Manual Product Mecanic Da 3HAC026660-001 RevB en

Product manual
Articulated robot
IRB 1600 - 5/1.2 type A IRB 1600 - 5/1.45 type A IRB 1600 - 6/1.2 type A IRB 1600 - 6/1.45 type A IRB 1600 - 7/1.2 type A IRB 1600 - 7/1.45 type A IRB 1600 - 8/1.2 type A IRB 1600 - 8/1.45 type A IRB 1600ID M2004
Product manual IRB 1600 - 5/1.2 type A IRB 1600 - 5/1.45 type A IRB 1600 - 6/1.2 type A IRB 1600 - 6/1.45 type A IRB 1600 - 7/1.2 type A IRB 1600 - 7/1.45 type A IRB 1600 - 8/1.2 type A IRB 1600 - 8/1.45 type A IRB 1600ID
M2004 Document ID: 3HAC026660-001
Copyright 2006-2008 ABB. All rights reserved.
Revision: B
The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual. Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like. In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein. This manual and parts thereof must not be reproduced or copied without ABB's written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this manual may be obtained from ABB at its then current charge.
Copyright 2006-2008 ABB All rights reserved. ABB AB Robotics Products SE-721 68 Vsters 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 robots 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 FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 1.2.3.7 Work inside the robot's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 1.2.3.8 Signal lamp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 1.2.3.9 Translate the information on safety and information labels . . . . . . . . . . . . . . . . . . . . . . . 29
1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.3.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 1.3.2 DANGER - Moving robots are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 1.3.3 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 1.3.4 WARNING - The brake release buttons may be jammed after service work . . . . . . . . . . . . . . . . 34 1.3.5 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 1.3.6 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 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

2.3 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.3.1 Lifting robot with roundsling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 2.3.2 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 2.3.3 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 2.3.4 Suspended mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 2.3.5 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 2.3.6 Fitting equipment on the robot (robot dimensions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 2.3.7 Installation of signal lamp for 1600 (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 2.3.8 Installation of signal lamp for 1600 ID (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.4 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
2.4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 2.4.2 Installation of additional mechanical stops on axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 2.4.3 Installation of additional mechanical stop on axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 2.4.4 Installation of additional mechanical stops on axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 2.4.5 Installation of position switch, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3HAC026660-001 Revision: B
Table of Contents
2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
2.5.1 Connectors on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 2.5.2 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 2.5.3 Customer connections on the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
2.6 Making robot ready for operation (Cleanroom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
2.6.1 Additional installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 3 Maintenance 89
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
3.2 Maintenance schedule and expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
3.3.1 Inspection, damper axes 2, 3 and 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

3.4 Replacement activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
3.4.1 Oil in gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 3.4.2 Oil change, gearbox axes 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 3.4.3 Oil change, gearbox axes 5- 6, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 3.4.4 Replacement of measurement system battery pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
3.5 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
3.5.1 Cleaning, complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 4 Repair 107
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
4.3 Complete manipulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4.3.1 Replacement of cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112 4.3.2 Replacement of cable harness, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 4.3.3 Replacement of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 4.4.1 Replacement of complete upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 4.4.2 Replacement of complete upper arm, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133 4.4.3 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 4.4.4 Replacement of wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 4.4.5 Replacement of wrist unit, IRB1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 4.4.6 Replacement of damper, axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 4.4.7 Replacement of damper, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 4.4.8 Replacement of Mechanical damper, axis 3, IRB 1600ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155 4.4.9 Replacement of damper, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 4.4.10 Remove upper arm AW Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 4.4.11 Fitting equipment on the robot, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
4.5 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
4.4 Upper and lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
4.5.1 Replacement of base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 4.5.2 Replacement of serial measurement unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169 4.5.3 Replacement of push button unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
4.6.1 Replacement of motor, axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 4.6.2 Replacement of motor, axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Table of Contents
4.6.3 Replacement of motor, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185 4.6.4 Replacement of motor, axis 3, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189 4.6.5 Replacement of motor, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193 4.6.6 Replacement of motor, axis 4, 1600ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196 4.6.7 Replacement of motor and timing belt, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199 4.6.8 Replacement of motor, axis 5, IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203 4.6.9 Replacement of motor and timing belt, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209 4.6.10 Replacement of motor, axis 6 IRB 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.7.1 Replacement of gearbox, axes 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214 4.7.2 Service work on gearboxes, axes 3, 4, 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218 5 Calibration information 219
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219 5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220 5.3 Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222 5.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225 5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227 6 Robot description 229
6.1 Type A of IRB 1600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 7 Reference information 231
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 7.2 Applicable safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231 7.3 Unit conversion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232 7.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 7.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236 7.6 Standard toolkit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 7.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 7.8 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239 8 Spare parts and exploded views
241
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241 8.2 Spare parts - base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242 8.3 Spare parts - base connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244 8.4 Spare parts - frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246 8.5 Spare parts - lower arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248 8.6 Spare parts - upper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250 8.7 Spare parts - options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253 8.8 Spare parts - upper arm 1600ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 254 9 Circuit diagram 261
9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 Index 263
Table of Contents
Overview
Overview
About this manual This manual contains instructions for: Usage This manual should be used during: installation, from lifting the robot to its work site and securing it to the foundation, to making it ready for operation maintenance work repair work and calibration. mechanical and electrical installation of the robot maintenance of the robot mechanical and electrical repair of the robot.
Who should read this manual? This manual is intended for: 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. installation personnel maintenance personnel repair personnel.
Organization of chapters The manual is organized in the following chapters:

Chapter
Safety, service
Contents
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 on how to avoid personal injuries and damage to the product. Required information about lifting and installation of the robot. Step-by-step procedures that describe how to perform maintenance of the robot. Based on a maintenance schedule that may be used to plan periodical maintenance. Step-by-step procedures that describe how to perform repair activities of the robot. Based on available spare parts. Procedures that do not require specific calibration equipment. General information about calibration.
Installation and commissioning Maintenance
Repair Calibration information
Continues on next page

3HAC026660-001 Revision: B 7
Overview Continued References Documentation referred to in the manual, is listed in the table below. Document name
Product specification - IRB 1600 Product manual - IRC5 Operating manual - IRC5 with Flexpendant Operating manual - Calibration pendulum Operating manual - Service Information System Application manual - Additional axes and stand alone controller Technical reference manual - System parameter
Document Id
3HAC023604-001 3HAC021313-001 3HAC16590-1 3HAC16578-1 3HAC025709-001 3HAC021395-001 3HAC17076-1
Note
Revisions Revision
A B
Description
First edition. See also Type A of IRB 1600 on page 229. AW equipped upper arm 1600ID, IRB 1600-6/1.2, IRB 1600-6/1.45, IRB 1600-8/1.2 and IRB 1600-8/1.45 added. Cleanroom added. Changes made in: Prerequisites in section Overview. Oil change in section Maintenance.
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 controllers, will be delivered with a Product manual that contain: Safety information Installation and commissioning (descriptions of mechanical installation, electrical connections) 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) 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
Technical reference manuals The following manuals describe the robot software in general and contain relevant reference information:
Application manuals
RAPID Overview: An overview of the RAPID programming language. RAPID Instructions, Functions and Data types: Description and syntax for all RAPID instructions, functions and data types. System parameters: Description of system parameters and configuration workflows.
Specific applications (for example 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 (for example cables, I/O boards, RAPID instructions, system parameters, CD with PC software) How to use the application Examples of how to use the application Continues on next page
Product documentation, M2004 Continued Operating manuals This group of manuals is aimed at those having first hand operational contact with the robot, that is production cell operators, programmers and trouble shooters. The group of manuals includes: Emergency safety information Getting started - IRC5 and RobotStudio Online IRC5 with FlexPendant RobotStudio Online Trouble shooting - IRC5 for the controller and robot
10
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
8. Remove the rear attachment screws, gearbox.
Note/Illustration
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
Art. no. is specified in Required equipment on page xx.
3.
Fit a new sealing, axis 2 to the gearbox.
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.
11
12
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.
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, for example: Operating Manual - IRC5 with FlexPendant (M2004) 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

Installation of safety devices Changing operating modes Restricting the working space
Detailed in document
Product manual for the robot Operating manual - IRC5 with FlexPendant (RobotWare 5.0) Product manual for the robot
Section
Installation and commissioning Operating modes Installation and commissioning
14
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, chapter Installation and Commissioning must always be followed. Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly. Those in charge of operations must make sure that safety instructions are available for the installation in question. Those who install the robot must have the appropriate training for the robot system in question and in any safety matters associated with it.
Nation/region specific regulations To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Non-voltage related risks
Safety zones, which have to be crossed before admittance, must be set up in front of the robot's working space. Light beams or sensitive mats are suitable devices. Turntables or the like should be used to keep the operator out of the robot's working space. The axes are affected by the force of gravity when the brakes are released. In addition to the risk of being hit by moving robot parts, you run the risk of being crushed by the parallel arm. Energy, stored in the robot for the purpose of counterbalancing certain axes, may be released if the robot, or parts thereof, 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, that is 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
15
1 Safety
1.2.2.1. Safety risks during installation and service work on robot Continued Complete robot Safety risk
Hot components!
Description
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

Cable packs are sensitive to mechanical damage!
Description
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them!
Gearboxes and motors Safety risk

Gears may be damaged if excessive force is used!
Description
CAUTION!
Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used!
16
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.
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.
18
1 Safety
1.2.2.4. Safety risks during operational disturbances
1.2.2.4. Safety risks during operational disturbances

General 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. 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.
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.
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 robots working space.
Voltage related risks, IRC5 controller A danger of high voltage is associated with for example the following parts: Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the controller. Units such as I/O modules, can be supplied with power from an external source. The 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 additional tools, or special power supply units for the machining process.
The external voltage connected to the controller remains live even when the robot is disconnected from the mains. Additional connections.
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 OFFposition. Power supply cables which are in motion during the working process may be damaged.
20
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 robot.
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 system (robot or controller)!
22
1 Safety
1.2.3.3. Emergency release of the robots arm
1.2.3.3. Emergency release of the robots 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 47.
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!
23
1 Safety
1.2.3.4. Brake testing
1.2.3.4. Brake testing

When to test During operation the holding brake 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 the holding brake of each axis motor may be checked as detailed below: 1. Run each robot axis to a position where the combined weight of the robot 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 robot does not change position as the motors are switched off, then the brake function is adequate.
24
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 system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s".
25
1 Safety
1.2.3.6. Safe use of the FlexPendant
1.2.3.6. Safe use of the FlexPendant
NOTE! The enabling device is a push button located on the side of the FlexPendant 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 FlexPendant, 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 FlexPendant with him/her, when entering the robot's working space. This is to prevent anyone else taking control of the robot without the programmer knowing.
26
1 Safety
1.2.3.7. Work inside the robot's working range
1.2.3.7. Work inside the robot's working range
WARNING! If work must be carried out within the robots 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 robots speed is limited to max. 250 mm/s when the operating mode selector is in position "manual mode with reduced speed". This should be the normal position when entering the working space. The position "manual mode with full speed (100%)" may only be used by trained personnel who are aware of the risks that this entails. Pay attention to the rotating axes of the robot! 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 robot or inside the cell. Test the motor brake on each axis, according to section Brake testing on page 24.
27
1 Safety
1.2.3.8. Signal lamp (optional)
1.2.3.8. Signal lamp (optional)

Description A signal lamp with an yellow fixed light can be mounted on the robot, as a safety device. Function The lamp is active in MOTORS ON mode. Further information Further information about the MOTORS ON/MOTORS OFF mode may be found in the controller documentation.
28
1 Safety
1.2.3.9. Translate the information on safety and information labels
1.2.3.9. 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. 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.
xx0500002517
Free space for adding a fourth language
29
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
DANGER
Signification
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, impact, fall from height etc. 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 crushing, impact, fall from height etc. The electrocution or electrical shock symbol indicates electrical hazards which could result in severe personal injury or death.
danger
WARNING
warning
ELECTRICAL SHOCK
Electrical shock
CAUTION
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 warnings that include function requirements when fitting and removing equipment, where there is a risk of damaging the product or causing a breakdown.

30 3HAC026660-001 Revision: B
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
31
1 Safety
1.3.2. DANGER - Moving robots are potentially lethal!
1.3.2. DANGER - Moving robots are potentially lethal!

Description Any moving robot is a potentially lethal machine. When running the robot, 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 working range of the robot. Elimination
Action
1. Before attempting to run the robot, make sure all emergency stop equipment is correctly installed and connected. 2. If possible, use the hold-to-run function whenever possible. The hold-to-run function is used in manual mode, not in automatic mode. 3. Make sure no personnel are present within the working range of the robot before pressing the start button.
Note
Emergency stop equipment such as gates, tread mats, light curtains, etc. How to use the hold-to-run function in RobotWare 5.0 is detailed in section How to use the hold-to-run function in the Operating manual - IRC5 with FlexPendant.
32
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, that is out of its reach behind safety fences, etc! 4. Pay special attention to the function of the part previously serviced!
33
1 Safety
1.3.4. WARNING - The brake release buttons may be jammed after service work
1.3.4. WARNING - The brake release buttons may be jammed after service work
Description The brake release unit has push buttons for brake release of each axis motor. When service work is performed inside the SMB recess that includes removal and refitting of the brake release unit, the brake release buttons may be jammed after refitting. In case the power is turned on while a brake release button is jammed in depressed position, the affected motor brake is released! This may cause serious personal injuries and damage to the robot. Elimination To eliminate the danger after service work has been performed inside the SMB recess, follow the procedure below. Action
1. Make sure the power is turned off. 2. Refit the push button guard, if removed. 3. Check the push buttons of the brake release unit by pressing them down, one by one. Make sure none of the buttons are jammed by the push button guard! 4. If a button gets jammed in the depressed position, the alignment of the push button unit must be adjusted so that the buttons can move freely! Remove the push button guard and: Make sure the centering piece (B) is properly fitted to the unit. (The piece aligns the unit vertically.) xx0600002776 Adjust the unit sideways so that the measurements x1 and x2 in the figure Art. no. for the centering piece is specified in Required equipment on to the right do not differ more than 1 page 173. mm from each other. 5. Refit the push button guard and check the buttons again by pressing them down, one by one.
Note/Illustration
34
1 Safety
1.3.5. WARNING - The unit is sensitive to ESD!
1.3.5. WARNING - The unit is sensitive to ESD!

Description ESD (electrostatic 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
1. Use a wrist strap
Note
Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly. The mat must be grounded through a currentlimiting resistor. The mat should provide a controlled discharge of static voltages and must be grounded.
2. Use an ESD protective floor mat. 3. Use a dissipative table mat.
Location of wrist strap button The wrist strap button is located in the right corner as shown in the illustration below.
xx0500002171
Wrist strap button
35
1 Safety
1.3.6. WARNING - Safety risks during work with gearbox oil
1.3.6. 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 lead to internal over-pressure inside the gearbox which in turn may: damage seals and gaskets completely press out seals and gaskets prevent the robot from moving freely. Mixing types of oil may cause severe damage to the gearbox!
-
Make sure not to overfill the gearbox when filling with oil! After filling, check the correct oil level.
Do not overfill!
Do not mix types of oil! Warm oil drains quicker than cold oil. When changing gearbox oil, first run the robot for a time to heat up the oil.
Heat up the oil! The specified amount of oil is After refilling, check the oil level. based on the total volume of the gearbox. When changing the oil, the amount of refilled oil may differ from the specified amount, depending on how much oil has previously been drained from the gearbox.
Specified amount depends on drained volume!
36
When filling gearbox oil, do not mix different types of oil unless specified in the instruction. Always use the type of oil specified by the manufacturer!
2 Installation and commissioning

2.1. Introduction

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.
37

2.2.1. Pre-installation procedure
2.2 Unpacking 2.2.1. Pre-installation procedure

General This instruction is primarily intended for use when unpacking and installing the robot for the first time. It also contains information useful during later re-installation of the robot. Checking the pre-requisites for installation The check-list below details what must be observed before proceeding with the actual installation of the robot: Action
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 has not been damaged, by visually inspecting its exterior. 3. Make sure the lifting device to be used is dimensioned to handle the weight of the robot. 4. If the robot is not to be installed directly, it must be stored. 5. Make sure the appointed operating environment of the robot conforms to the specifications. 6. Before taking the robot to its installation site, make sure the site conforms to applicable requirements. 7. Before moving the robot, make sure it does not tip over! 8. When these prerequisites have been met, the robot may be taken to its installation site. Lifting robot with roundsling on page 45.
Detailed in section:
Weight on page 38. Storage conditions on page 39. Operating conditions on page 39 and Protection classes on page 39. Loads on foundation on page 38 and Requirements, foundation on page 39.
Weight The table below shows the weight of the robot model. Robot model
IRB 1600 - x/1.2 IRB 1600 - x/1.45
Weight
247 kg 250 kg
Loads on foundation The table below shows the various forces and torques working on the robot during different kinds of operation. Note! These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum at the same time! Force
Force XY
Mounting
Floor mounted Suspended Wall mounted
Endurance load
1650 N 1650 N 3900 N
Max. load (emergency stop)

31500 N 3150 N 5300 N


2.2.1. Pre-installation procedure Continued Max. load (emergency stop)
- 2500 2200 N + 2500 2200 N 2400 N 3750 Nm 3750 Nm 3850 Nm 1400 Nm 1400 Nm 1430 Nm
Force
Force Z
Mounting
Floor mounted Suspended Wall mounted Floor mounted Suspended Wall mounted Floor mounted Suspended Wall mounted
Endurance load
- 2500 1150 N + 2500 1150 N 1300 N 1700 Nm 1700 Nm 2310 Nm 855 Nm 855 Nm 855 Nm
Torque XY
Torque Z
Requirements, foundation The table below shows the requirements for the foundation where the weight of the installed robot is included. Requirement
Levelness
Value
max. 0.5 mm
Note
The value for levelness aims at the circumstance of the three anchoring points in the robot base.
Storage conditions The table below shows the allowed storage conditions for the robot. Parameter
Min. ambient temperature Max. ambient temperature Max. ambient temperature (less than 24 hrs) Max. ambient humidity
Value
-25 C +55 C +70 C Max. 95% at constant temperature
Operating conditions The table below shows the allowed operating conditions for the robot. Parameter
Min. ambient temperature Max. ambient temperature Max. ambient humidity
Value
+5 C +45 C Max. 95% at constant temperature
Protection classes The table below shows the protection class of the robot. Equipment
Robot, standard Robot, Foundry Robot, Wash
Protection class
IP 54 IP 67 IP 67
39

2.2.2. Working range
2.2.2. Working range

General This section specifies the working ranges for the different robot models. The turning radius is also shown separately in the last figure. Illustration, working range IRB 1600 - x/1.2
xx0400001260
Pos
0 1 2 3 4 5 6 7
Positions at wrist center (mm)

X 750 150 494 1225 897 386 321 -808 Z 961.5 1561.5 470 486.5 -287 737 786 975
Angle (degrees)
axis 2 0 0 0 +90 +136 +136 -63 -63 axis 3 0 -90 +55 -90 -90 -235 +55 -90


2.2.2. Working range Continued Illustration, working range IRB 1600 - x/1.45
xx0400001261
Pos
0 1
Positions at wrist center (mm)

X 750 150 404 1450 800 448 -6 -1150 Z 1186.5 1786.5 643 486.5 -639 478 740 486.5
Angle (degrees)
axis 2 0 0 0 +90 +150 +150 -90 -90 axis 3 0 -90 +65 -90 -90 -245 +65 -90
2 3 4 5 6 7


2.2.2. Working range Continued Illustration, working range IRB 1600 ID
xx0700000136
Pos 0 1 2 3 4 5 6 7
Positions at wrist center (mm) X 790 150 380 1499,5 720,5 397,5 57,5 -1199,5 Z 1296,5 1836 579 486,5 -736,5 499,5 716,5 486,5
Angle (degrees) 0 0 0 +90 +150 +150 -90 -90 0 -80 +79 -80 -80 -238 79 -80
axis 2
axis 3


2.2.2. Working range Continued Working ranges Axis
Axis 1
IRB 1600 - x/1.2

+180 to -180
IRB 1600- x/1.45

+180 to -180
Note
Axis 1 working range has the following limitations: 45 when tilting the robot up to 30. 20 for a wall mounted IRB 1600-5/1.2 IRB 1600-6/1.2 IRB 1600-7/1.2 IRB 1600-5/1.45 IRB 1600-6/1.45 IRB 1600-7/1.45 45 for a wall mounted IRB 1600-8/1.2 IRB 1600-8/1.45
Axis 2
+110 to -63
+120 to -90
+136 to -63 (with +150 to -90 (with axis 1 limited to 100) axis 1 limited to 95) Axis 3 Axis 4 +55 to -235 +200 to -200 +190 to -190 revolutions +65 to -245 +200 to -200 +190 to -190 revolutions Default value Maximum value. The default working range for axis 4 can be extended by changing parameter values in the software. Default Maximum value. The default working range for axis 6 can be extended by changing parameter values in the software.
Axis 5 Axis 6
+115 to -115 +400 to -400 +288 to -288 revolutions
+115 to -115 +400 to -400 +288 to -288 revolutions


2.2.2. Working range Continued Turning radius The turning radius for the robot is shown in the figure below. Notice the differences depending on the length of the lower arm.
xx0400001259
(A)
Minimum turning radius axis 1 (all models)
44

2.3.1. Lifting robot with roundsling
2.3 On-site installation 2.3.1. Lifting robot with roundsling

Recommended lifting position The figure below shows the recommended lifting positions. It is important that the roundsling has free space and does not wear against any part of the robot.
A-A
A A
A A
A A
xx0400001296
Required equipment Equipment

Overhead crane Roundsling
Art. no.
-
Note
Lifting capacity: 500 kg. Length: 2 m. Lifting capacity: 500 kg.
Lifting the robot with roundsling Action

1. Move the robot to an appropriate lifting position. 2. Secure the roundsling safely at the lifting eye and at the overhead crane. Make sure the roundsling has free space and does not wear against any part of the robot.
Note
Shown in the figure Recommended lifting position on page 45. Capacity for the roundsling is specified in Required equipment on page 45. Attachment is shown in the figure Recommended lifting position on page 45.


2.3.1. Lifting robot with roundsling Continued Action
3.
Note
CAUTION!
The robot weighs 250 kg! All lifting equipment must be sized accordingly! 4.
WARNING!
Personnel must not, under any circumstances, be present under the suspended load! 5. Raise the overhead crane to lift the robot.
46

2.3.2. Manually releasing the brakes
2.3.2. Manually releasing the brakes

General The section below details how to release the holding brakes of each axis' motor. This may be done in one of three ways: using the brake release unit when the robot is connected to the controller. using the brake release unit when the robot is disconnected from the controller, but connected to an external power supply at the connector R1.MP. using an external voltage supply directly on the motor connector.
Using the brake release unit when the robot is connected to the controller This section details how to release the holding brakes using the internal brake release unit. Action
1. The internal brake release unit is located at the base of the robot and equipped with six buttons for controlling the axes brakes. The buttons are numbered according to the numbers of the axes.
Note/Illustration
xx0400001255
2.
DANGER!
When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways! Make sure no personnel is near the robot arm! 3. Release the holding brake on a particular robot axis by pressing the corresponding button on the internal brake release panel and keeping it depressed. The brake will function again as soon as the button is released.


2.3.2. Manually releasing the brakes Continued Using the brake release unit with an external power supply This section details how to release the holding brakes with the internal brake release unit using an external voltage supply. This is done if the robot is not connected to the controller. Action
1.
Note/Illustration
Also, be careful not to interchange the 24V and 0V pins. If they are mixed up, damage can be caused to a resistor diode and to the system board.
DANGER!
Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously! 2. Connect an external power supply to connector R1.MP. Supply: 0V on pin C10 24V on pin B8.
3. Push the brake release button to release the holding brakes, according to the previous procedure.
48
xx0400001302

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 at a horizontal level at the installation site. Hole configuration, base The figure below shows the hole pattern and dimensions of the robot base.
xx0400001300
Center of axis 1


2.3.3. Orienting and securing the robot Continued Dimension, mounting surface and guiding sleeve The figure below shows the dimension of the mounting surface and guiding sleeves, if used.
xx0400001306
Attachment bolts, specification

Attachment bolts, 3 pcs M16 x 60 (installation directly on foundation of steel) M16 x 70/80 (installation on foundation or base plate, using guiding sleeves) 17 x 30 x 3 Quality 8.8 (wall or angle mounted robot: Quality 12.9) 200 Nm
Washers, 3 pcs Quality Tightening torque


2.3.3. Orienting and securing the robot Continued
Guiding sleeves, 2 pcs (needed if wall or angle mounted, or if the robot is calibrated with AbsAcc)
Orienting and securing the robot to installation site Action

1. Make sure the installation site for the robot conforms to the specifications in section Preinstallation procedure on page 38. 2. Prepare the installation site with attachment holes. If the robot is calibrated with AbsAcc, it must be installed using guiding sleeves. Hole configuration of the base is shown in the figure Hole configuration, base on page 49. Dimension of mounting surface and the guiding sleeves are shown in the figure Dimension, mounting surface and guiding sleeve on page 50. Detailed in section Lifting robot with roundsling on page 45.
Note
3. Lift the robot to the installation site. 4. Guide the robot gently using two of the M16 attachment bolts while lowering it into its mounting position. 5. Fit and tighten the bolts and washers in the base attachment holes.
Specified in section Attachment bolts, specification on page 50.
51

2.3.4. Suspended mounting
2.3.4. Suspended mounting

General Initially the system is configured for mounting on the floor, without leaning. The method for mounting the robot in a suspended position is basically the same as for floor mounting. NOTE! With suspended installation, make sure that the gantry or corresponding structure is rigid enough to prevent unacceptable vibrations and deflections, so that optimum performance can be achieved. System parameters If the robot is mounted at any other angle, the system parameter gravity beta must be updated. Gravity beta specifies the robots mounting angle expressed in radians. NOTE! It is very important to configure gravity beta correctly so that the robot system can control the movements in the best possible way. Incorrect definition of mounting angle (gravity beta) will result in: Overloading the mechanical structure. Lower path performance and path accuracy. Some functions will not work properly: for example Load Identification & Collision detection.
Mounting angles and values The parameter gravity beta specifies the robots mounting angle in radians. It is calculated in the following way for a mounting angle of 45. Gravity beta = 45 x 3.141593/180 = 0.785398 radians. Example of position
Floor (A) Tilted (B) Wall (C) Suspended (D)
Mounting angle
0 30 90 180
Gravity beta
0.523599 1.570796 3.141593
0.000000 (Default)


2.3.4. Suspended mounting Continued
xx0600002779
A B C D
Floor mounted Tilted mounting, mounting angle 30 Wall mounted, mounting angle 90 Suspended mounting, mounting angle 180
Limitations in working area If tilting a floor mounted robot or mounting the robot on a wall, the working range of axis 1 is limited. These limitations are specified in the table Working ranges on page 43.


2.3.4. Suspended mounting Continued Defining the parameter The value of the system parameter Gravity beta must be redefined when changing the mounting angle of the robot. The parameter belongs to the type Robot, in the topic Motion. How to calculate a new value is detailed in Mounting angles and values on page 52. The parameter is further detailed in the Technical reference manual - System parameters. The parameter can be edited either with the FlexPendant or in RobotStudio Online. Read about how to change the parameter in the Operating manual - IRC5 with FlexPendant or in the Operating manual - RobotStudio Online. Article numbers for the manuals are specified in References on page 8.
54

2.3.5. Loads
2.3.5. Loads
General Any loads mounted on the manipulator must be defined correctly and carefully (with regard to the position of centre of gravity and inertia factor) in order to avoid jolting movements and overloading the motors. If this is not done correctly operation stops may result. References Load diagrams, permitted extra loads (equipment) and their positions as specified in the Product Specification. The loads must also be defined in the software as detailed in Operating manual - IRC5 with FlexPendant. Brake performance Manipulator motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB.
55

2.3.6. Fitting equipment on the robot (robot dimensions)
2.3.6. Fitting equipment on the robot (robot dimensions)

General This section shows the robot dimensions and available mounting holes on the robot. Main dimensions The figures below show the main dimensions of the robot. The remaining dimensions and mounting holes on the upper arm, frame and turning disk are shown in the following figures.
xx0400001253
(A) (B)
Centerline of axis 1 Smallest circumscribed radius, axis 1


2.3.6. Fitting equipment on the robot (robot dimensions) Continued Main dimension 1600 ID The figure below shows the main dimensions for 1600 ID robot.
xx0700000118
(A) (B)
Centerline of axis 1 Smallest circumscribed radius, axis 1


2.3.6. Fitting equipment on the robot (robot dimensions) Continued Mounting holes on the frame The three available mounting holes for equipment on the frame must be threaded according to the figure below.
xx0400001252
1)
Prepared for threading M8 x max depth 20 mm


2.3.6. Fitting equipment on the robot (robot dimensions) Continued Dimensions of the upper arm and mounting holes The figure below shows the dimensions of the upper arm and available mounting holes for equipment on the arm.
xx0600002859
(A) (B) (C) (D) (E)
Centerline of axis 3 Centerline of axis 4 Turning radius for axis 3 Smallest circumscribed radius for axis 4 Mounting holes for equipment (depth 10 mm)


2.3.6. Fitting equipment on the robot (robot dimensions) Continued Dimensions of the upper arm and mounting holes for 1600 ID The figure below shows the dimensions of the upper arm and available mounting holes for equipment on the arm.
xx0700000119


2.3.6. Fitting equipment on the robot (robot dimensions) Continued Dimensions of the turning disk The figure below shows the dimensions of the turning disk.
xx0200000063
Dimensions of the turning disk 1600ID The figure below shows the dimensions of the turning disk on a IRB 1600ID
xx0700000090
Fastener quality When fitting tools on the turning disk, use only screws with quality 12.9. When fitting equipment on other places, standard screws with quality 8.8 can be used.
61

2.3.7. Installation of signal lamp for 1600 (option)
2.3.7. Installation of signal lamp for 1600 (option)

General A signal lamp with an yellow fixed light can be mounted on the robot, as a safety device. The signal lamp is required on an UL/UR approved robot. The lamp is active in MOTORS ON mode. Location of signal lamp The signal lamp is fitted to the upper arm housing of the robot, as shown in the figure below.
xx0400001265
A C D E F
Signal lamp Cable gland Cable bracket Attachment holes for the signal lamp Cover, upper arm housing

Signal lamp
Art. no.
3HAC 022235-001
Note


2.3.7. Installation of signal lamp for 1600 (option) Continued Equipment
Gasket, customer connections Gasket, upper arm cover
Art. no.
3HAC 022050-001 3HAC 022049-001
Note
Replace if damaged. Replace if damaged.
Installation, signal lamp The procedure below details how to install the signal lamp to the robot. Action
1.
Note/Illustration
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the cover from the upper arm housing Shown in the figure Location of signal to get access to the connectors inside the lamp on page 62. housing. 3. Remove the protection plug (A) from the insertion hole in the contact panel. Run the cables of the lamp through the hole in the contact panel. Secure the cable gland in the hole.
xx0400001264
4. Connect the lamp connectors, R3.H1 and R3.H2 and place the cables safely inside the housing.
A: Plug with o-ring, M10
5. Take out the lamp unit through the hole in the upper arm housing cover and refit the cover. Make sure the gaskets are not damaged. 6. Fit the cable bracket of the signal lamp to the two mounting holes in the upper arm housing (B).
Shown in the figure Location of signal lamp on page 62. Shown in the figure Location of signal lamp on page 62.
xx0400001263
7. The signal lamp is now ready for use and is lit in MOTORS ON mode.
B: Mounting holes, M8 x 12
63

2.3.8. Installation of signal lamp for 1600 ID (option)
2.3.8. Installation of signal lamp for 1600 ID (option)

General A signal lamp with an yellow fixed light can be mounted on the robot, as a safety device. The signal lamp is reqired on an UL/UR approved robot. The lamp is active in MOTORS ON mode. Location of signal lamp The signal lamp is fitted to the upper arm housing of the robot, as shown in the figure below
xx0700000100
A B
Signal lamp Cover, upper arm housing
Required equipment
Equipment Signal lamp Drill Standard toolkit Art. no. 3HAC9258-1 Note Spare part list, upper arm on page 254 Diameter 22,5 mm The contents of the toolkit is defined in section, Standard toolkit on page 237


2.3.8. Installation of signal lamp for 1600 ID (option) Continued
Action
1.
Note/Illustration
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the cover from the upper arm housing. 3. On the cover there is a mark where the lamp is to be installed. Find the mark and drill a hole with a diameter of 22.5mm. 4. Fit the lamp and tighten the nut. 5. In the upper arm housing find the two cables marked R3.H1 and R3.H2 and connect them with the lamp 6. Refit the cover on the upper arm housing. 7. The signal lamp is now ready for use and is lit in MOTORS ON mode. Shown in the figure Location of signal lamp on page 64.
65

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) Axis 3, hardware (mechanical stop)
This section describes how to install hardware that restricts the working range. Notice that adjustments must also be made in the software. References to software manuals are given in the following installation procedures.
66

2.4.2. Installation of additional mechanical stops on axis 1

General This section details how to install additional mechanical stops on axis 1 in order to restrict the working range of the axis. Restrictions in working range The working range of axis 1 can be restricted by fitting one or two additional mechanical stops on the casted groove at the base. The figure below shows both the minimum and maximum working range of the robot, when restricted by the additional mechanical stops. The working range can be restricted freely within the shown scope, depending on where the mechanical stop is installed along the casted groove.
+6
-6
A
8 +16
A
-1 6 8
B B
xx0400001286
A B
Mounting position of two additional stops for maximum working area (168) Mounting position of two additional stops for minimum working area (64)


2.4.2. Installation of additional mechanical stops on axis 1 Continued Illustration, mechanical stop, axis 1 The additional mechanical stop of axis 1 is fitted to the base of the robot, as shown in the figure below.
xx0400001287
A B C E F G
Mechanical stop, axis 1 (additional) Attachment bolts and washers, mechanical stop Stop pin (standard) Casted groove Guiding pin Hidden stiffening ribs

Working range limit axis 1
Art. no.
3HAC023110-001
Note
Includes mechanical stops (2 pcs), attachment bolts and washers. Art. no. is specified in section References on page 8.
Technical reference manual - System parameters (RobotWare 5.0)


2.4.2. Installation of additional mechanical stops on axis 1 Continued Installation of mechanical stop, axis 1 The procedure below details how to install the mechanical stop to axis 1. Action
1.
Note/Illustration
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Place the stop at the base, with the guiding pin in the casted groove. Turn the stop until the holes align with the groove. The stop can be mounted in either direction, resulting in differences in the working range.
xx0400001288
Also see the figure Illustration, mechanical stop, axis 1 on page 68. 3. Drill two holes in the casted groove, with guidance from the circular and the elliptical hole. Drill the holes through 10.2 mm. If drilling in a stiffening rib, drill depth must be min. 30 mm. 4. Cut the threads M12. If cutting in a stiffening rib, thread depth must be min. 23 mm. 5. Fit the stop to the base without tightening the bolts. 6. Turn axis 1 manually and check the working area between the stops.
How to release the holding brake of the axis motor is detailed in section Manually releasing the brakes on page 47. 2 pcs/stop: M12 x 40, tightening torque: 85 Nm.
7. Tighten the bolts.
8. The software working range limitations must be re- The system parameters that must defined to correspond to the changes in the be changed in RobotWare 5.0 mechanical limitations of the working range. (Upper joint bound and Lower joint bound) are further detailed in Technical reference manual System parameters. 9.
WARNING!
If the mechanical stop is deformed after a hard collision, it must be replaced!
69

2.4.3. Installation of additional mechanical stop on axis 2
2.4.3. Installation of additional mechanical stop on axis 2

General This section details how to install an additional mechanical stop on axis 2 in order to restrict the working range of the axis. Restrictions in working range The working range of axis 2 can be restricted by fitting an additional mechanical stop at the frame. The working range can only be restricted backwards, as shown in the figures below. Notice the different working ranges for the different models!
xx0400001289
xx0400001290


2.4.3. Installation of additional mechanical stop on axis 2 Continued Illustration, mechanical stop, axis 2 The additional mechanical stop for axis 2 is fitted together with a damper to the frame, as shown in the figure below.
xx0400001291
A B C D E F
Mechanical stop, axis 2 Attachment bolts, mechanical stop (2 pcs) Attachment holes, mechanical stop Damper, axis 2 Washer Attachment screw, damper

Art. no.
3HAC023108-001
Note
Includes mechanical stop, damper and attachment bolts. Art. no. is specified in section References on page 8.
Technical reference manual - System parameters (RobotWare 5.0)
Installation of mechanical stop, axis 2 The procedure below details how to install the mechanical stop to axis 2. Action
1.
Note/Illustration
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Fit the mechanical stop to the frame, without tightening the bolts. Attachment holes are shown in the figure Illustration, mechanical stop, axis 2 on page 71.


2.4.3. Installation of additional mechanical stop on axis 2 Continued Action
3. Make sure that the stop is in contact with the lower boss on the gearbox, as the arrow shows in the figure to the right.
Note/Illustration
xx0400001292
NOTE!
It is important that the mechanical stop is fitted in contact with the lower boss on the gearbox! 4. Tighten the attachment bolts. 2 pcs; M8 x 35, tightening torque: 25 Nm.
5. Fit the damper to the mechanical stop, with its Shown in the figure Illustration, attachment screw and washer. Tighten the screw. mechanical stop, axis 2 on page 71.
6. The software working range limitations must be re-defined to correspond to the changes in the mechanical limitations of the working range.
The system parameters that must be changed in RobotWare 5.0 (Upper joint bound and Lower joint bound) are further detailed in Technical reference manual System parameters.
7.
WARNING!
72


General This section details how to install an additional mechanical stop on axis 3 in order to restrict the working range of the axis. Restrictions in working range The working range of axis 3 can be restricted into two different working areas, as shown in the two figures below. Notice the differences between the different models.
xx0400001283
A B
Robot models IRB 1600 - x/1.2 Working range A Working range B


2.4.4. Installation of additional mechanical stops on axis 3 Continued
xx0400001284
A B
Robot models IRB 1600 - x/1.45 Working range A Working range B
Illustration, mechanical stop, axis 3 The mechanical stop is installed at the upper arm housing, as shown in the figure below.
xx0400001285
A B
Mechanical stop, axis 3 Attachment screws and washers (2 pcs)


2.4.4. Installation of additional mechanical stops on axis 3 Continued Required equipment Equipment
Art. no.
3HAC023109-001
Note
Includes mechanical stop, attachment screws and washers. Art. no. is specified in section References on page 8.
Technical reference manual System parameters (RobotWare 5.0)
Installation of mechanical stop, axis 3 The procedure below details how to install the mechanical stop to axis 3. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Fit the mechanical stop to the two mounting holes Shown in the figure Illustration, at the upper arm housing, with the two attachment mechanical stop, axis 3 on page 74. screws and washers. Tighten the screws. 2 pcs: M8 x 25, tightening torque: 25 Nm. 3. The software working range limitations must be re-defined to correspond to the changes in the mechanical limitations of the working range. The system parameters that must be changed in RobotWare 5.0 (Upper joint bound and Lower joint bound) are further detailed in Technical reference manual System parameters.
4.
WARNING!
75

2.4.5. Installation of position switch, axis 1
2.4.5. 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.
xx0400001356
A B C D E F G H I
Position switch Attachment screws, position switch, 2 pcs: M6 x 30 Holder ring (2 parts) Attachment screws, holder ring, 6 pcs: M8 x 12 Cam Bracket Attachment screws, housing, 2 pcs: M6 x 8 Cable straps Attachment screws, attachment plate, 2 pcs: M6 x 16

Position switch, axis 1
Art. no.
3HAC023973001
Note
Includes 3 switches. All parts are included in the delivery. Instruction of how to cut the cams is enclosed in the kit. Art. no. is specified in section References on page 8.
Technical reference manual System parameters (RobotWare 5.0)


2.4.5. Installation of position switch, axis 1 Continued Installation, position switch axis 1 The procedure below details how to install the position switch to the robot. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Fit the two holder rings underneath the frame with the six attachment screws. 3. Cut the cams according to instructions, enclosed with the position switch kit. 4. Fit the cams to the holder ring with the attachment screws. 5. Attach the position switch to the bracket with two attachment screws. Shown in the figure Location of position switch, axis 1 on page 76. M6 x 12. 2 pcs, M6 x 30. Shown in the figure Location of position switch, axis 1 on page 76. 6 pcs, M8 x 12.
6. 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 76. 2 pcs, M6 x 8. 7. 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 76. Adjust the height of the switches with shims until each roller aligns with corresponding cam.
xx0400001358
A. B. C. D. 8. Secure the cabling inside the housing with cable straps.
Attachment plate Shims Roller Cam
Shown in the figure Location of position switch, axis 1 on page 76.


2.4.5. Installation of position switch, axis 1 Continued Action
9. Connect the position switch cabling.
Note
The cabling and connection points are specified in section Position switch cables, robot base to controller (option) on page 82. The system parameters that must be changed in RobotWare 5.0 (Upper joint bound and Lower joint bound) are further detailed in Technical reference manual System parameters.
10. The software working range limitations must be re-defined to correspond to the changes in the mechanical limitations of the working range.
78

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 connectors.
xx0400001262
A B
Connection for air Connection for signal lamp


2.5.1. Connectors on robot Continued Connectors on the robot upper arm IRB 1600ID The figure below shows connections on the upper arm IRB 1600 ID
R4.FB5
R4.FB6
R4.MP5
R4.MP6
R3.FB3 R3.FB4 R3.FB5 R3.FB6 R3.MP3 R3.MP4 R3.MP5 R3.MP6

xx0700000038
80

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 controller are divided into the following categories: Cable category
Robot cables
Description
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 81. Handles supply to and feedback from any position switches on the robot. Specified in the table Position switch cables, robot base to controller (option) on page 82. 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). Also specified in the table Customer cables (option) on page 83. Handles power supply to and control of the external axes' motors as well as feedback from the servo system. See the Application manual - Additional axes and stand alone controller (M2004)1).
Position switch cables (option)
Customer cables (option)
External axes cables (option)
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
Robot cable, power Transfers drive power from the drive units in the control cabinet to the robot motors. Transfers resolver data from and power supply to the serial measurement board.
Connection Connection point, cabinet point, robot

XS1 R1.MP
Robot cable, signals
XS2
R1.SMB
Robot cable, power, for robots with standard protection Cable (standard)
Robot cable, power, 7 m Robot cable, power, 15 m Robot cable, power, 22 m
Art. no.
3HAC2492-1 3HAC2529-1 3HAC2539-1


2.5.2. Robot cabling and connection points Continued Cable (standard)
Robot cable, power, 30 m
Art. no.
3HAC2564-1
Robot cable, power, for robots with foundry and wash protection Cable (foundry)
Robot cable, power, 7 m Robot cable, power, 15 m Robot cable, power, 22 m Robot cable, power, 30 m
Art. no.
3HAC9038-1 3HAC9038-2 3HAC9038-3 3HAC9038-4
Robot cable, signals Cable

Robot cable, signal, shielded, 7 m Robot cable, signal, shielded, 15 m Robot cable, signal, shielded, 22 m Robot cable, signal, shielded, 30 m
Art. no.
3HAC2493-1 3HAC2530-1 3HAC2540-1 3HAC2566-1
Position switch cables, robot base to controller (option) The cable is delivered in one length only and should be wound to suitable length. Cabling between robot base and controller Cable
Position switch cable, axis 1, 30 m
Art. no.
3HAC7997-4
Connection Connection point, point, robot cabinet

R1.LS XS8


2.5.2. Robot cabling and connection points Continued Customer cables (option) The customer cables specified below are connected between robot and controller. The customer cables are ordered according to current protection class of the robot. Customer cables for robots with standard protection Cable (standard)
Customer cable, power-signal, 7 m Customer cable, power-signal, 15 m Customer cable, power-signal, 22 m Customer cable, power-signal, 30 m
Art. no.
3HAC3353-1 3HAC3354-1 3HAC3355-1 3HAC3356-1
Connection point, robot

R1.CP/CS R1.CP/CS R1.CP/CS R1.CP/CS
Customer cables for robots with foundry and wash protection Cable (foundry and wash)
Customer cable, power-signal, 7 m Customer cable, power-signal, 15 m Customer cable, power-signal, 22 m Customer cable, power-signal, 30 m
Art. no.
3HAC8183-1 3HAC8183-2 3HAC8183-3 3HAC8183-4
Connection point, robot

R1.CP/CS R1.CP/CS R1.CP/CS R1.CP/CS
83

2.5.3. Customer connections on the robot
2.5.3. Customer connections on the robot

General For connection of equipment on the robot, there are cables integrated into the robot cabling. This section specifies recommendations for the customer connections. The air and electrical connectors are shown in the figure Connectors on the robot on page 79. Air connection Connection
Air inlet (at the base) Air outlet (at the upper arm housing) 1/4"
Dimension
The integrated air hose is sized as specified in the table below. Inner diameter
8 mm
Max. pressure
0.8 MPa / 115 psi
Customer connectors R2.CS and R2.CP The customer connectors R2.CS and R2.CP can be used with either: a connector set from ABB for standard connection specified connector components from Souriau, or connectors that meet Military standard MIL-C-26482 series 1.
These connectors are further detailed in following sections. Connector set from ABB for standard connection Equipment
Connection set R2.CP/R2.CS
ABB art. no.

3HAC025396-001
Note
Only for standard connection.
Specified connector components from Souriau The components specified below are from connector manufacturer Souriau and can be used for connection to R2.CS and R2.CP.
xx0400001339
A B C 84
Pin connector Pin Backshell


2.5.3. Customer connections on the robot Continued Recommended pin connectors Pin connector
Pin connector, standard connection, CS (Customer Signal) Pin connector, standard connection, CP (Customer Power) Pin connector, integrated wirefeeder cabling, CS Pin connector, Integrated wirefeeder cabling, CP
Souriau art. no.

UT0W6 1626 P-H UT0W6 1210 P-H UT0W6 1626 P-H UT06 1412 P-H04
Recommended pins (turned) Turned pins for cable area...

0.21 - 0.93 mm2 (standard connection, CP/CS and integrated wirefeeder cabling, CS) 0.13 - 0.25 mm2 (integrated wirefeeder cabling, CP) 0.25 - 0.5 mm (integrated wirefeeder cabling, CP) 0.5 - 1.5 mm2 (integrated wirefeeder cabling, CP)
2
Pin diameter
1 mm 1.6 mm 1.6 mm 1.6 mm
Souriau art. no.

RM18W3K RM24M9K RM20M12K RM16M23K
Recommended backshell Backshell

Backshell, standard connection, CS Backshell, standard connection, CP Backshell, integrated wirefeeder cabling, CS Backshell, integrated wirefeeder cabling, CP
Souriau art. no.

UT0 16JC UT0 12JC UT0 16JC UT0 14JC
Connectors that meet Military standard The connectors specified below meet Millitary standard MIL-C-26482 series 1 and can be used for connection to R2.CS and R2.CP (only for standard customer connection). The figure below shows a complete connector, including pin connector and backshell.
xx0400001340
Connector for crimping The complete pin connectors for crimping include pin connector and backshell. Connector for crimping
Complete pin connector, CS Complete pin connector, CP Turned pin 0.2 - 0.5 mm
2
Military standard MIL-C-26482

MS3126*1626S MS3126*1210S M39029/31-240


2.5.3. Customer connections on the robot Continued Connector for crimping
Turned pin 0.5 - 1.5 mm
2

M29029/31-228
Connector for soldering The complete pin connectors for soldering include pin connector, backshell and pins. Connector for soldering
Complete pin connector, CS Complete pin connector, CP

MS3116*1626S MS3116*1210S
86

2.6.1. Additional installation procedure.
2.6 Making robot ready for operation (Cleanroom) 2.6.1. Additional installation procedure.
General Cleanroom robots are specially designed to work in a cleanroom environment. Cleanroom robots are designed in order to prevent from particle emission from the robot. For example some articles in the robot's design, which normally are exposed to some wear during operation, are unpainted. If replaced, these articles must be replaced with new unpainted ones. Cleanroom class 5 Particle emission from the robot fulfill Cleanroom class 5 standard according to DIN EN ISO 14644-1. Preparations before commissioning a Cleanroom robot During transport and handling of a Cleanroom robot, it is likely that the robot has been contaminated with particles of different sorts. Therefore the Cleanroom robot must be minutely cleaned before commissioning.
87

2.6.1. Additional installation procedure.
88
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, that is 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 before performing any service work.
89
3 Maintenance
3.2.1. Specification of maintenance intervals
3.2 Maintenance schedule and expected component life 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.
90
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. Maintenance schedule The table below specifies the required maintenance activities and intervals: Maintenance Equipment activity
Change Gearbox oil, axes 5 and 6 IRB1600 Gearbox oil, axes 5-6 IRB1600ID
Interval
20,000 hrs
Detailed in section
Oil change, gearbox axes 5 and 6 on page 97. Oil change, gearbox axes 5- 6, IRB 1600ID on page 100 Replacement of measurement system battery pack on page 103. Cleaning, complete robot on page 105.
Change
20,000 hrs
Change
Battery, measurement system 12 - 36 mths 2)
Cleaning
Complete robot
Regular 1)
1. A regular interval implies that the activity is to be performed regularly, but the actual interval may not be specified by the robot manufacturer. The interval depends on the operation cycle of the robot, its working environment and movement pattern. Generally, the more contaminated environment, the closer the intervals. The more demanding movement pattern (sharper bending cable harness), the closer the intervals.
2. 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 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.
91
3 Maintenance
3.2.3. Expected component life
3.2.3. Expected component life

General The life of any component depends on how hard it is run, and it can vary greatly. Expected life Component
Robot cable harness IRB 1600 Robot cable harness IRB 1600ID Cabling for position switch Gearbox
Expected life
2,000,000 cycles 2,000,000 cycles 2,000,000 cycles 40,000 hrs
Note
See note 1) See note 1) See note 1)
1. The expected life can also be affected by grouping harnesses/cables other than standard options. The life expectancy is based on a test cycle that for every axis goes from the calibration position to minimum angle, to maximum angle and back to the calibration position. Deviations from this test cycle will result in differences in expected life!
92
3 Maintenance
3.3.1. Inspection, damper axes 2, 3 and 5
3.3 Inspection activities 3.3.1. Inspection, damper axes 2, 3 and 5

Location of dampers The figure below shows the location of all the dampers to be inspected.
xx0400001217
A B
Damper, axis 2 Attachment screw
xx0400001215
A B
Damper, axis 3 Cast tab

3 Maintenance
3.3.1. Inspection, damper axes 2, 3 and 5 Continued
xx0600002806
A B
Damper, axis 5 Recess

Standard toolkit
Art. no.
-
Note
The contents are defined in section Standard toolkit on page 237.
Inspection, dampers The procedure below details how to inspect the dampers. Action
1.
Note
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Check all dampers for damage, such as cracks or Shown in the figure Location of existing impressions that are larger than 1 mm. dampers on page 93. 3. Check attachment screws for deformation. 4. If any damage is detected, the damper must be replaced with a new one! Replacement is detailed in sections: Replacement of damper, axis 2 on page 151 Replacement of damper, axis 3 on page 153 Replacement of damper, axis 5 on page 157.
94
DANGER!
3 Maintenance
3.4.1. Oil in gearboxes
3.4 Replacement activities 3.4.1. Oil in gearboxes

Location of gearboxes
xx0500001427
A
Gearbox, axis 1 Gearbox, axis 2 Gearbox, axis 3 Gearbox, axis 4 Gearboxes, axes 5 and 6 IRB1600
B C D E
Type and amount of oil in gearboxes 1600 Gearbox

Axis 1 Axis 2 Axis 3, IRB1600 Axis 4, IRB1600 Axis 5-6 (wrist unit), IRB1600.
Type of oil
Mobilgear 600 XP 320 Mobilgear 600 XP 320 Mobilgear 600 XP 320 Mobilgear 600 XP 320 Optimol BM 100
Art. no.
11712016-604 11712016-604 11712016-604 11712016-604 3HAC 0860-1
Amount
1200 ml 1000 ml 500 ml 350 ml Total amount: 350 ml (new wrist) Amount at oil change: 300 ml

3 Maintenance
3.4.1. Oil in gearboxes Continued Type and amount of oil in gearboxes 1600ID
xx0700000285
Gearbox
Axis 3, IRB1600ID Axis 4, IRB1600ID Axis 5 Wrist Axis 5-6 IRB1600ID
Type of oil
Mobilgear 600 XP 320 Mobilgear 600 XP 320 Mobilgear 600 XP 320 Optimol BM 100
Art. no.
11712016-604 11712016-604 11712016-604 3HAC 0860-1
Amount
350 ml 15 ml 130 ml 20 ml
500 ml
Wrist Axis 6, IRB1600ID Grease
96
3 Maintenance
3.4.2. Oil change, gearbox axes 5 and 6
3.4.2. Oil change, gearbox axes 5 and 6

Location of oil plugs The gearboxes for axes 5 and 6 are located in the wrist unit as shown in the figure below.
xx0600002846
A B
Oil plug, draining and filling Oil plug, vent hole
Required equipment Equipment, etc.

Lubricating oil
Art. no.
3HAC 0860-1
Amount
Note
Total amount: 350 Optimol BM 100 ml (new wrist) Amount at oil change: 300 ml Capacity: 400 ml. The contents are defined in section Standard toolkit on page 237. These procedures include references to the tools required.
Oil collecting vessel Standard toolkit

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

3 Maintenance
3.4.2. Oil change, gearbox axes 5 and 6 Continued Draining, wrist unit The procedure below details how to drain oil from the gearboxes in the wrist unit. Action
1.
Note/Illustration
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 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 36. 3. Position the robot as shown in the figure to the Vessel capacity is specified in section right: Required equipment on page 97! upper arm: upwards for a standing robot axis 4: 180, to a position where the oil plug (A), faces downwards.
NOTE!
The total amount of oil will not be drained. There will remain approximately 50 ml in the wrist unit.
xx0500001434
A. Oil plug, draining and filling The position for an inverted robot is the opposite! 4. Remove the both oil plugs. Shown in the figure Location of oil Both oil plugs must be removed in order to drain plugs on page 97. the wrist unit properly. 5. Refit the oil plug, vent hole.

3 Maintenance
3.4.2. Oil change, gearbox axes 5 and 6 Continued Filling oil, wrist unit The procedure below details how to fill oil in the gearboxes in the wrist unit. Action
1.
Note/Illustration
DANGER!
WARNING!
Handling gearbox oil involves several safety risks. Before proceeding, please observe the safety information in section WARNING Safety risks during work with gearbox oil on page 36. 3. Remove the oil plug, draining and filling. Shown in the figure Location of oil plugs on page 97!
4. Position the robot as shown in the figure to the The oil quality and amount is specified right: in section Required equipment on page 97! upper arm: downwards for a standing robot axis 4: 90, to a position where the oil plug (A), faces upwards. Fill oil in the wrist unit through the oil plug.
xx0500001435
A: Oil plug, draining and filling The position for an inverted robot is the opposite. 5. Refit the oil plug.
99
3 Maintenance
3.4.3. Oil change, gearbox axes 5- 6, IRB 1600ID
3.4.3. Oil change, gearbox axes 5- 6, IRB 1600ID

Location of oil plugs The oil plug for axes 5 are located in the wrist unit as shown in the figure below.
xx0700000030
A B
Oil plug, draining and filling Oil plug, draining ventilation plug.

Lubricating oil Oil collecting vessel Standard toolkit The contents are defined in section Special tools on page 238. See references to these procedures in the step-by-step instructions below.
Art.no.
3HAC0860-1
Amount
Note
Amount at oil change: Optimol BM 100 100 ml.
Other tools and procedures may be required.
Draining, wrist unit The procedure below details how to drain oil from the gearboxes in the wrist unit. Action
1.
Note/Illustration
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

3 Maintenance
3.4.3. Oil change, gearbox axes 5- 6, IRB 1600ID Continued Action
2.
Note/Illustration
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 36. 3. Position the robot as shown in the Vessel capacity is specified in section figure to the right: Required equipment on page 100. upper arm: upwards for a standing robot. axis 4: - 90, to a position where the oil plug (A), faces downwards.
NOTE!
The total amount of oil will not be drained. There will remain approximately 20 ml in the wrist unit.
xx0700000033
4. Remove the oil plug (A) and the ventilation plug (B). 5. Tap the wrist of all oil.
Shown in figure Location of oil plugs on page 100. About 100 ml

3 Maintenance
3.4.3. Oil change, gearbox axes 5- 6, IRB 1600ID Continued Filling oil, wrist unit The procedure below details how to fill oil in the gearboxes in the wrist unit. Action Note/Illustration
1. Position the robot as shown in the figure to Vessel capacity is specified in section the right: Required equipment on page 100. upper arm: upwards for a standing robot. axis 4: + 90, to a position where the oil plug (A), faces upwards. Fill 180 ml new oil in the wrist.
xx0700000034
A. oil plugs, filling possition. 2. Refit the oil plug and the ventilation plug.
102
3 Maintenance
3.4.4. Replacement of measurement system battery pack
3.4.4. Replacement of measurement system battery pack

Location of battery pack The battery pack for the measurement system is located inside the base of the robot, as shown in the figure below.
xx0500001390
Base cover, including gasket. Battery pack is located beneath the cover.
Battery pack on serial measurement unit The battery pack is attached to the serial measurement unit as shown in the figure below.
xx0500001393
A B C
Battery pack Velcro strap Connector X3

3 Maintenance
3.4.4. Replacement of measurement system battery pack Continued Required equipment Equipment
Battery pack Gasket, base cover Standard toolkit Circuit diagram
Spare part no.

3HAC 16831-1 3HAC 022047-001 -
Note
Replace if damaged. The contents are defined in section Standard toolkit on page 237. See chapter Circuit diagram.
Replacement, battery pack The procedure below details how to replace the battery pack. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the base cover from the robot by unscrewing its attachment screws. 3. Disconnect the battery from the serial measurement unit. 4. Remove the battery pack. 5. Fit the new battery pack and connect it to the Spare part no. is specified in Required serial measurement unit (X3). equipment on page 104. Shown in the figure Battery pack on serial measurement unit on page 103. 6. Check the base cover gasket, replace if damaged. 7. Refit the base cover to the robot. 8. Update the revolution counters. Spare part no. is specified in Required equipment on page 104. Shown in the figure Location of battery pack on page 103. Detailed in section Updating revolution counters on page 225. Shown in the figure Location of battery pack on page 103.
104
3 Maintenance
3.5.1. Cleaning, complete robot
3.5 Cleaning activities 3.5.1. Cleaning, complete robot

General The protection class of Foundry and Wash versions is IP 67, i.e. the robot is watertight. Required equipment Equipment, etc.
May be used on version Foundry and Wash! Steam cleaner
Art. no. Note

Water pressure at nozzle: max. 2,500 kN/ m 2 (25 bar) Type of nozzle: fan jet, min. 45 spread Flow: max. 100 litres/min. Water temperature: max. 80 C Max. water pressure on enclosures: 50 kN/m 2 (0.5 bar) Fan jet nozzle should be used, min. 45 spread Flow: max. 100 liters/min. Cloth with mild detergent
May be used on version Foundry and Wash! High pressure water cleaner
May be used on version Cleanroom and Standard. Vacuum cleaner
Do's and don'ts! The section below specifies some special considerations when cleaning the robot. Always!
Always use cleaning equipment as specified above! Any other cleaning equipment may shorten the life of paintwork, rust inhibitors, signs, or labels! Always check that all protective covers are fitted to the robot before cleaning!
Never! Never point the water jet at bearing seals, contacts, and other seals! Never spray from a distance closer than 0.4 m! Never remove any covers or other protective devices before cleaning the robot! Never use any cleaning agents, e.g. compressed air or solvents, other than those specified above! Never spray connectors and similar items with a high pressure cleaner!
105
3 Maintenance
3.5.1. Cleaning, complete robot
106
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, for example 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 chapter . 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 before commencing any service work.
107
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.
Leakdown tester Leak detection spray
Art. no.
3HAC0207-1 -
Note
Procedure Action
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 signifibe 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? 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.
Note
108
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.
Grease
Art. no.
3HAB3537-1
Note
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 pretensioning is carried out and also rotated during the pre-tensioning sequence. 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.
109
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.
Grease
Art. no.
3HAB3537-1
Note
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
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.
Note
3. Lubricate the seal with grease just before fitting. (Not too Art. no. is specified in early as there is a risk of dirt and foreign particles adhering Equipment on page 110. 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.

4 Repair
4.2.3. Mounting instructions for seals Continued 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. 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

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.
Note
111
4 Repair
4.3.1. Replacement of cable harness
4.3 Complete manipulator 4.3.1. Replacement of cable harness

Location of cable harness The cable harness is run through the robot from the base to the upper arm housing. The location of the harness is shown in several figures, next to the procedures, later on in this section. Views of the cable harness may also be found in the chapter Spare parts and exploded views. Required equipment Equipment
Cable harness IRB 1600/1.45 Cable harness IRB 1600/1.45, Customer connections Cable harness IRB 1600/1.45, Wire feeder Cable harness IRB 1600/1.2, Customer connections Gasket, upper arm cover Gasket, customer connections Gasket, base cover Gasket, gearbox axis 1-2 VK-cover VK-cover Cable ties Centering piece 3HAC025815-001 Fitted to the push button unit in order to align it correctly. Replace if damaged. The contents are defined in section Standard toolkit on page 237. See chapter Circuit diagram.
Spare part no.

3HAC 021827-001 3HAC 021828-001 3HAC 021830-001 3HAC 021828-003 3HAC 022049-001 3HAC 022050-001 3HAC 022047-001 3HAC 022048-001 3HAA 2166-23 3HAA 2166-21
Note
No application interface.
Replace if damaged. Replace if damaged. Replace if damaged. Replace if damaged. Upper and lower covers. 2 pcs Middle cover.
Standard toolkit
Circuit diagram

4 Repair
4.3.1. Replacement of cable harness Continued Illustration, covers to remove The figure below shows all the covers that must be removed from the robot in order to get access to the cable harness and all the brackets.
xx0400001248
A B
Upper and lower VK-cover Arm housing cover, with gaskets VK-cover (also shown with the cover removed) Cover, frame, with gasket Base cover, with gasket
C D E
Removal, cable harness The procedure below details how to remove the complete cable harness from the robot. Action
1.
Note/Illustration
DANGER!

4 Repair
4.3.1. Replacement of cable harness Continued Action
2. Remove all the covers: Remove the covers of the upper arm housing, frame and base. Push out the upper and lower VK-cover from the inside. Remove the middle VK-cover from the lower arm.
Note/Illustration
All the covers are shown in the figure Illustration, covers to remove on page 113.
CAUTION!
Be careful not to damage the cabling and cable bracket inside the lower arm when removing the middle VK-cover! The figure to the right shows the space underneath the cover. The gray areas are safe for insertion of a tool that may be inserted with a maximum depth of 20 mm! 3. The cable bracket inside the lower arm is attached to the cable harness. Move the bracket to the new cabling. 4. Disconnect all the connectors inside the upper arm Shown in the figure Illustration, housing. cabling inside upper arm housing on page 115. 5. Remove all cable ties, clamps and brackets inside Attachment points inside the upper the upper arm housing. arm housing are shown in the figure Illustration, cabling inside upper arm housing on page 115. 6. Disconnect all the connectors inside the frame. Shown in the figure Illustration, cabling inside frame on page 117.
xx0400001247
7. Remove the fastening plate, all cable ties and Attachment points inside the frame brackets from inside the frame. Remove the cable are shown in the figure Illustration, clamp unit from the fastening plate. cabling inside frame on page 117.
8. Disconnect all the connectors at the base and remove the SMB unit from the base.
Shown in the figure Illustration, cabling inside base on page 118.
NOTE!
Do not lose the centering piece fitted to the push button unit! 9. Remove all cable ties and brackets at the base. 10. Pull out the cabling from the upper arm housing and pull it down through the lower arm. 11. Continue pulling down the cable harness through the frame and pull it out at the rear of the base. Shown in the figure Illustration, cabling inside base on page 118.

4 Repair
4.3.1. Replacement of cable harness Continued Illustration, cabling inside upper arm housing The figure below shows how the cabling is run inside the upper arm housing.
xx0400001250
A B C D
Signal cabling; connectors for motors on axes 3, 4, 5 and 6: R3.FB3, R3.FB4, R3.FB5 and R3.FB6 Power cabling; connectors for motors on axes 3, 4, 5 and 6: R3.MP3, R3.MP4, R3.MP5 and R3.MP6 Optional connector: R2.CP Optional connector: R2.CS Distance console with contact panel Cable clamp unit Attachment screws, cable clamp unit (2 pcs, only one shown) Clamp, signal cabling Clamp, motor cabling Connector plate Connector holder Cable tie, connector holder
E F G H I J K L

4 Repair
4.3.1. Replacement of cable harness Continued Refitting, cable harness in upper arm housing and lower arm The procedure below details how to refit the cabling inside the upper arm housing. The cable layout is shown in the figure Illustration, cabling inside upper arm housing on page 115. Action
1.
Note/Illustration
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Insert the cabling to axes 3, 4, 5 and 6 up through the lower arm and into the upper arm housing. 3. Place the cable bracket correctly inside the lower Spare part no. is specified in arm and secure it by refitting the VK-cover. Required equipment on page 112.
xx0400001247
Cable bracket is attached to the cabling with 2 screws, M6x8. 4. Fasten the cabling inside the upper arm housing Shown in the figure Illustration, by fitting the cable clamp unit to the distance cabling inside upper arm housing on console with two attachment screws. page 115. 5. Fit the motor and signal cabling to the connector Hexagon nut: M5. 1 pc for each plate with clamps. clamp.
6. Reconnect the signal cable connectors and slide Shown in the figure Illustration, them into the connector holder. cabling inside upper arm housing on Notice that one of the cable ties in the connector page 115. holder plate must be removed in order to insert the cables into the holder. Refit it when the connectors are inserted. 7. Reconnect the motor cable connectors. 8. Reconnect optional connectors, if any, at the contact panel. 9. Place the cabling correctly inside the housing and secure it with cable ties. The cable layout is shown in the figure Illustration, cabling inside upper arm housing on page 115.
10. Refit the arm housing cover with eight attachment 8 pcs, M6. screws. Check the two gaskets and replace, if Shown in the figure Illustration, damaged. covers to remove on page 113. Spare part no. is specified in Required equipment on page 112. 11. Fit new VK-covers to the lower arm. Spare part no. is specified in Required equipment on page 112.

4 Repair
4.3.1. Replacement of cable harness Continued Action
12. Continue refitting the cable harness according to procedure Refitting, cable harness in frame and base on page 119.
Note/Illustration
Illustration, cabling inside frame The figure below shows how the cabling is run inside the frame.
xx0400001249
A
Power cabling; connectors for motors on axes 1 and 2: R3.MP1 and R3.MP2 Signal cabling; connectors for motors on axes 1 and 2: R3.FB1 and R3.FB2 Cable clamp unit (attachment screws behind the fastening plate) Fastening plate Attachment screws and nuts
B C D E

4 Repair
4.3.1. Replacement of cable harness Continued Illustration, cabling inside base The figure below shows how the cabling is run inside the base. Optional cabling is also shown in the figure, but not further specified.
xx0500001388
A B C D E F G H
Power cabling Signal cabling Clamp with hexagon nut Attachment screws, cable clamp unit Hexagon nut, SMB plate Fastening plate SMB unit Cable clamp unit

4 Repair
4.3.1. Replacement of cable harness Continued Refitting, cable harness in frame and base The procedure below details how to refit the cabling inside the frame and the base. The cable layout is shown in the figures Illustration, cabling inside frame on page 117 and Illustration, cabling inside base on page 118. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Run the cables from the lower arm into the frame. 3. Fit the cable clamp unit to the fastening plate Shown in the figure Illustration, cabling with two attachment screws, but do not secure inside frame on page 117. the plate to the frame yet. 4. Run the cabling down to the base. Pull it out at the rear of the base. 5. Connect all the connectors inside the frame Shown in the figure Illustration, cabling and secure all plates and cable brackets inside inside frame on page 117. the frame with attachment screws and nuts. 6. In the base, secure the cabling to the bottom Shown in the figure Illustration, cabling fastening plate: inside base on page 118. fit the cable clamp unit with two attachment screws (M6). fit the separate cables with clamps and hexagon nuts. 7. Refit the SMB unit to the fastening plate with hexagon nuts. 8. Refit the centering piece (B) to the push button unit in order to align it vertically. Also make sure that the unit is correctly aligned sideways: the measurements x1 and x2 in the figure to the right should not differ more than 1 mm from each other! Shown in the figure Illustration, cabling inside base on page 118.
xx0600002777
Art. no. for the centering piece is specified in Required equipment on page 112. 9. Refit the push button guard to the robot base. 10.
WARNING!
Before continuing any service work, please observe the safety information in section WARNING - The brake release buttons may be jammed after service work on page 34!

4 Repair
4.3.1. Replacement of cable harness Continued Action Note
11. Connect the: Shown in the figure Illustration, cabling signal cable connectors to the SMB unit inside base on page 118. power cable connector to the housing in the base optional cabling, if any ground cable. 12. Refit the covers to the frame and to the base. Replace the gaskets, if damaged. Shown in the figure Illustration, covers to remove on page 113. Spare part no. is specified in Required equipment on page 112. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information.
13. Recalibrate the robot!
120
4 Repair
4.3.2. Replacement of cable harness, IRB 1600ID
4.3.2. Replacement of cable harness, IRB 1600ID

Location of the harness The location of the harness is shown in several figures, next to the procedures, later on in this section.
R4.FB5
R4.FB6
R4.MP5
R4.MP6

xx0700000038
A B E F
R4.FB6 R4.FB5 R4.MP6 R4.MP5

Standard toolkit Circuit diagram
Spare part no.
Note
Contents, standard toolkit.

4 Repair
4.3.2. Replacement of cable harness, IRB 1600ID Continued Equipment
Cable ties VK- cover Cable harness axis 5-6. 3HAA 2166-23 3HAC027523-002 Upper and lower covers. 2 pcs IRB 1600 AW
Spare part no.
Note
Removal, cable harness lower arm and upper arm back The procedure below describes removal of the complete cable harness in upper arm back.

xx0700000105
Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the cover to the upper arm.

4 Repair
4.3.2. Replacement of cable harness, IRB 1600ID Continued Action
3. Remove the hexagon nut with flange (A) holding the two (2) clamps.
Note
xx0700000106
A. Hexagon nut with flange 4. Disconnect R3.FB3 - R3.FB6. 5. Disconnect R3.MP3 - R3.MP6. 6. Remove the cable harness from the lower Follow instructions in section Removal, arm. cable harness.
Removal, cable harness upper arm tube 1600ID The procedure below describes removal of the complete cable harness in upper arm tube.
xx0700000099
A B C D
Cover plate Clamp R4.FB5 R4.FB6

4 Repair
4.3.2. Replacement of cable harness, IRB 1600ID Continued
E F G H I J R4.MP6 R4.MP5 R3.MP5 R3.MP6 R3.FB5 R3.FB6
Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the upper arm tube. 3. Remove all the Torx pan head screw (A) holding the cover. Described in section Replacement of motor, axis 5, IRB 1600ID.
xx0700000113
A. Torx pan head screw M6x12 B. Hexagon nut with flange M5 4. Remove the cover plate.
TIP!
The spare part cable harness 3HAC027523-002 includes a galvanized coverplate without paint. If a painted cover is prefered, use the old cover plate.

4 Repair
4.3.2. Replacement of cable harness, IRB 1600ID Continued Action
5. Remove the cable pulling it out through the passage (A).
Note
xx0700000114
Refitting, cable harness The procedure below describes refitting of the complete cable harness. Action
1. Refit the cable harness. 2. Refit the upper arm tube. 3. Refit the connections in the upper arm.
Note
Described in section Refitting, cable harness in upper arm housing and lower arm on page 116 Described in section Refitting, motor axis 5 on page 207. Shown in figure Location of the harness on page 121.
125
4 Repair
4.3.3. Replacement of complete arm system
4.3.3. Replacement of complete arm system

Location of complete arm system The complete arm system includes complete upper and lower arm.
xx0500001443
A B C
VK-cover (attachment screws underneath cover) Cover, frame Cover, base

Lifting slings VK-cover Sealing ring (V-ring) Isopropanol Locking liquid Standard toolkit Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.
Art. no.
3HAA 2166-23 3HAB 3732-13 -
Note
Replace if damaged. Used to clean the mating surfaces. Loctite 574 The contents are defined in section Standard toolkit on page 237. These procedures include references to the tools required.
Removal, complete arm system The procedure below details how to remove the complete arm system from the robot. Action
1. Move the robot to its calibration position.
Note

4 Repair
4.3.3. Replacement of complete arm system Continued Action
2.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 3. Remove the covers from the base and the frame. 4. Release the cable harness from below upwards The cable layouts inside the base and to the lower arm by: the frame are shown in the figures: disconnecting all the connectors inside Illustration, cabling inside the base and the frame. base on page 118. removing all cable ties and brackets Illustration, cabling inside inside the base and the frame. frame on page 117. 5. Push out the VK-cover from inside of the frame. Shown in the figure Location of complete arm system on page 126. 6.
CAUTION!
The complete arm system weighs 55 kg! All lifting equipment used must be sized accordingly! 7. Fit lifting slings to the upper arm to unload the weight of the complete arm system. 8. Unscrew the 12 attachment screws and remove the one washer. Be careful when pulling the cabling through base, frame and lower arm. Use tape to bunch the connectors and protect them. 9. Gently pull out the cabling from the frame and base while lifting away the complete arm system.
10. Check the sealing ring. Replace if damaged.
Refitting, complete arm system The procedure below details how to refit the complete arm system to the robot. Action
1.
Note/Illustration
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Clean the mating surfaces on both the lower arm and on the frame with isopropanol. Also clean the area where the sealing ring is fitted, if it has been removed.

4 Repair
4.3.3. Replacement of complete arm system Continued Action Note/Illustration
3. Fit the sealing ring properly to the frame. Replace it Art. no. is specified in Required if damaged. equipment on page 126.
xx0400001245
4. Lubricate the attachment holes at the mating surface on the frame with Loctite 574. 5.
A: Sealing ring B: Mating surface
CAUTION!
The complete arm system weighs 55 kg! All lifting equipment used must be sized accordingly! 6. Fit the lifting slings to the complete arm system and lift it into position while inserting the cabling into the frame. 7. Fit the lower arm against the frame, fit the one washer and secure with the 12 attachment screws. 8. Refit the cabling inside the frame and the base. 12 pcs; M10 x 40, tightening torque: 70 Nm. Detailed in section Refitting, cable harness in frame and base on page 119. Art. no. is specified in Required equipment on page 126. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information.
9. Fit a new VK-cover to the lower arm. 10. Recalibrate the robot!
11.
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 33.
128
4 Repair
4.4.1. Replacement of complete upper arm
4.4 Upper and lower arm 4.4.1. Replacement of complete upper arm
General The complete upper arm is considered a spare part, including wrist, gearboxes and motors. Location of upper arm The figure below shows the location of the upper arm on the robot and some of the upper arm components. A more detailed view of the upper arm may be found in the spare part view Upper arm, exploded view 2 on page 252 in part 2 of the Product manual.
xx0400001218
A B
Arm housing cover, including gaskets for the cover and the contact panel VK cover. Upper arm attachment screws inside

Upper arm, spare
Spare part no.

3HAC026567-001
Art. no.
Note
Includes the wrist unit. All gearboxes are filled with oil at delivery. Note! This upper arm spare is interchangeable with upper arm spare with art. no. 3HAC 023630-001. But this change of upper arm requires software 5.07.01. Replace if damaged. Replace if damaged.
VK-cover Sealing ring (V-ring)
3HAA 2166-23 3HAB 3732-19
Gasket, upper arm cover 3HAC 022049-001

4 Repair
4.4.1. Replacement of complete upper arm Continued Equipment
Gasket, customer connections Grease Locking liquid Lifting slings Standard toolkit
Spare part no.

3HAC 022050-001
Art. no.
Note
Replace if damaged.
3HAB 3537-1 To lubricate the sealing ring (V-ring). The contents are defined in section Standard toolkit on page 237. These procedures include references to the tools required. Loctite 574
Removal, complete upper arm The procedure below details how to remove the complete upper arm from the robot. Action
1. Move the upper arm to a horizontal position. 2.
Note/Illustration
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 3. Remove the arm housing cover from the upper Shown in the figure Location of upper arm. arm on page 129. 4. Disconnect all connectors inside the arm housing and loosen the cabling from straps and brackets. 5. Remove the VK-cover from the lower arm by pushing it out from the inside. Pull out the cabling from the arm housing. 6. Secure the weight of the arm with lifting slings. 7. The cabling and all connectors inside the upper arm housing are shown in the figure Illustration, cabling inside upper arm housing on page 115. Shown in the figure Location of upper arm on page 129.
CAUTION!
The complete upper arm weighs 34 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel!

4 Repair
4.4.1. Replacement of complete upper arm Continued Action
8. Remove the 10 attachment screws (A) and the single washer (B).
Note/Illustration
xx0400001219
9. Remove the upper arm, lift it away and place it securely.
Refitting, complete upper arm The procedure below details how to refit the complete upper arm to the robot. Action
1.
Note/Illustration
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Wipe the contact surfaces clean on both the upper and lower arm. 3.
CAUTION!
The complete upper arm weighs 34 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel!
4. Attach lifting slings to the upper arm and lift it. 5. Lubricate the sealing ring (A) with grease and fit it to the upper arm. Replace the sealing ring, if damaged.
xx0400001220
6. Lubricate the the contact surface, upper arm, with Loctite 574.
A: Sealing ring, spare part no. is specified in Required equipment on page 129. B: Contact surface.

4 Repair
4.4.1. Replacement of complete upper arm Continued Action
7. Lift the upper arm to mounting position, fit the washer (B) and secure the upper arm with the 10 attachment screws (A).
Note/Illustration
10 pcs: M10 x 40. Tightening torque: 70 Nm.
xx0400001219
8. Run the cabling through the lower arm and into the arm housing. 9. Connect all the connectors in the arm housing Refitting of the cabling in the upper and secure the cabling with brackets and straps. arm housing is further detailed in section Refitting, cable harness in upper arm housing and lower arm on page 116. 10. Refit the arm housing cover to the upper arm. Shown in the figure Location of upper Check the two gaskets in the cover and replace arm on page 129. them, if damaged. Spare part no. is specified in section Required equipment on page 129. 11. Refit a new VK-cover to the lower arm. Shown in the figure Location of upper arm on page 129. Spare part no. is specified in section Required equipment on page 129. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information.
13.
DANGER!
132
4 Repair
4.4.2. Replacement of complete upper arm, IRB 1600ID
4.4.2. Replacement of complete upper arm, IRB 1600ID

NOTE! Recalibration of robot axis 3-6 is required after replacement of upper arm. Location of upper arm The complete upper arm is considered a spare part, including wrist, gearboxes and motors. The figure below shows the location of the upper arm and connection to the lower arm.
xx0700000045
A B C D
VK -Cover Socket head cap screw M10x40 Cable harness V-ring

Upper arm, spare
Spare part no.
Art. no.
Note
Includes the wrist unit. All gearboxes are filled with oil at delivery.

4 Repair
4.4.2. Replacement of complete upper arm, IRB 1600ID Continued Equipment
Standard tool kit VK-cover V-ring axis 3 Gasket, customer connections Pendulum calibration tool 3HAA 2166-23 3HAB3732-19 3HAC 022050-001 Replace if damaged
Spare part no.
Art. no.
Note
Contents, standard toolkit
Remove, complete upper arm The procedure below details how to remove the complete upper arm from the robot. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Put the manipulator in synchronization position for Axis 3.
xx0700000075
A. Synchronization mark Axis 3

4 Repair
4.4.2. Replacement of complete upper arm, IRB 1600ID Continued Action
3. Remove the cover arm housing from the upper arm, using standard tools.
Note
xx0700000077
A. Cover Arm Housing B. Torx pan head screw 4. Disconnect all connectors inside the arm housing and loosen the cabling from straps and brackets. 5. Described in section Removal, cable harness lower arm and upper arm back.
CAUTION!
The complete upper arm weighs 39 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel! 6. Secure the weight of the arm with lifting slings.
xx0700000060

4 Repair
7. Knock out the VK-cover from the motor side. 8. Remove the 10 attachment screws (A) and the single washer, use standard tools.
Note
xx0700000057
A. Socket head cap screw M10x40 9. Carefully remove the upper arm.
Refitting, complete upper arm The procedure below details how to refit the complete upper arm to the robot. Action
1. Wipe the contact surfaces clean on both the upper and lower arm. 2. Attach lifting slings to the upper arm and lift it.
Note
3. Clean the contact surface.
A
xx0700000076
A. Contact surface.

4 Repair
4. Carefully refitting the upper arm to the lower arm, make sure that the new upper arm is mounted in the synchronization position.
Note
xx0700000075
A. Synchronization mark Axis 3 5. Refit the 10 attachment screws (A) and the single washer, use standard tools. Tightening torque: 70 Nm
xx0700000057
A. Socket head cap screw M10x40 6. Run the cabling through the lower arm and into the arm housing. 7. Connect all the connectors in the arm housing and secure the cabling with brackets and straps. Refitting of the cabling in the upper arm housing is further detailed in section Refitting, cable harness..

4 Repair
8. Refit the cover arm housing to the upper arm, using standard tools Contents, standard toolkit.
Note
xx0700000077
A. Cover Arm Housing B. Torx pan head screw 9. Refit a new VK-cover to the lower arm. replace it, if damaged. 10. Recalibrate the robot. Spare part no. is specified in section Required equipment on page 129. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information.
11.
DANGER!
138
4 Repair
4.4.3. Replacement of complete lower arm
4.4.3. Replacement of complete lower arm

Location of lower arm The lower arm is located on the robot as shown in the figure below. A more detailed view of the lower arm may be found in the spare part view Lower arm, exploded view on page 249 in part 2 of the Product manual.
xx0400001246
A B C
Lower arm VK-cover VK-cover, middle

Lower arm, spare Lower arm, short, spare VK-cover VK-cover
Spare part no.

3HAC 023558-001 3HAC 023559-001 3HAA 2166-23 3HAA 2166-21
Note
IRB 1600 - 7/.12 IRB 1600 - 7/1.45 IRB 1600 - 5/1.2 IRB 1600 - 5/1.45 In the middle of the lower arm.

4 Repair
4.4.3. Replacement of complete lower arm Continued Equipment
Sealing ring (V-ring) Isopropanol Locking liquid Standard toolkit
Spare part no.

3HAB 3732-13
Note
Replace if damaged. Used to clean the mating surfaces. Loctite 574 The contents are defined in section Standard toolkit in the Product manual, reference information! These procedures include references to the tools required.
Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.
Removal, lower arm The procedure below details how to remove the complete lower arm. Action
1.
Note/Illustration
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the complete upper arm. 3. Remove the VK-covers. Detailed in section Removal, complete upper arm on page 130. Shown in the figure Location of lower arm on page 139.
CAUTION!
Be careful not to damage the cabling and cable bracket inside the lower arm when removing the middle VK-cover! The figure to the right shows the space underneath the cover. The gray areas are safe for insertion of a tool that may be inserted with a maximum depth of 20 mm! 4. Pull down the cabling through the lower arm and pull it out. 5.
xx0400001247
CAUTION!
The lower arm weighs 20 kg! Use a suitable lifting device to avoid injury to personnel! 6. Fit the lifting device to the lower arm to secure the weight of the arm. 7. Unscrew the 12 attachment screws and remove the single washer. 8. Gently pull out the cabling while lifting away the lower arm. Be careful with the connectors, they are sensitive to damage!

4 Repair
4.4.3. Replacement of complete lower arm Continued Action
9. Check the sealing ring. Replace it if damaged.
Note/Illustration
Spare part no. is specified in Required equipment on page 139.
Refitting, lower arm The procedure below details how to refit the complete lower arm. Action
1. Clean the mating surfaces on both the lower arm and on the frame with isopropanol. Also clean the area where the sealing ring is fitted. 2. Fit the sealing ring properly to the frame. Replace it if Spare part no. is specified in damaged. Required equipment on page 139.
Note/Illustration
xx0400001245
3. Lubricate the mating surface on the frame with Loctite 574.

A: Sealing ring B: Mating surface
4.
CAUTION!
The lower arm weighs 20 kg! Use a suitable lifting device to avoid injury to personnel! 5. Fit the lifting device to the lower arm and lift it into position. 6. Insert the cabling into the lower arm. 7. Fit the lower arm against the frame, fit the washer and secure with the 12 attachment screws. 8. Push the cabling up through the lower arm and place the cable bracket inside the lower arm correctly. 9. Fit new VK-covers to the lower arm. Spare part no. is specified in Make sure that the cable bracket inside the lower arm Required equipment on page 139. is secured beneath the middle VK-cover. 10. Refit the upper arm. Detailed in section Refitting, complete upper arm on page 131. 12 pcs; M10 x 40, tightening torque: 70 Nm.

4 Repair
4.4.3. Replacement of complete lower arm Continued Action
Note/Illustration
Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information.
12.
DANGER!
142
4 Repair
4.4.4. Replacement of wrist unit
4.4.4. Replacement of wrist unit

Location of wrist unit The wrist unit is located in the frontmost part of the upper arm. A more detailed view of the upper arm, including the wrist unit, is found in the spare part view .Upper arm, exploded view 1 on page 251 in part 2 of the Product manual.
xx0600002847
A B C
Attachment screws, wrist unit (3 pcs) Oil plug (only one shown) Wrist unit

Spare part no.

3HAC 026569-001
Art. no.
Note
Standard and Foundry versions. O-ring sealingplate not included! Note! The wrist, standard/ Foundry is not interchangeable with art. no. 3HAC 10475-1! Must be replaced. Note! The o-ring sealingplate is not interchangeable with art.no. 3HAC 7191-1!
Wrist, Standard/ Foundry
O-ring sealingplate
3HAC 025420-001
Grease Standard toolkit
3HAC 3537-1 For lubricating the o-ring sealingplate. The contents are defined in section Standard toolkit on page 237.

4 Repair
4.4.4. Replacement of wrist unit Continued Equipment, etc.
Spare part no.
Art. no.
Note
These procedures include references to the tools required.
Removal, wrist unit The procedure below details how to remove the complete wrist unit. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Drain the oil from the wrist unit. 3. Remove the wrist unit by unscrewing its three attachment screws. Detailed in section Oil change, gearbox axes 5 and 6 on page 97. Shown in the figure in section Location of wrist unit on page 143.
Refitting, wrist unit The procedure below details how to refit the complete wrist unit. Action
1. Move the robot to a position where the upper arm is vertical. 2.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 3. Lightly lubricate the o-ring sealingplate with grease. Art. no. is specified in section Required equipment on page 143.
4. In order to release the brake, connect the Connect to connector R3.MP5 or 6: 24 VDC power supply to motors: +: pin 7 -: pin 8 5. Fit the o-ring sealingplate to the upper arm. Fit the wrist unit to the upper arm with the three attachment screws, while making sure that the gears mate properly. 6. Perform a leak-down test. 7. Refill the wrist unit with oil. Use a new o-ring! Spare part no. is specified in Required equipment on page 143. 3 pcs, M8 x 25, tightening torque: 28 Nm.
Detailed in section Performing a leak-down test on page 108. Detailed in section Oil change, gearbox axes 5 and 6 on page 97.

4 Repair
4.4.4. Replacement of wrist unit Continued Action
Note
9.
DANGER!
145
4 Repair
4.4.5. Replacement of wrist unit, IRB1600ID
4.4.5. Replacement of wrist unit, IRB1600ID

NOTE! After replacement of motors/motor or gearbox in a manipulator, recalibration is required. Location of wrist unit The wrist unit is located in the frontmost part of the upper arm.
G B
F C
xx0700000025
A B C D E F G
Upper arm Wrist Hexagon socket head screw M5x25 Hexagon socket head screw M5X16 (10.9) (Short head) Hexagon socket head screw M5x25 Hexagon socket head screw M8x35
Motor axis 6

Wrist, ID O-ring Grease Standard toolkit 3HAC3537-1 For lubricating the o-ring sealing plate. Contents, standard toolkit.
Spare part no. Art. No.
Note

4 Repair
4.4.5. Replacement of wrist unit, IRB1600ID Continued Equipment
Arm
Spare part no. Art. No.

3HAC9037-1
Note
For adjusting the gear play, motor/ pinion. See references to these procedures in the step-by-step instructions below.
Other tools and procedures may be required.
Loctite 542
12690014-412
Removal, wrist unit The procedure below details how to remove the complete wrist unit. Action
1.
Note
DANGER!
Turn of all electric power, hydraulic and pneumatic pressure supplies to the robot!. 2. Remove the AW equipment in the upper arm. 3. The plug (A) in figure covering the screw (C). Remove the plug using standard tools (B). Remove the screw for looking of motor axis 5, (C) in figure Location of wrist unit on page 146.
Shown in Remove AW Gun on page 160
xx0700000092
A. Plug. B. Standard tool, Contents, standard toolkit. C. Hexagon socket head screw M5X16 (Short head).

4 Repair
4.4.5. Replacement of wrist unit, IRB1600ID Continued Action
4. Remove the VK-Cover (A).
Note
xx0700000054
A. VK-Cover 5. Gently pull the cables out of the upper arm VKcover hole. 6. Disconnect through the VK-hole the cable harness contacts, R4.FB6 and R4.MP6.
xx0700000053
A. Contact R4.FB6 B. Contact R4.MP6 7. Remove the three attachment screws (A).
xx0700000052
A. Hex socket head cap screw M8x35 8. Remove the wrist with motor 6 from the upper arm tube.

4 Repair
9. Remove the three screws, hexagon socket head screw M5x25 (E). Remove the axis 6 motor (C).
Note
xx0700000091
A. B. C. D. E.
Contact R4.FB6 Contact R4.MP6 Motor axis 6 Hexagon socket head screw M8x35 Hexagon socket head screw M5x25
Refitting, wrist unit The procedure below details how to refit the complete wrist unit. Action
1.
Note
NOTE!
If the screws (A) for the Motor Console (B) are removed, use Loctite 542 12690014-412 on the screws when refitting. Refit the Hex socket head cap screw M5x25 Tightening torque 4,1 Nm
xx0700000353
A. Hex socket head cap screw M5x25 B. Motor Console 2. Refit the axis 6 motor using Tightening torque 4,1 Nm the three hexagon socket head screw M5x25, shown as (D) in figure Location of wrist unit on page 146

4 Repair
3. Carefully refit the wrist with motor to the upper arm tube. Use a string to pull the cable harness back through the VKhole in the upper arm tube.
Note
xx0700000093
A. String 4. Use standard tools to refit the Shown as (H) in figure Location of wrist unit on page three hexagon socket head 146. screw (M8x35). Tightening torque 24 Nm 5. Reconnect through the VKhole the cable harness contacts R4.FB6 and R4.MP6. 6. Tightening the hexagon socket head screw M5X16 (Short head). 7. Tightening the plug (A). Tightening torque 6 Nm Make sure that all the cabling is placed correctly inside the upper arm tube.
Shown as (E) in figure Location of wrist unit on page 146. Tightening torque 6 Nm
xx0700000092
8. Refit the AW equipment in the Shown in Refitting, wrist unit on page 149 upper arm. 9. Recalibrate the robot. Shown in Introduction, calibration information.
150
4 Repair
4.4.6. Replacement of damper, axis 2

Location of damper, axis 2 The damper, axis 2, is located as shown in the figure below.
xx0400001217
A B
Damper, axis 2 Attachment screw and washer

Damper, axis 2
Spare part no.

3HAC 022013-001
Note
The contents are defined in section Standard toolkit on page 237. These procedures include references to the tools required.
Standard toolkit Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.
Removal, damper axis 2 The procedure below details how to remove the damper, axis 2. Action
1. Run the robot to a position that enables you to access the attachment screw of damper, axis 2.
Note

4 Repair
4.4.6. Replacement of damper, axis 2 Continued Action
2.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 3. Remove the damper by unscrewing the single attachment screw and washer.
Refitting, damper axis 2 The procedure below details how to refit the damper, axis 2. Action
1. Run the robot to a position that enables access to the attachment screw of the damper, axis 2. 2.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 3. Secure the damper with the attachment screw and washer. 4. 1 pc: M6 x 16.
DANGER!
152
4 Repair

Location of damper, axis 3 The damper, axis 3, is shown in the figure below. A more detailed view of the damper and its position may be found in the spare part view Upper arm, exploded view 2 on page 252 in part 2 of the Product manual.
xx0400001215
A B
Damper, axis 3 Cast tab
Required equipment
Equipment, etc.
Damper, axis 3 Standard toolkit
Spare part no.

3HAC 022260-001
Note
Removal, damper axis 3 The procedure below details how to remove the damper, axis 3. Action
1. Run the robot to a position that enables access to damper, axis 3. 2.
Note
Shown in the figure Location of damper, axis 3 on page 153.
DANGER!

4 Repair
4.4.7. Replacement of damper, axis 3 Continued Action
3. Remove the damper by gently prying it from the cast tab.
Note
Refitting, damper axis 3 The procedure below details how to refit the damper, axis 3. Action Note
1. Run the robot to a position that enables access to the Shown in the figure Location of location where the damper, axis 3, is fitted. damper, axis 3 on page 153. 2.
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 3. Refit the damper by gently pressing it onto the cast tab on the upper arm. 4.
DANGER!
154
4 Repair
4.4.8. Replacement of Mechanical damper, axis 3, IRB 1600ID
4.4.8. Replacement of Mechanical damper, axis 3, IRB 1600ID

Location of damper, axis 3 The location of damper, axis 3.
A B
xx0700000043
A B
Torx counters. head screw Mechanical damper

Spare part no.
Art. no.
3HAC027626-001
Note
Mechanical damper Standard tools
Removal, Mechanical damper axis 3 The procedure below details how to remove the damper, axis 3. Action
1. Run the robot to a position that enables access to damper, axis 3. 2.
Note
DANGER!

4 Repair
4.4.8. Replacement of Mechanical damper, axis 3, IRB 1600ID Continued Action
3. Remove the damper.
Note
Use standard tools, Contents, standard toolkit.
Refitting, Mechanical damper axis 3 The procedure below details how to refit the damper, axis 3. Action
1. Refit the damper. 2.
Note
Use standard tools, Contents, standard toolkit.
DANGER!
156
4 Repair

Location of damper, axis 5 The damper, axis 5, is located as shown in the figure below!
xx0600002806
A B
Damper, axis 5 Recess

Damper, axis 5 Standard toolkit
Spare part no.

3HAB 8964-1
Note
Removal, damper axis 5 The procedure below details how to remove the damper, axis 5.
Action
Note
1. Run the robot to a position that enables the end of the Shown in the figure Location of damper to be pushed into the recess in the wrist unit. damper, axis 5 on page 157. 2.
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 3. Unhook the end of the damper, and push it into the recess. 4. Manually move the wrist (robot axis 5) away from the damper to pull it out.

4 Repair
4.4.9. Replacement of damper, axis 5 Continued Refitting, damper axis 5 The procedure below details how to refit the damper, axis 5. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Push the end of the damper into the gap between the wrist unit and upper arm. 3. Manually move the wrist (robot axis 5) in order to pull the damper into position. 4. Fold out the damper hooks to secure it in position. 5. Make sure the damper is turned the correct way!
DANGER!
158
4 Repair
4.4.10. Remove upper arm AW Gun
4.4.10. Remove upper arm AW Gun

Location of AW Gun The location of the AW equipment.
xx0700000153
A B C D
Wire feeder (customer option) Weld gun (BINZEL) Welding cable (BINZEL) Brace (BINZEL)

Standard tools
Spare part no.
Art. no.
Note
Contents, standard toolkit.

4 Repair
4.4.10. Remove upper arm AW Gun Continued Remove AW Gun The section below shows how to remove the AW. equipment from the upper arm of a IRB 1600 ID. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the welding cable (C) from the weld gun by twisting the locking sleeve (A) counter clockwise. Loosen the locking screw (B) and pull out the welding cable.
xx0700000151
A. Locking sleeve B. Locking screw C. Welding cable

3. Remove the two screws holding the brace.
xx0700000273
A. BINZEL Brace

4 Repair
4.4.10. Remove upper arm AW Gun Continued Action
4. Remove the welding cable from the wire feeder and pull it out.
Note
xx0700000142
A. Wire feeder B. Welding cable 5. The locking ring (A) has a thread, loosen it counter clockwise and remove it. Remove the locking sleeve (B). Remove all 6x M5 screw (C).
xx0700000150
A. Locking ring B. Locking sleeve C. Screw M5
Refit AW Gun The section below shows how to refit the AW. equipment to the upper arm of a IRB 1600 ID. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot.

4 Repair
4.4.10. Remove upper arm AW Gun Continued Action
2. Refit the welding gun using the 6X Socket head cap screw M5 (C). Refit the locking sleeve (B). Lock the sleeve using the locking ring (A).
Note
xx0700000150
A. Locking ring B. Locking sleeve C. Screw M5 3. Refit the welding cable (C). Lock the cable using the screw (B).
xx0700000151
A. Locking sleeve B. Locking screw C. Welding cable 4. Refit the brace (A).
xx0700000273
162
4 Repair
4.4.11. Fitting equipment on the robot, IRB 1600ID
4.4.11. Fitting equipment on the robot, IRB 1600ID

Location of shelf, wire feeder
A B
E D
xx0700000311
A B
Bracket ESAB wire feeder Shelf, wire feeder Hexagon nut with flange M5 Knob Plain washer (8,4x16x1,6) Hex socket head cap screw (M8x12)
C D E F
Fitting the wire feeder shelf Action Note
1. Fit the Shelf, wire feeder Shown in figure Location of shelf, wire feeder on page 163 (B) using the four (4) Hex socket head cap screw (F).

4 Repair
4.4.11. Fitting equipment on the robot, IRB 1600ID Continued Action
2. Fit the bracket on the wire feeder using the four (4) Hexagon nut with flange (A).
Note
xx0700000312
A. Hexagon nut with flange M5 B. Knob 3. Fit the wire feeder with the mounted bracket on the Shelf, wire feeder and mount the two knobs.
164
4 Repair
4.5.1. Replacement of base
4.5 Frame and base 4.5.1. Replacement of base

Location of base The base is located at the bottom of the robot as shown in the figure below. A more detailed view of the base may be found in the spare part view Base, exploded view on page 243 in part 2 of the Product manual.
xx0500001453
A B
Base Attachment screws and washer, base-gearbox unit (VK-cover removed)

Base, spare V-ring (sealing ring) VK-cover Lifting slings Locking liquid
Spare part no.

3HAC 023552-001 3HAB 3732-21 3HAA 2166-26
Art. no.
Note
Replace if damaged.
Loctite 574 For sealing the base to the gearbox 1-2. 3HAB 3537-1 For lubricating the V-ring.
Grease

4 Repair
4.5.1. Replacement of base Continued Equipment
Isopropanol Standard toolkit -
Spare part no.
Art. no.
Note
For cleaning the mating surfaces. The contents are defined in section Standard toolkit on page 237. These procedures include references to the tools required.
Removal, base The procedure below details how to remove the base from the robot. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the cabling inside the base and pull it up to the gearbox unit. 3. Remove the serial measurement unit. 4. Unfasten the base from the installation site by removing the attachment bolts from the foundation. 5.
The cable layout in the base is shown in the figure Illustration, cabling inside base on page 118. Detailed in section Removal, serial measurement unit on page 170.
CAUTION!
The robot weighs 250 kg! All lifting equipment must be sized accordingly! 6. Fit the lifting slings to the robot, lift it and place it Art. no. is specified in Required with the side of the lower arm downwards on a equipment on page 165. work bench. Be careful not to damage the motor connectors! 7. Remove the VK-cover from the base.
TIP!
Push out the cover from inside or drill a hole in the cover through which a tool can be inserted in order to bend out the cover.

4 Repair
4.5.1. Replacement of base Continued Action
8.
Note
CAUTION!
The base weighs 81 kg! All lifting equipment used must be sized accordingly! 9. Secure the weight of the base and remove the gearbox/base attachment screws and washer. 10. Separate the base from the gearbox unit. Shown in the figure Location of base on page 165.
Refitting, base The procedure below details how to refit the base to the robot. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Place the robot with the side of the lower arm downwards on a workbench. Be careful not to damage the motor connectors. 3. Clean the mating surfaces between the base and the gearbox unit with isopropanol. 4. Check the V-ring on the gearbox unit. Lubricate Spare part no. is specified in Required with grease if needed. Replace it if damaged! equipment on page 165. 5. Lubricate the mating surface on the base with Loctite 574. 6.
CAUTION!
The base weighs 81 kg! All lifting equipment used must be sized accordingly! 7. Lift the base to mounting position. 8. Secure the base to the gearbox unit with the gearbox/base attachment screws and washer. Shown in the figure Location of base on page 165. 16 pcs, M10 x 40, tightening torque: 70 Nm. Spare part no. is specified in Required equipment on page 165.
9. Refit a new VK-cover to the base. 10.
CAUTION!
The robot weighs 250 kg! All lifting equipment must be sized accordingly! 11. Turn the robot to stand upright.

4 Repair
4.5.1. Replacement of base Continued Action
12. Secure the base to the foundation.
Note
Attachment bolts and tightening torque are specified in section Attachment bolts, specification on page 50.
13. Pull down the cabling and refit it inside the base. The cable layout inside the base is shown in the figure Illustration, cabling inside base on page 118. 14. Refit the serial measurement unit. 15. Recalibrate the robot. Detailed in section Refitting, serial measurement unit on page 171. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information.
16.
DANGER!
168
4 Repair
4.5.2. Replacement of serial measurement unit
4.5.2. Replacement of serial measurement unit

Location of serial measurement unit The serial measurement unit is located inside the base of the robot, as shown in the figure below. A more detailed view of the unit and its position may be found in the spare part view Base, exploded view on page 243 in part 2 of the Product manual.
xx0500001390
Base cover, including gasket. Serial measurement unit is located beneath the cover.
Serial measurement unit layout The complete spare part of the serial measurement unit is shown in the figure below.
xx0500001391
A B C D E
Connector SMB Connector SMB1-4 Connector SMB 3-6 Hexagon nuts (totally 4 pcs) Battery pack

4 Repair
4.5.2. Replacement of serial measurement unit Continued Required equipment Equipment
Serial measurement unit Gasket, base cover Centering piece
Spare part no.

3HAC 023424-001 3HAC 022047-001 3HAC025815-001
Note
Fitted to the push button unit in order to align it correctly. Replace if damaged. The contents are defined in section Standard toolkit on page 237. See chapter Circuit diagram.
Standard toolkit Circuit diagram
Removal, serial measurement unit The procedure below details how to remove the serial measurement unit from the robot. Action
1.
Note/Illustration
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the push button guard (A) from the The guard must be removed to ensure a base. correct refitting of the brake release buttons.
xx0600002744
3. Remove the centering piece (B) from the push button unit.
xx0600002776
4. Remove the base cover from the robot. 5. Disconnect all the connectors from the serial measurement unit.
Shown in the figure Location of serial measurement unit on page 169.
6. Unscrew the four hexagon nuts on the Shown in the figure Serial measurement serial measurement unit enough to enable unit layout on page 169. lifting the unit. Do not remove the nuts.

4 Repair
4.5.2. Replacement of serial measurement unit Continued Action
7. Lift and pull the serial measurement unit backwards, over the lip (A), and lift it away.
Note/Illustration
xx0500001455
Refitting, serial measurement unit The procedure below details how to refit the serial measurement unit to the robot. Action
1. Fit the serial measurement unit on to the four pins (A).
Note/Illustration
xx0500001392
2. Slide the unit into position, within the lips, and secure with the four hexagon nuts. Make sure the unit is positioned as straight as possible! The push buttons can otherwise get jammed. 3. Reconnect all the connectors to the unit. 4. Refit the centering piece (B) to the push button unit in order to align it vertically. Also make sure that the unit is correctly aligned sideways: the measurements x1 and x2 in the figure to the right should not differ more than 1 mm from each other! Shown in the figure Serial measurement unit layout on page 169.
xx0600002777
Art. no. for the centering piece is specified in Required equipment on page 170.

4 Repair
4.5.2. Replacement of serial measurement unit Continued Action
5. Refit the push button guard to the robot base. 6.
Note/Illustration
WARNING!
Before continuing any service work, please observe the safety information in section WARNING - The brake release buttons may be jammed after service work on page 34! 7. Check the gasket of the base cover. Replace it Spare part no. is specified in Required if damaged. equipment on page 170. 8. Refit the base cover. 9. Update the revolution counters! Shown in the figure Location of serial measurement unit on page 169. Detailed in section Updating revolution counters on page 225.
172
4 Repair
4.5.3. Replacement of push button unit
4.5.3. Replacement of push button unit

Location of push button unit The push button unit for brake release is located inside the base of the robot, as shown in the figure below. A more detailed view of the component and its location is shown in the spare part view Base, exploded view on page 243 in part 2 of the Product manual.
xx0500001390
Base cover, including gasket. Push button unit is located beneath the cover.
Push button unit on serial measurement unit The push button unit is attached to the serial measurement unit as shown in the figure below.
xx0500001394
A B C
Push button unit Hexagon nuts (2 pcs) Hexagon nuts, SMB unit (4 pcs)

Push button unit
Spare part no.

3HAC 020967-001
Note
Includes brake release board and push buttons.

4 Repair
4.5.3. Replacement of push button unit Continued Equipment
Gasket, base cover Centering piece
Spare part no.

3HAC 022047-001 3HAC025815-001
Note
Fitted to the push button unit in order to align it correctly. Replace if damaged. The contents are defined in section Standard toolkit on page 237.
Standard toolkit
Removal, push button unit The procedure below details how to remove the push button unit from the robot. Action
1.
Note/Illustration
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the push button guard (A) from the base. The guard must be removed to ensure a correct refitting of the push button unit.
xx0600002744
3. Remove the centering piece (B) from the push button unit.
xx0600002776
4. Remove the base cover from the robot. 5. Disconnect all the connectors from the brake release board. 6. Unscrew the four hexagon nuts on the SMB unit enough to enable lifting the unit. Do not remove the nuts.
Shown in the figure Location of push button unit on page 173.
Shown in the figure Push button unit on serial measurement unit on page 173.

4 Repair
4.5.3. Replacement of push button unit Continued Action
7. Lift and pull the serial measurement unit backwards, over the lip (A), and lift it away.
Note/Illustration
xx0500001455
8. Remove the two hexagon nuts from the push button unit. 9. Remove the push button unit by lifting it up.
Shown in the figure Push button unit on serial measurement unit on page 173.
Refitting, push button unit The procedure below details how to refit the push button unit to the robot. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Fit the new push button unit to the serial measurement unit in the robot base. Spare part no. is specified in Required equipment on page 173. Shown in the figure Push button unit on serial measurement unit on page 173. Shown in the figure Push button unit on serial measurement unit on page 173.
3. Secure the unit with two hexagon nuts.
4. Push in and secure the SMB unit with the four Shown in the figure Push button unit on hexagon nuts. serial measurement unit on page 173. 5. Refit the centering piece (B) to the push button unit in order to align it vertically. Also make sure that the unit is correctly aligned sideways: the measurements x1 and x2 in the figure to the right should not differ more than 1 mm from each other!
xx0600002777
6. Refit the push button guard to the robot base.

4 Repair
4.5.3. Replacement of push button unit Continued Action
7.
Note
WARNING!
Before continuing any service work, please observe the safety information in section WARNING - The brake release buttons may be jammed after service work on page 34! 8. Reconnect all the connectors to the board. 9. Check the gasket of the base cover. Replace Spare part no. is specified in Required it if damaged. equipment on page 173. 10. Refit the base cover. Shown in the figure Location of push button unit on page 173.
176
4 Repair
4.6.1. Replacement of motor, axis 1
4.6 Motors 4.6.1. Replacement of motor, axis 1

Location of motor The axis 1 motor is located on the frame, as shown in the figure below. A more detailed view of the motor and its position may be found in the spare part view Frame, exploded view on page 247 in part 2 of the Product manual.
xx0400001256
A B C D E
Motor, axis 1 Connector plate for motor cabling Cover, frame Attachment screws, motor (4 pcs) Motor cover
Required equipment Equipment Spare part no. Art. no. Note

Cable harness, motor axes 1-2 must be ordered separately.
Rot. ac motor incl. pinion, 3HAC 023557-001 spare Cable harness, motor axes 1-2 O-ring 3HAC 023754-001 21522012-428
O-ring, motor. Replace if damaged.

4 Repair
4.6.1. Replacement of motor, axis 1 Continued Equipment
Power supply
Spare part no.
Art. no.
-
Note
Replace if damaged. 24 VDC, max 1.5 A For releasing the brakes. Used to clean mating surfaces.
Gasket, gearbox axis 1-2 3HAC 022048-001
Isopropanol Grease Rotation tool, motor Standard toolkit
3HAB 3537-1 3HAC022266-003 -
The contents are defined in section Standard toolkit on page 237. See chapter Circuit diagram.
Circuit diagram
Removal, motor axis 1 The procedure below details how to remove the motor, axis 1. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the cover, frame. 3. Disconnect the connectors for the motor, axis 1. 4. Loosen the connector plate from the frame and pull out the motor cabling.
Shown in the figure Location of motor on page 177.
5. In order to release the brakes, connect the 24 VDC power Connect to connector supply to the motor. R3.MP1: +: pin 7 -: pin 8 6. Unscrew the four attachment screws from the motor. 7. Remove the motor by gently lifting it straight up, making sure the motor pinion is not damaged against the gear. 8. Disconnect the brake release voltage from the motor connector. Shown in the figure Location of motor on page 177.

4 Repair
4.6.1. Replacement of motor, axis 1 Continued Refitting, motor axis 1 The procedure below details how to refit the motor, axis 1. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Clean the mating surface on the frame. 3. Make sure the o-ring on the circumference of the motor is seated properly. Lubricate the o-ring with grease. 4. Remove the motor cover from top of the motor. Art. no. is specified in Required equipment on page 177. Shown in the figure Location of motor on page 177.
5. In order to release the brakes, connect the 24 VDC Connect to connector R3.MP1: power supply to the motor. +: pin 7 -: pin 8 6. Fit the rotation tool to the end of the motor shaft. 7. Fit the motor, making sure the motor pinion is properly mated to the gear of gearbox, axis 1. Use the rotation tool to rotate the motor pinion, when mating it to the gear. 8. Secure the motor with four attachment screws and 4 pcs, M8 x 25. washers, but do not tighten yet. 9. Adjust the motor in relation to the gear in the There should be a barely noticable gearbox: gear play. use the rotation tool to wiggle the motor shaft back and forth to feel the play. Tap with a plastic mallet. position the motor pinion at at least two other positions by turning axis 1 manually and check the gear play again. 10. Tighten the motor attachment screws. 11. Disconnect the brake release voltage. 12. Refit the motor cover to top of the motor. Shown in the figure Location of motor on page 177. Tightening torque: 35 Nm. Art. no. is specified in Required equipment on page 177.
13. Insert the motor cabling through the frame and 4 pcs. secure the connector plate with attachment screws. 14. Connect all the connectors inside the frame. The cable layout is shown in the figure Illustration, cabling inside frame on page 117. Spare part no. is specified in Required equipment on page 177.
15. Refit the cover, frame. Replace the gasket, if damaged.

4 Repair
4.6.1. Replacement of motor, axis 1 Continued Action
Note
17.
DANGER!
180
4 Repair

Location of motor axis 2 The motor axis 2 is located on the front of the robot as shown in the figure below. A more detailed view of the motor and its position may be found in the spare part view Frame, exploded view on page 247 in part 2 of the Product manual.
xx0400001257
A B C D E
Motor, axis 2 Cover, frame Connector plate for motor cabling Bracket and cable tie Motor cover

Rot. ac motor incl. pinion, spare
Spare part no.

3HAC 023557-001
Art. no.
Note
Cable harness, motor axes 1-2 must be ordered separately.
Cable harness, motor 3HAC 023754-001 axes 1-2 O-ring 21522012-428 Must be replaced when replacing motor. Replace if damaged. 3HAB 3537-1 For lubricating the o-ring. For cleaning mating surfaces. The contents are defined in section Standard toolkit on page 237. For adjusting the gear play, motor/pinion
Gasket, gearbox axis 3HAC 022048-001 1-2 Grease Isopropanol Standard toolkit
Rotation tool, motor
3HAC022266003

4 Repair
4.6.2. Replacement of motor, axis 2 Continued Equipment, etc.
Power supply Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit Diagram -
Spare part no.
Art. no.
-
Note
24 VDC, 1.5 A. For releasing the brakes. These procedures include references to the tools required.
See chapter Circuit diagram.
Removal, motor axis 2 The procedure below details how to remove the axis 2 motor. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the cover, frame. 3. Disconnect the motor connectors inside the frame. Shown in the figure Location of motor axis 2 on page 181. Connectors: R3.MP2 R3.FB2
4. Cut any cable ties and remove any brackets or clamps securing the cables. 5. Remove the connector plate by removing its attachment Shown in the figure Location screws, and pull the cables out from the frame. of motor axis 2 on page 181. 6.
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! 7. In order to release the brakes, connect the 24 VDC power supply to the motor. 8. Connect to connector R3.MP2 +: pin 7 -: pin 8
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. 9. Remove the motor by unscrewing its four attachment screws and plain washers. Shown in the figure Location of motor axis 2 on page 181.

4 Repair
10. Remove the motor by gently pulling it out, making sure the motor pinion does not get damaged while moving it away from the gear. 11. Disconnect the brake release voltage. 12. Remove any remaining oil from the gearbox by siphoning it off.
Note
Refitting, motor axis 2 The procedure below details how to refit the axis 2 motor. Action
1. Make sure the mating surfaces on the motor and the gearbox are clean and free from burrs. If necessary, clean the surfaces with isopropanol. 2. Make sure the o-ring on the circumference of the Art. no. is specified in section motor is seated properly. Required equipment on page 181. Lightly lubricate the o-ring with grease. 3. In order to release the brakes, connect the 24 VDC power supply to the motor. 4. Remove the motor cover from top of the motor. Connect to connector R3.MP2: +: pin 7 -: pin 8 Shown in the figure Location of motor axis 2 on page 181.
Note
5. Fit the rotation tool to the end of the motor shaft. Art. no. is specified in section Required equipment on page 181. 6. Fit the motor, making sure the motor pinion is properly mated to gearbox 2. Use the rotation tool to rotate the motor pinion, when mating it to the gear. 7. Secure the motor with four attachment screws and plain washers, but do not tighten yet.
Make sure the motor is turned the right way, i.e. connections upwards. Make sure the motor pinion does not get damaged! 4 pcs, M8 x 25. Tightening torque: approx 2 Nm. There should be a barely noticable gear play.
8. Adjust the motor in relation to the gear in the gearbox. Use the rotation tool to wiggle the motor shaft back and forth to feel the play. Tap with a plastic mallet. 9. Refit the motor cover to the top of the motor. Be careful not to damage the cables! 10. Tighten the motor attachment screws. 11. Disconnect the brake release voltage. 12. Refit the connector plate with its attachment screws. 13. Reconnect the motor connectors inside the frame. 14. Refit all cable ties, and the bracket underneath the frame.
Tightening torque: 35 Nm. Shown in the figure Location of motor axis 2 on page 181. Cable layout is shown in the figure Illustration, cabling inside frame on page 117. Shown in the figure Location of motor axis 2 on page 181.

4 Repair
15. Refit the cover, frame. Replace the gasket, if damaged.
Note
Shown in the figure Location of motor axis 2 on page 181. Art. no. for the gasket is specified in section Required equipment on page 181. Detailed in section Performing a leak-down test on page 108. Type of oil and amount is specified in section Amount of oil. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information.
16. Perform a leak-down test. 17. Refill the gearbox with oil. 18. Recalibrate the robot!
19.
DANGER!
184
4 Repair

Location of motor The motor of axis 3 is located inside the upper arm housing, as shown in the figure below. A more detailed view of the motor and its position may be found in the spare part view Upper arm, exploded view 1 on page 251 in part 2 of the Product manual.
xx0400001258
A B
Motor, axis 3 Attachment screws and washers of the motor (4 pcs) Signal connector R3.FB3 Power connector R3.MP3 Connector holder Upper arm housing cover Cable tie
C D E F G

Rot. ac motor incl pinion O-ring Gasket, upper arm cover Gasket, customer connections
Spare part no.

3HAC 021798-001 21522012-426 3HAC 022049-001 3HAC 022050-001
Art. no.
Note
Replace if damaged. Replace if damaged. Replace if damaged.

4 Repair
4.6.3. Replacement of motor, axis 3 Continued Equipment
Isopropanol Grease Rotation tool, motor Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit diagram
Spare part no.
Art. no.
3HAB 3537-1 3HAC022266-003
Note
Used for cleaning the mating surfaces. Used for lubricating the oring. For adjusting the gear play. These procedures include references to the tools required.
Removal, motor axis 3 The procedure below details how to remove the axis 3 motor. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove any additional mechanical stops from axis 3. 3. Move: axis 2 to calibration position upper arm backwards against the mechanical stop. This position enables removal of the motor without draining of the gearbox, axis 3.
xx0500001447
4. Remove the upper arm housing cover. 5. Disconnect the motor connectors R3.MP3 and R3.FB3.
Shown in the figure Location of motor on page 185. Shown in the figure Location of motor on page 185.

4 Repair
6.
Note
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! 7. In order to release the brakes, connect the 24 VDC power supply to the motor. 8. Remove the motor, axis 3, by unscrewing its attachment screws and washers. Lift the motor gently straight out, making sure the motor pinion is not damaged. 9. Disconnect the brake release voltage. Connect to connector R3.MP3: +: pin 7 -: pin 8
1. Clean the mating surfaces inside the upper arm housing and on the motor with isopropanol. 2. Make sure the o-ring on the circumference of the motor is seated properly. Ligthly lubricate it with grease. Replace the o-ring if damaged. Art .no. is specified in section Required equipment on page 185.
Note
3. In order to release the brakes, connect the 24 VDC Connect to connector R3.MP3: power supply to the motor. +: pin 7 -: pin 8. 4. Fit the motor to the upper arm housing, making sure the motor pinion is properly mated to the gear of axis 3. 5. Fit the attachment screws and washers but do not 4 pcs, M6 x 20. tighten them yet. Shown in the figure Location of motor on page 185. 6. Fit the rotation tool to the end of the motor shaft. Art. no. is specified in Required equipment on page 185.
7. Adjust the motor in relation to the gear. There should be a barely noticable Use the rotation tool to wiggle the motor shaft back gear play. and forth to feel the play. 8. Tighten the motor attachment screws. 9. Disconnect the brake release voltage. 10. Reconnect the motor connectors, run and secure Cable layout is shown in the figure the cabling correctly inside the upper arm housing. Illustration, cabling inside upper arm housing on page 115. 11. Refit the cover, upper arm housing. Check both the Shown in the figure Location of gaskets and replace, if damaged. motor on page 185. Art. no. is specified in section Required equipment on page 185. Tightening torque: 10 Nm.

4 Repair
12. Refit any additional mechanical stops.
Note
Detailed in section Installation of additional mechanical stops on axis 3 on page 73. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information.
14.
DANGER!
188
4 Repair
4.6.4. Replacement of motor, axis 3, IRB 1600ID

NOTE! After replacement of motors/motor in a manipulator, recalibration is required. Location of motor The motor of axis 3 is located inside the upper arm housing, as shown in the figure below.
xx0700000008
A B C D E
Motor, axis 3 Attachment screws and washers of the motor (4 pcs) Signal connector R3.FB3 Power connector R3.MP3 Connector holder
Required equipment
Equipment
Rot. ac motor incl pinion O-ring Isopropanol
Spare part no.

3HAC 021798-001 3HAB3772-100
Art.no.
Note
Used for cleaning the mating surfaces. Contents, standard toolkit
Grease Standard tools Circuit diagram Pendulum Calibration tool

4 Repair
4.6.4. Replacement of motor, axis 3, IRB 1600ID Continued Removal, motor axis 3 Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. In order to release the brakes, Connect to connector R3.MP3: connect the 24 VDC power +: pin 7 supply to the motor. -: pin 8 3. Remove any additional mechanical stops from axis 3. 4. Move: axis 2 to calibration position upper arm backwards against the mechanical stop This position enables removal of the motor without draining oil of the gearbox, axis 3.
xx0700000010
5. Remove the upper arm housing cover. 6. Disconnect the motor connectors R3.MP3 and R3.FB3.
Shown in the figure Location of motor on page 189 Shown in the figure Location of motor on page 189

4 Repair
4.6.4. Replacement of motor, axis 3, IRB 1600ID Continued Action
7.
Note
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 fall down! 8. Remove the motor, axis 3, by unscrewing its attachment screws and washers. Lift the motor gently straight out, making sure the motor pinion is not damaged.
B C A E D
xx0700000050
A. B. C. D. E. 9. Remove the resolver cover for refitting on the new motor. 10. Disconnect the brake release voltage.
Hex socket head cap screw O-ring Motor axis 3 Resolver cover O-ring
1. Clean the mating surfaces inside the upper arm housing and on the motor with Isopropanol. 2. Make sure the o-ring on the circumference of the motor is seated properly. Lubricate it with grease. Replace the o-ring if damaged. Part number is specified in section Required equipment on page 185.
Note

4 Repair
3. Fit the new motor to the upper arm housing, making sure the motor pinion is properly mated to the gear of axis 3. 4. Fit the attachment screws and washers but do not tighten them yet. 5. Fit the rotation tool to the end of the motor shaft. 4 pcs, M6 x 20. Shown in the figure Location of motor on page 189. Part number is specified in Required equipment on page 185.
Note
6. Adjust the motor in relation to the gear. There should be a barely Use the rotation tool to wiggle the motor shaft back noticeable gear play. and forth to feel the play. 7. Tighten the motor attachment screws. 8. Refit the resolver cover on the new motor. 9. Reconnect the motor connectors, run and secure the cabling correctly inside the upper arm housing. 10. Refit the cover, upper arm housing. Cable layout is shown in the figure Illustration, cabling inside upper arm housing on page 115. Shown in the figure Location of motor on page 189. Art. no. is specified in section Required equipment on page 185. Detailed in section Installation of additional mechanical stops on axis 3 on page 73. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information. Tightening torque: 10 Nm.
11. Refit any additional mechanical stops.
12. Recalibrate the robot.
13.
DANGER!
192
4 Repair

Location of motor The axis 4 motor is located inside the upper arm housing, as shown in the figure below. A more detailed view of the component and its position may be found in the spare part view Upper arm, exploded view 1 on page 251 in part 2 of the Product manual.
xx0400001273
A
Motor, axis 4 Cover, upper arm housing Connector plate Signal connector, R3.FB4 Power connector, R3.MP4 Attachment screw and washer, motor (4 pcs)
B C D E F

O-ring Gasket, customer connections Grease
Spare part no.

3HAB 3772-81 3HAC 022050-001
Art. no.
Note
Replace if damaged. Replace if damaged. Replace if damaged.
Rot. ac motor incl pinion 3HAC 021799-001 Gasket, upper arm cover 3HAC 022049-001
3HAB 3537-1
Used for lubricating the oring.

4 Repair
4.6.5. Replacement of motor, axis 4 Continued Equipment, etc.
Standard toolkit
Spare part no.
Art. no.
Note
Power supply Rotation tool, motor Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit Diagram
3HAC022266003
24 VDC, max. 1,5 A. For releasing the brakes. For adjusting the gear play. These procedures include references to the tools required.
Removal, motor axis 4 The procedure below details how to remove the motor, axis 4. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Manually move the robot to a position where the upper arm points straight down. 3. Remove the cover from the upper arm housing. 4. Remove the connector plate to get access to the axis 4 motor. 5. Disconnect the connectors R3.MP4 and R3.FB4 from the axis 4 motor. 6. In order to release the brakes, connect the 24 VDC Connect to connector R3.MP4 power supply to the motor. +: pin 7 -: pin 8 7. Remove the motor, axis 4 by unscrewing the motor Shown in the figure Location of attachment screws. motor on page 193. 8. Lift the motor to get the pinion away from the gear and disconnect the brake release voltage. 9. Remove the motor by gently lifting it out. Make sure the motor pinion is not damaged! Shown in the figure Location of motor on page 193. This will enable the motor 4 to be removed without draining the oil in the gearbox.

4 Repair
4.6.5. Replacement of motor, axis 4 Continued Refitting, motor axis 4 The procedure below details how to refit the motor, axis 4. Action Note
1. Clean the mating surfaces on the motor and the Shown in the figure Location of motor gearbox. on page 193. 2. Make sure the o-ring on the circumference of Art. no. is specified in section the motor is seated properly. Lightly lubricate Required equipment on page 193. the o-ring with grease . 3. In order to release the brakes, connect the 24 VDC power supply to the motor. 4. Fit the motor with the attachment screws and washers. Until the motor shaft is adjusted to the gear, as described in following steps, only tighten the screws lightly. 5. Fit the rotational tool to the end of the motor shaft. Connect to connector R3.MP4 +: pin 7 -: pin 8 Shown in the figure Location of motor on page 193. Tightening torque: approx. 2 Nm. 4 pcs, M6 x 20. Art. no. is specified in section Required equipment on page 193.
6. Adjust the motor in relation to the gear in the There should be a barely noticable gearbox. gear play. Use the arm tool to wiggle the motor shaft back and forth to feel the play. 7. Tighten the motor attachment screws. Shown in the figure Location of motor on page 193. Tightening torque: 10 Nm.
8. Reconnect the motor connectors R3.MP4 and R3.FB4. 9. Refit the connector plate. 10. Make sure all the cabling is placed correctly inside the upper arm housing.
Shown in the figure Location of motor on page 193. Cable layout is shown in the figure Illustration, cabling inside upper arm housing on page 115.
11. Refit the cover to the upper arm housing. Check Art. no. is specified in Required both the gaskets and replace, if damaged. equipment on page 193. 12. Perform a leak-down test. 13. Recalibrate the robot! Detailed in section Performing a leakdown test on page 108. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information.
14.
DANGER!
195
4 Repair
4.6.6. Replacement of motor, axis 4, 1600ID
4.6.6. Replacement of motor, axis 4, 1600ID

NOTE! After replacement of motors/motor in a manipulator, recalibration is required. Location of motor
xx0700000017
A B C D E F
Motor, axis 4 Cover, upper arm housing Connector plate Signal connector, R3.FB4 Power connector, R3.MP4 Attachment screw and washer, motor (4 pcs)

4 Repair
4.6.6. Replacement of motor, axis 4, 1600ID Continued Required equipment Equipment, etc.
O-ring Standard toolkit
Spare part no.

3HAB 3772-81
Art. no.
Note
Rot. ac motor incl pinion 3HAC 021799-001 The contents are defined in section Standard toolkit on page 237, in part 2 of the Product manual. 24 VDC, max. 1,5 A. For releasing the brakes.
The contents are defined in section Standard toolkit on page 237, in part 2 of the Product manual. Rotation tool, motor Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit Diagram Pendulum Calibration tool
For adjusting the gear play. These procedures include references to the tools required.
3HAC 4540-1
Removal, motor axis 4 Action

1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the cover from the upper arm housing. 3. Remove the connector plate to get access to the axis 4 motor. 4. Disconnect the connectors R3.MP4 and R3.FB4 from the axis 4 motor. 5. Remove the motor, axis 4 by unscrewing the motor Shown in the figure Location of attachment screws. motor on page 196. 6. Lift the motor to get the pinion away from the gear and disconnect the brake release voltage. 7. Remove the motor by gently lifting it out. Make sure the motor pinion is not damaged! Shown in the figure Location of motor on page 196.
Refitting, motor axis 4 Action

1. Clean the mating surfaces on the motor and the gearbox.
Note

4 Repair
4.6.6. Replacement of motor, axis 4, 1600ID Continued Action Note
2. Make sure the o-ring on the circumference of the Art. no. is specified in section. motor is seated properly. Lightly lubricate the o-ring with grease. 3. Fit the motor with the attachment screws and washers. Until the motor shaft is adjusted to the gear, as described in following steps, only tighten the screws lightly. 4. Tighten the motor attachment screws. Shown in the figure Location of motor on page 196. Tightening torque: approx. 2 Nm. 4 pcs, M6 x 20. Shown in the figure Location of motor on page 196. Tightening torque: 10 Nm.
5. Reconnect the motor connectors R3.MP4 and R3.FB4. 6. Refit the connector plate. 7. Refit the cover to the upper arm housing. 8. Recalibrate the robot. General calibration information is included in section Introduction. Shown in the figure Location of motor on page 196.
198
4 Repair
4.6.7. Replacement of motor and timing belt, axis 5

Location of motor The motor and timing belt of axis 5 is located inside the upper arm housing, as shown in the figure below. A more detailed view of the motor and its position may be found in the spare part view Upper arm, exploded view 1 on page 251 in part 2 of the Product manual.
xx0400001279
A B C D E F G H
Motor, axis 5 Cover, upper arm housing Connector plate Signal cable, motor 5: R3.FB5 Power cable, motor 5: R3.MP5 Attachment screws and washers, motor bracket (2 pcs) Motor bracket Attachment screws and washers, motor (3 pcs)

4 Repair
4.6.7. Replacement of motor and timing belt, axis 5 Continued Required equipment Equipment
Rot. ac motor incl pinion Timing belt Gasket, customer connections Belt tightener Dynamometer Standard toolkit
Spare part no.

3HAC 021800-001 3HAC 021304-001
Art. no.
Note
Gasket, upper arm cover 3HAC 022049-001 3HAC 022050-001 3HAC024044-001 -
Replace if damaged. Replace if damaged.
Capacity: 100N The contents are defined in section Standard toolkit on page 237. These procedures include references to the tools required.
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit diagram
Belt tightener, 3HAC 024044-001 The belt tightener is a special tool that is used when adjusting the tension of the timing belt of axis 5. The length of the tool is important, since the tool is pulled with a given force.
xx0500001457

4 Repair
4.6.7. Replacement of motor and timing belt, axis 5 Continued Removal, motor axis 5 and timing belt The procedure below details how to remove the motor and the timing belt of axis 5. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the axis 4 motor. 3. Remove the motor and timing belt of axis 6. 4. Disconnect the axis 5 motor connectors: R3.MP5 and R3.FB5. 5. Move aside all cabling that is hindering access to the axis 5 motor. 6. Remove the motor bracket, including the motor, by unscrewing the two attachment screws and washers. 7. Remove the timing belt of axis 5. 8. Remove the motor bracket from the motor. Shown in the figure Location of motor on page 199. Detailed in section Removal, motor axis 4 on page 194. Detailed in section Removal, motor and timing belt, axis 6 on page 210.
Refitting, motor and timing belt axis 5 The procedure below details how to refit the motor and timing belt of axis 5. Action
1.
Note/Illustration
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Clean the mating surfaces on the motor and in the upper arm housing. 3. Fit the new motor to the motor bracket, previously removed from the old motor. 3 pcs, M6 x 20.

4 Repair
4.6.7. Replacement of motor and timing belt, axis 5 Continued Action Note/Illustration
4. Follow the steps below when fitting the motor: Art. no. is specified in Required Place the timing belt (B) round the motor equipment on page 200. pinion and place the belt round the axis 5 as fitting the motor in the upper arm housing. Fasten the motor bracket with two attachment screws (C), but do not tighten the screws yet. Use correct attachment holes, shown in the figure to the right! Adjust the belt tension by pulling the motor bracket, using the belt tightener and dynamometer, as shown in the figure to the right. Tighten the two attachment screws of the bracket (C) with a torque of 10 Nm.
xx0400001280
A. Motor axis 5 B. Timing belt, axis 5 C. Attachment screws and washers, motor bracket, 2 pcs, M6 x 20 D. Belt tightener, the dimensions are shown in the figure Belt tightener, 3HAC 024044-001 on page 200. F (Force): 24 N. 5. Refit the motor and timing belt of axis 6. 6. Refit the motor of axis 4. Detailed in section Refitting, motor and timing belt, axis 6 on page 210. Detailed in section Refitting, motor axis 4 on page 195.
8. Refit the cover to the upper arm housing. Check both the gaskets and replace, if damaged. 9. Recalibrate the robot!
Art.no. is specified in Required equipment on page 200. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information.
10.
DANGER!
202
7. Reconnect all connectors and place the cabling Cable layout shown in the figure Illuscorrectly inside the upper arm housing. tration, cabling inside upper arm housing on page 115.
4 Repair

NOTE! After replacement of motors/motor in a manipulator, recalibration is required. Location of motor, axis 5 The motor of axes 5 is located inside the upper arm as shown in the figure below.
xx0700000020
A
Arm Tube Hex socket head cap screw M8X20 Cable harness IRB1600ID Rotational ac motor Axis 5 Hex. socket head cap screw M6X20 O-ring Cable harness bracket
B C D E F

Rot. ac motor with pinion VK cover Standard toolkit 3HAA2166-19 3HAC020812-001 The contents are defined in section Standard toolkit on page 237, in part 2 of the Product manual.
Spare part no. Art. no.
Note
Axis 5

4 Repair
4.6.8. Replacement of motor, axis 5, IRB 1600ID Continued Equipment, etc.
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit Diagram 3HAC 6816-3
Spare part no. Art. no.
Note
These procedures include references to the tools required.
See chapter Circuit diagram in the Product manual, reference information. Nitrite
O-ring Cable grease Isopropanol
3HAB3772-81
Removal, motor axis 5 The procedure below details how to remove motor, axis 5. WARNING! Please observe the following before commencing any repair work on the manipulator: Motors and gears are HOT after running the robot! Touching the motors and gears may result in burns! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! Take any necessary measures to ensure that the manipulator does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.
NOTE! Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used. Action
1. Remove the cover (C) on the back of the upper arm tube (A). Rotate the upper arm to access all the screws (D). Remove the screws (B) holding the cable harness.
Note
xx0700000083
CAUTION!
After removal of the cover (mec stop), do not rotate axis 4 do to risk of cable harness damage.
A. B. C. D.
Arm Tube Torx pan head screw M6X12 Cover Torx pan head screw M6X12

4 Repair
2.
Note
DANGER!
Turn of all electric power, hydraulic and pneumatic pressure supplies to the robot!. 3. Remove the AW equipment from the upper arm. 4. Disconnect connection R4.FB5 and R4.MP5, from the backside. Shown in section Remove AW Gun on page 160
xx0700000080
A. R4.FB5 5. Remove the VK- Cover to access the cable connections inside the arm.
xx0700000054
A. VK-Cover 6. Gently pull the cables out of the upper arm.

7. Disconnect through the hole connection R4.FB6 and R4.MP6.
xx0700000053

4 Repair
8.
Note
CAUTION!
The upper arm tube weighs 12,3 kg without any additional equipment fitted. Use a suitable lifting device to avoid injury to personnel. 9. Secure the weight of the arm with lifting slings.
xx0700000088
10. Remove the seven (7) Hexagon socket head cap screw M8X20, holding the upper arm. 11. Remove the upper arm. 12. Remove the V-ring (A) and the support ring (B).
Position (B) in figure Location of motor, axis 5 on page 203.
xx0700000248
A. V-ring B. Support ring 13. Remove the four (4) Hexagon socket head cap screw M6X20 holding motor 5. Position (E), (D) in figure Location of motor, axis 5 on page 203
14. Remove the O-ring and change it if Position (F) in figure Location of motor, axis 5 on necessary. page 203. 15. Remove the resolver cover for reuse.

4 Repair
4.6.8. Replacement of motor, axis 5, IRB 1600ID Continued Refitting, motor axis 5 The procedure below details how to refit the motor of axis 5. Action
1. Clean the mating surfaces inside the upper arm housing and on the motor with Isopropanol. 2. Make sure the o-ring on the circum- Replace the o-ring if damaged. Part number is ference of the motor is seated specified in section Required equipment on page properly. Lubricate it with grease. 203. 3. Fit the motor to the upper arm housing, making sure the motor pinion is properly mated to the gear of axis 3. 4. Fit the attachment screws and washers but do not tighten them yet. 5. Fit the rotation tool to the end of motor shaft. 4 pcs, M6 x 20. Shown in the figure Location of motor, axis 5 on page 203. Part number is specified in Required equipment on page 203
Note
6. Adjust the motor in relation to the There should be a barely noticeable gear play. gear. Use the rotation tool to wiggle the motor shaft back and forth to feel the play. 7. Tighten the motors attachment scews. 8. Refit the V-ring and support ring. 9. Refit the cable harness bracket (G) in figure Location of motor, axis 5 on page 203, inside the upper arm tube, use the two torx pan head screw M6X12 (B). Wind the cable harness (A), in a spiral with four free turns around the axis as in figure Location of motor, axis 5 on page 203 Grease the cable harness with cable grease. Tightening torque: 10Nm
xx0700000089
A. Cable harness B. Torx pan head screw M6X12 10. Refitt the upper arm using the 7 Hex Shown in figure Location of motor, axis 5 on page socket head cap screw M8X20. 203. Tightening torque: 24 Nm 11. Reconnect through the VK-hole connection R4.FB6, and R4.MP6. Make sure all the cabling is placed correctly inside the upper arm housing. 12. Reconnect connection R4.FB5 and R4.MP5 from the backside.

4 Repair
13.
Note
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 33. 14. Refit the cover (mec stop) on the back of the upper arm tube. Rotate the upper arm to access all tree screws.
CAUTION!
Before refitting of the cover (mec stop), do not over rotate axis 4 do to risk of cable harness damage. 15. Recalibrate the robot. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in sections described in Introduction.
208
4 Repair

Location of motor The motor and timing belt of axis 6 are located inside the upper arm housing, as shown in the figure below. A more detailed view of the motor and its position may be found in the spare part view Upper arm, exploded view 1 on page 251 in part 2 of the Product manual.
xx0400001281
A B C D E F G H
Motor, axis 6 Cover, upper arm housing Connector plate Signal cable, axis 6 motor: R3.FB6 Power cable, axis 6 motor: R3.MP6 Attachment screws and washers, motor (3 pcs) Distance console with cable bracket and contact panel Cable tie

Rot. ac motor incl pinion Timing belt
Spare part no.

3HAC 021800-001 3HAC 6779-1
Art. no.
Note
Gasket, upper arm cover 3HAC 022049-001
Replace if damaged.

4 Repair
4.6.9. Replacement of motor and timing belt, axis 6 Continued Equipment
Gasket, customer connections Hook Dynamometer Standard toolkit
Spare part no.

3HAC 022050-001
Art. no.
Note
Replace if damaged.
3HAC024045-001 Capacity: 100N The contents are defined in section Standard toolkit on page 237. These procedures include references to the tools required.
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below. Circuit diagram
Removal, motor and timing belt, axis 6 The procedure below details how to remove the motor and timing belt of axis 6. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the cover from the upper arm housing. 3. Remove the connector plate. 4. Remove the complete distance console with cable brackets and contact panel. 5. Disconnect the motor cables for the axis 6 motor; R3.MP6 and R3.FB6. 6. Remove the axis 6 motor by unscrewing its three attachment screws and washers. 7. Remove the timing belt. Shown in the figure Location of motor on page 209.
Refitting, motor and timing belt, axis 6 The procedure below details how to refit the motor and timing belt of axis 6. Action
1. Clean the mating surfaces on the motor and in the upper arm housing.
Note/Illustration

4 Repair
4.6.9. Replacement of motor and timing belt, axis 6 Continued Action
2. Follow the steps below when fitting the motor: Place the timing belt (B) round the motor pinion and place the belt round the axis 6 as fitting the motor in the upper arm housing. Secure the motor with its tree attachment screws and washers (C), but do not tighten them yet. Attach the hook round the motor pinion (underneath the motor) and adjust the belt tension with a force of 80 N, using a dynamometer. Shown in the figure to the right. Tighten the motor attachment screws with a torque of 10 Nm.
xx0400001282
Note/Illustration
A. Motor, axis 6 B. Timing belt, axis 6 C. Attachment screws and washers, motor, 3 pcs, M6 x 20 D. Hook (motor pinion: 24.07 mm) F (Force): 80 N. 3. Refit the complete distance console. Shown in the figure Location of motor on page 209.
4. Refit the connector plate. Refit the cable tie. Shown in the figure Location of motor on page 209. 5. Reconnect the motor cables: R3.MP6 and R3.FB6. 6. Place all the cabling correctly inside the upper arm housing.
Cable layout is shown in the figure Illustration, cabling inside upper arm housing on page 115. Art. no. is specified in Required equipment on page 209. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information.
7. Refit the cover to the upper arm housing. Check both the gaskets and replace, if damaged. 8. Recalibrate the robot!
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 33.
211
4 Repair
4.6.10. Replacement of motor, axis 6 IRB 1600ID
4.6.10. Replacement of motor, axis 6 IRB 1600ID

NOTE! After replacement of motors/motor in a manipulator, recalibration is required. Location of motor The motor of axis 6 is located inside the upper arm housing, as shown in the figure below.
G B
F C
xx0700000025
A B C D E F G
Upper arm Wrist Motor, axis 6 Hexagon socket head screw M5x25 Hexagon socket head screw M5x16 10.9 (Short head) Hexagon socket head screw M5x25 Hexagon socket head screw M8x35

Rot. ac motor incl pinion Standard toolkit Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
Spare part no.

3HAC 021800-001
Art. no.
Note
Contents, standard toolkit. These procedures include references to the tools required.

4 Repair
4.6.10. Replacement of motor, axis 6 IRB 1600ID Continued Equipment
Circuit diagram
Spare part no.
Art. no.
Note
Removal of motor axis 6 Action

1. Remove the motor according to description in Removal, wrist unit on page 147
Note
Refitting of motor axis 6 Action

1. Refit the motor according to description in Refitting of motor axis 6 on page 213.
Note
213
4 Repair
4.7.1. Replacement of gearbox, axes 1-2
4.7 Gearboxes 4.7.1. Replacement of gearbox, axes 1-2

Location of gearbox unit, axes 1-2 The gearboxes of axes 1 and 2 are located as shown in the figure below. Note that both gearboxes, 1 and 2, are a single unit! A more detailed view of the gearbox and its position may be found in the spare part view Frame, exploded view on page 247 in part 2 of the Product manual.
xx0500001400
A B
Gearbox unit, axes 1-2 Attachment screws and washer, base-gearbox unit (VK-cover is removed)

Gearbox axis 1-2, spare
Spare part no.

3HAC 023555-001
Art. no.
Note
Includes: gearbox axis 1-2 V-ring (sealing ring) lubricating oil in vessel stop arm.
VK-cover Isopropanol
3HAA 2166-26 For cleaning the mating surfaces before fitting.

4 Repair
4.7.1. Replacement of gearbox, axes 1-2 Continued Equipment
Grease Locking liquid Lifting slings Standard toolkit
Spare part no.
Art. no.
3HAB 3537-1 -
Note
For lubricating the V-ring. Loctite 574 The contents are defined in section Standard toolkit on page 237. These procedures include references to the tools required.
Removal, gearbox unit axes 1-2 The procedure below details how to remove the complete gearbox unit, axes 1-2. Action
1.
Note
DANGER!
Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! 2. Remove the motor, axis 1. 3. Remove the motor, axis 2. 4. Remove the complete arm system. 5. Drain the oil from gearbox, axis 1.
Detailed in section Removal, motor axis 1 on page 178. Detailed in section Replacement of motor, axis 2 on page 181. Detailed in section Removal, complete arm system on page 126.
6. Unfasten the base from the installation site by removing the attachment bolts from the foundation. 7.
CAUTION!
The complete gearbox unit and base weighs 201 kg together! (Base: 81 kg, gearbox unit: 120 kg.) All lifting equipment used must be sized accordingly! 8. Fit the lifting slings to the base/gearbox unit and place it with the lower arm side downwards, on top of a suitable workbench.

4 Repair
4.7.1. Replacement of gearbox, axes 1-2 Continued Action
9. Remove the VK-cover from the bottom of the robot base.
Note
TIP!
When the cabling is removed, it may be easier to drill a hole through the cover or to try and push it out from the inside. 10. Secure the weight of the base with lifting slings. 11. Remove the gearbox/base attachment screws and washer. 12. Separate the base from the gearbox unit. Shown in the figure Location of gearbox unit, axes 1-2 on page 214.
Refitting, gearbox unit axes 1-2 The procedure below details how to refit the complete gearbox unit, axes 1-2. Action
1.
Note
DANGER!
CAUTION!
The complete gearbox unit weighs 120 kg (without the base)! All lifting equipment used must be sized accordingly!
3. Place the gearbox unit with the lower arm side downwards on a suitable workbench. 4. Clean the mating surfaces of the base and of the gearbox unit with isopropanol. 5. Lubricate the V-ring with grease and fit it to Art. no. is specified in Required the gearbox unit. equipment on page 214. 6. Fit a small amount of Loctite 574 on the mating surface in the gearbox unit. 7. Fit the base to the gearbox unit and secure Shown in the figure Location of gearbox it with the attachment screws and the unit, axes 1-2 on page 214. washer. 16 pcs, M10 x 40, tightening torque: 70 Nm. 8. Fit a new VK-cover to the base of the robot. Shown in the figure Location of gearbox unit, axes 1-2 on page 214. Spare part no. is specified in Required equipment on page 214.

4 Repair
4.7.1. Replacement of gearbox, axes 1-2 Continued Action
9.
Note
CAUTION!
The complete gearbox unit and base weighs 201 kg together! (Base: 81 kg, gearbox unit: 120 kg.) All lifting equipment used must be sized accordingly! 10. Fit the lifting slings to the base/gearbox unit, turn it right side up and move it to the installation site. 11. Secure the base to the foundation. Attachment bolts and the tightening torque are specified in section Attachment bolts, specification on page 50. Detailed in section Refitting, complete arm system on page 127. Detailed in sections: Refitting, motor axis 1 on page 179 Refitting, motor axis 2 on page 183. Detailed in section Performing a leakdown test on page 108. Type of oil and amount is specified in section Type and amount of oil in gearboxes. Type of oil and amount is specified in section Oil in gearboxes on page 95. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration information.
12. Refit the complete arm system. 13. Refit the motors, axes 1 and 2.
14. Perform a leak-down test. 15. Fill the two gearboxes with oil.
16. Fill the two gearboxes with oil. 17. Recalibrate the robot.
18.
DANGER!
217
4 Repair
4.7.2. Service work on gearboxes, axes 3, 4, 5 and 6
4.7.2. Service work on gearboxes, axes 3, 4, 5 and 6

Gearboxes, replacement The gearboxes of axes 3, 4, 5 and 6 are intended to run without requiring any repairs or maintenance work. This implies that they must under no circumstances be opened or serviced. If the gearboxes require replacement: axes 3 and 4: the complete upper arm is to be replaced. This procedure is detailed in section Replacement of complete upper arm on page 129. axes 5 and 6: the complete wrist unit is to be replaced. This procedure is detailed in section Replacement of wrist unit on page 143.
218
5 Calibration information
5.1. Introduction
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 220, 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, for example 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 225. 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
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, for example after a crash or when the robot has been changed for other reachability, it needs to be recalibrated for new resolver values. If the robot has Abslolute Accuracy calibration, it needs to be calibrated for new Absolute Accuracy.
219
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 calibration
Standard calibration
Description
Calibration method
The calibrated robot is positioned at home Calibration Pendulum position, that is the axes positions (angles) are (standard method) set to 0. 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. Based on standard calibration, and besides CalibWare positioning the robot at home position, the 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 motor positions as well as absacc-compensation 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 performance, the robot must be recalibrated for Absolute Accuracy!
Absolute Accuracy calibration (optional)
xx0400001197

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 - Absloute 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 further detailed in the application manual Absolute Accuracy Calibware 2.0. 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 238 in part 2 of the Product manual.
The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including Operating manual - Calibration Pendulum, which describes the method and the different routines further.
221
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 marks, IRB 1600 The illustration below shows the calibration marks and correct positions of the six axes of the robot. The marks shown in the figure are numbered according to the number of the axes.
xx0600002876

5.3. Calibration scales and correct axis position Continued Calibration scales, IRB 1600ID The illustration below shows the calibration marks and correct positions of the six axes of the robot. The marks shown in the figure are numbered according to the number of the axes.
xx0700000095
223
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, 6 axes Note! The figure shows an IRB 7600, but the positive direction is the same for all 6-axis robots, except the positive direction of axis 3 for IRB 6400R which is in the opposite direction!
xx0200000089
224
5.5. Updating revolution counters
5.5. Updating revolution counters

General This section details how to perform a rough calibration of each robot axis, that is 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
1. Select axis-by-axis motion mode. 2. Jog the robot to place the calibration marks within the tolerance zone. 3. When all axes are positioned, store the revolution counter settings. Shown in section Calibration scales and correct axis position on page 222. Detailed in section: Step 2 - Storing the revolution counter setting with the FlexPendant on page 225 (RobotWare 5.0).
Note
Correct calibration position of axis 4 and 6 When running the robot to calibration position, it is extremely important to make sure that axes 4 and 6 of the below mentioned robots are positioned correctly. The axes can be calibrated at the wrong turn, resulting in wrong calibrated robot. Make sure the axes are positioned according to the correct calibration values, not only according to the calibration marks. The correct values are found on a label, located either on the lower arm or underneath the flange plate on the base. At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before the revolution counters are updated. If one of the below mentioned axes are rotated one or more turns from its calibration position before updating the revolution counter, the correct calibration position will be lost due to uneven gear ratio. This affects the following robots: Robot variant
IRB 1600
Axis 4
No
Axis 6
Yes
If the calibration marks seem to be wrong (even if the motor calibration data is correct), try to rotate the axis one turn, update the revolution counter and check the calibration marks again (try both directions, if needed). 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.

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. 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 227.
226
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
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, 9E9]]\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 in correctly. If they do not, update the revolution section Calibration scales and counters! correct axis position on page 222. How to update the revolution counters is detailed in section Updating revolution counters on page 225.
Note
Using the Jogging window on the FlexPendant, IRC5 This section describes how to jog the robot to all axes zero position.
Action
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 correctly. If they do not, update the revolution counters!
Note
The calibration marks are shown in section Calibration scales and correct axis position on page 222. How to update the counters is detailed in section Updating revolution counters on page 225.
227
6 Robot description
6.1. Type A of IRB 1600
6 Robot description
Type A - new upper arm and wrist Type A of IRB 1600 have a new upper arm, complete and a new wrist unit. As a result of this, the following parts differ from earlier versions: Upper arm, complete Wrist unit O-ring sealingplate
How to know which type the robot is? The identification plate on the cabinet and the lower arm of the robot tells if the robot has a new upper arm and wrist or not. Those robots with a new upper arm and wrist are named IRB 1600, type A. Those robots which are not equipped with a new upper arm and wrist are simply named IRB 1600 (no type specified). Which parts are interchangeable and which are not? The following parts are interchangeable. The upper arm, complete with spare part no. 3HAC026567-001 is interchangeable with spare part no. 3HAC023630-001. Note! Software version 5.07.01 is needed!
The following parts are not interchangeable: The wrist unit with spare part no. 3HAC026569-001 is not interchangeable with spare part no. 3HAC10475-1. The o-ring sealingplate with spare part no. 3HAC025420-001 is not interchangeable with spare part no. 3HAC 7191-1.
Other changes in this product manual, compared to product manual IRB 1600, 3HAC023637-001 The content in this product manual is the same as in the product manual with art. no. 3HAC023637-001, except for the new upper arm complete and the new wrist unit for type A. In order to distinguish IRB 1600 type A from earlier versions, a new art. no. has been created. There has been a few other changes in the manual, not related to the IRB 1600 type A. These changes are described below: The cable harness for motors axes 1-2 has got a new spare part no. The motors axes 12 (3HAC023557-001) and the cable harness, motors axes 1-2 (3HAC023754-001) now have two separate spare part no:s. Some cable harnesses have been replaced.
For details, see Base, spare part list on page 242 and Frame, spare part list on page 246.
229
6 Robot description
230
7 Reference information
7.1. Introduction
7.1. Introduction
General This chapter includes general information, complementing the more specific information in the different procedures in the manual.
7.2. Applicable safety standards

Health and safety standards, robot The robot, controlled by the IRC5, conforms to the following standards: Standard
EN ISO 12100-1 EN ISO 12100-2 EN 954-1 EN ISO 10218-1:2006 EN ISO 60204-1:2005 EN 61000-6-4 (option) EN 61000-6-2
Description
Safety of machinery, terminology Safety of machinery, technical specifications Safety of machinery, safety related parts of control systems Robots for industrial environments - Safety requirements - Part 1 Robot Safety of machinery - Electrical equipment of machines - Part 1 General requirements EMC, Generic emission EMC, Generic immunity
Standard
IEC 204-1 IEC 529
Description
Electrical equipment of industrial machines Degrees of protection provided by enclosures
Standard
Description
Manipulating industrial robots, coordinate systems and motions
ISO 9787
Standard
ANSI/RIA 15.06/1999 ANSI/UL 1740-1998 (option) CAN/CSA Z 434-03 (option)
Description
Safety Requirements for Industrial Robots and Robot Systems Safety Standard for Robots and Robotic Equipment (Max. payload 6 kg fulfilment). Industrial Robots and Robot Systems - General Safety Requirements (Max. payload 6 kg fulfilment).
231
7.3. Unit conversion
7.3. Unit conversion

Converter table Use the table below to convert units used in this manual. Quantity
Length Weight Pressure Force Moment Volume
Units
1m 1 kg 1 bar 1N 1 Nm 1L 3.28 ft 2.21 lb 100 kPa 0.738 lbf 0.738 lbf-tn 0.264 US gal 14.5 psi 39.37 in
232
7.4. Screw joints
7.4. Screw joints

General This section details how to tighten the various types of screw joints on the robot. 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 on page 234 below. Screw dimensions of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or smaller may be tightened without a torque wrench if this is done by trained and qualified personnel. Lubricant
Molycote 1000 (molybdenum disulphide grease)
Art. no.
11712016-618

7.4. 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, that is 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. Dimension
M2.5 M3 M4 M5 M6
Tightening torque (Nm) Class 4.8, oil-lubricated

0.25 0.5 1.2 2.5 5.0
The table below specifies the recommended standard tightening torque for oil-lubricated screws with Allen head screws. Tightening torque (Nm) Class 8.8, oil-lubricated
6 10 24 47 82 200
Dimension
M5 M6 M8 M10 M12 M16
34 67 115 290
40 80 140 340
The table below specifies the recommended standard tightening torque for Molycotelubricated screws with Allen head screws. Dimension
M8 M10 M12 M16 234
Tightening torque (Nm) Tightening torque (Nm) Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated
28 55 96 235 34 66 115 280

7.4. 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. Dimension
1/8 1/4 3/8 1/2 3/4
Tightening torque Nm - Nominal

12 15 20 40 70
Tightening torque Nm - Min.

8 10 15 30 55
Tightening torque Nm - Max.

15 20 25 50 90
235
7.5. Weight specifications
7.5. Weight specifications

Definition In installation, 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!
236
7.6. Standard toolkit
7.6. 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
1 1 1 1 1 1 1 1 1 1 1
Tool
Ring-open-end spanner 8-19 mm Socket head cap 2.5-17 mm Torx socket no: 20-60 Torque wrench 10-100 Nm Small screwdriver Plastic mallet Ratchet head for torque wrench 1/2 Socket head cap no: 5, socket 1/2" bit L 20 mm Socket head cap no: 6, socket 1/2" bit L 20 mm Socket head cap no: 8, socket 1/2" bit L 20 mm Small cutting plier
237
7.7. Special tools
7.7. 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 237, and of special tools, listed directly in the instructions and also gathered in this section. Special tools The table below specifies all the tools, not considered standard, used when performing service activities on the robot The special tools are also listed directly in the instructions. Description
Rotation tool, motor Dynamometer Hook Belt tightener Lifting tool, gearbox Lifting tool, upper arm
Art. no.
3HAC022266-003 3HAC024045-001 3HAC024044-001 3HAC023364-001 3HAC023386-001
Note
Used to adjust the gear play on all motors. Capacity: 100N Used to tighten the timing belt of axis 6, together with the dynamometer. Used to tighten the timing belt of axis 5, together with the dynamometer.
Calibration equipment, Calibration Pendulum The table below specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method. Description
Calibration Pendulum toolkit
Art. no.
3HAC15716-1
Note
Complete kit that also includes operating manual.
238
7.8. 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.
239
240
8 Spare parts and exploded views

8.1. Introduction

8.1. Introduction
Overview This section specifies all articles considered spare parts of the robot. The spare parts are also specified as required equipment directly in the repair instruction of the current spare part. The list of required equipment in each instruction also specifies necessary replacement articles and all required service tools.
241

8.2. Spare parts - base
8.2. Spare parts - base

Base, spare part list The spare parts for the base are listed below and shown in the following figure. Item no. Description
1 2 3 4 6 7 8 9 11 12 13 14 100 102 106 108 109 Base, spare Stop pin Cover base, spare Gasket, base cover VK-cover Serial measurement unit Push button unit Battery pack Push button guard Signal cable SMB Torx pan head screw Centering piece Cable harness IRB 1600/1.45
Spare part no.

3HAC 023552-001 3HAB 3258-1 3HAC 023554-001 3HAC 022047-001 3HAA 2166-26 3HAC 023424-001 3HAC 020967-001 3HAC 16831-1 3HAC 6499-1 3HAC 4050-1 9ADA 618-56 3HAC025815-001 3HAC 021827-001
Dimension
D=180, B=12
Lithium 34x102x63
Steel 8.8-A2F M6 x 16
Cable harness IRB 1600/1.45, Customer 3HAC 021828-001 connections Cable harness IRB 1600/1.45, Wire feeder Cable harness, Motor 1-2 Cable harness IRB 1600/1.2, Customer connections 3HAC 021830-001 3HAC 023754-001 3HAC 021828-003


8.2. Spare parts - base Continued Base, exploded view
xx0500001382
243

8.3. Spare parts - base connections
8.3. Spare parts - base connections

Base connections, spare part list The spare parts for connections at the base are listed below and shown in the following figure. Item no. Description
80 81 82 84 85 86 87 88 89 90 92 93 Gasket Housing 40P Surface mounted housing HIP. 16/40 AG Cover, cable harness wire feeder Cover Key pin Plug Protective hood Dust cap Environmental dust cap Dust cap Protection cover 40-p
Spare part no.

3HAB 9040-1 3HAB 6411-1 3HAC 022964-001 3HAC 022918-002 3HAC 6823-1 5217687-9 3HAC 11719-1 25222101-8 5217649-9 3HAA 1001-727 3HAA 1001-630 3HAC 7816-1
Dimension
115x46 T=3
D=11.4-13


8.3. Spare parts - base connections Continued Base connections, illustrations
xx0500001383
245

8.4. Spare parts - frame
8.4. Spare parts - frame

Frame, spare part list The spare parts are listed below and shown in the following figure. Item no. Description
13 20 21 22 23 24 25 26 27 27 28 100-109 Torx pan head screw Gearbox axis 1-2, spare Stop arm Cover, gearbox axis 1-2 Gasket, gearbox axis 1-2 Damper, axis 2 V-ring (sealing ring) Sealing ring (V-ring) Rot. ac motor incl. pinion, spare Rot. ac motor incl. pinion, Cleanroom O-ring Cabling
Spare part no.

9ADA 618-56 3HAC 023555-001 3HAC 022001-001 3HAC 023556-001 3HAC 022048-001 3HAC 022013-001 3HAB 3732-21 3HAB 3732-13 3HAC 023557-001 3HAC031018-001 21522012-428 See section Base, spare part list on page 242Base, spare part list on page 242. 3HAC 023754-001
Dimension
V-150A 135x12.8 V-110-L 99x10.5
Nitrile rubber 79.5x3
108
Cable harness motor 1 - 2


8.4. Spare parts - frame Continued Frame, exploded view
xx0600002845
247

8.5. Spare parts - lower arm
8.5. Spare parts - lower arm

Lower arm, spare part list The spare parts are listed below and shown in the following figure. Item no. Description
40 41 42 43 100-109 Lower arm, spare Lower arm, short, spare VK-cover VK-cover Cabling
Spare part no.

3HAC 023558-001 3HAC 023559-001 3HAA 2166-23 3HAA 2166-21 See section Base, spare part list on page 242.
Dimension
D=120, B=12 D=68, B=8


8.5. Spare parts - lower arm Continued Lower arm, exploded view
xx0500001385
249

8.6. Spare parts - upper arm
8.6. Spare parts - upper arm

Spare part list, upper arm The spare parts listed below are shown in the exploded views, located on the next two pages. Item no. Description
13 60 61 62 63 64 65 66 67 68 69 70 71 Torx pan head screw Upper arm, spare Rot. ac motor incl pinion O-ring Rot. ac motor incl pinion Timing belt Timing belt O-ring sealingplate Wrist, Standard/Foundry Rot. ac motor incl pinion O-ring Damper, axis 3 Sealing ring (V-ring)
Spare part no.

9ADA 618-56 3HAC026567-001 3HAC 021799-001 3HAB 3772-81 3HAC 021800-001 3HAC 6779-1 3HAC 021304-001 3HAC 025420-001 3HAC 026569-001 3HAC 021798-001 21522012-426 3HAC 022260-001 3HAB 3732-19
Dimension
Nitrile rubber D1=41, D2=3
Nitrile rubber 74.5x3 Flourinated rubber/ V-95A 85x11
72 73 74 75 73 77 79 88 89 90 91 94 95 96 100-109
Damper, axis 5 Arm housing cover, spare Gasket, upper arm cover Gasket, customer connections Contact panel Connector panel Contact pane, Wire feeder Protective hood Dust cap Environmental dust cap Dust cap Plug with o-ring M10 Coupling Lamp unit Cabling
3HAB 8964-1 3HAC 023560-001 3HAC 022049-001 3HAC 022050-001 3HAC 022173-001 3HAC 022173-002 3HAC 022173-006 25222101-8 5217649-9 3HAA 1001-727 5217649-82 3HAC 022881-003 3HAB 3333-20 3HAC 022235-001 See section Base, spare part list on page 242. D=11.4-13


8.6. Spare parts - upper arm Continued Upper arm, exploded view 1
xx0600002854


8.6. Spare parts - upper arm Continued Upper arm, exploded view 2
xx0600002856
252

8.7. Spare parts - options
8.7. Spare parts - options

General This section specifies available options for the robot. Spare parts - options Option no.
213-1
Description
Lamp unit
Spare part no.

3HAC022235-001
Note
Installed as detailed in section Installation of signal lamp for 1600 (option) on page 62. Only for standard connection. Includes 3 switches. Installed as detailed in section Installation of position switch, axis 1 on page 76. Installed as detailed in section Installation of additional mechanical stops on axis 1 on page 67. Installed as detailed in section Installation of additional mechanical stop on axis 2 on page 70. Installed as detailed in section Installation of additional mechanical stops on axis 3 on page 73.
431-1 25-3
Connection set R2.CP/ R2.CS Position switch, axis 1
3HAC025396-001 3HAC023973-001
28-1
3HAC023110-001
32-1
3HAC023108-001
34-1
3HAC023109-001
253

8.8. Spare parts - upper arm 1600ID

Location of upper arm 1600ID The location of upper arm 1600ID. Spare part list, upper arm The spare parts listed below are shown in the exploded views, located on the next pages. Item no.
1
Description
Wrist.
Spare part no.

3HAC027716-001
Part no.
Dimension
without motor, plates and screws.
Cable harness IRB 1600ID on page 255 Motor axis 3 (Motors and Orings on page 256 O-ring motor axis 3 (Motors and Orings on page 256) Motor axis 4 and 5 (Motors and Orings on page 256) O-ring motor 4 and 5 (Motors and Orings on page 256) Motor axis 6 Cover arm housing 3HAC027874-001 Covers and mechanical stops on page 257)
3HAC027523-001
plate, no colour
3HAC021798-001
2152 2012-426
3HAC021799-001
3HAB3772-81
7 8
3HAC17342-1
10
Cover upper arm tube (Covers and mechanical stops on page 257 Indicator lamp (Indicator lamp on page 258) Sealing ring(V-ring) axis 3 (Exploaded view on page 259) V-ring(V 130A) axis 4 (Exploaded view on page 259)
3HAC027877-001
11
3HAC9258-1
12
3HAB3732-19
13
3HAB3732-25

Mecanical stop (Covers and mechanical stops on page 257
3HAC027626-001
plate, no colour

8.8. Spare parts - upper arm 1600ID Continued Cable harness IRB 1600ID
xx0700000156


8.8. Spare parts - upper arm 1600ID Continued Motors and O-rings
xx0700000157


8.8. Spare parts - upper arm 1600ID Continued Covers and mechanical stops
xx0700000158


8.8. Spare parts - upper arm 1600ID Continued Indicator lamp
xx0700000159


8.8. Spare parts - upper arm 1600ID Continued Exploaded view
13
12
xx0700000160
259

260
9 Circuit diagram
9.1. Introduction
9 Circuit diagram
9.1. Introduction
Overview This chapter includes the circuit diagram for the robot.

9 Circuit diagram
9.1. Introduction Continued
262
The information in this document is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this document. Except as may be expressly stated anywhere in this document, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like. In no event shall ABB be liable for incidental or consequential damages arising from use of this document. This document and parts thereof must not be reproduced or copied without ABB's written permission, and contents therof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted. Additional copies of this document may be obtained from ABB at its then current charge.
We reserve all rights in this document and in the information contained therein.Reproduction, use or disclosure to third parties without express authority is strictly forbidden. Copyright 2003 ABB
Copyright 2007 ABB ALL right reserved.

ABB Automation Technologies AB Robotics SE-721 68 Vsters Sweden
Latest revision:
Lab/Office:
Status:
2007-03-19
Approved
Prepared by, date: Approved by, date:
COPYRIGHT page Title page/cover sheet
Document no.
3HAC021351-003
= IRB1600 Plant: + Manipulator Location: Sublocation: + Rev. Ind Page 1 Next 2 Total 15
01
Customer Robot serial number(s) Drawing number Drawing version

Manufacture Type Type of installation Control cabinet Mains voltage Supply Control voltage Year of construction Project start Project manager Last revision Designed by Designed date Number of pages
: : : Manipulator :
: : : : : : : : : : : : : : : sestper 2007-03-22 15 2007-03-22
Latest revision:
Lab/Office:
Status:
2007-03-19
Approved
TITLE PAGE Title page/cover sheet
Document no.
3HAC021351-003
= IRB1600 Plant: + Manipulator Location: Sublocation: + Rev. Ind Page 2 Next 11 Total 15
01
R4.MP5 R4.FB5 R3.FB3 R3.FB4 R3.FB5 R3.FB6 R4.MP6 R4.FB6 R3.MP3 R3.MP4 R3.MP5 R3.MP6 R3.H1 R3.H2
IRB 1600 ID
R2.CS Air R2.CP R2.CBUS
R3.FB3 R3.FB4 R3.FB5 R3.FB6
R3.MP3 R3.MP4 R3.MP5 R3.MP6 R3.H1 R3.H2
R3.MP1 R3.MP2 R3.FB1 R3.FB2 R4.FB1
R1.CP/CS R1.CBUS R1.CP R1.CS R1.LS
R4.MP2 R4.FB2
R4.MP1
Air R1.MP R1.SMB
R1.FB1-2 R1.FB3-6 R2.SMB
R2.G R2.BU R2.BU1-6
Latest revision:
Lab/Office:
Status:
Manipulator Connection Points

Document no.
3HAC021351-003
= Connection Points Plant: + Manipulator Location: Sublocation: + Rev. Ind Page 11 Next 20 Total 15
01
-BU Brake Release (Simplified)1 -R1.MP

C8 C9 B8
BRAKE REL BRAKE REL BRAKE PB
BU BU BU
R2.BU R2.BU1-6
2 3 2 A 3 K 2
-2
-BRAKE REL 1 / +AXIS 1/22.1
Brake Bleed Circuit C10 B7
0V BRAKE 0V BRAKE
BU BU
-1
-0V BRAKE 1 / +AXIS 1/22.1
A K 4
-4
B4 B3 C2 C1
EXT LIM 2 EXT LIM 1 LIM 2 LIM 1
BU BU BU BU
Brake Bleed Circuit 3
-3 -5 -6
-0V BRAKE 2 / +AXIS 2/23.2 -PTC2 / +AXIS 2/23.2 -PTC6 / +AXIS 6/27.2 +AXIS 6 IRB1600ID/29.2 -BRAKE REL 3 / +AXIS 3/24.2
A K 8
-8
Brake Bleed Circuit
-7
PE
GNYE
PE
A K 10
-10
11
-9 -11 -12 -14 -BRAKE REL 5 / +AXIS 5/26.2 +AXIS 5 IRB1600ID/28.2
12
A K 14
-13
-0V BRAKE 5 / +AXIS 5/26.2 +AXIS 5 IRB1600ID/28.2 -BRAKE REL 6 / +AXIS 6/27.2 +AXIS 6 IRB1600ID/29.2
A K 16
-16
-15
-0V BRAKE 6 / +AXIS 6/27.2
Latest revision:
Lab/Office:
Status:
2007-03-19
Brake Release Unit

Approved
Document no.
3HAC021351-003
= IRB1600 Plant: + BU Location: Sublocation: + Rev. Ind Page 20 Next 21 Total 15
01
SMB
R1.SMB
A B C D E F K L J
R2.SMB SDI SDI-N SDO SDO-N 0V +24V +BATSUP 0V BATLD WH BU WH OG WH GN GY RD

9 5 8 4 3 7 6 2
R2.SMB
9 5 8 4
SIGNAL CABLE AXIS 7 (OPTION)

3
R1.SMB1.7
7 5 6 12 2 4 11
R1.SMB1.7
5 12 4 11 2 9
R2.FB7 X7 0V X7 Y7 0V Y7 0V EXC 2 EXC 2 BU WH WH OG WH GN

A B C D E F
M KEYPIN 2 9
G
+ -+ -+ -
R2.G(X3) 0V +
2 1
R2.G(X3)
2 1
Latest revision:
Lab/Office:
Status:
2007-03-19
Serial Measuring Board

Approved
Document no.
3HAC021351-003
= IRB1600 Plant: + SMB Location: Sublocation: + Rev. Ind Page 21 Next 22 Total 15
01
-MU1 -R1.MP
A1
-R3.MP1 M1R M1R 1.1 1.10 1.2 1.11 1.3 1.12 1.8
9 9 3 3 2 2 1 1
-R4.MP1 M1R 1
1 1 R (U) PE
A2
M1S M1S
M1S
3
2 2 S (V)
M ~
T (W)
A3
M1T M1T
M1T
-PE
PE
PE
GNYE
PE
PE
GNYE
-PE12 / +AXIS 2/23.4

B2
PTC1
1.6
5 6
5 6
A5
-PTC12 / +AXIS 2/23.4 BRAKE REL.1 0V BRAKE.1 1.4 1.5

7 8 7 8
+BU/20.7 / +BU-BRAKE REL 1 +BU/20.7 / +BU-0V BRAKE 1
BRAKE REL.1 4 0V BRAKE.1 5
7 8
Brake
8
-FB1 -SMB -R2.FB1-2

2 14 2 14
-R3.FB1 X1 0V X1 GY WH
6 1 6 1
IS 2/23.1 IS 3/24.1 IS 4/25.1 IS 5/26.1 IS 6/27.1 00ID/28.1 00ID/29.1
X1 0V X1
WHBU BU
-R4.FB14 1 4 1
Resolver
3 15 3 15
Y1 0V Y1
VT WH
7 2
7 2
Y1 0V Y1
WHOG OG
5 2
5 2
6 18
6 18
0V EXC EXC
WH BU
8 3
8 3
0V EXC EXC
GN WHGN
6 3
6 3
Latest revision:
Lab/Office:
Status:
2007-03-19
Axis 1
Approved
Document no.
3HAC021351-003
= IRB1600 Plant: + AXIS 1 Location: Sublocation: + Rev. Ind Page 22 Next 23 Total 15
01
-MU2 -R1.MP
A4
-R3.MP2 M2R M2R 1.13 1.18 1.14 1.19 1.15 1.20

9 9 3 3 2 2 1 1
-R4.MP2 M2R 1
1 1 R (U) PE
D1
M2S M2S
M2S
3
2 2 S (V)
M ~
T (W)
D2
M2T M2T
M2T
-PE +AXIS 1/22.3 / -PE12 +AXIS 1/22.3 / -PTC12 +BU/20.7 / -PTC2

A6
PE
GNYE
PE
PE
GNYE
5 6
5 6
PTC 2
1.22
BRAKE REL.2 0V BRAKE.2
1.16 1.17
7 8
7 8
4 5
7 8
Brake
8
-SMB -FB2 -R2.FB1-2

4 16 4 16
+AXIS 1/22.1
-R3.FB2 X2 0V X2 GN WH
6 1 6 1
X2 0V X2
WHBU BU
4 1 4 1
Resolver
5 17 5 17
Y2 0V Y2
YE WH
7 2
7 2
Y2 0V Y2
WHOG OG
5 2
5 2
7 19
7 19
0V EXC EXC
WH OG
8 3
8 3
0V EXC EXC
GN WHGN
6 3
6 3
Latest revision:
Lab/Office:
Status:
2007-03-19
Axis 2
Approved
Document no.
3HAC021351-003
01
-MP3 -R1.MP
D3
-R3.MP3 M3R 2.10

1 1 R (U) PE
3
D4
M ~
T (W)
M3S
2.11
S (V)
B1
M3T
2.12
+AXIS 4/25.5 / -PE43
PE
PE
GNYE
+AXIS 4/25.5 / -PTC34
6 B5
-PTC35 / +AXIS 5/26.6 +AXIS 5 IRB1600ID/28.4 BRAKE REL.3 2.13

7 8 7
+BU/20.7 / +BU-BRAKE REL 3
Brake
8
-0V BRAKE 3 / +AXIS 6/27.6 +AXIS 6 IRB1600ID/29.3 SIGNAL LAMP (OPTION) R3.H1
C7
MONLMP
2.6
R3.H2
1 1
-SMB -R3.FB3-6 11
+AXIS 1/22.1
11
X3 0V X3
RDBN RDGN
-R3.FB3 6 1
-FB3
6 1
23
23
Resolver 12
12
Y3 0V Y3
RDYE RDGY
7 2
7 2
24
24
13
13
0V EXC EXC
BKGY BKYE
8 3
8 3
25
25
Latest revision:
Lab/Office:
Status:
2007-03-19
Axis 3
Approved
Document no.
3HAC021351-003
01
-MU4 -R1.MP
A10
-R3.MP4 M4R 2.14

1 1 R (U) PE
3
A9
M ~
T (W)
M4S
2.15
S (V)
A8
M4T
2.16
-PE
PE
2.9 -PE43 / +AXIS 3/24.6 +AXIS 6/27.5 +AXIS 6 IRB1600ID/29.4 / -PTC46
6 B6
-PTC34 / +AXIS 3/24.6 BRAKE REL.4 2.17

7 8 7
+BU/20.7 / +BU-BRAKE REL 4
Brake
8
-0V BRAKE4 / +AXIS 5/26.6 +AXIS 5 IRB1600ID/28.3 -SMB -R2.FB3-6 2
-FB4 2
+AXIS 1/22.1
X4 0V X4
RDBU RD
-R3.FB4 6 1 6 1
14
14
Resolver 3
Y4 0V Y4
BKBN BKGN
7 2
7 2
15
15
0V EXC EXC
BU BUPK
8 3
8 3
19
19
-0V EXC45 / +AXIS 5/26.6 +AXIS 5 IRB1600ID/28.3 -EXC45 / +AXIS 5/26.6 +AXIS 5 IRB1600ID/28.3 Latest revision:
Lab/Office:
Status:
2007-03-19
Axis 4
Approved
Document no.
3HAC021351-003
01
-MU5 -R1.MP
A7
-R3.MP5 M5R 2.18

+AXIS 5 IRB1600ID/28.7 1 1 R (U) PE
3
D10
M ~
T (W)
M5S
2.19
S (V)
D9
M5T
2.20
+AXIS 6/27.6 / -PE65
GNYE
+AXIS 3/24.5 / +AXIS 3-PTC35

B9 C5
5 6
5 6
0V PTC
2.22
BRAKE REL.5 0V BRAKE 5
2.21 2.23
7 8
Brake
8
+AXIS 4/25.5 / +AXIS 4-0V BRAKE4
-SMB -R2.FB3-6 4
-R3.FB5 X5 0V X5 BKPK BKBU
-FB5
6 1
+AXIS 1/22.1 4
16
+AXIS 5 IRB1600ID/28.7 6 1
16
Resolver 5
Y5 0V Y5
BKRD BK
7 2
7 2
17
17
+AXIS 4/25.6 / +AXIS 4-0V EXC45 +AXIS 4/25.6 / +AXIS 4-EXC45
8 3
8 3
-0V EXC56 / +AXIS 6/27.6 -EXC56 / +AXIS 6/27.6
Latest revision:
Lab/Office:
Status:
2007-03-19
Axis 5
Approved
Document no.
3HAC021351-003
01
-R1.MP
D8
-R3.MP6 M6R 2.1
-MU6
1 R (U) PE
+AXIS 6 IRB1600ID/29.7 1
3
D7
M ~
T (W)
M6S
2.2
S (V)
B10
M6T
2.3
-PE
PE
2.8 -PE65 / +AXIS 5/26.6
GNYE
+BU/20.7 / +BU-PTC6
PTC
2.5
5 6
5 6
C6
+AXIS 4-PTC46 / +AXIS 4/25.6 BRAKE REL.6 0V BRAKE 6 2.4 2.7

7 8 7
Brake
8
+AXIS 3/24.5 / +AXIS 3-0V BRAKE 3 -SMB -R2.FB3-6

+AXIS 1/22.1 9
-FB6 21
+AXIS 6 IRB1600ID/29.7
BUBN BUGN
X6 0V X6
R3.FB6 6 1
6 1
21
Resolver 10
10
BUYE BUGY
Y6 0V Y6
7 2
7 2
22
22
8 3
8 3
Latest revision:
Lab/Office:
Status:
2007-03-19
Axis 6
Approved
Document no.
3HAC021351-003
01
-MU5 -R1.MP
A7
-R3.MP5 M5R 2.18

1 1
-R4.MP5 M5R 17
+AXIS 5/26.7 1 1 R (U) PE
D10
M5S
2.19
M5S
18
3
2 2 S (V)
M ~
T (W)
D9
M5T
2.20
M5T
19
+AXIS 6 IRB1600ID/29.4 / -PE65
PE
24
GNYE
+AXIS 3/24.5 / +AXIS 3-PTC35

B9 C5
5 6
5 6
PTC PTC
20 21
5 6
5 6
0V PTC
2.22
2.21 2.23
7 8
7 8
BRAKE REL.5 22 0V BRAKE.5 23
7 8
Brake
8
+AXIS 4/25.5 / +AXIS 4-0V BRAKE4 -SMB -R2.FB3-6 4
+AXIS 1/22.1 4
16
-R3.FB5 X5 0V X5 BKPK BKBU

6 1 6 1
X5 0V X5
GN WH
-FB5 -R4.FB5 +AXIS 5/26.7 6 1 6 1
16
Resolver 5
Y5 0V Y5
BKRD BK
7 2
7 2
Y5 0V Y5
YE WH
7 2
7 2
17
17
8 3
8 3
0V EXC EXC
WH OG
8 3
8 3
-0V EXC56 / +AXIS 6 IRB1600ID/29.4 -EXC56 / +AXIS 6 IRB1600ID/29.4 Latest revision:

Lab/Office:
Status:
2007-03-19
Axis 5 IRB1600ID
Approved
Document no.
3HAC021351-003
= IRB1600 Plant: + AXIS 5 IRB1600ID Location: Sublocation: + Rev. Ind Page 28 Next 29 Total 15
01
-MU6 -R1.MP
D8
-R3.MP6 M6R 2.1

1 1
-R4.MP6 M6R 1
+AXIS 6/27.7 1 1 R (U) PE
D7
M6S
2.2
M6S
M 3 ~
2 2 S (V)
T (W)
B10
M6T
2.3
M6T
-PE
PE
2.8
PE
GNYE
-PE65 / +AXIS 5 IRB1600ID/28.4 +BU/20.7 / +BU-PTC6 PTC 2.5

5 6 C6 5 6
PTC PTC
4 5
5 6
5 6
+AXIS 4-PTC46 / +AXIS 4/25.6 BRAKE REL.6 0V BRAKE.6 2.4 2.7

7 8 7 8
+BU/20.7 / +BU-BRAKE REL 6 / +BU-0V BRAKE 6
6 7
7 8
Brake
8
+AXIS 3/24.5 / +AXIS 3-0V BRAKE 3 -SMB -R2.SMB3-6 9
-FB6 9
+AXIS 1/22.1
R3.FB6 BUBN BUGN X6 0V X6

6 1 6 1
R4.FB6
+AXIS 6/27.7
GY WH
X6 0V X6
6 1
6 1
21
21
Resolver 10
10
BUYE BUGY
Y6 0V Y6
7 2
7 2
VT WH
Y6 0V Y6
7 2
7 2
22
22
+AXIS 5 IRB1600ID/28.4 / +AXIS 5 IRB1600ID-0V EXC56 +AXIS 5 IRB1600ID/28.4 / +AXIS 5 IRB1600ID-EXC56
8 3
8 3
WH BU
0V EXC EXC
8 3
8 3
Latest revision:
Lab/Office:
Status:
2007-03-19
Axis 6 IRB1600ID
Approved
Document no.
3HAC021351-003
= IRB1600 Plant: + AXIS 6 IRB1600ID Location: Sublocation: + Rev. Ind Page 29 Next 30 Total 15
01
-R1.CP/CSA1 B1 C1 D1 A2 B2 C2 D2 A3
-R2.CP CPA CPB CPC CPD CPE CPF CPJ CPK CPH CPG BK BN RD OG YE GN BU VT GY GNYE
A B C D E F J K H
-R1.CP/CSA
-R2.CP CBUS1 CBUS2 CP1 CP2 CP3 CP4 CP5 CP6

A B C D E F G H
CUSTOMER CONNECTION POWER (OPTION) KUNDANSLUTNING KRAFT (OPTION)
B C D E F G H
CUSTOMER CONNECTION CANBUS (OPTION) KUNDANSLUTNING CANBUS (OPTION)
B5 C5 D5 A6 B6 C6 D6 A7 B7 C7 D7 A8 B8 C8 D8 A9 B9 C9 D9 A10 B10 C10 D10
CSA CSB CSC CSD CSE CSF CSG CSH CSJ CSK CSL CSM CSN CSP CSR CSS CST CSU CSV CSW CSX CSY CSZ
WHBN WHRD WHOG WHYE WHGN WHBU WHVT WHGY GYBK GYBN GYRD GYOG GYYE GYGN GYBU GYVT GYWH GNBK GNBN GNRD GNOG GNBU GNVT
-R2.CS
A B C D E F G H J K L M N P R S T U V W X Y Z
CUSTOMER CONNECTION SIGNAL (OPTION) KUNDANSLUTNING SIGNAL (OPTION)
Latest revision:
Lab/Office:
Status:
2007-03-19
Customer Connections
Approved
Document no.
3HAC021351-003
= IRB1600 Plant: + CC Location: Sublocation: + Rev. Ind Page 30 Next 31 Total 15
01
R1.LS -PE
A B D C
R2.LS1-1 GNYE BK BN BU BK One switch En brytare Two switches Tv brytare Three switches Tre brytare
R2.LS1-2 -PE
E F H G
GNYE BK BN BU BK
R2.LS1-3 -PE
J K M L
GNYE BK BN BU BK KEY PIN / STIFT
Latest revision:
Lab/Office:
Status:
2007-03-19
Position Indicator Axis 1; Option

Approved
Document no.
3HAC021351-003
= IRB1600 Plant: + LS Location: Sublocation: + Rev. Ind Page 31 Next Total 15
01
Index
A
Absolute Accuracy, calibration 221 Absolute Accuracy, guiding sleeves 51 air connections, pressure 84 arm system replacing 126 attachment bolts, robot-foundation 50
B
backshells, customer connection 84 base brake release buttons 47 hole configuration 49 replacing 165 screws, tightening torque 167 spare part number 165 battery pack replacing 103 replacing, interval 91 spare part number 104 belt tightener axis 5 article number 200 measure 200 brake release unit releasing the brakes 47 replacing 173 spare part number 173 brakes testing function 24 brakes, releasing external power supply to connector R1.MP 48 manually 47 power supply on motor axis 1 178 power supply to motor axis 2 182 power supply to motor axis 3 187 power supply to motor axis 4 194
calibration manuals 221 calibration position 225 checking 227 jogging to, FlexPendant 227 scales 222 calibration, Absolute Accuracy 221 CalibWare 220 check, installation site 38 cleaning robot, interval 91 cleaning, robot 105 complete arm system replacing 126 connecting the robot and controller, cabling 81 Connection of external safety devices 14 connectors air 84 customer 84 MIL-C-26482 series 1 85 on robot, figure 79 R2.CS and R2.CP pins, customer connection 84 Souriau 84 cracks, damper 94 customer connections 79
D
damage, damper 94 damper, axis 2 93 attachment screw 152 replacing 151 spare part number 151 damper, axis 3 inspection 93 replacing 153 spare part number 153 damper, axis 5 inspection 93 replacing 157 spare part number 157 dimensions guiding sleeves 50 mounting surface 50 robot 56 direction of axes 224
C
cable harness inside base, figure 118 inside frame, figure 117 inside upper arm, figure 115 replacing 112 spare part number 112 cabling inside base, figure 118 inside frame, figure 117 inside upper arm, figure 115 replacing 112 spare part number 112 cabling between robot and controller 81 cabling, robot 81 calibrating roughly 225 calibration Absolute Accuracy type 220 marks/scales 222 rough 225 standard type 220 when to calibrate 219
E
environment 39 equipment, robot 56 ESD damage elimination 35 sensitive equipment 35 wrist strap connection point 35 explanation, safety symbols 30 extra equipment 56 extra loads 55
F
figures base, hole configuration 49 brake release buttons 47 263
Index
cabling inside base 118 cabling inside frame 117 cabling inside upper arm housing 115 connectors on robot 79 gearboxes 95 mounting surface 50 power supply to connector R1.MP 48 fitting, equipment 56 FlexPendant jogging to calibration position 227 MoveAbsJ instruction 227 updating revolution counters 225 foundation loads 38 requirements 39 frame replacing 214 spare part number 214
installation checking site prior robot installation 38 equipment 56 mechanical stop axis 2 70 mechanical stops axis 3 73 mechanical stops, axis 1 67 position switch axis 1 76 robot, attachment bolts 50 signal lamp 62 intervals, maintenance 91 inverted mounting 52
L
lamp unit article number 62 installation 62 lifting, robot 45 limitations in working range, tilted and wall mounted 43 loads 55 loads, foundation 38 location of connectors 79 lower arm removing together with upper arm 126 replacing 139 screws, tightening torque 141 spare part number 139
G
gaskets, spare part number base cover 173 gearbox axis 1-2 177 upper arm cover 209 upper arm customer connections 209 gearbox, axes 1-2 replacing 214 spare part number 214 gearboxes location on robot, figure 95 type of oil and amount 95 gearboxes, axes 3-6 replacing 218 service work 218 gearboxes, axes 5 and 6 amount and type of oil 97 oil change 97 Gravity Beta 52
M
maintenance intervals 91 maintenance schedule 91 measurement system battery pack, replacing 103 measurement system battery pack, spare part number 104 mechanical stop axis 2 article number 71 installation 70 mechanical stop axis 3 article number 75 screws, tightening torque 75 mechanical stops axis 1 article number 68 installation 67 screws, tightening torque 69 mechanical stops axis 2 screws, tightening torque 72 mechanical stops axis 3 installation 73 motor axis 1 brake release with power supply 178 replacing 177 spare part number 177 tightening torque 179 motor axis 2 brake release with power supply 182 replacing 181 spare part number 181 tightening torque 183 motor axis 3 brake release with power supply 187 replacing 185 screws, tightening torque 187, 192 spare part number 185 3HAC026660-001 Revision: B
hole configuration base 49
I
illustration base connections 245 illustrations base, exploded 243 base, hole configuration 49 brake release buttons 47 cabling inside base 118 cabling inside frame 117 cabling inside upper arm housing 115 connectors on robot 79 frame, exploded 247 gearboxes 95 lower arm, exploded 249 mounting surface 50 power supply to connector R1.MP 48 upper arm, exploded 251, 252 inspection 93 264
Index
motor axis 4 brake release with power supply 194 replace 193 screws, tightening torque 195, 198 spare part number 193 motor axis 5 replacing 199 screws, tightening torque 202 spare part number 200 motor axis 6 replacing 209 screws, tightening torque 211 spare part number 209 motor connectors 79 mounting, equipment 56 MoveAbsJ instruction FlexPendant 227
axis 2 70 axis 3 73 revolution counters storing on FlexPendant 225 updating 225 robot cleaning 105 connectors 79 dimensions 56 equipment, fitting 56 lifting 45 orienting and securing 49 robot position 222 when draining wrist unit 98, 101, 102 when filling oil in wrist unit 99
S
safety equipment position switch axis 1 76 Safety, service 14 safety, symbols 30 scales on robot 222 schedule, maintenance 91 securing, robot 49, 50 serial measurement unit battery pack, replacing 103 battery pack, spare part number 104 replacing 169 spare part number 170 signal connectors 79 signal lamp article number 62 installation 62 SMB unit battery pack, replacing 103 battery pack, spare part number 104 replacing 169 spare part number 170 Souriau, connector 84 spare parts base 242, 243 base connections 244, 245 frame 246, 247 lower arm 248, 249 optional equipment 253 upper arm 250, 251, 252 special tools 238 storage, conditions 39 suspended mounting 52 symbols, safety 30 sync marks 222 system parameter Gravity Beta 52
N
negative directions, axes 224
O
oil change gearbox axes 5 and 6 97 gearboxes, axes 5 and 6, intervals 91 safety risks 36 wrist unit 97 wrist unit, intervals 91 oil in gearboxes amount 95 article numbers 95 type 95 operating, conditions 39 orienting, robot 49
P
permitted extra loads 55 position switch axis 1 76 position switch axis 1 article number 76 position, robot 222 when draining wrist unit 98, 101, 102 when filling oil in wrist unit 99 positions at wrist center, 1.2 reach 40 positions at wrist center, 1.45 reach 41 positive directions, axes 224 protection classes, IP class 39 push button unit releasing the brakes 47 replacing 173 spare part number 173
R
releasing brakes external power supply to connector R1.MP 48 manually 47 replacing together 126 requirements, foundation 39 restricting working range axis 1 67, 76
T
testing, brakes 24 tightening torques, attachment screws base-gearbox unit 167 lower arm-frame 141 mechanical stop axis 1 69 mechanical stop axis 2 72 265
Index
mechanical stop axis 3 75 motor axis 1 179 motor axis 2 183 motor axis 3 187, 192 motor axis 4 195, 198 motor axis 5 202 motor axis 6 211 robot to foundation, attachment bolts 50 upper arm 132 wrist unit 144 tilted mounting 52 timing belt axis 5 adjusting the tension 202 replacing 199 spare part number 200 timing belt axis 6 adjusting the tension 211 replacing 209 spare part number 209 tools belt tightener axis 5, article number 200 belt tightener axis 5, measure 200 Calibration Pendulum equipment 238 dynamometer axis 5 and 6 209 for service 238 hook axis 6, article number 209 rotational tool, article number 193 turning radius 44
screws, tightening torque 144 spare part number 143
U
updating revolution counters 225 upper and lower arm 126 upper arm removing together with lower arm 126 replacing 129 screws, tightening torque 132 spare part number 129
V
Validity and responsibility 14 VK-covers, spare part number at base 165 lower arm, lower 139 lower arm, middle 139 lower arm, upper 129
W
wall mounting 52 weight base 167 complete arm system 127, 128 gearbox unit 216 lower arm 140, 141 robot 38, 46, 166, 167 upper arm 130, 131 working range 43 restricting axis 1 76 wrist unit amount and type of oil 97 oil change 97 replacing 143 266 3HAC026660-001 Revision: B
ABB AB Robotics Products S-721 68 VSTERS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592
3HAC026660-001, Revision B, en

Manual Product Mecanic Da 3HAC026660-001 RevB en

Uploaded by

Copyright:

Available Formats

Manual Product Mecanic Da 3HAC026660-001 RevB en

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Manual Product Mecanic Da 3HAC026660-001 RevB en

Uploaded by

Copyright:

Available Formats

Product manual

1.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.2.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 2.2.2 Working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

2.6.1 Additional installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 3 Maintenance 89

3.3.1 Inspection, damper axes 2, 3 and 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

3.5.1 Cleaning, complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 4 Repair 107

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

4.4 Upper and lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

6.1 Type A of IRB 1600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229 7 Reference information 231

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261 Index 263

Copyright 2006-2008 ABB. All rights reserved.

Organization of chapters The manual is organized in the following chapters:

Installation and commissioning Maintenance

Repair Calibration information

Continues on next page

Copyright 2006-2008 ABB. All rights reserved.

Product documentation, M2004

Product documentation, M2004

Copyright 2006-2008 ABB. All rights reserved.

How to read the product manual

How to read the product manual

Fit a new sealing, axis 2 to the gearbox.

How to read the product manual

Copyright 2006-2008 ABB. All rights reserved.

Copyright 2006-2008 ABB. All rights reserved.

1.2 General safety information 1.2.1. Safety in the robot system

Related information Type of information

Cabling Safety risk

Gearboxes and motors Safety risk

Copyright 2006-2008 ABB. All rights reserved.

1.2.2.2. Safety risks related to tools/workpieces

Copyright 2006-2008 ABB. All rights reserved.

1.2.2.3. Safety risks related to pneumatic/hydraulic systems

Copyright 2006-2008 ABB. All rights reserved.

1.2.2.4. Safety risks during operational disturbances

Copyright 2006-2008 ABB. All rights reserved.

1.2.2.5. Risks associated with live electric parts

1.2.3. Safety actions 1.2.3.1. Safety fence dimensions

Copyright 2006-2008 ABB. All rights reserved.

1.2.3.2. Fire extinguishing

Copyright 2006-2008 ABB. All rights reserved.

1.2.3.3. Emergency release of the robots arm

Copyright 2006-2008 ABB. All rights reserved.

1.2.3.4. Brake testing

Copyright 2006-2008 ABB. All rights reserved.

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

Copyright 2006-2008 ABB. All rights reserved.

1.2.3.6. Safe use of the FlexPendant

Copyright 2006-2008 ABB. All rights reserved.

1.2.3.7. Work inside the robot's working range

Copyright 2006-2008 ABB. All rights reserved.

1.2.3.8. Signal lamp (optional)

Copyright 2006-2008 ABB. All rights reserved.

1.2.3.9. Translate the information on safety and information labels

Copyright 2006-2008 ABB. All rights reserved.

Free space for adding a fourth language

1.3 Safety related instructions 1.3.1. Safety signals, general