Contents - Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Overview
- Product documentation, M2000/M2000A
- Product documentation, M2004
- How to read the product manual
- Safety
- General safety information
- Safety risks
- Safety risks related to tools/workpieces
- Safety risks related to pneumatic/hydraulic systems
- Safety risks during operational disturbances
- Risks associated with live electric parts
- Safety actions
- Fire extinguishing
- Emergency release of the robot's arm
- Brake testing
- Risk of disabling function "Reduced speed 250 mm/s
- Safe use of the FlexPendant
- Work inside the manipulator's working range
- Signal lamp (optional)
- Translate the information on safety and information labels
- Safety related instructions
- DANGER - Moving manipulators are potentially lethal
- DANGER - First test run may cause injury or damage
- WARNING - The brake release buttons may be jammed after service work
- WARNING - The unit is sensitive to ESD
- WARNING - Safety risks during work with gearbox oil
- Installation and commissioning
- Unpacking
- Working range and type of motion
- Risk of tipping / stability
- On-site installation
- Lifting robot with roundslings
- Lifting robot with lifting slings
- Manually releasing the brakes
- Lifting the base plate
- Securing the base plate
- Orienting and securing the robot
- Fitting equipment on robot
- Installation of base spacers (option)
- Installation of cooling fan for motors, axes 1-3 (option)
- Loads
- Restricting the working range
- Mechanically restricting the working range of axis 1
- Mechanically restricting the working range of axis 2
- Mechanically restricting the working range of axis 3
- Installation of position switches (option)
- Electrical connections
- Making robot ready for operation (Foundry Prime)
- Commissioning (Foundry Prime)
- Maintenance
- Maintenance schedule and expected component life
- Maintenance schedule
- Expected component life
- Inspection activities
- Inspection, oil level gearbox axis 2
- Inspection, oil level gearbox axis 3
- Inspection, oil level gearbox axis 4
- Inspection, oil level, gearbox axis 5
- Inspection, oil level gearbox axis 6
- Inspection, balancing device
- Inspection, cable harness
- Inspection, information labels
- Inspection, mechanical stop, axis 1
- Inspection, additional mechanical stops
- Inspection, damper axes 2-5
- Inspection, position switch axes 1, 2 and 3
- Inspection, signal lamp
- Inspection of air hoses (Foundry Prime)
- Replacement/changing activities
- Oil change, gearbox axis 1
- Oil change, gearbox axis 2
- Oil change, gearbox, axis 3
- Oil change, gearbox, axis 4
- Oil change, gearbox, axis 5
- Oil change, gearbox axis 6
- Replacement of SMB battery
- Lubrication activities
- Rust preventive, bearing axis 1 (Foundry Prime)
- Rust preventive, bearing axis 4 (Foundry Prime)
- Rust preventive, support bearing in wrist (Foundry Prime)
- Cleaning activities
- Service Information System, M2000
- Description of Service Information System (SIS)
- SIS system parameters
- Setting the SIS parameters
- Reading the SIS output logs
- Exporting the SIS data
- Repair
- General procedures
- Mounting instructions for bearings
- Mounting instructions for seals
- Complete robot
- Replacement of cable harness, axes 1-4
- Replacement of cable harness, axes 5-6
- Replacement of cabling, axis 5 motor
- Replacement of complete arm system
- Replacement of air nipple and hose (Foundry Prime)
- Upper and lower arm
- Replacement of complete wrist unit
- Replacement of upper arm
- Replacement of complete lower arm
- Replacement of lower arm shaft
- Securing the lower arm
- Frame and base
- Replacement of brake release unit
- Replacement of spherical roller bearing, balancing device
- Replacement of balancing device
- Unloading the balancing device
- Restoring the balancing device
- Motors
- Replacement of motor axis 2
- Replacement of motor, axis 3
- Replacement of motor, axis 4
- Replacement of motor, axis 5
- Replacement of motor, axis 6
- Gearboxes
- Replacement of gearbox axis 2
- Replacement of gearbox, axis 3
- Replacement of gearbox, axis 6
- Calibration information
- Calibration methods
- Calibration scales and correct axis position
- Calibration movement directions for all axes
- Updating revolution counters
- Checking the calibration position
- Additional calibration instruction, IRB4400
- Decommissioning
- Decommissioning of balancing device
- Reference information
- Applicable Safety Standards
- Unit conversion
- Screw joints
- Weight specifications
- Standard toolkit
- Special tools
- Lifting equipment and lifting instructions
- Spare part / part list
- Spare part list
- Part list
- Rebuilding parts
- Part list, overview
- Base incl frame ax 1
- Axis 3-4
- Axis 3-4, Foundry
- Axis 3-4 Foundry Prime
- Wrist, type 2, standard
- Wrist, type 2, Foundry
- Wrist, type 2, insulated
- Wrist, type 2, Foundry Prime
- Material set, manipulator, 3HAC 13263-1
- Material set, axis 1-2, 3HAC 13264-1
- Material set, balancing device, 3HAC 13265-1
- Arm extension set, 450 mm, 3HAC 12311-5
- Exploded views
- Base incl. Frame
- Frame - lower arm 1
- Frame - lower arm 2
- Upper arm
- Wrist complete
- Circuit Diagram
- Circuit diagram 3HAC 025744-001
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Overview93HAC020993-001 Revision: G© Copyright 2004-2008 ABB. All rights reserved.OverviewAbout this manualThis manual contains instructions for• mechanical and electrical installation of the robot• maintenance of the robot• mechanical and electrical repair of the robot.UsageThis manual should be used during• installation, from lifting the robot to its work site and securing it to the foundation tomaking it ready for operation• maintenance work• repair work.Who should read this manual?This manual is intended for:• installation personnel• maintenance personnel• repair personnel.PrerequisitesA maintenance/repair/ installation craftsman working with an ABB Robot must:• be trained by ABB and have the required knowledge of mechanical and electricalinstallation/repair/maintenance work.Organization of chaptersThe manual is organized in the following chapters:Chapter ContentsSafety Safety information that must be read through before performingany installation or service work on robot. Contains general safetyaspects as well as more specific information about how to avoidpersonal injuries and damage to the product.Installation and commis-sioningRequired information about lifting and installation of the robot.Maintenance Step-by-step procedures that describe how to performmaintenance of the robot. Based on a maintenance schedulethat may be used in the work of planning periodical maintenance.Repair Step-by-step procedures that describe how to perform repairactivities of the robot. Based on available spare parts.Calibration information Procedures that do not require specific calibration equipment.Decommissioning Environmental information about the robot and its components.Continues on next page
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