Contents - Table Of Contents
- Table Of Contents
- Table Of Contents
- Overview
- Product documentation, M2004
- How to read the product manual
- Safety
- General safety information
- Safety risks
- Safety risks related to tools/workpieces
- Safety risks related to pneumatic/hydraulic systems
- Safety risks during operational disturbances
- Risks associated with live electric parts
- Safety actions
- Fire extinguishing
- Emergency release of the robot's arm
- Brake testing
- Risk of disabling function "Reduced speed 250 mm/s
- Safe use of the FlexPendant
- Work inside the robot's working range
- Signal lamp (optional)
- Translate the information on safety and information labels
- Safety related instructions
- DANGER - Moving robots are potentially lethal
- DANGER - First test run may cause injury or damage
- WARNING - The brake release buttons may be jammed after service work
- WARNING - The unit is sensitive to ESD
- WARNING - Safety risks during work with gearbox oil
- Installation and commissioning
- Unpacking
- Working range
- On-site installation
- Manually releasing the brakes
- Orienting and securing the robot
- Suspended mounting
- Loads
- Fitting equipment on the robot (robot dimensions)
- Installation of signal lamp for 1600 (option)
- Installation of signal lamp for 1600 ID (option)
- Restricting the working range
- Installation of additional mechanical stops on axis 1
- Installation of additional mechanical stop on axis 2
- Installation of additional mechanical stops on axis 3
- Installation of position switch, axis 1
- Electrical connections
- Robot cabling and connection points
- Customer connections on the robot
- Making robot ready for operation (Cleanroom)
- Maintenance
- Maintenance schedule and expected component life
- Maintenance schedule
- Expected component life
- Inspection activities
- Replacement activities
- Oil change, gearbox axes 5 and 6
- Oil change, gearbox axes 5- 6, IRB 1600ID
- Replacement of measurement system battery pack
- Cleaning activities
- Repair
- General procedures
- Mounting instructions for bearings
- Mounting instructions for seals
- Complete manipulator
- Replacement of cable harness, IRB 1600ID
- Replacement of complete arm system
- Upper and lower arm
- Replacement of complete upper arm, IRB 1600ID
- Replacement of complete lower arm
- Replacement of wrist unit
- Replacement of wrist unit, IRB1600ID
- Replacement of damper, axis 2
- Replacement of damper, axis 3
- Replacement of Mechanical damper, axis 3, IRB 1600ID
- Replacement of damper, axis 5
- Remove upper arm AW Gun
- Fitting equipment on the robot, IRB 1600ID
- Frame and base
- Replacement of serial measurement unit
- Replacement of push button unit
- Motors
- Replacement of motor, axis 2
- Replacement of motor, axis 3
- Replacement of motor, axis 3, IRB 1600ID
- Replacement of motor, axis 4
- Replacement of motor, axis 4, 1600ID
- Replacement of motor and timing belt, axis 5
- Replacement of motor, axis 5, IRB 1600ID
- Replacement of motor and timing belt, axis 6
- Replacement of motor, axis 6 IRB 1600ID
- Gearboxes
- Service work on gearboxes, axes 3, 4, 5 and 6
- Calibration information
- Calibration methods
- Calibration scales and correct axis position
- Calibration movement directions for all axes
- Updating revolution counters
- Checking the calibration position
- Robot description
- Reference information
- Unit conversion
- Screw joints
- Weight specifications
- Standard toolkit
- Special tools
- Lifting equipment and lifting instructions
- Spare parts and exploded views
- Spare parts - base
- Spare parts - base connections
- Spare parts - frame
- Spare parts - lower arm
- Spare parts - upper arm
- Spare parts - options
- Spare parts - upper arm 1600ID
- Circuit diagram
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Overview73HAC026660-001 Revision: C© Copyright 2006-2008 ABB. All rights reserved.OverviewAbout this manualThis manual contains instructions for:• mechanical and electrical installation of the robot• maintenance of the robot• mechanical and electrical repair of the robot.UsageThis manual should be used during:• installation, from lifting the robot to its work site and securing it to the foundation, tomaking it ready for operation• maintenance work• repair work and calibration.Who should read this manual?This manual is intended for:• installation personnel• maintenance personnel• repair personnel.PrerequisitesA maintenance/repair/ installation craftsman working with an ABB Robot must:• be trained by ABB and have the required knowledge of mechanical and electricalinstallation/repair/maintenance work.Organization of chaptersThe manual is organized in the following chapters:Chapter ContentsSafety, service Safety information that must be read through before performingany installation or service work on robot. Contains general safetyaspects as well as more specific information on how to avoidpersonal injuries and damage to the product.Installation and commis-sioningRequired information about lifting and installation of the robot.Maintenance Step-by-step procedures that describe how to performmaintenance of the robot. Based on a maintenance schedule thatmay be used to plan periodical maintenance.Repair Step-by-step procedures that describe how to perform repairactivities of the robot. Based on available spare parts.Calibration information Procedures that do not require specific calibration equipment.General information about calibration.Continues on next page
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