1 Reference information1.1. Introduction113HAC023297-001 Revision: A1 Reference information1.1. IntroductionGeneralThis chapter includes general information, complementing the more specific information inthe Product manual (part 1 of 2), procedures.

Overview

Product documentation, M2000/M2000A

Product documentation, M2004

Reference information

Applicable Safety Standards

Unit conversion

Screw joints

Weight specifications

Document references

Standard toolkit

Performing a leak-down test

Lifting equipment and lifting instructions

Mounting instructions for bearings

Mounting instructions for seals

Spare part / part list

Foldouts

Circuit diagram

ABB M2000 Reference Manual

Description

Principle layout

Terms and concepts

Safety instructions

Unpacking and handling safety

Commissioning safety

Technical specifications and requirements

Dimensions

Width and height measurements

Technical requirements for the robot

Variants and options

Zone division

Ordering list

Unpacking and handling

Mechanical installation

Maintenance intervals

Maintenance instructions

M2004

How to read the product manual

Safety

General safety information

General information

Limitation of Liability

Related information

Safety risks

Safety risks related to gripper

Safety risks related to tools/workpieces

Safety risks related to pneumatic/hydraulic systems

Safety risks during operational disturbances

Safety risks during installation and service

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 Teach Pendant Unit

Work inside the manipulator's working range

Safety related instructions

DANGER - Moving manipulators are potentially lethal

WARNING - The unit is sensitive to ESD

WARNING - Safety risks during work with gearbox oil

Installation and commissioning

Unpacking

Working range, IRB 140

Risk of tipping/Stability

On-site installation

Manually releasing the brakes

Orienting and securing the manipulator

Restricting the working space

Fitting equipment on manipulator

Loads

Suspended mounting

Bolt pattern

Electrical connections

Maintenance

Maintenance schedules

Inspection activities

Inspection, robot cabling

Inspection, timing belts

Cleaning activities

Changing/ replacing activities

Repair

Complete robot

Replacement of complete upper arm

Replacement of complete lower arm

Replacement of base, spare

Upper arm

Replacement of damper, axis 3

Replacement of damper, axis 5

Replacement of cover, arm housing

Lower arm

Replacement of damper, axis 2

Replacement of indicator lamp

Frame and base

Replacement of console

Replacement of serial measurement unit and battery pack

Replacement of control cable

Motors

Replacement of motor, axis 2

Replacement of motor and timing belt, axis 3

Replacement of motor, axis 4

Replacement of motor and timing belt, axes 5 or 6

Adjustments and measurements

Measuring the gear play, axis 6

Gearboxes

Service work on gearbox, axis 4

Calibration information

Calibration methods

Calibration scales and correct axis position

Calibration movement directions for all axes

Updating revolution counters

Checking the calibration position

Safe use of the FlexPendant

Work inside the robot's working range

Signal lamp (optional)

Translate the information on safety and information labels

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

Robot transportation precautions

Securing the robot

Working range and type of motion

Risk of tipping / stability

Lifting robot with roundslings

Lifting the base plate

Securing the base plate

Orienting and securing the robot

Fitting cable package attachments (Cleanroom)

Fitting equipment on robot

Installation of cooling fan for motors, axes 1 and 2 (option)

Restricting the working range

Mechanically restricting the working range of axis 1

Mechanically restricting the working range of axis 2

Mechanically restricting the working range of axis 3

Making robot ready for operation (Foundry Prime)

Commissioning (Foundry Prime)

Making robotready for operation, (Cleanroom)

Maintenance schedule and expected component life

Maintenance schedule

Expected component life

Inspection, oil level gearbox axis 2

Inspection, oil level gearbox axis 3

Inspection, oil level gearbox axis 4

Inspection, oil level, gearbox axis 5

Inspection, oil level gearbox axis 6

Inspection, balancing device

Inspection, cable harness

Inspection of air hoses (Foundry Prime)

Inspection, information labels

Inspection, mechanical stop, axis 1

Inspection, additional mechanical stops

Inspection, damper axes 2-5

Inspection, signal lamp (option)

Replacement / Changing activities

Oil change, gearbox axis 1

Oil change, gearbox axis 2

Oil change, gearbox, axis 3

Oil change, gearbox, axis 4

Oil change, gearbox, axis 5

Oil change, gearbox axis 6

Replacement of SMB battery

Lubrication activities

Rust preventive measures, bearing axis 1 (Foundry Prime)

Rust preventive measures, bearing axis 4 (Foundry Prime)

Rust preventive measures, support bearing in wrist (Foundry Prime)

General procedures

Replacement of cabling, axis 5 motorIRB 6640

Replacement of cable harness, Cleanroom

Replacement of cable harness, axes 1-4- IRB 6640ID

Replacement of cable harness, axes 5-6 - IRB 6640ID

Replacement of complete arm system

Replacement of air nipple and hose (Foundry Prime)

Upper and lower arm

Replacement of complete wrist unit

Replacement of complete wrist unit, IRB 6640ID

Replacement of upper arm

Overview of this manual

CAUTION - Hot parts may cause burns

Safety risks related to tools/work pieces

Emergency release of the manipulator's arm

Safety stops

Safety symbols on manipulator labels

WARNING - Safety risks during work with gearbox lubricants (oil or grease)

Working range, IRB 7600 - 150/3.5

Working range, IRB 7600 - 340/2.8

Working range, IRB 7600 - 400/2.55, IRB 7600 - 500/2.55

Working range, IRB 7600 - 500/2.3

Risk of tipping/stability

On-site Installation

Lifting robot with lifting slings

Manually releasing the brakes, external brake release unit

Installation of base spacers (option)

Installation of cooling fan for motors, axes 1-3 (option)

Installation of Foundry Plus Cable guard (option no. 908-1)

Installation of position switches (option)

Maintenance schedule and expected life

Inspecting, mechanical stop pin, axis 1

Inspection, mechanical stop, axes 1, 2 and 3

Inspection, position switch axes 1, 2 and 3

Inspection, UL-lamp

ABB M2000 Reference Manual

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