page

3HAC026048-001 Revision: A 107
4 Repair
4.4.1. Replacement of shaft and bearings, tilthouse

Continued

B Press washer, 3HAC023963-007

C Hex socket head cap screw, 9ADA183-25, 2 pcs, M6 x 25
D Connection rod, M16, length= 400 mm
E Nut, 3HAC5507-1
G Nut, 3HAC023963-028
H Sleeve, 3HAC023963-037

Removal, shaft and bearings

The procedure below details how to remove the shaft and bearings.

Action Note/Illustration
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Remove the upper parallel rod. Detailed in section Removal, upper
rod on page 124.
3. Remove the both VK covers by making a hole in Shown in the figure Location of
the middle and bending them off. shaft and bearings on page 102.
4. Remove the both protection hoods and lock nuts. Shown in the figure Location of
shaft and bearings on page 102.
5. Gather the required parts to assemble a The assembly is shown in the fig-
dismounting tool for the tilthouse shaft from the ure Dismounting tool, tilthouse shaft
toolkit for service. on page 104.
Art. no. for the toolkit is specified in
Required equipment on page 103.
6. Insert the dismounting tool, tilthouse shaft
through the shaft. Fit the nut (A) to the end of the
bar and use the pad (B) when pulling out the
© Copyright 2006-2008 ABB. All rights reserved.
shaft.

xx0600002590

7. Connect the hydraulic pump to the cylinder and Art. no. is specified in Required
pull out the shaft. equipment on page 103.
8. Rebuild the dismounting tool into a dismounting The assembly is shown in the figure
tool, bearing race, upper arm. Dismounting tool, bearing race,
upper arm on page 105.
9. Remove the bearing races and sealings from the
seating, using the dismounting tool.

Continues on next page

108 3HAC026048-001 Revision: A
 4 Repair
4.4.1. Replacement of shaft and bearings, tilthouse

Continued

Action Note/Illustration
10. If removing the remaining bearing race from the The assembly is shown in the figure
shaft, rebuild the tool to a dismounting tool, Dismounting tool, bearing race,
bearing race, tilthouse shaft. tilthouse shaft on page 105.

Refitting, shaft and bearings

The procedure below details how to refit the shaft, bearings and the tilthouse.

Action Note/Illustration
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Lubricate the seating (A) of the bearings and Art. no. is specified in Required
sealing rings in the upper arm with bearing equipment on page 103.
grease.

xx0500002580

3. Gather the required parts to assemble a Art. no. for the toolkit is specified in
mounting tool for the bearing race and sealings Required equipment on page 103.
© Copyright 2006-2008 ABB. All rights reserved.

from the toolkit for service. The assembly of the tool is shown in
Following steps detail the fitting of the bearing, the figure Mounting tool, bearing race
additional information is also found in section and sealing, upper arm on page 107.
Mounting instructions for bearings on page 87.

Continues on next page

3HAC026048-001 Revision: A 109
4 Repair
4.4.1. Replacement of shaft and bearings, tilthouse

Continued

Action Note/Illustration
4. Fit a new sealing ring to the press washer (A)
and place it on the inner side of the seating, as
shown in the figure to the right.
Fasten the bar (B) to the press washer.

xx0500002582

Spare part no. for the sealing ring is

specified in Required equipment on
page 103 and it is shown in the figure
Location of shaft and bearings on
page 102.
5. If not already fitted, fit the press washer to the Shown in the figure Mounting tool,
hydraulic cylinder, using the two M6 bolts. bearing race and sealing, upper arm
on page 107.
6. Thread the bearing race on to the press Spare part no. for the bearing is
washer/hydraulic cylinder and fit the complete specified in Required equipment on
assembly to the bar. page 103.
7. Fit the nut to the end of the bar. Shown in the figure Mounting tool,
bearing race and sealing, upper arm
on page 107.
8. Press both the sealing ring and the bearing race
into the seating.
9. Repeat the procedure to fit the other bearing Spare part no. is specified in Required
race and the new sealing ring with dust lip to the equipment on page 103.
opposite side.
10. Press the inner bearing race on to the shaft, by The assembly of the mounting tool is
using a mounting tool, assembled of the parts in shown in the figure Mounting tool,
the toolkit for service. bearing race, tilthouse shaft on page
107. © Copyright 2006-2008 ABB. All rights reserved.
11. Lubricate the shaft and the mounting surfaces Art. no. is specified in Required
in the upper arm and in the tilthouse with equipment on page 103.
bearing grease.
12. Gather the required parts to assemble a The assembly of the mounting tool is
mounting tool for the tilthouse shaft from the shown in the figure Mounting tool,
toolkit for service. tilthouse shaft on page 106.
13. Place the tilthouse in mounting position and
insert the shaft through the upper arm and
tilthouse.

Continues on next page

110 3HAC026048-001 Revision: A
 4 Repair
4.4.1. Replacement of shaft and bearings, tilthouse

Continued

Action Note/Illustration
14. Insert the bar (A) through the shaft and secure
with press washer (B).

xx0500002584

15. If not already fitted, fit the press washer to the Shown in the figure Mounting tool,
hydraulic cylinder with the two M6 bolts. tilthouse shaft on page 106.
16. Thread the remaining bearing race on to the bar
and fit also the hydraulic cylinder and the nut.
17. Press the both bearings into the upper arm, on
either ends of the shaft, with a hydraulic pump.
Use the pad (G).
Press until the both bearings reaches bottom.

xx0500002585

18. Lubricate the both bearings with bearing 25 ml in each bearing. Art. no. is
grease. specified in Required equipment on
page 103.
© Copyright 2006-2008 ABB. All rights reserved.

19. Apply locking liquid to the both lock nuts and fit Shown in the figure Location of shaft
the nuts on each side of the shaft, facing the flat and bearings on page 102.
surface outwards. Locking liquid is specified in Required
Tighten one of them with 30 Nm. Tighten the equipment on page 103.
other with 35 Nm, untighten it and retighten with
30 Nm.
20. Fit the protection hoods on each side of the Shown in the figure Location of shaft
shaft. Replace them if damaged! and bearings on page 102.
21. Fit new VK covers on each side of the upper Spare part no. is specified in Required
arm. equipment on page 103.
Shown in the figure Location of shaft
and bearings on page 102.
22. Fit four M6 screws, including washers, to the Shown in the figure Location of shaft
lubrication holes. and bearings on page 102.
Spare part no. for washer is specified
in Required equipment on page 103.
23. Refit the upper parallel rod. Detailed in section Refitting, upper
rod on page 125.

Continues on next page

3HAC026048-001 Revision: A 111
4 Repair
4.4.1. Replacement of shaft and bearings, tilthouse

Continued

Action Note/Illustration
24. Recalibrate the robot. Calibration is detailed in a separate
calibration manual, enclosed with the
calibration tools.
General calibration information is
included in section Calibration
information on page 175.
25.

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 32.

© Copyright 2006-2008 ABB. All rights reserved.

112 3HAC026048-001 Revision: A

 4 Repair
4.4.2. Replacement of turning disk

4.4.2. Replacement of turning disk

Location of turning disk

The turning disk is located at the frontmost part of the robot, as shown in the figure below.
A more detailed view of the component and its position may be found in section Tilthouse,
exploded view on page 219 in part 2 of the Product manual.

xx0500001938

A Turning disk
B Attachment screws and o-rings, turning disk (6 pcs)

Required equipment

Equipment Spare part no. Art. no. Note

Turning disk 3HAC023881-001
O-ring 3HAB3772-16 Replace if damaged.
© Copyright 2006-2008 ABB. All rights reserved.

O-ring 3HAB3772-89 6 pcs; one o-ring at each

attachment screw. Replace if
damaged.
Locking liquid - Loctite 243
Standard toolkit - The contents are defined in
section Standard toolkit on
page 190, in part 2 of the
Product manual.
Calibration Pendulum 3HAC15716-1 Complete kit that also
toolkit includes operating manual.
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the step-
by-step instructions
below.

Continues on next page

3HAC026048-001 Revision: A 113
4 Repair
4.4.2. Replacement of turning disk

Continued

Removal, turning disk

The procedure below details how to remove the turning disk from the robot.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Drain the oil from the axis 6 gearbox. Detailed in section Draining oil,
gearbox axis 6 on page 81.
3. Remove the turning disk by removing its six Shown in the figure Location of
attachment screws and washers. turning disk on page 113.

Refitting, turning disk

The procedure below details how to refit the turning disk to the robot.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Make sure that the o-ring is fitted properly to the Spare part no. is specified in
turning disk. Replace it if damaged! Required equipment on page 113.
3. Lubricate and fit the six o-rings to the holes of the Spare part no. is specified in
attachment screws. Replace if damaged! Required equipment on page 113.

© Copyright 2006-2008 ABB. All rights reserved.

4. Fit the turning disk to the axis 6 gearbox with the 6 pcs; M8x20.
six attachment screws and o-rings, using locking Tightening torque: 30 Nm.
liquid. Locking liquid is specified in
Required equipment on page 113.
Shown in the figure Location of
turning disk on page 113.
5. Perform a leak-down test. Detailed in section Performing a
leak-down test on page 86.
6. Refill the gearbox with oil. Detailed in section Filling oil,
gearbox axis 6 on page 82.
7. Recalibrate the robot. Calibration is detailed in a
separate calibration manual,
enclosed with the calibration tools.
General calibration information is
included in section Calibration
information on page 175.

Continues on next page

114 3HAC026048-001 Revision: A
 4 Repair
4.4.2. Replacement of turning disk

Continued

Action Note
8.

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 32.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 115

4 Repair
4.4.3. Replacement of complete upper arm

4.4.3. Replacement of complete upper arm

Location of upper arm

The upper arm is located as shown in the figure below.
A more detailed view of the component and its position may be found in section Robot IRB
260, exploded view 1 of 2 on page 206 in part 2 of the Product manual.

xx0600002601 © Copyright 2006-2008 ABB. All rights reserved.

A Upper arm
B Linkage (upper parallel rod, link and lower parallel rod)
C Parallel bar

Required equipment

Equipment Spare part no. Art. no. Note

Sealing ring 3HAC7877-2 2 pcs. Always replace with
new.
Shaft end 3HAC025034-
001
VK-cover 3HAC12165-2 2 pcs.
Grease 3HAB3537-1 For lubrication of mounting
surfaces.
Locking liquid - Loctite 243

Continues on next page

116 3HAC026048-001 Revision: A
 4 Repair
4.4.3. Replacement of complete upper arm

Continued

Equipment Spare part no. Art. no. Note

Lifting straps - For lifting the upper arm.
Guide pins 3HAC024097- 3 pcs required. Length: 62
006 mm. Diameter: 6 mm. Thread:
M6x12. Used for guiding the
shaft end of the upper arm into
place.
Toolkit for service 3HAC023963- If additional aid is required for
026 pulling out the shaft from the
upper arm, a tool can be
assembled from the loose
parts in the kit.
The assembly is shown in the
figure Press tool, link on page
130.
Hydraulic pump, 80 3HAC13086-1
Mpa
Extended KM nut (KM7) 3HAC023963- Length: 135 mm.
040
Standard toolkit - The contents are defined in
section Standard toolkit on
page 190, in part 2 of the
Product manual.
Calibration Pendulum 3HAC15716-1 Complete kit that also includes
toolkit operating manual.
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the step-
by-step instructions
below.

Removal, upper arm

© Copyright 2006-2008 ABB. All rights reserved.

The procedure below details how to remove the upper arm from the robot.

Action Note/Illustration
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Disconnect all the connectors at the tilthouse Shown in the figure Location of cable
(motor and customer connections) and unit, axis 6 on page 96.
unfasten the cabling from the upper arm by
removing all brackets available.

Continues on next page

3HAC026048-001 Revision: A 117
4 Repair
4.4.3. Replacement of complete upper arm

Continued

Action Note/Illustration
3. Remove the linkage. Detailed in sections:
• Removal, upper rod on page
124
• Removal, lower rod on page
127
• Removal, link on page 131
4. Remove the parallel bar. Detailed in section Removal, parallel
bar on page 139.
5.

Caution!
The complete upper arm weighs 23 kg without
any additional equipment fitted! Use a suitable
lifting device to avoid injury to personnel!
6. Fit the lifting equipment to the upper arm
according to the figure to the right.

xx0500002549

7. Remove the distance and the radial sealing

from the end shaft.

© Copyright 2006-2008 ABB. All rights reserved.

xx0600002607

8. Untighten and remove the lock nut with the Art. no. is specified in Required
extended KM nut. equipment on page 116.
9. Remove the bearing.
10. Unfasten the shaft end by removing the
flanged bolts from inside the lower arm.

Continues on next page

118 3HAC026048-001 Revision: A
 4 Repair
4.4.3. Replacement of complete upper arm

Continued

Action Note/Illustration
11. Remove the VK cover from the opposite side
by making a hole in the middle.
Be careful not to damage the parts
underneath!
12. Untighten and remove the lock nut and the
bearing also from this side of the upper arm.
13. Unscrew the attachment screw and washer If necessary, use the press tool, link as
and remove the end shaft from both sides. a puller tool (fit the auxiliary shaft to
the upper arm shaft). Assembly of the
tool is shown in the figure Press tool,
link on page 130.
14. Make sure the cabling lies freely inside the Note! The tilthouse is movable, be
upper arm. Then lift the upper arm while careful not to damage it!
feeding the cabling from inside the arm.

Refitting, upper arm

The procedure below details how to refit the upper arm to the robot.

Action Note/Illustration
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

Caution!
The complete upper arm weighs 23 kg without
© Copyright 2006-2008 ABB. All rights reserved.

any additional equipment fitted! Use a suitable

lifting device to avoid injury to personnel!
3. Make sure that the sealing rings are fitted Spare part no. is specified in Required
properly in the upper arm, facing the flat equipment on page 116.
surface outwards! Replace them if any
damage is detected!

xx0600002602

A. Sealing rings

Continues on next page

3HAC026048-001 Revision: A 119
4 Repair
4.4.3. Replacement of complete upper arm

Continued

Action Note/Illustration
4. Fit the lifting equipment to the upper arm
according to the figure to the right.
Note! The tilthouse is movable, be careful not
to damage it!

xx0500002549

5. Lubricate the mounting holes of the upper arm Art. no. is specified in Required
with grease. equipment on page 116.
6. Insert the cabling into the upper arm while
placing the arm into mounting position.
7. Secure the upper arm to the lower arm by
fastening the shaft end (A) with the attachment
screw and washer (B), as shown in the figure
to the right.

xx0600002603

A. Shaft end
B. 1 pc, M12 x 60, (UNBRAKO
© Copyright 2006-2008 ABB. All rights reserved.
12.9) and washer. Tightening
torque: 90 Nm.
Reused screws may be used, providing
they are lubricated as detailed in
section Screw joints on page 186
before fitting.
8. Fit three guide pins to the other shaft end. The guide pins and the spare part no.
for the shaft end are specified in
Required equipment on page 116.

Continues on next page

120 3HAC026048-001 Revision: A
 4 Repair
4.4.3. Replacement of complete upper arm

Continued

Action Note/Illustration
9. Secure the other side of the upper arm to the
lower arm by fitting the shaft end with
guidance from the guide pins.

xx0600002605

A. Shaft end
B. Guide pins, 3 pcs
C. Attachment screw and washer
10. Remove the guide pins and secure the shaft Specified in Required equipment on
end with three flanged bolts from the inside of page 116.
the lower arm, using locking liquid. Do not
tighten yet.
11. Fit the one attachment screw and washer (C in 1 pc, M12 x 60, UNBRAKO 12.9.
the previous figure) to the shaft end. Tightening torque: 90 Nm.
Reused screws may be used, providing
they are lubricated as detailed in
section Screw joints on page 186
before fitting.
12. Tighten the flanged bolts. Tightening torque: 10 Nm.
13. Return to the other side of the upper arm and Specified in Required equipment on
prepare the lock nut by lubricating it with page 116.
locking liquid.
14. Fit the tapered roller bearing and the lock nut
(flat side outwards) to the shaft end.
© Copyright 2006-2008 ABB. All rights reserved.

xx0600002606

A. Tapered roller bearing

B. Lock nut, tightening torque: 35
Nm.
15. Fit a new VK cover to the upper arm.

Continues on next page

3HAC026048-001 Revision: A 121
4 Repair
4.4.3. Replacement of complete upper arm

Continued

Action Note/Illustration
16. Fit the other tapered roller bearing and Art. no. is specified in Required
lubricated lock nut to the opposite side of the equipment on page 116.
upper arm.
Use the extended KM nut and tighten the lock
nut with 55 Nm, then untighten and retighten
with 35 Nm.
17. Fit the distance and the radial sealing to the
shaft end by hand.
Note! Make sure to fit the radial sealing with
the flat side outwards!

xx0600002607

A. Radial sealing
B. Distance
18. Refit the parallel bar. Detailed in section Refitting, parallel
bar on page 140.
19. Refit the linkage. Detailed in sections:
• Refitting, link on page 132
• Refitting, upper rod on page
125
• Refitting, lower rod on page 127
20. Run the cable unit inside the upper arm. Cable run, connectors and brackets
Reconnect all connectors and refit all are shown in the figure Location of
brackets. cable unit, axis 6 on page 96.

© Copyright 2006-2008 ABB. All rights reserved.

The refitting is further detailed in
section Refitting, cable unit axis 6 on
page 99.
21. Recalibrate the robot. Calibration is detailed in a separate
calibration manual, enclosed with the
calibration tools.
General calibration information is
included in section Calibration
information on page 175.
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 32.

122 3HAC026048-001 Revision: A

 4 Repair
4.4.4. Replacement of linkage - upper rod

4.4.4. Replacement of linkage - upper rod

Overview
The link system consists of three basic parts - upper rod, lower rod and link. The procedures
below details how to remove and refit the upper rod.

Location of upper rod

The upper rod is located as shown in the figure below.
© Copyright 2006-2008 ABB. All rights reserved.

xx0600002615

A Upper rod
B Sealing ring (2 pcs)
C Support washer (4 pcs)
D Lock nut (2 pcs)
E Link

Required equipment

Equipment Spare part no. Art no. Note

Parallel rod upper 3HAC024575-001
Needle bearing 3HAB6432-1 Replace if damaged.
Continues on next page
3HAC026048-001 Revision: A 123
4 Repair
4.4.4. Replacement of linkage - upper rod

Continued

Equipment Spare part no. Art no. Note

Support washer 3HAB6279-1 Replace if damaged.
Bearing grease 3HAB3537-1 Used to lubricate the
bearings.
Locking liquid 3HAB7116-1 Loctite 243
Press sleeve 3HAC023963-013 Used for pressing new
bearings into the rod, if
replaced.
Standard toolkit The contents are defined in
section Standard toolkit on
page 190, in part 2 of the
Product manual.
Other tools and These procedures include
procedures may be references to the tools
required. See required.
references to these
procedures in the
step-by-step instruc-
tions below.

Removal, upper rod

The procedure below details how to remove the upper rod of the linkage.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Put the robot in a position where it is Check especially that the lock nut at the
possible to reach all parts that shall be link is possible to be removed.
© Copyright 2006-2008 ABB. All rights reserved.
removed.
3. Remove the lock nuts holding the upper rod
at each end.
4. Remove the support washers from the
upper rod.
5. Remove the upper rod. Note! The support washers on the inside
of the rod can stick to the grease of the
bearings when the rod is being removed.
Remove them from the rod!
6. Remove the support washers and the
sealing rings.
Remove residual grease.

Continues on next page

124 3HAC026048-001 Revision: A
 4 Repair
4.4.4. Replacement of linkage - upper rod

Continued

Refitting, upper rod

The procedure below details how to refit the upper rod of the linkage.

Action Note
1. If needed, replace the bearings in the rod. Spare part no. is specified in
Use the press sleeve. Required equipment on page 123.
Note! The bearings are sensitive for pushes. Make
sure they are not damaged!
2. Lubricate the bearings properly with bearing grease. Specified in Required equipment
on page 123.
3. Refit the sealing rings on the shaft ends of the link Shown in the figure Location of
and tilthouse. upper rod on page 123.
4. Refit the support washers on the shaft ends. Shown in the figure Location of
upper rod on page 123.
5. Refit the upper rod to its place on the shafts. Check that the rod is pushed in
completely.
6. Refit the support washers on the outside of the
upper rod, on the shaft ends.
7. Refit the lock nuts on the link and tilthouse, using Tightening torque: 20 Nm.
locking liquid.
8.

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 32.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 125

4 Repair
4.4.5. Replacement of linkage - lower rod

4.4.5. Replacement of linkage - lower rod

Overview
The linkage consists of three basic parts - upper rod, lower rod and link. The procedures
below details how to remove and refit the lower rod.

Location of lower rod

The lower rod is located as shown in the figure below.

xx0600002617 © Copyright 2006-2008 ABB. All rights reserved.

A Lower rod
B Sealing ring (2 pcs)
C Support washer (4 pcs)
D Lock nut (2 pcs)
E Link

Required equipment

Equipment Spare part no. Art no. Note

Needle bearing 3HAC3311-1 Replace if damaged.
Support washer 3HAC7253-1 Replace if damaged.
Bearing grease 3HAB3537-1
Locking liquid 3HAB7116-1 Loctite 243
Press sleeve 3HAC023963-013 Used for pressing new
bearings into the rod.
Continues on next page
126 3HAC026048-001 Revision: A
 4 Repair
4.4.5. Replacement of linkage - lower rod

Continued

Equipment Spare part no. Art no. Note

Standard toolkit The contents are defined
in section Standard toolkit
on page 190, in part 2 of
the Product manual.
Other tools and These procedures
procedures may be include references to the
required. See tools required.
references to these
procedures in the
step-by-step instruc-
tions below.

Removal, lower rod

The procedure below details how to remove the lower rod of the linkage.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. If the upper rod is removed, secure the link This is done in order to prevent the link
with a roundsling in a crane. Use the hole in from moving if the upper rod also is being
the middle of the link. removed.
3. Remove the lock nuts holding the lower rod Shown in the figure Location of lower rod
at each end. on page 126.
4. Remove the support washers. These can stick to the grease and can
easy be forgotten and lost when removing
the lock nuts.
Shown in the figure Location of lower rod
© Copyright 2006-2008 ABB. All rights reserved.

on page 126.
5. Remove the lower rod. Note! The support washers on the inside
of the rod can stick to the grease of the
bearings when the rod is being removed.
Remove them from the rod!
6. Remove the support washers and the
sealing rings and remove residual grease.

Refitting, lower rod

The procedure below details how to refit the lower rod of the linkage.

Action Note
1. If needed, replace the bearings. Spare part no. is specified in
Use a press sleeve. Required equipment on page 126.
Note! The bearings are sensitive for pushes. Art. no. for the press sleeve is also
Make sure they are not damaged! specified in Required equipment on
page 126.

Continues on next page

3HAC026048-001 Revision: A 127
4 Repair
4.4.5. Replacement of linkage - lower rod

Continued

Action Note
2. Lubricate the bearings properly with bearing Specified in Required equipment on
grease. page 126.
3. Refit the sealing rings to the shaft ends on the Shown in the figure Location of lower
link and frame. rod on page 126.
4. Refit the support washers to the shaft ends. Tip! Putting some grease on the
support washers will keep them in
position.
Shown in the figure Location of lower
rod on page 126.
5. Refit the lower rod on the shaft ends of the link Check that the lower rod is pushed
and frame. completely in.
6. Refit the support washers on the outside of the
lower rod, on the link and frame shafts.
7. Refit the lock nuts on the shaft ends, using Tightening torque: 20 Nm.
locking liquid. Locking liquid is specified in
Required equipment on page 126.
8.

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 32.

© Copyright 2006-2008 ABB. All rights reserved.

128 3HAC026048-001 Revision: A

 4 Repair
4.4.6. Replacement of linkage - link

4.4.6. Replacement of linkage - link

Overview
The link system consists of three basic parts - upper rod, lower rod and link. The procedures
below details how to remove and refit the link.

Location of link
The link is located at the upper arm as shown in the figure below. It is fitted to the same shaft
that holds the upper arm to the lower am.
© Copyright 2006-2008 ABB. All rights reserved.

xx0600002619

A Link
B Bearing (shown as complete bearing, but the outer race should already be
mounted inside the seating prior to refitting of link)
C Lock nut
D Protection hood
E VK cover
F Screws and washers for lubrication and venting holes (3 pcs)

Continues on next page

3HAC026048-001 Revision: A 129
4 Repair
4.4.6. Replacement of linkage - link

Continued

Required equipment

Equipment Spare part no. Art. no. Note

Protection hood 2522 2101-17 Replace if damaged!
VK-cover 3HAC12165-2 Replace if damaged!
Toolkit for service 3HAC023963- A tool for pressing the bearing
026 and the link to the upper arm
shaft is assembled from the
loose parts in the kit.
The assembly is shown in the
figure Press tool, link on page
130.
Bearing grease 3HAB3537-1
Locking liquid - Loctite 243
Standard toolkit - The contents are defined in
section Standard toolkit on
page 190, in part 2 of the
Product manual.
Other tools and These procedures include
procedures may be references to the tools
required. See references required.
to these procedures in
the step-by-step instruc-
tions below.

Press tool, link

The tool for fitting the bearing and the link to the upper arm shaft includes the parts shown in
the figure below (included in the toolkit for service).
Note! The parts cannot be ordered separately, but are included in the complete toolkit! The
article numbers are only given for identification!

© Copyright 2006-2008 ABB. All rights reserved.

xx0600002618

A Hydraulic cylinder, 3HAC11731-1

E Nut, 3HAC5507-1
O Connecting rod, 3HAC023081-003
P Press housing, 3HAC024097-002

Continues on next page

130 3HAC026048-001 Revision: A
 4 Repair
4.4.6. Replacement of linkage - link

Continued

R Auxiliary shaft, 3HAC024097-005

S Screw, M6x12, 9ADA183-24 (2 pcs)
T Distance, 3HAC023062-001

Removal, link
The procedure below details how to remove the link from the robot.

Action Note/Illustration
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Secure the link with a roundsling in a crane.
Use the hole in the middle of the link.
3. Remove the upper and lower rods. Detailed in sections:
• Removal, upper rod on page
124.
• Removal, lower rod on page
127.
4. Remove the center screw and washer in the
hole for filling grease.
5. Use compressed air to remove the VK cover. Shown in the figure Location of link on
Blow with a very low air pressure into the hole page 129.
for filling grease. Put one hand with some paper on top
Note! A very low air pressure is needed! of the VK cover in order to catch it
when released.
6. Remove the protection hood.
7. Remove the lock nut. Shown in the figure Location of link on
page 129.
© Copyright 2006-2008 ABB. All rights reserved.

8. Fit the auxiliary shaft on the shaft in order to let Included in the toolkit for service. Art.
the weight of the link rest on it. no. is specified in Required
equipment on page 130.
9. Loosen the roundsling and turn the link up side Note! Loosen the roundsling some
down in order to find room to knock on it from the before knocking! Otherwise the link
inside as close to its center as possible. may be locked by the lifting power.
10. Use a pair of levers, to bend the link loose.
11. Remove the link.
12. Wipe off residual grease.

Continues on next page

3HAC026048-001 Revision: A 131
4 Repair
4.4.6. Replacement of linkage - link

Continued

Refitting, link
The procedure below details how to refit the link to the robot.

Action Note/Illustration
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Check that the bearings and the radial sealing
inside the link seating are undamaged.
3. Make sure that the radial sealing and the distance
are fitted to the shaft end in the upper arm.

xx0600002607

A. Radial sealing
B. Distance
The fitting is further detailed in
section Refitting, upper arm on
page 119.
4. Lubricate the shaft end with bearing grease. Specified in Required equipment on
page 130. © Copyright 2006-2008 ABB. All rights reserved.
5. Gather the required parts to assemble a press tool The assembly is shown in the Press
for the link and bearing from the toolkit for service. tool, link on page 130.
Art. no. for the toolkit is specified in
Required equipment on page 130.
6. Fit the auxiliary shaft to the shaft end.
7. Thread the link and the bearing onto the auxiliary
shaft.
8. Fit the remaining parts of the press tool and press
the link and the bearing onto the shaft end.
9. Apply locking liquid to the lock nut and fit it to the Specified in Required equipment on
shaft end, facing the flat surface outwards. page 130.
Fit it first with a tightening torque of 55 Nm, then
unscrew it and fit it once again. This time with a
tightening torque of 35 Nm.

Continues on next page

132 3HAC026048-001 Revision: A
 4 Repair
4.4.6. Replacement of linkage - link

Continued

Action Note/Illustration
10. Fit a protection hood to the lock nut. It must be Spare part no. is specified in
replaced if damaged! Required equipment on page 130.
Shown in the figure Location of link
on page 129.
11. Fit the VK cover. Replace if damaged! Spare part no. is specified in
Required equipment on page 130.
12. Fill the link with grease, and refit the three screws
and washers.
Note! Fill through the center hole. The two holes
at the sides are meant for venting while filling.
13. Refit the upper and lower rods. Detailed in sections:
• Refitting, upper rod on page
125.
• Refitting, lower rod on page
127.
14.

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 32.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 133

4 Repair
4.5.1. Replacement of complete lower arm

4.5 Lower arm

4.5.1. Replacement of complete lower arm

Location of lower arm

The lower arm is located as shown in the figure below.
A more detailed view of the component and its position may be found in section Axes 1-3,
spare part view 2 on page 211 in part 2 of the Product manual.

© Copyright 2006-2008 ABB. All rights reserved.

xx0500002548

A Lower arm
B Sealing ring
C Attachment screw (12 pcs)
D Spring tension plate

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Lower arm 3HAC025729-001
Sealing ring (V-ring) 3HAB3732-13 Replace if damaged.

Continues on next page

134 3HAC026048-001 Revision: A
 4 Repair
4.5.1. Replacement of complete lower arm

Continued

Equipment, etc. Spare part no. Art. no. Note

Bearing grease 3HAB 3537-1 Used to lubricate the sealing
ring.
Hoisting equipment -
Standard toolkit The contents are defined in
section Standard toolkit on
page 190, in part 2 of the
Product manual.
Calibration Pendulum 3HAC15716- Complete kit that also
toolkit 1 includes operating manual.
Other tools and These procedures include
procedures may be references to the tools
required. See references required.
to these procedures in
the step-by-step instruc-
tions below.

Removal, lower arm

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!
2. Remove the upper arm. Detailed in section Removal, upper arm on
page 117.
3.
© Copyright 2006-2008 ABB. All rights reserved.

Caution!
The lower arm weighs 27 kg! Use a
suitable lifting device to avoid injury to
personnel!

Continues on next page

3HAC026048-001 Revision: A 135
4 Repair
4.5.1. Replacement of complete lower arm

Continued

Action Note/Illustration
4. Fit the lifting equipment to the lower arm to
secure its weight.

xx0200000439

5. Remove the parallel bar. Detailed in section Removal, parallel bar on

page 139.
6. Remove the parallel arm. Detailed in section Removal, parallel arm
on page 148.
7. Pull down the cabling from inside the lower
arm and remove any cable attachments.
8. Remove the attachment screws and the Shown in the figure Location of lower arm
spring tension plate. on page 134.
9. Remove the lower arm.

Refitting, lower arm

The procedure below details how to refit the complete lower arm.

Action Note © Copyright 2006-2008 ABB. All rights reserved.

1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Move the damper and calibration marking to
the new lower arm.
3. Make sure that the sealing ring is fitted Spare part no. is specified in Required
properly to the gearbox, undamaged and equipment on page 134.
properly lubricated with grease. If damaged, Shown in the figure Location of lower
replace with a new one. arm on page 134.

Continues on next page

136 3HAC026048-001 Revision: A
 4 Repair
4.5.1. Replacement of complete lower arm

Continued

Action Note
4.

Caution!
The lower arm weighs 27 kg! Use a suitable
lifting device to avoid injury to personnel!
5. Lift the lower arm into position.
6. Fit the spring tension plate to the lower arm 12 pcs; M10 x 40. Tightening torque:
and secure the arm to the gearbox with the 12 72 Nm.
attachment screws.
7. Refit the parallel arm. Detailed in section Refitting, parallel
arm on page 149.
8. Refit the parallel bar. Detailed in section Refitting, parallel
bar on page 140.
9. Refit the upper arm. Detailed in section Refitting, upper arm
on page 119.
10. Refit the cabling. Detailed in section Refitting, cable unit
axis 6 on page 99.
11. Recalibrate the robot! Calibration is detailed in a separate
calibration manual, enclosed with the
calibration tools.
General calibration information is
included in section Calibration
information on page 175.
12.

Danger!
Make sure all safety requirements are met
when performing the first test run. These are
© Copyright 2006-2008 ABB. All rights reserved.

further detailed in section DANGER - First test

run may cause injury or damage! on page 32.

3HAC026048-001 Revision: A 137

4 Repair
4.5.2. Replacement of parallel bar

4.5.2. Replacement of parallel bar

Location of parallel bar

The parallel bar is located as shown in the figure below.
A more detailed view of the component and its position may be found in section Axes 1-3,
spare part view 1 on page 210 in part 2 of the Product manual.

xx0500002552

A Parallel bar
B Attachment screw (2 pcs)

© Copyright 2006-2008 ABB. All rights reserved.

C Locking washer (2 pcs)
D Bearing sealing (2 pcs)
E Bearing sealing (2 pcs)
F Parallel arm
G Spherical roller bearing (2 pcs)

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Parallel bar complete 3HAC025714- Includes:
001 • spherical roller
bearings
• bearing sealings
Spherical roller bearing 3HAA2167-12 2 pcs

Continues on next page

138 3HAC026048-001 Revision: A
 4 Repair
4.5.2. Replacement of parallel bar

Continued

Equipment, etc. Spare part no. Art. no. Note

Bearing sealing 3HAC10088-4 One at each end of the bar.
(Item D in the figure
Location of parallel bar on
page 138.)
Bearing sealing 3HAC10089-2 One at each end of the bar.
(Item E in the figure
Location of parallel bar on
page 138.)
Locking liquid 3HAB7116-1 Loctite 243
Bearing grease 3HAB3537-1
Press tool, parallel bar 3HAB6324-1
bearing
Mounting tool, parallel bar 3HAB6331-1
Standard toolkit - The contents are defined in
section Standard toolkit on
page 190, in part 2 of the
Product manual.
Calibration Pendulum toolkit 3HAC15716- Complete kit that also
1 includes operating manual.
Other tools and procedures These procedures include
may be required. See references to the tools
references to these required.
procedures in the step-by-
step instructions below.

Removal, parallel bar

The procedure below details how to remove the parallel bar from the robot.

Action Note
1.
© Copyright 2006-2008 ABB. All rights reserved.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

Caution!
The complete upper arm weighs 23 kg without
any additional equipment fitted! Use a suitable
lifting device to avoid injury to personnel!

Continues on next page

3HAC026048-001 Revision: A 139
4 Repair
4.5.2. Replacement of parallel bar

Continued

Action Note
3. Use a crane to secure the weight of the upper If the upper arm is also to be
arm. removed, secure the weight as
shown in the figure below.

xx0500002549

4. Remove the attachment screw from the upper Shown in the figure Location of
and lower end. parallel bar on page 138.
5. Remove the locking washer from both ends. Shown in the figure Location of
parallel bar on page 138.
6. Insert a screw in the center of each end, to be M8
used as support.
7. Use a puller to pull out the parallel bar.
8. Remove the bearings and seals. Shown in the figure Location of
parallel bar on page 138.

Refitting, parallel bar

The procedure below details how to refit the parallel bar to the robot.

Action Note
1.

© Copyright 2006-2008 ABB. All rights reserved.

-

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Make sure the weight of the upper arm is Use a crane!
properly secured.
3. Fit the new spherical roller bearings to the Shown in the figure Location of parallel
parallel bar using the press tool, parallel bar bar on page 138.
bearing. Lubricate the bearings with bearing Art. no. is specified in Required
grease. equipment on page 138.
4. Fit new bearing sealings to the shaft ends Shown in the figure Location of parallel
and lubricate the shaft ends with grease. bar on page 138.
Spare part no. is specified in Required
equipment on page 138.
5. Refit the parallel bar, using the mounting Art. no. is specified in Required
tool, parallel bar. equipment on page 138.
Note! Press by hand!
6. Fit new bearing sealings to the bearings.

Continues on next page

140 3HAC026048-001 Revision: A
 4 Repair
4.5.2. Replacement of parallel bar

Continued

Action Note
7. Refit the locking washer. Shown in the figure Location of parallel
bar on page 138.
8. Refit the attachment screw at both ends of M8 x 16.
the bar, using locking liquid. Loctite 243
Shown in the figure Location of parallel
bar on page 138.
9. Recalibrate the robot! Calibration is detailed in a separate
calibration manual, enclosed with the
calibration tools.
General calibration information is
included in section Calibration
information on page 175.
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 32.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 141

4 Repair
4.6.1. Replacement of SMB unit

4.6 Frame and base

4.6.1. Replacement of SMB unit

Location of SMB unit

The SMB unit (SMB = serial measurement board) is located on the left hand side of the base,
as shown in the figure below.
A more detailed view of the component and its position may be found in section Axes 1-3,
spare part view 5 on page 215 in part 2 of the Product manual.
Note that the robot is shown with the SMB cover already removed!

© Copyright 2006-2008 ABB. All rights reserved.

xx0200000451

A Cable, battery/SMB board

B Battery
C Serial measurement board
D Lock nuts

Required equipment

Equipment Spare part no. Art. no. Note

Gasket, cover 3HAC3200-1 Must always be replaced!
Serial measurement unit 3HAC 17396-1

Continues on next page

142 3HAC026048-001 Revision: A
 4 Repair
4.6.1. Replacement of SMB unit

Continued

Equipment Spare part no. Art. no. Note

Standard toolkit The contents are defined in
section Standard toolkit on
page 190, in part 2 of the
Product manual.
Circuit Diagram - See chapter Circuit diagram
in the Product manual,
reference information.
Other tools and These procedures include
procedures may be references to the tools
required. See references required.
to these procedures in the
step-by-step instructions
below.

SMB unit, layout

© Copyright 2006-2008 ABB. All rights reserved.

xx0600002645

A Connector R2.SMB4-6
B Connector R2.SMB1-3
C Connector R2.SMB1-2 (external axis)
D Connector R2.SMB
E Connector R2.G (battery unit)

Continues on next page

3HAC026048-001 Revision: A 143
4 Repair
4.6.1. Replacement of SMB unit

Continued

Replacement, SMB unit

The procedure below details how to replace the SMB unit.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Remove the rear cover plate (A) from the base
by unscrewing the attachment screws (B).

xx0200000399

3. Remove the SMB battery. Detailed in section Replacement, SMB

battery on page 84.
4. Remove the SMB cover by unscrewing its
attachment screws.
Pull the battery cable through the hole in the
SMB cover.
5. Remove the two locknuts and washers from
the pins securing the board.
6. Gently disconnect the connectors from the All connectors are shown in the figure
SMB unit when pulling the board out. Also SMB unit, layout on page 143.
disconnect the battery cable from the SMB
unit.
7. Gently connect the connectors to the new All connectors are shown in the figure
SMB unit and push the board in. SMB unit, layout on page 143.

© Copyright 2006-2008 ABB. All rights reserved.

8. Refit the SMB cover using the attachment lock
nuts.
Pull the battery cable through the hole in the
SMB cover.
9. Reassemble the two locknuts and washers to
the pins securing the board.
10. Refit the SMB battery.
11. Fit a new gasket to the cover and refit the Always replace a removed gasket with
cover with the attachment screws. a new!
Art. no. is specified in Required
equipment on page 142.
12. Update the revolution counters! Detailed in section Updating revolution
counters on page 180.

144 3HAC026048-001 Revision: A

 4 Repair
4.6.2. Replacement of brake release unit

4.6.2. Replacement of brake release unit

Location of brake release unit

The brake release unit is located behind the flange plate at the robot base, as shown below.

xx0200000459

A Brake release unit with buttons

Required equipment

Equipment, etc. Spare part no. Note

BU w. buttons DSQC 563 3HAC16035-1
Standard toolkit - The contents are defined in section
Standard toolkit on page 190, in
part 2 of the Product manual.
Other tools and procedures may These procedures include
be required. See references to references to the tools required.
these procedures in the step-by-
step instructions below.
© Copyright 2006-2008 ABB. All rights reserved.

Replacement, brake release unit

The procedure below details how to replace the brake release unit from the robot base.

Action
1.

Danger!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
2. Remove the cover at the rear of the base.
3. Unscrew the six attachment screws of the brake release unit on the outside of the base.
4. Disconnect the cable from the brake release unit and remove the unit from the base.
5. Reconnect the cable to the new brake release unit and fit it to the base.
6. Secure the unit with its six attachment screws on the outside of the base.

Continues on next page

3HAC026048-001 Revision: A 145
4 Repair
4.6.2. Replacement of brake release unit

Continued

Action
7. Refit the cover to the rear of the base.
8.

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 32.

© Copyright 2006-2008 ABB. All rights reserved.

146 3HAC026048-001 Revision: A

 4 Repair
4.6.3. Replacement of parallel arm

4.6.3. Replacement of parallel arm

Location of parallel arm

The parallel arm is located at the frame, as shown in the figure below.

xx0600002591

A Parallel arm
© Copyright 2006-2008 ABB. All rights reserved.

B Parallel bar

Required equipment

Equipment Spare part no. Art. no. Note

Parallel arm complete 3HAC025727-001 Includes:
• groove ball bearing
• sealing ring
Bearing grease 3HAB 3537-1
Standard toolkit The contents are defined
in section Standard toolkit
on page 190, in part 2 of
the Product manual.
Calibration Pendulum toolkit 3HAC15716- Complete kit that also
1 includes operating
manual.

Continues on next page

3HAC026048-001 Revision: A 147
4 Repair
4.6.3. Replacement of parallel arm

Continued

Equipment Spare part no. Art. no. Note

Other tools and procedures These procedures include
may be required. See references to the tools
references to these required.
procedures in the step-by-
step instructions below.

Removal, parallel arm

The procedure below details how to remove the parallel arm.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Remove the parallel bar. Detailed in section Removal,
parallel bar on page 139.
3. Remove the parallel arm by removing its eight
attachment screws and washers.

© Copyright 2006-2008 ABB. All rights reserved.

Continues on next page

148 3HAC026048-001 Revision: A
 4 Repair
4.6.3. Replacement of parallel arm

Continued

Assembly, parallel arm

The figure below shows the assembly of the parallel arm.

xx0200000450

A Parallel arm
B Sealing V- ring (2 pcs)
C Groove ball bearing
D Attachment screws and washers (8 pcs)
© Copyright 2006-2008 ABB. All rights reserved.

Refitting, parallel arm

The procedure below details how to refit the complete parallel arm to the robot.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Fit the complete parallel arm to the robot with the 8 pcs; M10x60.
eight attachment screws and washers. Tightening torque: 72 Nm.
3. Refit the parallel bar. Detailed in section Refitting, parallel
bar on page 140.

Continues on next page

3HAC026048-001 Revision: A 149
4 Repair
4.6.3. Replacement of parallel arm

Continued

Action Note
4. Recalibrate the robot! Calibration is detailed in a separate
calibration manual, enclosed with
the calibration tools.
General calibration information is
included in section Calibration
information on page 175.
5.

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 32.

© Copyright 2006-2008 ABB. All rights reserved.

150 3HAC026048-001 Revision: A

 4 Repair
4.7.1. Replacement of motor, axis 1

4.7 Motors

4.7.1. Replacement of motor, axis 1

Location of motor, axis 1

The motor, axis 1, is located on the left hand side of the robot as shown in the figure below:
A more detailed view of the component and its position may be found in section Axes 1-3,
spare part view 1 on page 210.
© Copyright 2006-2008 ABB. All rights reserved.

xx0200000465

A Cover
B Connection box
C Attachment screws and washers, motor (4 pcs)
D Motor axis 1
E Correct orientation of holes

Continues on next page

3HAC026048-001 Revision: A 151
4 Repair
4.7.1. Replacement of motor, axis 1

Continued

Required equipment

Equipment Spare part no. Art. no. Note

Motor unit, axes 1 and 3 3HAC025712-001
O-ring 3HAB 3772-1 Always fit a new one!
Gasket 3HAB 3676-1
Measuring tool, motor 3HAB7887-1
Power supply - 24 VDC, max. 1.5 A. For
releasing the brakes.
Standard toolkit The contents are defined
in section Standard toolkit
on page 190, in part 2 of
the Product manual.
Calibration Pendulum 3HAC15716- Complete kit that also
toolkit 1 includes operating
manual.
Other tools and procedures These procedures include
may be required. See references to the tools
references to these required.
procedures in the step-by-
step instructions below.
Circuit Diagram See chapter Circuit
diagram in the Product
manual, reference infor-
mation.

Removal, motor axis 1

The procedure below details how to remove the motor, axis 1.

Action Note/Illustration
1.

- © Copyright 2006-2008 ABB. All rights reserved.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Remove the cover of the connection box. Shown in the figure Location of
motor, axis 1 on page 151
3. Disconnect the connectors R3.MP1 and
R3.FB1.

xx0200000401

• A: R3.MP1
• B: R3.FB1
• C: Connection box
Continues on next page
152 3HAC026048-001 Revision: A
 4 Repair
4.7.1. Replacement of motor, axis 1

Continued

Action Note/Illustration
4. Remove the connection box by unscrewing its Shown in the figure Location of
three attachment screws and plain washers. motor, axis 1 on page 151.
5. Use a marker pen to mark the position of the
motor (A).

xx0600002646

6. Unscrew the four attachment screws and Shown in the figure Location of
washers of the motor. motor, axis 1 on page 151.
7. Gently lift the motor straight up, making sure not
to damage the motor pinion.

Refitting, motor axis 1

The procedure below details how to refit the motor, axis 1.

Action Note/Illustration
1.

Danger!
Turn off all electric power, hydraulic and
© Copyright 2006-2008 ABB. All rights reserved.

pneumatic pressure supplies to the robot!

2. Check that the assembly surfaces are clean and
the motor is unscratched.
3. Fit the new o-ring. Always fit a new one, see art. no. in
Required equipment on page 152.
4. Fit the motor by gently lowering it straight down. Note the position of the motor! Use
the mark , made on the motor base
before removal. See also orientation
of the holes on top of the motor,
shown in the figure Location of
motor, axis 1 on page 151.
5. Tighten the four attachment screws and washers. 4 pcs. TIghtening torque: 2 Nm.
6. In order to release the brakes, connect the 24 Connect power supply to connector
VDC power supply to the motor. R3.MP1:
• + : pin 7
• - : pin 8

Continues on next page

3HAC026048-001 Revision: A 153
4 Repair
4.7.1. Replacement of motor, axis 1

Continued

Action Note/Illustration
7. Fit the measuring tool to the rear of the motor. Art. no. is specified in Required
equipment on page 152.
Shown in the figure below.
8. Rotate the motor shaft several turns, using the
measuring tool.
There must always be some backlash, meaning
that the shaft should go easy to rotate!
9. Place the tip of a dial indicator against the scribed The tip of the dial indicator must
mark on the measuring tool. measure on a 50 mm radius from
the center of the motor shaft.

xx0200000473

A. Measuring tool
10. Set the gear play to 0.02 mm, which corresponds
to a reading on the dial indicator of 0.13 mm.
11. Pull gently in one direction. Note the reading.
(The gear must not turn.)
12. Then gently knock on the tool in the other
direction and note the reading. The difference in
reading = gear play. The gear play should be 0.02

© Copyright 2006-2008 ABB. All rights reserved.

mm which corresponds to a reading on the dial
indicator of 0.13 mm.
13. Tighten the motor attachment screws. 4 pcs. Tightening torque: 23 Nm.
14. Refit the connection box with the three Shown in the figure Location of
attachment screws and plain washers. motor, axis 1 on page 151.
Make sure the gasket is fitted properly!
15. Reconnect the connectors R3.MP1 and R3.FB1.

xx0200000406

• A: R3.MP1
• B: R3.FB1
• C: Connection box

Continues on next page

154 3HAC026048-001 Revision: A
 4 Repair
4.7.1. Replacement of motor, axis 1

Continued

Action Note/Illustration
16. Refit the cover of the connection box. Shown in the figure Location of
motor, axis 1 on page 151.
17. Recalibrate the robot. Calibration is detailed in a separate
calibration manual, enclosed with
the calibration tools.
General calibration information is
included in section Calibration
information on page 175.
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 32.
© Copyright 2006-2008 ABB. All rights reserved.

3HAC026048-001 Revision: A 155

4 Repair
4.7.2. Replacement of motor, axis 2

4.7.2. Replacement of motor, axis 2

Location of motor, axis 2

The motor, axis 2, is located on the left hand side of the robot as shown in the figure below:

© Copyright 2006-2008 ABB. All rights reserved.

xx0200000470

A Attachment screws, cover (5 pcs)

B Cover
C Connection box
D Gasket
E Motor, axis 2
F Attachment screws, motor (4 pcs)
G O-ring
H Correct orientation of holes on top of motor

Continues on next page

156 3HAC026048-001 Revision: A
 4 Repair
4.7.2. Replacement of motor, axis 2

Continued

Required equipment

Equipment, etc. Spare part no. Art. no. Note

Motor unit, axis 2 3HAC025713-001
O-ring 3HAB 3772-1 Always fit a new one!
Gasket 3HAB 3676-1
Measuring tool, motor 3HAB7887-1
Power supply 24 VDC, max. 1.5 A. For
releasing the brakes.
Standard toolkit The contents are defined in
section Standard toolkit on
page 190, in part 2 of the
Product manual.
Calibration Pendulum 3HAC15716- Complete kit that also
toolkit 1 includes operating manual.
Other tools and procedures These procedures include
may be required. See references to the tools
references to these required.
procedures in the step-by-
step instructions below.
Circuit Diagram See chapter Circuit diagram
in the Product manual,
reference information.

Removal, motor axis 2

The procedure below details how to remove the motor, axis 2.

Action Note/Illustration
1.

-
© Copyright 2006-2008 ABB. All rights reserved.

Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Remove the cover of the connection box. Shown in the figure Location of
motor, axis 2 on page 156.
3. Disconnect the motor connectors R3.MP2 and
R3.FB2.

xx0200000401

• A: R3.MP2
• B: R3.FB2
• C: Connection box

Continues on next page

3HAC026048-001 Revision: A 157
4 Repair
4.7.2. Replacement of motor, axis 2

Continued

Action Note/Illustration
4. Remove the connection box by unscrewing its
three attachment screws and plain washers.
5. Use a marker pen to mark out the position of the
motor.
6. Secure the robot arms before
unscrewing any of the attachment
screws of the axis 2 motor.

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!

xx0300000107

7.

Warning!
Oil will be running out of the motor attachment hole
when removing the motor! It may also be hot! Take
any necessary measures to collect the oil. © Copyright 2006-2008 ABB. All rights reserved.
8. Unscrew the four attachment screws and washers Shown in the figure Location of
of the motor. motor, axis 2 on page 156.
9. Remove the motor by gently lifting it straight out.

Refitting, motor axis 2

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!

Continues on next page

158 3HAC026048-001 Revision: A
 4 Repair
4.7.2. Replacement of motor, axis 2

Continued

Action Note/Illustration
2. Check that the assembly surfaces are clean and
the motor is unscratched.
3. Fit the o-ring. Always fit a new one, see art. no. in
Required equipment on page 157.
4. Fit the motor by gently lifting it straight on. Note the position of the motor! Use
the mark on the motor base, made
before removing the motor. Also see
the orientation holes on the motor
cover, shown in the figure Location of
motor, axis 2 on page 156.
5. Fit the four attachment screws and tighten them 4 pcs. Tightening torque: 2 Nm.
slightly. Make the adjustments described below
before tightening the screws properly.
6. In order to release the brakes, connect the 24 Connect to connector R3.MP2:
VDC power supply to the motor. • +: pin 7
• -: pin 8
7. Fit the measuring tool to the rear of the motor. See the figure below.
Art. no. is specified in Required
equipment on page 157.
8. Rotate the motor shaft several turns, using the
measuring tool.
There must always be some backlash, meaning
that the shaft should go easy to rotate!
9. Place the tip of a dial indicator against the The tip of the dial indicator must
scribed mark on the measuring tool. measure on a 50 mm radius from the
center of the motor shaft.
© Copyright 2006-2008 ABB. All rights reserved.

xx0200000473

A. Measuring tool
10. Set the gear play to 0.02 mm, which corresponds
to a reading on the dial indicator of 0.13 mm.
11. Pull gently in one direction. Note the reading. See the figure above.
(The gear must not turn.)
12. Then gently knock on the tool in the other See the figure above.
direction and note the reading. The difference in
reading = gear play. The gear play should be
0.02 mm which corresponds to a reading on the
dial indicator of 0.13 mm.

Continues on next page

3HAC026048-001 Revision: A 159
4 Repair
4.7.2. Replacement of motor, axis 2

Continued

Action Note/Illustration
13. Tighten the four attachment screws. 4 pcs. Tightening torque: 23 Nm.
14. Perform a leak-down test. Detailed in section Performing a
leak-down test on page 86.
15. Fill the gearbox with oil. Type and amount of oil is specified in
section Oil in gearboxes on page 80.
16. Refit the connection box and secure with the Shown in the figure Location of
three attachment screws and plain washers. motor, axis 2 on page 156.
Make sure that the gasket is fitted properly!
17. Reconnect connectors R3.MP2 and R3.FB2.

xx0200000401

• A: R3.MP2
• B: R3.FB2
• C: Connection box
18. Refit the cover of the connection box. Shown in the figure Location of
motor, axis 2 on page 156.
19. Recalibrate the robot. Calibration is detailed in a separate
calibration manual, enclosed with the
calibration tools.
General calibration information is
included in section Calibration
information on page 175.
20.

© Copyright 2006-2008 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 32.

160 3HAC026048-001 Revision: A

 4 Repair
4.7.3. Replacement of motor, axis 3

4.7.3. Replacement of motor, axis 3

Location of motor, axis 3

The motor, axis 3, is located on the right hand side of the robot, as shown in the figure below:
A more detailed view of the component and its position may be found in section Axes 1-3,
spare part view 2 on page 211 in part 2 of the Product manual.
© Copyright 2006-2008 ABB. All rights reserved.

xx0200000471

A Attachment screws, cover

B Cover
C Connection box
D Gasket
E Motor, axis 2
F Attachment screws, motor (4 pcs)
G O-ring
H Correct orientation of holes on top of motor

Continues on next page

3HAC026048-001 Revision: A 161
4 Repair
4.7.3. Replacement of motor, axis 3

Continued

Required equipment

Equipment Spare part no. Art. no. Note

Motor unit, axes 1 and 3 3HAC025712-001
Gasket 3HAB 3676-1
O-ring 3HAB 3772-1 Always fit a new one.
Measuring tool, motor 3HAB7887-1
Power supply - 24 VDC, max. 1.5 A. For
releasing the brakes.
Standard toolkit - The contents are defined in
section Standard toolkit on
page 190, in part 2 of the
Product manual.
Calibration Pendulum 3HAC15716- Complete kit that also
toolkit 1 includes operating manual.
Other tools and These procedures include
procedures may be references to the tools
required. See references required.
to these procedures in
the step-by-step instruc-
tions below.
Circuit Diagram - See chapter Circuit diagram
in the Product manual,
reference information.

Removal, motor axis 3

The procedure below details how to remove the motor, axis 3.

Action Note/Illustration
1.

© Copyright 2006-2008 ABB. All rights reserved.

-

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Remove the cover of the connection box. Shown in the figure Location of
motor, axis 3 on page 161.
3. Disconnect the motor connectors R3.MP3 and
R3.FB3.

xx0200000401

• A: R3.MP3
• B: R3.FB3
• C: Connection box

Continues on next page

162 3HAC026048-001 Revision: A
 4 Repair
4.7.3. Replacement of motor, axis 3

Continued

Action Note/Illustration
4. Remove the connection box by unscrewing its Shown in the figure Location of
three attachment screws and plain washers. motor, axis 3 on page 161.
5. Use a marker pen to mark out the position of the
motor.
6. Secure the upper arm before
loosening any of the screws on the
motor!

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!

xx0300000107

7.

Warning!
Oil will be running out of the motor attachment
hole when removing the motor! It may also be
hot! Take any necessary measures to collect the
oil.
8. Unscrew the four attachment screws and plain Shown in the figure Location of
washers of the motor. motor, axis 3 on page 161.
© Copyright 2006-2008 ABB. All rights reserved.

9. Remove the motor by gently lifting it straight out.

Refitting, motor axis 3

The procedure below details how to refit the motor, axis 3.

Action Note/Illustration
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Check that the assembly surfaces are clean
and the motor is unscratched.

Continues on next page

3HAC026048-001 Revision: A 163
4 Repair
4.7.3. Replacement of motor, axis 3

Continued

Action Note/Illustration
3. Fit a new o-ring to the motor. Always mount a new one, see art. no.
in section Required equipment on page
162.
4. Fit the motor, by gently lifting it straight on. Note the position of the motor! Use the
mark on the motor base, made before
removal. Also see the orientation holes
on the motor cover, shown in the figure
Location of motor, axis 3 on page 161.
5. Tighten the four screws lightly. Tightening torque: 2 Nm.
6. In order to release the brakes, connect the 24 Connect to connector R3.MP3:
VDC power supply to the motor. • +: pin 7
• -: pin 8
7. Fit the measuring tool to the rear of the motor. See the figure below.
Art. no. is specified in Required
equipment on page 162.
8. Rotate the motor shaft several turns, using the See the figure below.
measuring tool.
There must always be some backlash,
meaning that the shaft should go easy to
rotate!
9. Place the tip of a dial indicator against the The tip of the dial indicator must
scribed mark on the measuring tool. measure on a 50 mm radius from the
center of the motor shaft.

© Copyright 2006-2008 ABB. All rights reserved.

xx0200000473

A. Measuring tool
10. Set the gear play to 0.02 mm, which
corresponds to a reading on the dial indicator
of 0.13 mm.
11. Pull gently in one direction. Note the reading. See the figure above.
(The gear must not turn.)
12. Then gently knock on the tool in the other See the figure above.
direction and note the reading. The difference
in reading = gear play. The gear play should be
0.02 mm which corresponds to a reading on
the dial indicator of 0.13 mm.
13. Tighten the four motor attachment screws. 4 pcs. Tightening torque: 23 Nm.

Continues on next page

164 3HAC026048-001 Revision: A
 4 Repair
4.7.3. Replacement of motor, axis 3

Continued

Action Note/Illustration
14. Perform a leak-down test. Detailed in section Performing a leak-
down test on page 86.
15. Refill the gearbox with oil. Type and amount of oil is specified in
section Oil in gearboxes on page 80.
16. Refit the connection box with the three Shown in the figure Location of motor,
attachment screws and plain washers. axis 3 on page 161.
Make sure that the gasket is fitted properly!
17. Reconnect the motor connectors R3.MP3 and
R3.FB3.

xx0200000401

• A: R3.MP3
• B: R3.FB3
• C: Connection box
18. Refit the cover of the connection box. Shown in the figure Location of motor,
axis 3 on page 161.
19. Recalibrate the robot. Calibration is detailed in a separate
calibration manual, enclosed with the
calibration tools.
General calibration information is
included in section Calibration
information on page 175.
20.

Danger!
© Copyright 2006-2008 ABB. All rights reserved.

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 32.

3HAC026048-001 Revision: A 165

4 Repair
4.7.4. Replacement of motor, axis 6

4.7.4. Replacement of motor, axis 6

Location of motor, axis 6

The motor, axis 6 is located in the tilthouse, as shown in the figure below.
A more detailed view of the component and its position may be found in section Tilthouse,
exploded view on page 219 in part 2 of the Product manual.

xx0500001940

A Motor, axis 6
B Attachment screws and washers, axis 6 motor (4 pcs)
C Motor connectors, R3.MP6 and R3.FB6

Required equipment

© Copyright 2006-2008 ABB. All rights reserved.

Equipment Spare part no. Art. no. Note
Rot. ac motor incl. 3HAC025734-001
pinion
Power supply - 24 VDC, max. 1.5 A. For
releasing the brakes.
Locking liquid - Loctite 243
Standard toolkit - The contents are defined in
section Standard toolkit on
page 190, in part 2 of the
Product manual.
Calibration Pendulum 3HAC15716-1 Complete kit that also
toolkit includes operating manual.
Circuit diagram - See chapter Circuit diagram
in the Product manual,
reference information.

Continues on next page

166 3HAC026048-001 Revision: A
 4 Repair
4.7.4. Replacement of motor, axis 6

Continued

Removal, motor, axis 6

The procedure below details how to remove the motor, axis 6 from the robot.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Disconnect the motor connectors R2.MP6 and
R2.FB6.
3. In order to release the brakes, connect the 24 VDC Connect to connector R3.MP6:
power supply to the motor. • +: pin 4
• -: pin 5
4. Unscrew the four attachment screws and washers. Shown in the figure Location of
motor, axis 6 on page 166.
5. Remove the motor by gently lifting it straight up.
Be careful not to damage the motor pinion!

Refitting, motor, axis 6

The procedure below details how to refit the motor, axis 6 to the robot.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and pneumatic
© Copyright 2006-2008 ABB. All rights reserved.

pressure supplies to the robot!

2. In order to release the brakes, connect the 24 VDC Connect to connector R3.MP6:
power supply to the motor. • +: pin 4
• -: pin 5
3. Gently fit the motor to the tilthouse. Be careful not
to damage the motor pinion when mating it to the
gearbox!
4. Secure the motor with its four attachment screws Shown in the figure Location of
and washers, using locking liquid. motor, axis 6 on page 166.
4 pcs; M6x20.
Tightening torque: 10 Nm.
Locking liquid is specified in
Required equipment on page 166.
5. Disconnect the brake release voltage.
6. Perform a leak-down test. Detailed in section Performing a
leak-down test on page 86.
7. Reconnect the motor connectors R3.MP6 and
R3.FB6.

Continues on next page

3HAC026048-001 Revision: A 167
4 Repair
4.7.4. Replacement of motor, axis 6

Continued

Action Note
8. Recalibrate the robot. Calibration is detailed in a
separate calibration manual,
enclosed with the calibration
tools.
General calibration information is
included in section Calibration
information on page 175.
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 32.

© Copyright 2006-2008 ABB. All rights reserved.

168 3HAC026048-001 Revision: A

 4 Repair
4.8.1. Replacement of gearbox, axis 1-3

4.8 Gearboxes

4.8.1. Replacement of gearbox, axis 1-3

Location of gearbox, axis 1-3

The axis 1 gearbox is located between the frame and base as shown in the figure below.
Axis 1 gearbox is of the conventional type, manufactured with high precision. Together with
the gearboxes for axes 2 and 3, it forms a complete unit.
A more detailed view of the component and its position may be found in section Axes 1-3,
spare part view 1 on page 210 in part 2 of the Product manual.
Note! The gearbox is not normally serviced or adjusted.

xx0300000007
© Copyright 2006-2008 ABB. All rights reserved.

A Attachment screws, gearbox unit

B Bottom plate

Required equipment

Equipment Spare part no. Art. no. Note

Gearbox, axes 1-3 3HAC025711-001
Standard toolkit - The contents are defined
in section Standard toolkit
on page 190, in part 2 of
the Product manual.
Calibration Pendulum 3HAC15716-1 Complete kit that also
toolkit includes operating
manual.

Continues on next page

3HAC026048-001 Revision: A 169
4 Repair
4.8.1. Replacement of gearbox, axis 1-3

Continued

Equipment Spare part no. Art. no. Note

Other tools and procedures These procedures include
may be required. See references to the tools
references to these required.
procedures in the step-by-
step instructions below.

Removal, gearbox axis 1-3

The procedure below details how to remove the gearbox, axis 1-3.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and pneumatic
pressure supplies to the robot!
2. Remove the cable unit, axes 1-3. Detailed in section Removal, cable
unit, axes 1-3 on page 91.
3. Remove the complete lower arm. Detailed in section Removal, lower
arm on page 135.
4. Remove the motor, axis 1. Detailed in section Removal,
motor axis 1 on page 152.
5. Remove the motor, axis 2. Detailed in section Removal,
motor axis 2 on page 157.
6. Remove the motor, axis 3. Detailed in section Removal,
motor axis 3 on page 162.
7.

© Copyright 2006-2008 ABB. All rights reserved.

Caution!
The complete gearbox unit weighs 200 kg (without
the base)! All lifting equipment used must be sized
accordingly!
8. Place the remaining parts of the robot upside-down
on a table or similar surface and remove the
bottom plate.
9. Undo the 12 attachment screws.
10. Lift away the base from the gearbox unit.

Continues on next page

170 3HAC026048-001 Revision: A
 4 Repair
4.8.1. Replacement of gearbox, axis 1-3

Continued

Refitting, gearbox axis 1-3

The procedure below details how to refit the gearbox, axis 1-3.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2.

Caution!
The complete gearbox unit weighs 200 kg
(without the base)! All lifting equipment used
must be sized accordingly!
3. Place the gearbox unit upside-down on a table or
similar surface.
4. Fit the base to the gearbox unit and secure with 12 pcs; M12x50. Tightening torque:
the 12 screws and washers. 54 Nm.
5. Refit the bottom plate to the base.
6. Turn the base and gearbox unit around and Further detailed in section Orienting
secure to the installation site. and securing the robot on page 47.
7. Refit the motor, axis 1. Detailed in section Refitting, motor
axis 1 on page 153.
8. Refit the motor, axis 2. Detailed in section Refitting, motor
axis 2 on page 158.
9. Refit the motor, axis 3. Detailed in section Refitting, motor
axis 3 on page 163.
© Copyright 2006-2008 ABB. All rights reserved.

10. Refit the complete lower arm. Detailed in section Refitting, lower
arm on page 136.
11. Refit the cable unit, axes 1-3. Detailed in section Refitting,
gearbox axis 1-3 on page 171.
12. Calibrate the robot. Calibration is detailed in a separate
calibration manual, enclosed with
the calibration tools.
General calibration information is
included in section Calibration
information on page 175.
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 32.

3HAC026048-001 Revision: A 171

4 Repair
4.8.2. Replacement of gearbox, axis 6

4.8.2. Replacement of gearbox, axis 6

Location of gearbox, axis 6

The gearbox, axis 6, is located at the frontmost part of the robot, as shown in the figure below.

xx0500001939

A Gearbox, axis 6
B Attachment screws, gearbox (8 pcs)

Required equipment

Equipment Spare part no. Art. no. Note

RV-6E, i=79 3HAC025110-001
O-ring 3HAB3772-88 Replace if damaged!
Locking liquid - Loctite 243
Bearing grease 3HAB3537-1 Used to lubricate o-rings and
contact surfaces.
Standard toolkit - The contents are defined in © Copyright 2006-2008 ABB. All rights reserved.
section Standard toolkit on
page 190, in part 2 of the
Product manual.
Calibration Pendulum 3HAC15716-1 Complete kit that also
toolkit includes operating manual.
Other tools and These procedures include
procedures may be references to the tools
required. See references required.
to these procedures in
the step-by-step instruc-
tions below.

Continues on next page

172 3HAC026048-001 Revision: A
 4 Repair
4.8.2. Replacement of gearbox, axis 6

Continued

Removal, gearbox, axis 6

The procedure below details how to remove the gearbox, axis 6 from the robot.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
2. Drain the oil from the gearbox. Detailed in section Draining oil,
gearbox axis 6 on page 81.
3. Remove the turning disk. Detailed in section Removal,
turning disk on page 114.
4. Remove the gearbox from the robot by removing Shown in the figure Location of
its attachment screws and washers. gearbox, axis 6 on page 172.
5. If necessary, press out the gearbox by inserting Press out holes: 2 x M5.
screws into the two M5 holes on the gearbox.

Refitting, gearbox, axis 6

The procedure below details how to refit the gearbox, axis 6 to the robot.

Action Note
1.

Danger!
Turn off all electric power, hydraulic and
pneumatic pressure supplies to the robot!
© Copyright 2006-2008 ABB. All rights reserved.

2. Lubricate the contact surfaces inside the housing

with grease.
3. Make sure the o-ring is lubricated and fitted Spare part no. is specified in
properly to the upper side of the gearbox. Required equipment on page 172.
Replace if damaged!
4. Refit the gearbox with the attachment screws 8 pcs; M5x25.
and washers, using locking liquid. Tightening torque: 8 Nm. Locking
liquid is specified in Required
equipment on page 172.
5. Refit the turning disk. Detailed in section Refitting, turning
disk on page 114.
6. Perform a leak-down test. Detailed in section Performing a
leak-down test on page 86.
7. Refill the gearbox with oil. Detailed in section Filling oil,
gearbox axis 6 on page 82.

Continues on next page

3HAC026048-001 Revision: A 173
4 Repair
4.8.2. Replacement of gearbox, axis 6

Continued

Action Note
8. Recalibrate the robot. Calibration is detailed in a separate
calibration manual, enclosed with
the calibration tools.
General calibration information is
included in section Calibration
information on page 175.
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 32.

© Copyright 2006-2008 ABB. All rights reserved.

174 3HAC026048-001 Revision: A

 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 176, 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 180. This will occur when:
• the battery is discharged
• a resolver error occurs
• the signal between a resolver and measurement board is interrupted
• a robot axis is moved with the control system disconnected
© Copyright 2006-2008 ABB. All rights reserved.

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 Absolute Accuracy calibration, it needs to be calibrated for new Absolute
Accuracy.

3HAC026048-001 Revision: A 175

5 Calibration information
5.2. Calibration methods

5.2. Calibration methods

Overview
This section specifies the different types of calibration and the calibration methods that are
supplied from ABB.

Types of calibration

Type of calibra-
Description Calibration method
tion
Standard The calibrated robot is positioned at home Calibration Pendulum
calibration position, i.e. the axes positions (angles) are (standard method)
set to 0º.
Standard calibration data is found in the file
calib.cfg, supplied with the robot at delivery.
The file identifies the correct resolver/motor
position corresponding to the robot home
position.
From deliveries together with RobotWare 5.0.5
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
Absolute Accuracy Based on standard calibration, and besides CalibWare
calibration positioning the robot at home position, the
(optional) Absolute Accuracy calibration also
compensates for:
• mechanical tolerances in the robot
structure
• deflection due to load.
Absolute Accuracy calibration focuses on
positioning accuracy in the Cartesian
coordinate system for the robot.
Absolute Accuracy data is found in the file
absacc.cfg, supplied with the robot at delivery.
The file replaces the calib.cfg file and identifies
© Copyright 2006-2008 ABB. All rights reserved.
motor positions as well as absacc-compensa-
tion parameters.
From deliveries together with RobotWare 5.0.6
and higher, the data will instead be found on
the SMB (serial measurement board) in the
robot, and not in a separate file.
A robot calibrated with AbsAcc has a sticker
next to the identification plate of the robot.
To regain 100% Absolute Accuracy perfor-
mance, the robot must be recalibrated for
Absolute Accuracy!

xx0400001197

Continues on next page

176 3HAC026048-001 Revision: A
 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.
The calibration equipment for Calibration Pendulum is delivered as a complete toolkit,
including the operating manual for Calibration Pendulum, which describes the method and
the different routines further.

CalibWare - Absolute Accuracy calibration

In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy
is used as a TCP calibration. The tool CalibWare guides through the calibration process and
calculates new compensation parameters. This is detailed further in the manual CalibWare 2.0
Users Guide (M2000).
If a service operation is done to a robot with Absolute Accuracy, a new absolute accuracy
calibration is required in order to establish full performance. For most cases after motor and
transmission replacements that do not include taking apart the robot structure, standard
calibration is sufficient. Standard calibration also supports wrist exchange.

References
Article numbers for the calibration tools are listed in section Special tools on page 191 in part
2 of the Product manual. A calibration manual is enclosed with the calibration tools.
The article numbers for the operating manuals for calibration are also listed in section
© Copyright 2006-2008 ABB. All rights reserved.

References on page 8.

3HAC026048-001 Revision: A 177

5 Calibration information
5.3. Calibration scales and correct axis position

5.3. Calibration scales and correct axis position

Introduction
This section specifies the calibration scale positions and/or correct axis position for all robot
models.

Calibration scales, IRB 260

When axis 3 is put in calibration position, the mark on the calibration plate is visible above
the mechanical stop, as shown in the figure below.

© Copyright 2006-2008 ABB. All rights reserved.

xx0500002485

A Mechanical stop of axis 3

B Calibration mark on calibration plate, axis 3
C Calibration plate and marking, axis 6
D Punch, axis 1, 3HAB8223-1
E Punch, axis 2, 3HAB8223-1 (1 marking)

178 3HAC026048-001 Revision: A

 5 Calibration information
5.4. Calibration movement directions for all axes

5.4. Calibration movement directions for all axes

Overview
When calibrating, the axis must consistently be run towards the calibration position in the
same direction, in order to avoid position errors caused by backlash in gears etc. Positive
directions are shown in the figure below.
This is normally handled by the robot calibration software.

Calibration movement directions, 4 axes

Note! The figure shows an IRB 260, but the positive direction is the same for all 4-axis robots
© Copyright 2006-2008 ABB. All rights reserved.

xx0500001927

3HAC026048-001 Revision: A 179

5 Calibration information
5.5. Updating revolution counters

5.5. Updating revolution counters

General
This section details how to perform a rough calibration of each robot axis, i.e. updating the
revolution counter value for each axis, using the pendant.

Step 1 - Manually running the robot to the calibration position

This procedure details the first step when updating the revolution counter; manually running
the robot to the calibration position.

Action Note
1. Select axis-by-axis motion mode.
2. Jog the robot to place the calibration marks Shown in section Calibration scales and
within the tolerance zone. correct axis position on page 178.
3. When all axes are positioned, store the Detailed in sections:
revolution counter settings. Step 2 - Storing the revolution counter
setting with the FlexPendant on page 180
(RobotWare 5.0).

Step 2 - Storing the revolution counter setting with the FlexPendant

This procedure details the second step when updating the revolution counter; storing the
revolution counter setting with the FlexPendant (RobotWare 5.0).

Action
1. On the ABB menu, tap Calibration.
All mechanical units connected to the system are shown along with their calibration
status.

© Copyright 2006-2008 ABB. All rights reserved.

Continues on next page

180 3HAC026048-001 Revision: A
 5 Calibration information
5.5. Updating revolution counters

Continued

Action
2. Tap the mechanical unit in question.
A screen is displayed: tap Rev. Counters.

en0400000771

3. Tap Update Revolution Counters....

A dialog box is displayed, warning that updating the revolution counters may change
programmed robot positions:
• Tap Yes to update the revolution counters.
• Tap No to cancel updating the revolution counters.
Tapping Yes displays the axis selection window.
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.
© Copyright 2006-2008 ABB. All rights reserved.

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!
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.
See section Checking the calibration position on page 182.

3HAC026048-001 Revision: A 181

5 Calibration information
5.6. Checking the calibration position

5.6. Checking the calibration position

General
Check the calibration position before beginning any programming of the robot system. This
may be done in one of two ways:
• Using a MoveAbsJ instruction with argument zero on all axes
• Using the Jogging window on the teach pendant

Using a MoveAbsJ instruction on the FlexPendant, IRC5

This section describes how to create a program, which runs all the robot axes to their zero
position.

Action Note
1. On ABB menu tap Program Editor.
2. Create a new program.
3. Use MoveAbsJ in the Motion&Proc menu.
4. Create the following program: MoveAbsJ
[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,9E
9]]\NoEOffs, v1000, z50, Tool0
5. Run the program in manual mode.
6. Check that the calibration marks for the axes align The calibration marks are shown
correctly. If they do not, update the revolution in section Calibration scales and
counters! correct axis position on page
178.
How to update the revolution
counters is detailed in section
Updating revolution counters on
page 180.

Using the Jogging window on the FlexPendant, IRC5

This section describes how to jog the robot to all axes zero position.
© Copyright 2006-2008 ABB. All rights reserved.
Action Note
1. Tap Jogging in the ABB menu.
2. Tap Motion mode to choose group of axes to jog.
3. Tap axes 1-3 to jog axes 1, 2 or 3.
4. Manually run the robots axes to a position where the axis
position value read on the FlexPendant, is equal to zero.
5. Check that the calibration marks for the axes align The calibration marks are
correctly. If they do not, update the revolution counters! shown in section Calibration
scales and correct axis
position on page 178.
How to update the counters
is detailed in section
Updating revolution counters
on page 180.

182 3HAC026048-001 Revision: A

 6 Reference information
6.1. Introduction

6 Reference information
6.1. Introduction

General
This chapter includes general information, complementing the more specific information in
the Product manual (part 1 of 2), procedures.
© Copyright 2006 ABB. All rights reserved.

3HAC 026048-001 Revision: - 183

6 Reference information
6.2. Applicable safety standards

6.2. Applicable safety standards

Overview
The robot conforms to the standards specified below.

Standards, EN

Standard Description
EN ISO 12100-1 Safety of machinery, terminology
EN ISO 12100-2 Safety of machinery, technical specifications
EN 954-1 Safety of machinery, safety related parts of control systems
EN 60204 Electrical equipment of industrial machines
EN 775 Electrical equipment of industrial machines
EN 61000-6-4 (option) EMC, Generic emission
EN 61000-6-2 EMC, Generic immunity

Standards, IEC

Standard Description
IEC 60204-1 Electrical equipment of industrial machines
IEC 60529-1 Degrees of protection provided by enclosures

Standards, ISO

Standard Description
ISO 10218 Manipulating industrial robots, safety
ISO 9787 Manipulating industrial robots, coordinate systems and motions

Additional standards

Standard Description
ANSI/RIA 15.06/1999 Safety requirements for industrial robots and robot systems
© Copyright 2006 ABB. All rights reserved.

ANSI/UL 1740-1998 (option) Safety standard for robots and robotic equipment
CAN/CSA Z 424-03 (option) Industrial robots and robot systems - general safety require-
ments

184 3HAC 026048-001 Revision: -

 6 Reference information
6.3. Unit conversion

6.3. Unit conversion

Converter table
Use the table below to convert units used in this manual.

Quantity Units
Length 1m 3.28 ft 39.37 in
Weight 1 kg 2.21 lb
Pressure 1 bar 100 kPa 14.5 psi
Force 1N 0.738 lbf
Moment 1 Nm 0.738 lbf-tn
Volume 1L 0.264 US gal
© Copyright 2006 ABB. All rights reserved.

3HAC 026048-001 Revision: - 185

6 Reference information
6.4. Screw joints

6.4. Screw joints

General
This section details how to tighten the various types of screw joints on the robot and the
controller.
The instructions and torque values are valid for screw joints comprised of metallic materials
and do not apply to soft or brittle materials.

UNBRAKO screws
UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It
features special surface treatment (Gleitmo as described below), and is extremely resistant to
fatigue.
Whenever used, this is specified in the instructions, and in such cases, no other type of
replacement screw is allowed! Using other types of screws will void any warranty and may
potentially cause serious damage or injury!

Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.
Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this
the screw must be discarded and replaced with a new one.
When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should
be used.

Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the repair,
maintenance or installation procedure descriptions.
In such cases, proceed as follows:
1. Apply lubricant to the screw thread.
2. Apply lubricant between the plain washer and screw head.
3. Tighten to the torque specified in section Tightening torque below. Screw dimensions © Copyright 2006 ABB. All rights reserved.
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.

Molycote 1000 (molybdenum disulphide grease) 1171 2016-618

Continues on next page

186 3HAC 026048-001 Revision: -
 6 Reference information
6.4. Screw joints

Continued

Tightening torque
Before tightening any screw, note the following:
• Determine whether a standard tightening torque or special torque is to be applied. The
standard torques are specified in the tables below. Any special torques are specified in
the Repair, Maintenance or Installation procedure description. Any special torque
specified overrides the standard value.
• Use the correct tightening torque for each type of screw joint.
• Only use correctly calibrated torque keys.
• Always tighten the joint by hand, and never use pneumatical tools.
• Use the correct tightening technique, i.e. do not jerk. Tighten the screw in a slow,
flowing motion.
• Maximum allowed total deviation from the specified value is 10%!
The table below specifies the recommended standard tightening torque for oil-lubricated
screws with slotted or cross-recess head screws.

Tightening torque (Nm)

Dimension
Class 4.8, oil-lubricated
M2.5 0.25
M3 0.5
M4 1.2
M5 2.5
M6 5.0

The table below specifies the recommended standard tightening torque for oil-lubricated
screws with Allen head screws.

Tightening torque Tightening torque Tightening torque

(Nm) (Nm) (Nm)
Dimension
Class 8.8, oil-lubri- Class 10.9, oil-lubri- Class 12.9, oil-lubri-
cated cated cated
M5 6 - -
© Copyright 2006 ABB. All rights reserved.

M6 10 - -
M8 24 34 40
M10 47 67 80
M12 82 115 140
M16 200 290 340

The table below specifies the recommended standard tightening torque for Molycote-
lubricated screws with Allen head screws.

Tightening torque (Nm) Tightening torque (Nm)

Dimension
Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
M8 28 34
M10 55 66
M12 96 115
M16 235 280
Continues on next page
3HAC 026048-001 Revision: - 187
6 Reference information
6.4. Screw joints

Continued

The table below specifies the recommended standard tightening torque for water and air
connectors when one or both connectors are made of brass.

Tightening torque Tightening torque Tightening torque

Dimension
Nm - Nominal Nm - Min. Nm - Max.
1/8 12 8 15
1/4 15 10 20
3/8 20 15 25
1/2 40 30 50
3/4 70 55 90

© Copyright 2006 ABB. All rights reserved.

188 3HAC 026048-001 Revision: -

 6 Reference information
6.5. Weight specifications

6.5. Weight specifications

Definition
In all repair and maintenance procedures, weights of the components handled are sometimes
specified. All components exceeding 22 kg (50 lbs) are high-lighted in this way.
To avoid injury, ABB recommends the use of lifting equipment when handling components
with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each
manipulator model.

Example
Below is an example of how a weight specification is presented, inside a procedure table:

Action Note

Caution!
The motor weighs 32 kg! All lifting equipment used
must be sized accordingly!
© Copyright 2006 ABB. All rights reserved.

3HAC 026048-001 Revision: - 189

6 Reference information
6.6. Standard toolkit

6.6. Standard toolkit

General
All service (repairs, maintenance and installation) procedures contain lists of tools required
to perform the specified activity.
All special tools required are listed directly in the procedures while all the tools that are
considered standard are gathered in the Standard toolkit and defined in the table below.
This way, the tools required are the sum of the Standard Toolkit and any tools listed in the
instruction.

Contents, standard toolkit

Qty Tool
1 Ring-open-end spanner 8-19mm
1 Socket head cap 2,5-17mm
1 Torx socket no:20-60
1 Torque wrench 8-100Nm
1 Small screwdriver
1 Plastic mallet
1 Ratchet head for torque wrench 1/2
1 KM nut (KM7)
1 Socket head cap no:5, socket 1/2"" bit L 20mm
1 Socket head cap no:6, socket 1/2"" bit L 20mm
1 Socket head cap no:8, socket 1/2"" bit L 20mm
1 Small cutting plier

© Copyright 2006 ABB. All rights reserved.

190 3HAC 026048-001 Revision: -

 6 Reference information
6.7. Special tools

6.7. Special tools

General
All service instructions contain lists of tools required to perform the specified activity. The
required tools are a sum of standard tools, defined in section Standard toolkit on page 190,
and of special tools, listed directly in the instructions and also gathered in this section.

Special tools
The table below specifies the special tools required during service procedures. The tools are
also specified directly in concerned procedures for repair.

Item Description Art. no. Note

- Guide pins 3HAC024097-006 3 pcs required. Length: 62 mm.
Diameter: 6 mm. Thread: M6x12.
Used for guiding the shaft end of the
upper arm into place.
- Hydraulic pump, 80 Mpa 3HAC13086-1
- Press tool, parallel bar 3HAB6324-1
bearing
- Mounting tool, parallel bar 3HAB6331-1
- Measuring tool, motor 3HAB7887-1 Used when refitting motor axes 1, 2
and 3.
- Extended KM nut (KM7) 3HAC023963-040 Length: 135 mm.
- Toolkit for service 3HAC023963-026 The kit contains loose parts that are
assembled into different tools for
different service occasions.
The content is specified in the
following table (Content, toolkit for
service, 3HAC023963-026 on page
191).
The different assemblies are shown
in the figures on the following
pages, as in the service procedures
that require the tool assembly.
© Copyright 2006 ABB. All rights reserved.

H Press sleeve 3HAC023963-013

Content, toolkit for service, 3HAC023963-026

The table below specifies the loose parts in the toolkit for service. The item numbers refer to
the items shown in the figures for each assembly of the complete tools, on following pages.

Item Description Art. no. Note

A Hydraulic cylinder 3HAC11731-1
B Press washer 3HAC023963-007
C Hex socket head cap screw 9ADA183-25 2 pcs, M6 x 25
D Connection rod - M16, length= 400 mm
E Nut 3HAC5507-1
F Sleeve 3HAC023963-027 D= 70 mm
G Nut 3HAC023963-028 D= 28 mm

Continues on next page

3HAC 026048-001 Revision: - 191
6 Reference information
6.7. Special tools

Continued

Item Description Art. no. Note

H Press sleeve 3HAC023963-038 D= 48.8 mm
I Connection rod 3HAC025192-006 M16, length= 280 mm
J Pad 3HAC023963-029
K Press washer 3HAC023963-014 D= 70 mm
L Press head 3HAC023963-039 D= 55 mm
M Sleeve 3HAC023963-037 D= 55 mm
N Press sleeve 3HAC023963-015 D= 70 mm
O Connecting rod 3HAC023081-003 Mxx, length= xx mm
P Press housing 3HAC024097-002
R Auxiliary shaft 3HAC024097-005
S Hex socket head cap screw 9ADA183-24 2 pcs, M6 x 12
T Distance 3HAC023062-001

Special tools, location of usage

The toolkit for service includes loose parts that are assembled into different tools, depending
on usage. The figure below shows some of the assembled tools and where to use them on the
robot. The detailed assemblies are shown in separate figures, referred to in the item list.

© Copyright 2006 ABB. All rights reserved.

xx0600002588

A Dismounting tool, tilthouse shaft. Assembly is shown in the figure Dismounting

tool, tilthouse shaft on page 193.

Continues on next page

192 3HAC 026048-001 Revision: -
 6 Reference information
6.7. Special tools

Continued

B Mounting tool, tilthouse shaft. Assembly is shown in the figure Mounting tool,
tilthouse shaft on page 194.
C Mounting tool, bearing race and sealing, upper arm. Assembly is shown in the
figure Mounting tool, bearing race and sealing, upper arm on page 195.
D Dismounting tool, bearing race, upper arm. Assembly is shown in the figure
Dismounting tool, bearing race, upper arm on page 195.
E Press tool, link. Assembly is shown in the figure Press tool, link on page 198.
F Press sleeve, art. no. specified in the table Special tools on page 191.

Dismounting tool, tilthouse shaft

The tool for removing the tilthouse shaft from the tilthouse is assembled with the parts shown
in the figure below (included in the toolkit for service).
Note! The parts cannot be ordered separately, but are included in the complete toolkit! The
article numbers are only given for identification.

xx0600002589

A Hydraulic cylinder, 3HAC11731-1

B Press washer, 3HAC023963-007
C Hex socket head cap screw, 9ADA183-25, 2 pcs, M6 x 25
D Connection rod, M16, length= 400 mm
© Copyright 2006 ABB. All rights reserved.

E Nut, 3HAC5507-1
F Sleeve, 3HAC023963-027
G Nut, 3HAC023963-028
J Pad, 3HAC023963-029

Continues on next page

3HAC 026048-001 Revision: - 193
6 Reference information
6.7. Special tools

Continued

Mounting tool, tilthouse shaft

The tool for fitting the tilthouse shaft to the tilthouse is assembled with the parts shown in the
figure below (included in the toolkit for service).
Note! The parts cannot be ordered separately, but are included in the complete toolkit! The
article numbers are given only for identification.

xx0500002581

A Hydraulic cylinder, 3HAC11731-1

B Press washer, 3HAC023963-007
C Hex socket head cap screw, 9ADA183-25, 2 pcs, M6 x 25
D Connection rod, M16, length= 400 mm
E Nut, 3HAC5507-1
J Pad, 3HAC023963-029
K Press washer, 3HAC023963-014

© Copyright 2006 ABB. All rights reserved.

Continues on next page

194 3HAC 026048-001 Revision: -
 6 Reference information
6.7. Special tools

Continued

Mounting tool, bearing race and sealing, upper arm

The tool for fitting the bearing race and sealing to the upper arm is assembled with the parts
shown in the figure below (included in the toolkit for service).
Note! The parts cannot be ordered separately, but are included in the complete toolkit! The
article numbers are given only for identification.

xx0500002582

A Hydraulic cylinder, 3HAC11731-1

B Press washer, 3HAC023963-007
C Hex socket head cap screw, 9ADA183-25, 2 pcs, M6 x 25
E Nut, 3HAC5507-1
I Connection rod, 3HAC025192-006
L Press head, 3HAC023963-039
N Press sleeve, 3HAC023963-015

Dismounting tool, bearing race, upper arm

The tool for removing the bearing race from the upper arm is assembled with the parts shown
in the figure below (included in the toolkit for service).
Note! The parts cannot be ordered separately, but are included in the complete toolkit! The
© Copyright 2006 ABB. All rights reserved.

article numbers are given only for identification.

xx0600002656

A Hydraulic cylinder, 3HAC11731-1

B Press washer, 3HAC023963-007
Continues on next page
3HAC 026048-001 Revision: - 195
6 Reference information
6.7. Special tools

Continued

C Hex socket head cap screw, 9ADA183-25, 2 pcs, M6 x 25

E Nut, 3HAC5507-1
F Sleeve, 3HAC023963-027
G Nut, 3HAC023963-028
H Press sleeve, 3HAC023963-038
I Connection rod, 3HAC025192-006

Dismounting tool, bearing race, tilthouse shaft

The tool for removing the bearing race from the tilthouse shaft is assembled with the parts
shown in the figure below (included in the toolkit for service).
Note! The parts cannot be ordered separately, but are included in the complete toolkit! The
article numbers are given only for identification.

xx0600002657

A Hydraulic cylinder, 3HAC11731-1

B Press washer, 3HAC023963-007
C Hex socket head cap screw, 9ADA183-25, 2 pcs, M6 x 25
D Connection rod, M16, length= 400 mm
E Nut, 3HAC5507-1
G Nut, 3HAC023963-028 © Copyright 2006 ABB. All rights reserved.

M Sleeve, 3HAC023963-037

Continues on next page

196 3HAC 026048-001 Revision: -
 6 Reference information
6.7. Special tools

Continued

Mounting tool, bearing race, tilthouse shaft

The tool for fitting a bearing race to the tilthouse shaft is assembled with the parts shown in
the figure below (included in the toolkit for service).
Note! The parts cannot be ordered separately, but are included in the complete toolkit! The
article numbers are given only for identification.

xx0600002658

A Hydraulic cylinder, 3HAC11731-1

B Press washer, 3HAC023963-007
C Hex socket head cap screw, 9ADA183-25, 2 pcs, M6 x 25
D Connection rod, M16, length= 400 mm
E Nut, 3HAC5507-1
G Nut, 3HAC023963-028
H Sleeve, 3HAC023963-037
© Copyright 2006 ABB. All rights reserved.

Continues on next page

3HAC 026048-001 Revision: - 197
6 Reference information
6.7. Special tools

Continued

Press tool, link

The tool for fitting the bearing and the link to the upper arm shaft includes the parts shown in
the figure below (included in the toolkit for service).
Note! The parts cannot be ordered separately, but are included in the complete toolkit! The
article numbers are only given for identification!

xx0600002618

A Hydraulic cylinder, 3HAC11731-1

E Nut, 3HAC5507-1
O Connecting rod, 3HAC023081-003
P Press housing, 3HAC024097-002
R Auxiliary shaft, 3HAC024097-005
S Screw, M6x12, 9ADA183-24 (2 pcs)
T Distance, 3HAC023062-001

Calibration equipment, Calibration Pendulum

The table below specifies the calibration equipment needed when calibrating the robot with
the Calibration Pendulum method.
© Copyright 2006 ABB. All rights reserved.

Description Art. no. Note

Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating
manual.

198 3HAC 026048-001 Revision: -

 6 Reference information
6.8. Lifting equipment and lifting instructions

6.8. Lifting equipment and lifting instructions

General
Many repair and maintenance activities require different pieces of lifting equipment, which
are specified in each procedure.
The use of each piece of lifting equipment is not detailed in the activity procedure, but in
the instruction delivered with each piece of lifting equipment.
This implies that the instructions delivered with the lifting equipment should be stored for
later reference.
© Copyright 2006 ABB. All rights reserved.

3HAC 026048-001 Revision: - 199

6 Reference information
6.8. Lifting equipment and lifting instructions

© Copyright 2006 ABB. All rights reserved.

200 3HAC 026048-001 Revision: -

 7 Spare part lists and exploded views
7.1. Introduction

7 Spare part lists and exploded views

7.1. Introduction

Definitions
This chapter specifies all spare parts and replacement articles of the robot.
© Copyright 2006 ABB. All rights reserved.

3HAC 026048-001 Revision: - 201

7 Spare part lists and exploded views
7.2. Spare parts - overview

7.2. Spare parts - overview

Overview - spare parts

The location of the different plates, labels and signs are shown in section Inspection of
information labels on page 78.

Note/ specified in
Item Qty Description Spare part no.
section:
1 1 Cover Foundry - Spare parts - cover on
page 203
2 1 Instruction plate 3HAC2814-2 Warning of brake release.
3 1 Robot IRB 260 - Spare parts - robot IRB
260 on page 205
4 3 Instruction plate 2945 4489-16
5 1 Rating label 3HAB9549-1
6 5 Warning sign 3HAC1589-1 Lightning flash.
7 1 Instruction plate 3HAC025469-001 Lifting of robot.
10 1 Conn.set R1.CP/CS, 3HAC12558-2
Foundry
11 1 CP/CS Conn .set 3HAC025223-001
12 2 ABB Logotype 3HAC0453-2
13 3 Calibration label 3HAC024307-001
14 1 Position switch axis 1 3HAC12062-1 Includes one switch.
14 1 Position switch axis 1 3HAC12062-2 Includes two switches.
14 1 Position switch axis 1 3HAC12062-3 Includes three switches.
15 1 Stop axis 1 3HAB 7298-1
16 1 Signal lamp 3HAC025254-001
- - Material set 3HAC24116-001 Spare parts - material set
cabling axis 6 on page 221

© Copyright 2006 ABB. All rights reserved.

202 3HAC 026048-001 Revision: -

 7 Spare part lists and exploded views
7.3. Spare parts - cover

7.3. Spare parts - cover

Cover, spare part list

The items specified below are shown in the figure Cover, spare part view on page 204.

Item Qty Description Spare part no. Dimension/Note

63 9 Torx pan head roll. screw 9ADA629-43
104 1 Cover 2400 machined 3HAC8722-1
105 1 Gasket, cover 3HAC3200-1
121 1 BU w. buttons DSQC 563 3HAC16035-1 Recommended spare part.
Replacement is detailed in
section Replacement of
brake release unit on page
145.
122 4 Distance bolt 2125 2052-198 M5X15
123 1 Push button guard 3HAC2744-1 Recommended spare part.
129 1 Signal cable SMB 3HAC7819-1 Recommended spare part.
157 1 Adaptor customer cabling 3HAB7328-1
158 1 Adaptor power cabling 3HAC2809-1
170 1 Cover pushbuttons 3HAC3197-1
© Copyright 2006 ABB. All rights reserved.

Continues on next page

3HAC 026048-001 Revision: - 203
7 Spare part lists and exploded views
7.3. Spare parts - cover

Continued

Cover, spare part view

© Copyright 2006 ABB. All rights reserved.

xx0500002436

204 3HAC 026048-001 Revision: -

 7 Spare part lists and exploded views
7.4. Spare parts - robot IRB 260

7.4. Spare parts - robot IRB 260

Robot IRB 260, spare part list

The items specified below are shown in the figures Robot IRB 260, exploded view 1 of 2 on
page 206 and Robot IRB 260, exploded view 2 of 2 on page 206.

Item Qty Description Spare part no. Note

1 1 Axis 1-3 - Spare parts are shown in
section Spare parts - axes 1-
3 on page 208.
2 1 Upper arm - Spare parts are shown in
section Spare parts - upper
arm on page 216.
3 1 Linkage - Spare parts are shown in
section Spare parts - linkage
on page 220.
4 1 Shaft end 3HAC024592-001 Recommended spare part.
5 1 Shaft end 3HAC025034-001 Recommended spare part.
6 1 Spacer, axis 2 3HAC025740-001
7 1 Spacer, axis 2 3HAC025741-001
8 1 Shaft end 3HAB5527-1
9 2 Lock nut 2126 2851-107
10 2 Taper roller bearing 3HAA2103-15
11 2 Radial sealing -
12 1 Lock nut 2126 2851-106
13 1 Distance -
14 2 Hex socket head cap screw 3HAB7700-71 M12x60, UNBRAKO 12.9
15 2 VK-cover 3HAC12165-2
16 2 Washer 3HAA1001-134 13x19x1,5
17 4 Ring -
18 8 Support washer 3HAB6279-1
19 4 Lock nut -
© Copyright 2006 ABB. All rights reserved.

20 1 Bearing sealing 3HAC10088-4

21 1 Locking washer 3HAB5523-1 D=34; T=4
22 1 Hex socket counters, head 2121 2852-449 M8x16 Steel 8,8 Fe/Zn 5c
23 Locking liquid - Loctite 243
24 1 Mechanical stop, axis 3 3HAC024253-001
25 3 Torx counters. head screw 9ADA624-56 M6x16 Steel 8.8-A2F
26 3 Torx pan head screw 9ADA618-53 M6x8 Steel 8.8-A2F
27 3 Washer 3HAC020537-001 D=6,4/12 T=1,6
28 6 Hex socket head cap screw 3HAB3402-37 M8x25 Steel 8.8 Gleitmo 610
29 2 Damper axis 2 3HAB8284-1
30 3 Plain washer 9ADA312-6
31 3 Flanged bolt -
32 3 Hex socket head cap screw 3HAB3409-25 M6x20 Steel 12.9 Gleitmo
610

Continues on next page

3HAC 026048-001 Revision: - 205
7 Spare part lists and exploded views
7.4. Spare parts - robot IRB 260

Continued

Item Qty Description Spare part no. Note

33 1 Protection hood 2522 2101-17
35 1 Lifting eye 2179 090-25
37 1 Plain washer 9ADA312-9 13x24x2,5
38 1 Bearing sealing 3HAC10089-2

Robot IRB 260, exploded view 1 of 2

xx0500001936

Robot IRB 260, exploded view 2 of 2

© Copyright 2006 ABB. All rights reserved.

xx0500001937

206 3HAC 026048-001 Revision: -

 7 Spare part lists and exploded views
© Copyright 2006 ABB. All rights reserved. 7.4. Spare parts - robot IRB 260

3HAC 026048-001 Revision: - 207

7 Spare part lists and exploded views
7.5. Spare parts - axes 1-3

7.5. Spare parts - axes 1-3

Axes 1-3, spare part list

The items specified below are shown in the figures Axes 1-3, spare part view 1 on page 210
and Axes 1-3, spare part view 2 on page 211.

Item Qty Description Spare part no. Dimension

1 1 Base Foundry 3HAC025710-001 Recommended spare part.
2 1 Gearbox, axes 1-3 3HAC025711-001 Recommended spare part.
Replacement is detailed in
section Replacement of
gearbox, axis 1-3 on page
169.
3 12 Hex socket head cap screw - M12x50 Steel 8.8 Gleitmo
610
4 12 Plain washer 9ADA312-9 13x24x2.5
5 2 Motor unit, axes 1 and 3 3HAC025712-001 Recommended spare part.
Replacement is detailed in
section Replacement of
motor, axis 1 on page 151
and Replacement of
motor, axis 3 on page 161.
6 3 O-ring 21522012-434 Recommended spare part.
7 12 Spring washer 21542033-9 8.4x18x2
8 4 Hex socket head cap screw - M8x65 Steel 12.9 Gleitmo
610
9 8 Hex socket head cap screw 3HAB3409-37 M8x25
11 8 Spring washer 21542033-10 10.5x23x2.5
12 12 Hex socket head cap screw 3HAB3409-50 M10x40
13 1 Spring tension plate 3HAC2205-1
14 1 Damper standard, axis 2 3HAC2180-1
15 1 Damper, axis 3 3HAB5512-1
16 4 Torx pan head roll. screw 9ADA629-56 M6x16 © Copyright 2006 ABB. All rights reserved.
17 8 Hex socket head cap screw 3HAB3409-57 M10x60
19 2 Sealing ring (V-ring) 3HAB3732-13 Recommended spare part.
32 1 Bearing sealing 3HAC10088-4 Recommended spare part.
33 1 Locking washer 3HAB5523-1 D=34; T=4
34 1 Hex socket counters, head 21212852-449 M8x16
35 1 Bearing sealing 3HAC10089-2 Recommended spare part.
36 1 Motor unit, axis 2 3HAC025713-001 Recommended spare part.
Replacement is detailed in
section Replacement of
motor, axis 2 on page 156.
41 14,700 Lubricating oil 11712016-604
ml
42 165g Bearing grease 3HAB3537-1 Shell Alvania WR2
43 1 ml Locking liquid - Loctite 243
46 1 Stop, axis 1 3HAB6687-1

Continues on next page

208 3HAC 026048-001 Revision: -
 7 Spare part lists and exploded views
7.5. Spare parts - axes 1-3

Continued

Item Qty Description Spare part no. Dimension

48 6 Washer 21512082-150 6.1x20x2
49 1 Friction washer 3HAC0447-1
50 1 Calibration mark, axis 2 3HAB5522-1
51 1 Parallel bar complete 3HAC025714-001
- 2 Spherical roller bearing 3HAA2167-12 Included in the complete
parallel bar.
134 15 Torx pan head tapp. screw 21212477-331
172 1 Parallel arm complete 3HAC025727-001
173 1 Lower arm 3HAC025729-001
© Copyright 2006 ABB. All rights reserved.

Continues on next page

3HAC 026048-001 Revision: - 209
7 Spare part lists and exploded views
7.5. Spare parts - axes 1-3

Continued

Axes 1-3, spare part view 1

© Copyright 2006 ABB. All rights reserved.

xx0500002047

Continues on next page

210 3HAC 026048-001 Revision: -
 7 Spare part lists and exploded views
7.5. Spare parts - axes 1-3

Continued

Axes 1-3, spare part view 2

© Copyright 2006 ABB. All rights reserved.

xx0500002065

Continues on next page

3HAC 026048-001 Revision: - 211
7 Spare part lists and exploded views
7.5. Spare parts - axes 1-3

Continued

Axes 1-3, spare part list

The items specified below are shown in the figures Axes 1-3, spare part view 3 on page 213,
Axes 1-3, spare part view 4 on page 214 and Axes 1-3, spare part view 5 on page 215.

Item Qty Description Spare part no. Dimension/Note

100 1 Cable unit, axes 1-3 3HAC025725-001 Recommended spare part.
Replacement is detailed in
section Replacement of
cable unit, axes 1-3 on
page 90.
102 1 Bottom plate 3HAC2828-1
103 1 Gasket 3HAC4554-1
106 1 Sealing 3HAC4113-1 Recommended spare part.
107 1 Bracket 3HAB5923-1
108 2 Holder for cableguide 3HAB3299-1
109 1 Cable guide 3HAB5924-1
110 1 Spring 3HAB3662-1
112 3 Cover 3HAC025749-1
115 1 Serial measurement unit 3HAC17396-1 Recommended spare part.
Replacement is detailed in
section Replacement of
SMB unit on page 142.
- 1 Battery pack 3HAC16831-1 Lithium battery.
Included in the serial
measurement unit kit.
Replacement is detailed in
section Replacement, SMB
battery on page 84.
116 1 Torx pan head screw - M5x16 Steel 8.8 Fe/ZN 5c
118 12 Hexagon nut with flange 9ADA290-1 M5
119 1 Cable straps, outdoors 21662055-3
135 63 Hex socket head cap screw 9ADA183-34 M8x12
137 6 Torx pan head roll. screw 9ADA629-44 M5x12 © Copyright 2006 ABB. All rights reserved.

138 1 Cable straps, outdoors 21662055-1

139 1 Coupling 3HAB3333-20
140 2 ml Locking liquid - Loctite 542
141 1 Protective hood 25222101-8
147 3 Gasket 3HAC4419-1
149 1 Gasket 3HAB7160-1
150 1 ml Flange sealing 12340011-116
151 300 Adhesive tape 11699198-301
mm
152 1 Bracket 3HAB5921-1
156 1 Parallel pin, hardened 3HAC3785-3
161 1 Sealing 3HAC5479-4
171 120 Profile 18661903-1
mm

Continues on next page

212 3HAC 026048-001 Revision: -
 7 Spare part lists and exploded views
7.5. Spare parts - axes 1-3

Continued

Axes 1-3, spare part view 3

© Copyright 2006 ABB. All rights reserved.

xx0500002084

Continues on next page

3HAC 026048-001 Revision: - 213
7 Spare part lists and exploded views
7.5. Spare parts - axes 1-3

Continued

Axes 1-3, spare part view 4

© Copyright 2006 ABB. All rights reserved.

xx0500002085

A The housing must be removed from the cabling for foundry option
B Conductors from R2.BU, R2.BU1-3, R2.BU4-6 and PE conductors under strap
C Option: internal connectors
D Option: external connectors

Continues on next page

214 3HAC 026048-001 Revision: -
 7 Spare part lists and exploded views
7.5. Spare parts - axes 1-3

Continued

Axes 1-3, spare part view 5

© Copyright 2006 ABB. All rights reserved.

xx0500002086

3HAC 026048-001 Revision: - 215

7 Spare part lists and exploded views
7.6. Spare parts - upper arm

7.6. Spare parts - upper arm

Upper arm, spare part list

The items specified below are shown in the figure Upper arm, exploded view on page 217.

Item Qty Description Spare part no. Dimension

1 1 Tilthouse - Spare parts are specified in
section Spare parts -
tilthouse on page 218.
2 1 Sealing ring with dust 3HAB3701-25 Recommended spare part.
lip
3 2 Protection hood 25222101-17
4 3 Sealing ring 3HAC7877-2 Recommended spare part.
5 2 Lock nut 21262851-106
6 2 Taper roller bearing 3HAA2103-14 Recommended spare part.
Replacement is detailed in
section Replacement of
shaft and bearings, tilthouse
on page 102.
7 2 VK-cover 3HAA2166-15 Recommended spare part.
8 1 Shaft 3HAC024867-001 Recommended spare part.
Replacement is detailed in
section Replacement of
shaft and bearings, tilthouse
on page 102.
9 1 Upper arm machining 3HAC025737-001
10 1 Ballplug 3HAC022673-001 Recommended spare part.
11 1 Protection cap 3HAC023027-001 Recommended spare part.
12 4 Torx pan head screw 9ADA618-53 M6x8
13 4 Washer 3HAC020537-001 D=6,4/12 T=1,6
Recommended spare part.
14 Locking liquid -
15 60 g Bearing grease 3HAB3537-1 Shell Alvania WR2 © Copyright 2006 ABB. All rights reserved.

Continues on next page

216 3HAC 026048-001 Revision: -
 7 Spare part lists and exploded views
7.6. Spare parts - upper arm

Continued

Upper arm, exploded view

© Copyright 2006 ABB. All rights reserved.

xx0500001934

3HAC 026048-001 Revision: - 217

7 Spare part lists and exploded views
7.7. Spare parts - tilthouse

7.7. Spare parts - tilthouse

Tilthouse, spare part list

The items specified below are shown in the figure Tilthouse, exploded view on page 219.

Item Qty Description Spare part no. Dimension

1 1 Tilthouse, machining 3HAC025733-001
2 1 Rot. ac motor incl. pinion 3HAC025734-001 Recommended spare part.
Replacement is detailed in
section Replacement of
motor, axis 6 on page 166.
3 1 RV-6E, i=79 3HAC025110-001 Recommended spare part.
Replacement is detailed in
section Replacement of
gearbox, axis 6 on page
172.
4 8 Hex socket head cap screw - M5x25 Steel 12.9 Gleitmo
610
5 8 Plain washer 9ADA312-5 5,3x10x1
6 1 Turning disk 3HAC023881-001 Recommended spare part.
Replacement is detailed in
section Replacement of
turning disk on page 113.
7 1 Sync. plate 3HAC024689-001
8 2 Torx pan head screw 9ADA618-32 M4x8
9 2 Magnetic plug 2522122-1
10 1 Plug 25291920-2 R 1/8"
11 1 Protection cover 3HAC025212-001
12 6 Hex socket head cap screw - M8x20 Steel 12.9 Gleitmo
610
13 6 O-ring 3HAB3772-89 Recommended spare part.
14 4 Hex socket head cap screw 9ADA183-25
15 4 Plain washer 9ADA312-6 © Copyright 2006 ABB. All rights reserved.
17 1 O-ring 3HAB3772-16 Recommended spare part.
18 70 ml Lubricating oil, Shell Tivela 3HAC021469-001
S150
19 1 Torx counters.head screw 9ADA624-69 M8x20
20 1 Washer 21524411-1 13,5x18x1,5

Continues on next page

218 3HAC 026048-001 Revision: -
 7 Spare part lists and exploded views
7.7. Spare parts - tilthouse

Continued

Tilthouse, exploded view

© Copyright 2006 ABB. All rights reserved.

xx0500001935

3HAC 026048-001 Revision: - 219

7 Spare part lists and exploded views
7.8. Spare parts - linkage

7.8. Spare parts - linkage

Linkage, spare part list

Item Qty Description Spare part no. Dimension

1 1 Parallel rod, lower 3HAC024576-001
2 1 Parallel rod upper 3HAC024575-001
3 1 Radial Seal 35x62x7 -
4 1 Link machining -
5 2 Taper roller bearing -
6 4 Needle bearing 3HAB6432-1

Linkage, exploded view

© Copyright 2006 ABB. All rights reserved.

xx0500001933

220 3HAC 026048-001 Revision: -

 7 Spare part lists and exploded views
7.9. Spare parts - material set cabling axis 6

7.9. Spare parts - material set cabling axis 6

Material set cabling axis 6, spare part list

The items specified below are shown in the figure Material set cabling axis 6, spare part view
on page 222.

Item Qty Description Spare part no. Dimension/Note

1 1 Cable unit axis 6 3HAC024115-001 Recommended spare part.
Replacement is detailed in
section Replacement of
cable unit, axis 6 on page
96.
2 1 Connection box CP/CS/AIR 3HAC024194-001 Recommended spare part.
3 1 Dust cap 3HEA800897-002
5 1 Coupling 3HAB3333-20
6 6 Torx pan head screw 9ADA618-57 M6x20 Steel 8.8-A2F
7 2 Square washer -
8 2 Torx pan head screw - M5x16 Steel 8.8 Fe/ZN 5c
9 1 Cable bracket tilt house 3HAC025783-001 Recommended spare part.
10 4 Torx pan head screw 9ADA618-23 M3x8 Steel 8.8-A2F
© Copyright 2006 ABB. All rights reserved.

Continues on next page

3HAC 026048-001 Revision: - 221
7 Spare part lists and exploded views
7.9. Spare parts - material set cabling axis 6

Continued

Material set cabling axis 6, spare part view

© Copyright 2006 ABB. All rights reserved.

xx0500002438

222 3HAC 026048-001 Revision: -

 8 Circuit diagram
8.1. Introduction

8 Circuit diagram
8.1. Introduction

Overview
This chapter includes the circuit diagram for the robot.
© Copyright 2006 ABB. All rights reserved.

3HAC 026048-001 Revision: - 223

8 Circuit diagram
8.1. Introduction

© Copyright 2006 ABB. All rights reserved.

224 3HAC 026048-001 Revision: -

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 Index

Symbols E
¶restricting endurance load 38
working range axis 1 63 ESD
damage elimination 33
A
sensitive equipment 33
Absolute Accuracy, calibration 177 explanation, safety symbols 29
application manual
article number 8 F
attachment screws figures
securing robot 47 connectors on robot 71
where to use special tools 192
B
fitting equipment on robot 49
brake release unit, replacing 145 FlexPendant
brakes jogging to calibration position 182
releasing manually 45 MoveAbsJ instruction 182
testing function 24 updating revolution counters 180
C forces and torques on robot 38
foundation 38
cabling axes 1-3, replacing 90 attachment screws 47
cabling axis 6, replacing 96 orienting and securing robot 47
cabling, position switch 73 requirements 39
cabling, robot 72
calibrating G
roughly 180 gearbox axes 1-3, replacing 169
calibration gearbox axis 6, replacing 172
Absolute Accuracy type 176 guide sleeves
Calibration Pendulum 177 securing robot 48
marks/scales 178
rough 180 H
standard method 177 hole configuration
standard type 176 robot base 47
when to calibrate 175 hydraulic pump 103, 117, 191
calibration manuals 177
I
Calibration Pendulum 177
calibration position 180 illustrations
checking 182 connectors on robot 71
jogging to, FlexPendant 182 inspection
scales 178 labels 78
calibration, Absolute Accuracy 177 installation
loads on foundation 38
© Copyright 2006-2008 ABB. All rights reserved.

CalibWare 176
chains mechanical stop axis 1 58
lifting of robot 42 mechanical stop axis 2 66
chains, lifting of robot 43 mechanical stop axis 3 69
conditions position switch axis 1 63
operating 39 prior to 38
storage 39 signal lamp 55
Connection of external safety devices 14 interval
connectors maintenance 77
on robot, figure 71 L
customer connections 71
labels, location 78
D lifting
dimensions 49 robot 42
direction of axes 179 upper arm 118
document references 8 lifting of robot
documentation chains 43
article numbers, other manuals 8 slings 42
references 8 linkage
drilling pattern, mechanical stop axis 1 60 replacing link 129
replacing lower rod 126
replacing upper rod 123

3HAC026048-001 Revision: A 225

Index

load diagram 54 replacing

loads 38 brake release unit 145
loads on foundation 38 cable unit axes 1-3 90
location of connectors 71 cabling axis 6 96
lower arm gearbox axes 1-3 169
replacing 134 gearbox axis 6 172
securing 136 link, linkage 129
lower arm 134, 136
M
lower rod, linkage 126
maintenance intervals 77 motor axis 1 151
maintenance schedule 77 motor axis 2 156
manually releasing the brakes 45 motor axis 3 161
manuals motor axis 6 166
reference documentation 8 parallel arm 147
mechanical stop parallel bar 138
axis 1 58 shaft and bearings at tilthouse 102
axis 2 66 SMB battery 83
axis 3 69 SMB unit 142
motion of axes 40 tie rod 138
motor axis 1, replacing 151 turning disk 113
motor axis 2, replacing 156 upper arm 116
motor axis 3, replacing 161 upper rod, linkage 123
motor axis 6, replacing 166 requirements
motor connectors 71 foundation 39
MoveAbsJ instruction restricting
FlexPendant 182 working range axis 1 58
N working range axis 2 66
working range axis 3 69
negative directions, axes 179 revolution counters
O storing on FlexPendant 180
updating 180
oil change
robot
gearbox axis 6 (wrist unit) 81
connectors 71
safety risks 34
dimensions 49
oil in gearboxes, type and amount 80
fitting equipment 49
operating conditions 39
orienting and securing 47
operating manual
spare parts 205
article number 8
robot position 178
option
signal lamp 55 S
© Copyright 2006-2008 ABB. All rights reserved.
orienting and securing robot 47 safety equipment
P mechanical stop axis 1 58
mechanical stop axis 2 66
parallel arm, replacing 147
mechanical stop axis 3 69
parallel bar, replacing 138
position switch axis 1 63
position switch
Safety, service 14
axis 1 63
safety, symbols 29
position switch axis 1
scales on robot 178
article number 64
schedule for maintenance 77
position, robot 178
signal connectors 71
positive directions, axes 179
signal lamp 55
product manual, controller
slings, lifting of robot 42
article number 8
SMB battery, replacing 83
product specification
SMB unit, replacing 142
article number 8
spare parts
protection class 39
axes 1-3 208
R cabling axis 6 221
R1.MP connector, supplying power to 46 cover 203
references, other manuals 8 linkage 220
releasing brakes 45 overview 202

226 3HAC026048-001 Revision: A

 Index

robot 205
tilthouse 218
upper arm 216
special tools 191
storage conditions 39
symbols, safety 29
sync marks. See calibration - marks.
T
technical reference manual
article number 8
testing, brakes 24
tie rod, replacing 138
tightening torque
gearbox axes 1-3 171
gearbox axis 6 173
lower arm 137
motor, axis 1 154
motor, axis 2 160
motor, axis 3 164
motor, axis 6 167
parallel arm 149
turning disk 114
upper arm 120
tilthouse shaft, replacing 102
tools
Calibration Pendulum equipment 198
dismounting tilthouse shaft 193
for service 191
hydraulic pump 103, 117, 191
mounting shaft and bearings at link 193, 198
mounting tilthouse bearing race and sealing 193, 195
mounting tilthouse shaft 193, 194
turning disk
attachment holes 52
dimensions 52
replacing 113
turning radius
axis 2 51
© Copyright 2006-2008 ABB. All rights reserved.

U
updating revolution counters 180
upper arm, replacing 116
V
Validity and responsibility 14
W
weight
gearbox unit 170, 171
lower arm 135, 137
robot 38, 44
upper arm 118, 119, 139
working range 40
restricting axis 1 58, 63
restricting axis 2 66
restricting axis 3 69

3HAC026048-001 Revision: A 227

228
Index

3HAC026048-001 Revision: A
© Copyright 2006-2008 ABB. All rights reserved.
 3HAC026048-001, Revision A, en

ABB AB
Robotics Products
S-721 68 VÄSTERÅS
SWEDEN
Telephone: +46 (0) 21 344000
Telefax: +46 (0) 21 132592