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M2004
ABB M2004 User Manual
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2 Inst
allatio
n and commis
sio
n
ing
2.2. Robot transportation
p
re
c
aution
s
59
3HAC022033-001 Revi
sion: K
© Copyright 2004-201
1 ABB. All rights reserved.
Recommended transport
support
Always use the recommended
transport support when transporting a robot with tool.
IRB 7600/IRB 66XX
xx0800000
039
Co
nti
nued
Continues on next
page
工控帮助教小舒QQ2823408167
长沙工控帮教育科技有限公司
60
62
Table of Contents
Default Chapter
5
Table of Contents
5
Overview of this Manual
11
Product Documentation, M2000/M2000A
16
Product Documentation, M2004
17
How to Read the Product Manual
19
1 Safety
21
Introduction to Safety Information
21
General Safety Information
22
Safety in the Manipulator System
22
Safety Risks
23
Safety Risks During Installation and Service Work on Manipulators
23
CAUTION - Hot Parts May Cause Burns
25
Safety Risks Related to Tools/Work Pieces
26
Safety Risks Related to Pneumatic/Hydraulic Systems
27
Safety Risks During Operational Disturbances
28
Risks Associated with Live Electric Parts
29
Safety Actions
31
Safety Fence Dimensions
31
Fire Extinguishing
32
Emergency Release of the Manipulator's Arm
33
Brake Testing
34
Risk of Disabling Function "Reduced Speed 250 MM/S
35
Safe Use of the Flexpendant
36
Work Inside the Manipulator's Working Range
37
Signal Lamp (Optional)
38
Safety Stops
39
What Is an Emergency Stop
39
Safety Related Instructions
41
Safety Signals in the Manual
41
Safety Symbols on Manipulator Labels
43
DANGER - Moving Manipulators Are Potentially Lethal
48
DANGER - First Test Run May Cause Injury or Damage
49
WARNING - the Brake Release Buttons May be Jammed after Service Work
50
WARNING - the Unit Is Sensitive to ESD
51
WARNING - Safety Risks During Work with Gearbox Lubricants (Oil or Grease)
53
2 Installation and Commissioning
55
Introduction
55
Robot Transportation Precautions
56
Securing the Robot
63
Unpacking
65
Pre-Installation Procedure
65
Working Range, IRB 7600 - 150/3.5
68
Working Range, IRB 7600 - 340/2.8
69
Working Range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55
70
Working Range, IRB 7600 - 500/2.3
71
Risk of Tipping/Stability
72
On-Site Installation
73
Lifting Robot with Fork Lift
73
Lifting Robot with Lifting Slings
81
Lifting Robot with Roundslings
83
Manually Releasing the Brakes
85
Manually Releasing the Brakes, External Brake Release Unit
88
Lifting the Base Plate
91
Securing the Base Plate
92
Orienting and Securing the Robot
96
Fitting Equipment on Robot
99
Installation of Base Spacers (Option)
104
Installation of Cooling Fan for Motors, Axes 1-3 (Option)
106
Installation of Foundry Plus Cable Guard (Option No. 908-1)
114
Loads
115
Restricting the Working Range
116
Introduction
116
Mechanically Restricting the Working Range of Axis 1
117
Mechanically Restricting the Working Range of Axis 2
119
Mechanically Restricting the Working Range of Axis 3
121
Installation of Position Switches (Option)
124
Electrical Connections
135
Robot Cabling and Connection Points
135
Making Robot Ready for Operation (Foundry Prime)
138
Additional Installation Procedure
138
Commissioning (Foundry Prime)
141
3 Maintenance
143
Introduction
143
Maintenance Schedule and Expected Life
144
Specification of Maintenance Intervals
144
Maintenance Schedule
145
Expected Component Life
151
Inspection Activities
152
Inspection, Oil Level Gearbox Axis 1
152
Inspection, Oil Level Gearbox Axis 2
155
Inspection, Oil Level Gearbox Axis 3
158
Inspection, Oil Level Gearbox Axis 4
160
Inspection, Oil Level, Gearbox Axis 5
163
Inspection, Oil Level Gearbox Axis 6
166
Inspection, Balancing Device
170
Inspection, Cable Harness
176
Inspecting, Mechanical Stop Pin, Axis 1
179
Inspection, Mechanical Stop, Axes 1, 2 and 3
181
Inspection, Damper Axes 2-5
183
Inspection, Position Switch Axes 1, 2 and 3
185
Inspection, Information Labels
189
Inspection, UL-Lamp
191
Inspection of Air Hoses (Foundry Prime)
193
Changing/Replacement Activities
194
Type of Oil
194
Determining Oil Type
195
Which Type of Oil Does the Gearbox Contain
195
Labels on the Robot
197
Article Numbers and Volumes, Alternative Kyodo Yushi TMO 150
199
Mixed Types of Oil May Cause Severe Damage
199
Rinsing Gearbox
200
Equipment
200
Oil Change, Gearbox Axis 1
201
Oil Change, Gearbox Axis 2
205
Oil Change, Gearbox, Axis 3
208
Oil Change, Gearbox, Axis 4
211
Oil Change, Gearbox, Axis 5
214
Oil Change, Gearbox Axis 6
217
Replacing SMB Battery
220
Lubrication Activities
223
Lubrication of Spherical Roller Bearing, Balancing Device
223
Rust Preventive Measures, Bearing Axis 1 (Foundry Prime)
225
Rust Preventive Measures, Sealing Axis 4 (Foundry Prime)
228
Rust Preventive Measures, Support Bearing in Wrist (Foundry Prime)
231
Cleaning Activities
233
Flushing a Contaminated Gearbox
233
Cleaning, Robot
235
Service Information System, M2000
237
Using the SIS System
237
Description of Service Information System (SIS)
238
SIS System Parameters
240
Setting the SIS Parameters
242
Reading the SIS Output Logs
244
Exporting the SIS Data
245
4 Repair
247
Introduction
247
General Procedures
248
Performing a Leak-Down Test
248
Mounting Instructions for Bearings
249
Mounting Instructions for Seals
251
Complete Robot
253
Replacement of Cable Harness, Axes 1-4
253
Replacement of Cable Harness, Axes 5-6
262
Replacement of Complete Arm System
265
Replacement of Air Nipple and Hose (Foundry Prime)
270
Upper and Lower Arm
277
Replacing Turning Disk
277
Replacement of Complete Wrist Unit
281
Replacement of Complete Upper Arm
285
Replacement of Complete Lower Arm
290
Frame and Base
299
Replacement of SMB Unit
299
Replacement of Brake Release Unit
303
Replacement of Balancing Device
309
Replacement of Spherical Roller Bearing, Balancing Device
318
Unloading the Balancing Device Using Hydraulic Press Tool
322
Restoring the Balancing Device Using a Hydraulic Press Tool
326
Motors
329
Replacement of Motor, Axis 1
329
Replacement of Motor Axis 2
335
Replacement of Motor, Axis 3
343
Replacement of Motor, Axis 4
350
Replacement of Motor, Axis 5
357
Replacement of Motor, Axis 6
361
Gearboxes
367
Replacement of Gearbox, Axis 1
367
Replacement of Gearbox, Axis 2
375
Replacement of Gearbox, Axis 3
382
Replacement of Gearbox, Axis 4
388
Replacement of Gearbox, Axis 5
393
Replacement of Gearbox, Axis 6
399
5 Calibration Information
405
Introduction
405
Calibration Methods
406
Calibration Scale and Correct Axis Position
408
Calibration Movement Directions for All Axes
409
Updating Revolution Counters
410
Checking the Calibration Position
414
6 Decommissioning
417
Environmental Information
417
Decommissioning of Balancing Device
418
7 Reference Information
421
Introduction
421
Applicable Safety Standards
422
Unit Conversion
424
Screw Joints
425
Weight Specifications
428
Standard Toolkit
429
Special Tools
430
Lifting Accessories and Lifting Instructions
433
8 Spare Part / Part List
435
Introduction
435
Spare Parts
436
Introduction
436
Spare Part List
437
Part List
439
Introduction
439
Rebuilding Parts
440
Part List, Overview
441
Mechanical Stop Axis 1, 3HAC12812-2
443
Base Incl Frame Axis 1, 3HAC12304-1
444
Axis 3-4, 3HAC13063-1 (IRB 7600 - 150/3.5, - 325/3.1, -340/2.8, -400/2.55, -500/2.55)
445
Axis 3-4, 3HAC13063-2 (IRB 7600 - 500/2.3)
448
Axis 3-4, Foundry, 3HAC13063-4 (IRB 7600 -150/3.5, - 325/3.1, - 340/2.8, - 400/2.55, - 500/2.55)
449
Axis 3-4 Foundry, 3HAC13063-5 (IRB 7600 - 500/2.3)
450
Wrist, 3HAC16628-4 / 3HAC16628-3
451
Material Set Robot, 3HAC13079-1
457
Material Set Axis 1-2, 3HAC13077-1
458
Material Set Balancing Device, 3HAC13082-1
461
Arm Extension Set, 956 MM, 3HAC12311-1 (IRB 7600 - 150/3.5)
462
Arm Extension Set, 250 MM, 3HAC12311-2 (IRB 7600 - 340/2,8)
463
9 Exploded Views
465
Introduction
465
Base Incl. Frame
466
Frame-Lower Arm 1
467
Frame-Lower Arm 2
468
Upper Arm
469
Wrist Complete
470
10 Circuit Diagram
471
About Circuit Diagrams
471
Circuit Diagram 3HAC 025744-001
473
Validity of Circuit Diagram 3HAC 025744-1
473
Circuit Diagram 3HAC 13347-1
474
Validity of Circuit Diagram 3HAC 13347-1
474
Index
475
Other manuals for ABB M2004
Reference Manual
54 pages
Product Specification
68 pages
System Settings
56 pages
5
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ABB M2004 Specifications
General
Brand
ABB
Model
M2004
Category
Robotics
Language
English
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