Contents - Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Overview of this manual
- Product documentation, M2000/M2000A
- Product documentation, M2004
- How to read the product manual
- Safety
- General safety information
- Safety in the manipulator system
- Safety risks
- CAUTION - Hot parts may cause burns
- Safety risks related to tools/work pieces
- 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 manipulator'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)
- Safety stops
- Safety related instructions
- Safety symbols on manipulator labels
- 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
- DANGER - Make sure that the main power has been switched off
- WARNING - The unit is sensitive to ESD
- WARNING - Safety risks during handling of batteries
- WARNING - Safety risks during work with gearbox lubricants (oil or grease)
- Installation and commissioning
- Robot transportation precautions
- Securing the robot
- Unpacking
- Working range, IRB 7600 - 150/3.5
- Working range, IRB 7600 - 340/2.8
- Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55
- Working range, IRB 7600 - 500/2.3
- Risk of tipping/stability
- On-site installation
- Lifting robot with lifting slings
- Lifting robot with roundslings
- Manually releasing the brakes
- Manually releasing the brakes, external brake release unit
- Lifting the base plate
- Securing the base plate
- Orienting and securing the robot
- Fitting equipment on robot
- Installation of base spacers (option)
- Extended working range, axis 1 (option 561-1)
- Installation of cooling fan for motors, axes 1-3 (option)
- Installation of Foundry Plus Cable guard (option no. 908-1)
- Loads
- Installation of signal lamp (option)
- 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
- Maintenance
- Maintenance schedule and expected 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
- Inspecting, mechanical stop pin, axis 1
- Inspection, mechanical stop, axes 1, 2 and 3
- Inspection, damper axes 2-5
- Inspection, position switch axes 1, 2 and 3
- Inspection, information labels
- Inspection, UL-lamp
- Changing/replacement activities
- Oil change, gearbox axis 1
- Changing oil, axis-2 gearbox
- Changing oil, axis-3 gearbox
- Oil change, gearbox, axis 4
- Oil change, gearbox, axis 5
- Oil change, gearbox axis 6
- Replacing the SMB battery
- Lubrication activities
- Cleaning, robot
- Lubrication of spherical roller bearing, balancing device
- 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 5-6
- Replacement of complete arm system
- Upper and lower arm
- Replacement of complete wrist unit
- Replacement of complete upper arm
- Replacement of complete lower arm
- Replacement of lower arm shaft
- Frame and base
- Replacement of brake release unit
- Replacing the balancing device
- Replacement of spherical roller bearing, balancing device
- Unloading the balancing device using hydraulic press tool
- Restoring the balancing device using a hydraulic press tool
- 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 4
- Replacement of gearbox, axis 5
- Replacement of gearbox, axis 6
- Calibration information
- Calibration methods
- Calibration scale and correct axis position
- Calibration movement directions for all axes
- Updating revolution counters
- Checking the calibration position
- Decommissioning
- Decommissioning of balancing device
- Reference information
- Applicable safety standards
- Unit conversion
- Screw joints
- Weight specifications
- Standard tools
- Special tools
- Lifting accessories and lifting instructions
- Spare part / part list
- Spare parts
- Spare part list
- Part list
- Rebuilding parts
- Part list, overview
- Mechanical stop axis 1, 3HAC12812-2
- Base incl frame axis 1, 3HAC12304-1
- 8.3.6 Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55
- Axis 3-4, 3HAC13063-2 (IRB 7600 - 500/2.3)
- 8.3.8 Axis 3-4, Foundry, 3HAC13063-4 (IRB 7600 -150/3.5, - 325/3.1, - 340/2.8, - 400/2.55
- Axis 3-4 Foundry, 3HAC13063-5 (IRB 7600 - 500/2.3)
- Wrist, 3HAC16628-4 / 3HAC16628-3
- Material set robot, 3HAC13079-1
- Material set axis 1-2, 3HAC13077-1
- Material set balancing device, 3HAC13082-1
- Arm extension set, 956 mm, 3HAC12311-1 (IRB 7600 - 150/3.5)
- Arm extension set, 250 mm, 3HAC12311-2 (IRB 7600 - 340/2,8)
- Exploded views
- Base incl. Frame
- Frame-Lower arm 1
- Frame-Lower arm 2
- Upper arm
- Wrist complete
- Circuit diagram
- Validity of circuit diagram 3HAC025744-1
- Validity of circuit diagram 3HAC13347-1
- Index
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4.2.2 Mounting instructions for bearingsGeneralThis section describes how to mount and grease different types of bearings on therobot.EquipmentNoteArt. no.Equipment, etc.Used to grease the bearings, if notspecified otherwise.3HAB3537-1GreaseAssembly of all bearingsFollow the following instructions while mounting a bearing on the robot.NoteActionTo avoid contamination, let a new bearing remain in its wrappinguntil it is time for fitting.1Ensure that the parts included in the bearing fitting are free fromburrs, grinding waste, and other contamination. Cast componentsmust be free of foundry sand.2Bearing rings, inner rings, and roller elements must not be subjec-ted to direct impact. The roller elements must not be exposed toany stresses during the assembly work.3Assembly of tapered bearingsFollow the preceding instructions for the assembly of the bearings when mountinga tapered bearing on the robot.In addition to those instructions, the following procedure must be carried out toenable the roller elements to adjust to the correct position against the race flange.NoteActionTension the bearing gradually until the recommended pre-tension is achieved.NoteThe roller elements must be rotated a specified number of turns before pre-tensioning is carried out and also rotated during the pre-tensioning sequence.1Make sure the bearing is properly aligned as this will directly affect the durab-ility of the bearing.2Greasing of bearingsThe bearings must be greased after assembly according to the followinginstructions:• The bearings must not be completely filled with grease. However, if spaceis available beside the bearing fitting, the bearing may be totally filled withgrease when mounted, as excessive grease will be pressed out from thebearing when the robot is started.• During operation, the bearing should be filled to 70-80% of the availablevolume.Continues on next page3HAC022033-001 Revision: M 237© Copyright 2007-2013 ABB. All rights reserved.4 Repair4.2.2 Mounting instructions for bearings
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