3HAC 022031-001 Revision: A
84
4.3.2. Refitting of cable harness
Location of cable harness
The cable harness is located throughout the manipulator as shown in the figure below.
Location of Connections in harness
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A Connector at manipulator base, R1.MP, R1.SMB and R1.C/CS
a1 Electrical connectors rear of the cover plate at the manipulator base , R1.MP1-3, R1.MP4-6, R1.CS, R1.CP, R1.H1, R2.BU, R2.BU1-3, R2.BU4-6,
a2 Connectors at the serial mesurement board (SMB-unit), R2.SMB1-2 (empty), R2.G (bat), R2.FB1-3 and R2.FB4-6
B Connectors at motor 2, R3.MP2 and R3.FB2
C Connectors at motor 3, R3.MP3, R3.FB3,R3.LS1 and R3.LS2 D Connectors at motor 1, R3.MP1, R3.FB1
E Connectors at motor 4 (5 kg option), R3.MP4 and R3.FB4 e Connectors at motor 4 (15 kg option), R3.MP4 and R3.FB4 F Connectors at motor 5, R3.MP5 and R3.FB5
G Connectors at motor 6, R3.MP6 and R3.FB6 H Connectors R3.H1 and R3.H2 (5 kg option) h Connectors R3.H1 and R3.H2 (15 kg option)
4.3.2. Refitting of cable harness
Refitting, cable harness, axes 1-3
The procedure below details how to refit the cable harness, axes 1-3.
Equipment, etc. Spare part
no. Art. no. Note Cable unit, axes 1-3 3HAC 4791-1
Cable unit, axes 4-6 3HAC 8865-1 Cable unit, axes 4-6 Opt
043
3HAC 8520-1 Option 043
Motor gasket for motor 1-3 3HAC 4419-1 Motor gasket for motor 4-6 3HAB 4429-1
Sealing 3HAB 5922-1
Loctite 574 1234 0011-116 Flange sealing
Cable straps 2166 2055-3 L=208mm
Circuit Diagram See chapter Circuit diagram in the
Product manual, reference information.
Standard toolkit The contents are defined in
section Standard toolkit in the Product manual, reference information!
Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.
These procedures include references to the tools required.
4.3.2. Refitting of cable harness
3HAC 022031-001 Revision: A
86
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.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them!
Step Action Note/Illustration
1. In order to facilitate refitting of the cable harness, run the manipulator to the specified position:
• Axis 6: no significance
Axes 2 and 3 may be tilted slightly to improve access.
2. Gently pull the down the cable harness through the center hole of axis 1.
3. Mount the motor case on motor 1-3 using the 3 screws
Note! Always mount a new gasket art no. 3HAC 4419-1
4. Reconnect all connectors at motor 1, 2 and 3. R3.Mp 1-3 (A) and R3.FB 1-3 (B)
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5. Mount the back cover of the motors 1-3 Use the 5 Torx screw fitted in the holes (C) in figure above.
6. Mount the upper bracket securing the cables to the arm house, using the two attachment screws.
4.3.2. Refitting of cable harness
7. Mount the adapter plate to the harness by using its two attachment screws (A).
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Note! Different manipulator versions are fitted with different plate versions. Make sure the correct one is used to avoid cable failure.
8. Mount all the screws securing the cable gland.
This attaches the cable harness to the frame.
Note! Make sure that each cable is mounted in the same position as the old ones, otherwise the conduit entry will not be watertight, use 6 cable straps no.
2166 2055-3
Note! Always use a new sealing no.
3HAB 5922-1 and combine it with a flange sealing type Loctite 574 no. 1234 0011-116 for best result.
Step Action Note/Illustration
4.3.2. Refitting of cable harness
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9. Connect connectors R2.FB 1-3 to the connection R2.SMB1-4 (C) on the SMB-unit .
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10. Mount the SMB-unit to the bracket with the nuts (D), be careful not to let the weight of the SMB-unit strain the cable!
(A). Described in Reassemble of SMB related equipment on page 127
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Note! The cable (A) between the battery (B) and the SMB-unit (C) may stay connected, in order to avoid recalibration of the robot.
11. Mount all the earth cables on the R1.M1-3 cable to the back of the cover.
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12. Connect connectors R1.MP1-3 and R2.BU1-3.
13. Mount the rear cover plate (A) on the manipulator with its attachment screws (B).
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Step Action Note/Illustration
4.3.2. Refitting of cable harness
Refitting, cable harness, axes 4-6
The procedure below details how to refit the cable harness, axes 4-6.
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.
CAUTION!
The cable packs are sensitive to mechanical damage! They must be handled with care, especially the connectors, in order to avoid damaging them!
Step Action Note/Illustration
1. In order to facilitate refitting of the cable harness, run the manipulator to the specified position:
• Axis 6: no significance
Axes 2 and 3 may be tilted slightly to improve access.
2. Gently pull the down the cable harness through the center of lower robot arm and through the hole of axis 1.
3. Mount the motor case on motor 4-6 using the 9 torx screws
Note! Always mount a new gasket art no.
3HAB 4429-1
4.3.2. Refitting of cable harness
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4. Reconnect all connectors at motor 4, 5 and 6. R3.Mp 4-6 (A) and R3.FB 1-3 (B)
A- R3.mp5 B- R3.mp6 C- R3.mp4 D- R3.fb5 E- R3.fb6 F- R3.fb4
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Step Action Note/Illustration
4.3.2. Refitting of cable harness
5. Mount the back cover of the motors 4-6
6. Mount the upper bracket securing the cables to the arm house, using the two attachment screws.
7. Mount the adapter plate to the harness by using its two attachment screws (A).
xx0200000404
Note! Different manipulator versions are fitted with different plate versions. Make sure the correct one is used to avoid cable failure.
8. Mount all the screws securing the cable gland.
This attaches the cable harness to the frame.
Note! Make sure that each cable is mounted at the same position as the old ones, otherwise the conduit entry will not be watertight.
Note! Always use a new sealing no. 3HAB 5922-1 and combine it with a flange sealing type Loctite 574 no. 1234 0011-116 for best result.
Step Action Note/Illustration
4.3.2. Refitting of cable harness
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9. Connect connectors R2.FB 4-6 to the connection R2.SMB4-6 (B) on the SMB-unit .
xx0200000400
10. Mount the SMB-unit to the bracket with the nuts (D), be careful not to let the weight of the SMB-unit strain the battery cable! (A). Described inReassemble of SMB related equipment on page 127
xx0200000398
Note! The cable (A) between the battery (B) and the SMB-unit (C) may stay connected, in order to avoid recalibration of the robot.
11. Mount all the earth cables on the R1.M4-6 cable to the back of the cover.
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12. Connect connectors R1.MP4-6 and R2.BU4-6.
13. Mount the rear cover plate (A) on the manipulator with its attachment screws (B).
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Step Action Note/Illustration
4.4.1. Removal of wrist IRB 2400/10/16.