Page 1 Product manual Articulated robot IRB 6640 - 180/2.55 IRB 6640 - 235/2.55 IRB 6640 - 205/2.75 IRB 6640 - 185/2.8 IRB 6640 - 130/3.2 IRB 6640ID - 200/2.55 IRB 6640ID - 170/2.75 M2004...
Page 3 Product manual IRB 6640 - 180/2.55 IRB 6640 - 235/2.55 IRB 6640 - 205/2.75 IRB 6640 - 185/2.8 IRB 6640 - 130/3.2 IRB 6640ID - 200/2.55 IRB 6640ID - 170/2.75 M2004 Document ID: 3HAC026876-001 Revision: C...
Page 4 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.
Page 5: Table Of Contents
Table of Contents Overview ................7 Product documentation, M2004 .
Page 6 Table of Contents 2.6.3 Mechanically restricting the working range of axis 2 ........95 2.6.4 Mechanically restricting the working range of axis 3 .
Page 7 Table of Contents 4.2.3 Mounting instructions for seals ..........191 4.3 Complete robot .
Page 8 Table of Contents 7.3 Unit conversion ..............389 7.4 Screw joints .
Page 9: Overview
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. Organization of chapters The manual is organized in the following chapters:...
Page 10 Overview Continued Chapter Contents Reference information Useful information when performing installation, maintenance or repair work. Includes lists of necessary tools, additional documents, safety standards etc. Spare part / part list Complete spare part list and complete list of robot components, shown in exploded views.
Page 11: Product Documentation, M2004
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.
Page 12 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 •...
Page 13: How To Read The Product Manual
How to read the product manual 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.
Page 14 How to read the product manual 3HAC026876-001 Revision: C...
Page 15: Safety
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.
Page 16: General Safety Information
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...
Page 17: Safety Risks
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 •...
Page 18 1 Safety 1.2.2.1. Safety risks during installation and service work on robot Continued Complete robot Safety risk Description Hot components! CAUTION! Motors and gears are HOT after running the robot! Touching motors and gears may result in burns! With higher environment temperature more surfaces on the robot are getting HOT and may result in burns too! Removed parts may result in collapse of robot!
Page 19: Safety Risks Related To Tools/Workpieces
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).
Page 20: Safety Risks Related To Pneumatic/Hydraulic Systems
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.
Page 21: Safety Risks During Operational Disturbances
1 Safety 1.2.2.4. Safety risks during operational disturbances 1.2.2.4. Safety risks during operational disturbances General • 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.
Page 22: Risks Associated With Live Electric Parts
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, need 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.
Page 23: Safety Actions
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.
Page 24: Fire Extinguishing
1 Safety 1.2.3.2. Fire extinguishing 1.2.3.2. Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the robot system (robot or controller)! 3HAC026876-001 Revision: C...
Page 25: Emergency Release Of The Robot's Arm
1 Safety 1.2.3.3. Emergency release of the robot’s arm 1.2.3.3. Emergency release of the robot’s 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: •...
Page 26: Brake Testing
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.
Page 27: Risk Of Disabling Function "Reduced Speed 250 Mm/S
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". 3HAC026876-001 Revision: C...
Page 28: Safe Use Of The Flexpendant
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.
Page 29: Work Inside The Robot's Working Range
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 robot’s 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.
Page 30: Signal Lamp (Optional)
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.
Page 31: Translate The Information On Safety And Information Labels
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.
Page 32: Safety Related Instructions
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: •...
Page 33 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.
Page 34: Danger - Moving Robots Are Potentially Lethal
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. Moreover, 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.
Page 35: Danger - First Test Run May Cause Injury Or Damage
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):...
Page 36: Warning - The Brake Release Buttons May Be Jammed After Service Work
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.
Page 37: Warning - The Unit Is Sensitive To Esd
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.
Page 38: Warning - Safety Risks During Work With Gearbox Oil
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...
Page 39: Installation And Commissioning
2 Installation and commissioning 2.1. Introduction 2 Installation and commissioning 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. 3HAC026876-001 Revision: C...
Page 40: Robot Transportation Precautions
Transportation in any other way than method 1 or 2 can seriously damage the robot.If the robot is incorrectly transported and the instructions are not followed, the robot is not covered by the warranty and ABB will not accept any compensation claim. Method 1 Transportation according to method 1 is strongly recommended by ABB.
Page 41 2 Installation and commissioning 2.2. Robot transportation precautions Continued Method 2 Transportation according to method 2 is approved by ABB, if use of method 1 is not possible. Always follow these instructions when transporting an ABB robot according to method 2: •...
Page 42 2 Installation and commissioning 2.2. Robot transportation precautions Continued IRB6620 xx0800000036 Transport Support Hexagon socket head cap screw M10x50 Threaded bar M10x280 Nut M10 Continues on next page 3HAC026876-001 Revision: C...
Page 43 2 Installation and commissioning 2.2. Robot transportation precautions Continued Transport position with a transport support All transportation of the robot with tool must follow these instructions. IRB 7600/IRB 66XX xx0800000040 Continues on next page 3HAC026876-001 Revision: C...
Page 44 2 Installation and commissioning 2.2. Robot transportation precautions Continued IRB 6620 xx0800000041 Continues on next page 3HAC026876-001 Revision: C...
Page 45 2 Installation and commissioning 2.2. Robot transportation precautions Continued Recommended transport support Always use the recommended transport support when transporting a robot with tool. IRB 7600/IRB 66XX xx0800000039 Continues on next page 3HAC026876-001 Revision: C...
Page 46 2 Installation and commissioning 2.2. Robot transportation precautions Continued IRB 6620 xx0800000038 3HAC026876-001 Revision: C...
Page 47: Securing The Robot
2 Installation and commissioning 2.3. Securing the robot 2.3. Securing the robot General This section describes how to secure the robot using the transport support. DANGER! Releasing the brakes is a hazardous action that may cause injury and damage property. It must be done with great care and only when absolutely necessary.
Page 48 2 Installation and commissioning 2.3. Securing the robot Continued Action Note 1. Mount the transport support lower end to the Do not tightening the screw. robot using the recommended screw joint, (A) See attachment point for the specific in figure. robot in section Transport position with a mounted...
Page 49: Unpacking
2 Installation and commissioning 2.4.1. Pre-installation procedure 2.4 Unpacking 2.4.1. Pre-installation procedure General This section is 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 checklist below details what must be observed before proceeding with the actual installation of the robot:...
Page 50 0.5 mm Max. tilt 5° The limit for the maximum load on the robot is reduced if the robot is tilted. Contact ABB for further information about acceptable loads. Min. resonance frequency 22 Hz Storage conditions, robot The table below shows the allowed storage conditions for the robot:...
Page 51 2 Installation and commissioning 2.4.1. Pre-installation procedure Continued Protection classes, robot The table below shows the protection class of the robot: Equipment Protection class Robot IP 67 Cooling fans (option) IP 54 3HAC026876-001 Revision: C...
Page 52: Working Range And Type Of Motion
The following figures show the working ranges of the robot models. The extreme positions of the robot arm are specified at the wrist center (dimensions in mm). IRB 6640 - 180/2.55, 235/2.55, 205/2.75, 185/2.8, 130/3.2 & IRB 6640ID - 200/2.55, 170/2.75 The illustration below shows the unrestricted working range. Measurements for the different robot variants, are shown as A to F, in the illustration below.
Page 53 2 Installation and commissioning 2.4.2. Working range and type of motion Continued Turning radius The turning radius, shown as A in the figure below, is specified for the different robot models below the figure. xx0600003399 IRB 6640 - 2.55 2550 mm IRB 6640 - 2.75 2755 mm IRB 6640 - 2.8...
Page 54 2 Installation and commissioning 2.4.2. Working range and type of motion Continued Axis Type of motion Range of movement Note Turn motion IRB 6640: +360º to -360º (default), ± 96 revolutions IRB 6640ID: +300º to -300º ±300º max The minimum combination of axes 4 and 6. NOTE! There are limitations of the range of movement with a DressPack/SpotPack application fitted to the robot! See product manual SpotPack/DressPack IRB 6640.
Page 55: Risk Of Tipping / Stability
2 Installation and commissioning 2.4.3. Risk of tipping / stability 2.4.3. Risk of tipping / stability Risk of tipping When the robot is not fastened to the foundation and standing still, the robot is not stable in the whole working area. Moving the arms will displace the center of gravity, which may cause the robot to tip over.
Page 56: On-Site Installation
2 Installation and commissioning 2.5.1. Lifting the robot with fork lift 2.5 On-site installation 2.5.1. Lifting the robot with fork lift General The robot may be moved using a fork lift, provided that available special aids are used. This section describes how to attach the fork lift equipment to the robot. Fork lift device set The fork lift device set, is fitted to the robot as shown in the figure below.
Page 57 2 Installation and commissioning 2.5.1. Lifting the robot with fork lift Continued Lifting the robot with fork lift The procedure below details how to secure the fork lift set in order to lift the robot and move it using fork lift ONLY! The illustration below shows the position of the robot when lifting it with fork lift.
Page 58 2 Installation and commissioning 2.5.1. Lifting the robot with fork lift Continued Action Note 3. Fit the four fork lift pockets on the base of Make sure the original screws are always the robot with its attachment screws. used (or replacements of equivalent quality: M20x50, quality 8.8)! Attachment points on the robot are shown in the figure below.
Page 59 2 Installation and commissioning 2.5.1. Lifting the robot with fork lift Continued Action Note 5. Double check that all four fork lift pockets are properly secured before lifting. xx0600002930 • A: Fork lift pocket • B: Attachment screw M20x50 quality 8.8 (2 pcs x 4). Tightening torque : 300 Nm 6.
Page 60: Lifting Robot With Roundslings
2 Installation and commissioning 2.5.2. Lifting robot with roundslings 2.5.2. Lifting robot with roundslings General The robot may be lifted with roundslings according to the illustration below. The illustration is identical with the label attached to the robot’s lower arm. Attachment points The figure below shows how to attach the roundslings to the robot.
Page 61 2 Installation and commissioning 2.5.2. Lifting robot with roundslings Continued xx0800000059 IRB 6640, Cleanroom variant Roundsling robot, 2.5 m (4 pcs). NOTE! It is important to apply the roundsling the way the figure shows. If not, the cable harness will be damaged. Roundsling upper arm, 2 m.
Page 62 2 Installation and commissioning 2.5.2. Lifting robot with roundslings Continued Lifting with roundslings Action Note 1. Attach the roundslings to the robot according to the figure Attachment points on page NOTE! For Cleanroom robots it is important to apply the roundslings: •...
Page 63: Manually Releasing The Brakes
2 Installation and commissioning 2.5.3. Manually releasing the brakes 2.5.3. Manually releasing the brakes General This section details how to release the holding brakes of each axis motor. Location of brake release unit The internal brake release unit is located at the frame, as shown in the figure below. xx0600003402 Internal brake release unit with push buttons.
Page 64 2 Installation and commissioning 2.5.3. Manually releasing the brakes Continued Supplying power to connector R1.MP If the robot is not connected to the controller, power must be supplied to connector R1.MP in the robot base in order to enable the brake release buttons on the robot. Action Note DANGER!
Page 65: Lifting The Base Plate
2 Installation and commissioning 2.5.4. Lifting the base plate 2.5.4. Lifting the base plate Required equipment Equipment Art. no. Note Lifting eye, M16 3HAC14457-4 3 pcs Lifting slings 3 pcs Length: approx. 2 m Hole configuration xx0200000096 Attachment holes for lifting eyes (x3) Lifting, base plate Action Note...
Page 66: Securing The Base Plate
2 Installation and commissioning 2.5.5. Securing the base plate 2.5.5. Securing the base plate General This section details how to secure the base plate. Base plate, dimensions xx0100000105 Continues on next page 3HAC026876-001 Revision: C...
Page 67 2 Installation and commissioning 2.5.5. Securing the base plate Continued xx0400000715 Four holes for alternative clamping, 4x Ø18 Continues on next page 3HAC026876-001 Revision: C...
Page 68 • attachment screws and washers for securing the robot to the base plate. A drawing of the base plate itself may be ordered from ABB Robotics! Standard toolkit The content is defined in section Standard toolkit on page 394. Other tools and procedures may These procedures include references be required.
Page 69 2 Installation and commissioning 2.5.5. Securing the base plate Continued Recommendations, quality The table specifies any recommendations made by ABB: Variable Recommendation Recommended foundation quality 1 Steel fibre reinforced concrete foundation, 30 kg/m3, class K30, t=250 mm Recommended foundation quality 2 Sturdy concrete foundation, double reinforced by ø10...
Page 70: Orienting And Securing The Robot
2 Installation and commissioning 2.5.6. Orienting and securing the robot 2.5.6. Orienting and securing the robot General This section details how to orient and secure the robot to the base plate in order to run the robot safely. The requirements made on the foundations are shown in the following tables and figures.
Page 71 2 Installation and commissioning 2.5.6. Orienting and securing the robot Continued Securing the robot The procedure below details how to secure the robot to the base plate after fitting the plate to the foundation. Action Note 1. Lift the robot. Detailed in section Lifting robot with roundslings on page...
Page 72 2 Installation and commissioning 2.5.6. Orienting and securing the robot Continued Hole configuration, base The illustration below shows the hole configuration used when securing the robot. xx0600003403 Cross section, guide sleeve hole The illustration below shows the cross section of the guide sleeve holes. xx0600003404 3HAC026876-001 Revision: C...
Page 73: Fitting Cable Package Attachments (Cleanroom)
2 Installation and commissioning 2.5.7. Fitting cable package attachments (Cleanroom) 2.5.7. Fitting cable package attachments (Cleanroom) Overview This section details how to fit the cable attachments for the cable harness (Cleanroom). How to replace the cable harness itself is detailed in section Replacement of cable harness, Cleanroom on page 207.
Page 74 2 Installation and commissioning 2.5.7. Fitting cable package attachments (Cleanroom) Continued Equipment Part no. Note Other tools and These procedures include procedures may be references to the tools required. required. See references to these procedures in the step-by-step instructions below. Fitting of cable package attachments - lower end The procedure below details how to install the attachments at the lower end of the cable harness (Cleanroom).
Page 75 2 Installation and commissioning 2.5.7. Fitting cable package attachments (Cleanroom) Continued Action Note 3. Fit the gripping clamp to the shelf with its attachment Locking liquid is specified in screws. Required equipment on page Lock screws with locking liquid. xx0800000008 Parts: •...
Page 76 2 Installation and commissioning 2.5.7. Fitting cable package attachments (Cleanroom) Continued Action Note 5. Fit the gripping clamp to the lower bracket, Locking liquid is specified in balancing cylinder with its attachment screws. Required equipment on page Lock screws with locking liquid. The screws are supplied with the kit.
Page 77 2 Installation and commissioning 2.5.7. Fitting cable package attachments (Cleanroom) Continued Action Note NOTE! The lower bracket is fitted slightly different depending on robot variant. See figure to the right! xx0800000014 • A: SW 2.55 • B: SW 2.75 8. Fit the two brackets for cable clamp on the lower Locking liquid is specified in arm with its attachment screws.
Page 78 2 Installation and commissioning 2.5.7. Fitting cable package attachments (Cleanroom) Continued Action Note 9. Fit the gripping clamp to the bracket for cable clamp Locking liquid is specified in with its attachment screws , M8x16 quality 8.8-A2F Required equipment on page (2 pcs) and washer 2 holes (2 pcs).
Page 79 2 Installation and commissioning 2.5.7. Fitting cable package attachments (Cleanroom) Continued Action Note 3. Fit the gripping clamp to the bracket for cable clamp Locking liquid is specified in with: Required equipment on page • attachment screws (2 pcs) • washer 2 holes •...
Page 80 2 Installation and commissioning 2.5.7. Fitting cable package attachments (Cleanroom) Continued Action Note 5. Fit the connection plate axis 3 with its attachment Locking liquid is specified in screws. Required equipment on page Lock screws with locking liquid. The screws are supplied with the kit. xx0800000026 Parts: •...
Page 81: Fitting Equipment On Robot
2 Installation and commissioning 2.5.8. Fitting equipment on robot 2.5.8. Fitting equipment on robot General The robot features mounting holes for additional equipment. Access to any of the following mounting holes may be obstructed by any additional cabling, equipment etc. fitted by the robot user. Make sure the required mounting holes are accessible when planning the robot cell.
Page 82 2 Installation and commissioning 2.5.8. Fitting equipment on robot Continued xx0600003405 Robot variant IRB 6640 - 2.55 2240 mm 520 mm 1075 mm IRB 6640 - 2.75 2445 mm 725 mm 1280 mm IRB 6640 - 2.8 2240 mm 520 mm 1075 mm IRB 6640 - 3.2 2445 mm...
Page 83 2 Installation and commissioning 2.5.8. Fitting equipment on robot Continued Robot variant IRB 6640 - 2.55 400 mm 13 mm 40 mm IRB 6640 - 2.75 500 mm 13 mm 30 mm IRB 6640 - 2.8 400 mm 13 mm 40 mm IRB 6640 - 3.2 500 mm...
Page 84 2 Installation and commissioning 2.5.8. Fitting equipment on robot Continued Illustration, fitting of extra equipment on frame The illustration below shows the mounting holes available for fitting extra equipment on the frame. xx0600003416 Continues on next page 3HAC026876-001 Revision: C...
Page 85 2 Installation and commissioning 2.5.8. Fitting equipment on robot Continued Illustration, fitting on turning disk The illustration below shows the mounting holes available for fitting equipment on the turning disk. xx0200000197 Continues on next page 3HAC026876-001 Revision: C...
Page 86 2 Installation and commissioning 2.5.8. Fitting equipment on robot Continued xx0500001580 Turning disk unit for robot versionIRB 6640ID. Fastener quality When fitting tools on the turning disk (see the figures above), only use screws with quality 12.9. When fitting other equipment standard screws with quality 8.8 may be used. 3HAC026876-001 Revision: C...
Page 87: Installation Of Cooling Fan For Motors, Axes 1 And 2 (Option)
2 Installation and commissioning 2.5.9. Installation of cooling fan for motors, axes 1 and 2 (option) 2.5.9. Installation of cooling fan for motors, axes 1 and 2 (option) General A cooling fan can be installed on the motors of axes 1and 2. However, cooling fans for axes 1 and 2 can not be combined! The cabling for the fans is available as: •...
Page 88 2 Installation and commissioning 2.5.9. Installation of cooling fan for motors, axes 1 and 2 (option) Continued Cooling fan The details of the cooling fan are shown in the figure below. xx0500002158 Fanbox Attachment screws, fanbox plates (9 pcs) Groove in the connector Tightening screws, fanbox (3 pcs) Required equipment Equipment...
Page 89 2 Installation and commissioning 2.5.9. Installation of cooling fan for motors, axes 1 and 2 (option) Continued Equipment Art. no. Note Standard toolkit The content is defined in section Standard toolkit on page 394. Circuit diagram See chapter Circuit diagram. 3HAC025744-001 Other tools and procedures These procedures include references to...
Page 90 2 Installation and commissioning 2.5.9. Installation of cooling fan for motors, axes 1 and 2 (option) Continued Installation, fan The procedure below details how to install the cooling fan on motors, axes 1 or 2 . Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 91 2 Installation and commissioning 2.5.9. Installation of cooling fan for motors, axes 1 and 2 (option) Continued Installation, separate fan cabling axis 1 or 2 The procedure below details how to install the separate cabling for the cooling fan of axis 1 or 2.
Page 92 2 Installation and commissioning 2.5.9. Installation of cooling fan for motors, axes 1 and 2 (option) Continued Action Note 7. Secure the cable bracket to the bracket of the robot cabling inside the frame. Run the cable underneath the robot cabling and out through the side of the frame, at motor, axis 1 .
Page 93: Loads
Specification. The loads must also be defined in the software as detailed in Operating manual IRC5 with FlexPendant. Stop time and braking distances Robot motor brake performance depends on any loads attached. For further information about brake performance, please contact ABB. 3HAC026876-001 Revision: C...
Page 94: Restricting The Working Range
2 Installation and commissioning 2.6.1. Introduction 2.6 Restricting the working range 2.6.1. 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 axis may be restricted: •...
Page 95: Mechanically Restricting The Working Range Of Axis 1
2 Installation and commissioning 2.6.2. Mechanically restricting the working range of axis 1 2.6.2. Mechanically restricting the working range of axis 1 General The working range of axis 1 is limited by fixed mechanical stops and can be reduced by adding additional mechanical stops giving 7.5 or 15 graduation, between 22.5°...
Page 96 2 Installation and commissioning 2.6.2. Mechanically restricting the working range of axis 1 Continued Equipment, etc. Art. no. Note Technical reference manual - System Art. no. is specified in section parameters (RobotWare 5.0) References. Installation, mechanical stops axis 1 The procedure below details how to fit the mechanical stops of axis 1 to the robot. An assembly drawing is also enclosed with the product.
Page 97: Mechanically Restricting The Working Range Of Axis 2
2 Installation and commissioning 2.6.3. Mechanically restricting the working range of axis 2 2.6.3. Mechanically restricting the working range of axis 2 General The working range of axis 2 is limited by fixed mechanical stops and can be reduced by adding up to six additional mechanical stops with 15 graduation in respective direction.
Page 98 2 Installation and commissioning 2.6.3. Mechanically restricting the working range of axis 2 Continued Action Note 2. Fit and tighten the additional stops in a row, Tightening torque: 115 Nm. starting from the fixed stop. Shown in the figure Mechanical stops, axis 2 on page 3.
Page 99: Mechanically Restricting The Working Range Of Axis 3
2 Installation and commissioning 2.6.4. Mechanically restricting the working range of axis 3 2.6.4. Mechanically restricting the working range of axis 3 General The working range of axis 3 is limited by fixed mechanical stops and can be reduced by adding additional mechanical stops with 20 graduation in respective direction.
Page 100 2 Installation and commissioning 2.6.4. Mechanically restricting the working range of axis 3 Continued Installation, mechanical stops axis 3 The procedure below details how to fit the mechanical stops for axis 3 to the robot. An assembly drawing is also enclosed with the product. Action Note DANGER!
Page 101: Electrical Connections
2 Installation and commissioning 2.7.1. Robot cabling and connection points 2.7 Electrical connections 2.7.1. 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...
Page 102 2 Installation and commissioning 2.7.1. Robot cabling and connection points Continued Cable Art. no. Robot cable, power, 22 m 3HAC11818-3 Robot cable, power, 30 m 3HAC11818-4 Robot cable, signals Cable Art. no. Robot cable, signal, shielded, 7 m 3HAC7998-1 Robot cable, signal, shielded, 15 m 3HAC7998-2 Robot cable, signal, shielded, 22 m 3HAC7998-3...
Page 103: Making Robot Ready For Operation (Foundry Prime)
Humidity 100% Washing detergent with pH <9.0 Washing detergent must contain rust inhibitor and be approved by ABB Cleaning bath temperature <60°C, used in a typical waterjet cleaning application at suitable speed. Air specification for pressurizing of robot The air must be dry and clean, such as instrument air. The table below details the air specifications.
Page 104 2 Installation and commissioning 2.8.1. Additional installation procedure Continued WARNING! If the pressurized air contains oil, it could result in a brake failure in the motors and cause the robot arms to fall down, leading to personal injury or physical damage. WARNING! If the air pressure exceeds the specified, it could result in a brake failure in the motors and cause the robot arms to fall down, leading to personal injury or physical damage.
Page 105 2 Installation and commissioning 2.8.1. Additional installation procedure Continued Protecting robot from high pressure water WARNING! No part of the robot should be exposed to direct high pressure jet of water. The sealings between the moving parts on the wrist should not be exposed to direct or rebounding high- pressure jet of water.
Page 106: Commissioning (Foundry Prime)
2 Installation and commissioning 2.8.2. Commissioning (Foundry Prime) 2.8.2. Commissioning (Foundry Prime) General The following should be taken in consideration when running a robot in a water jet application cell: CAUTION! Never switch off the overpressure in motors and serial measurement compartment during cooling down of robot after it has been switched off.
Page 107: Making Robotready For Operation, (Cleanroom)
2 Installation and commissioning 2.9.1. Additional installation procedure, Cleanroom 2.9 Making robotready for operation, (Cleanroom) 2.9.1. Additional installation procedure, Cleanroom 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 is maintenance work possible to perform without cracking the paint.
Page 108 2 Installation and commissioning 2.9.1. Additional installation procedure, Cleanroom 3HAC026876-001 Revision: C...
Page 109: Maintenance
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.
Page 110: Maintenance Schedule And Expected Component Life
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: •...
Page 111: Maintenance Schedule
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.
Page 112 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Equipment Interval Detailed in section activity Changing Axis 3 gear oil: First change after: Do not mix with other oils! 6 000 h Kyodo Yushi TMO Oil change, gearbox, axis 3 Second change on page 160 after: 24 000 h Changing...
Page 113 3 Maintenance 3.2.2. Maintenance schedule Continued • If the robot is run at ambient temperatures higher than 50°C, the equipment may require maintenance more frequently. • The service time for gearboxes, axes 4 and 5, is not calculated by the SIS, see expected life in section Expected component life on page 114.
Page 114 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Equipment Interval Detailed in section activity Analysis Oil gearbox axis 6 3000h or 6 Inspection, oil level gearbox axis mths 6 on page 125 Changing Axis 1 gear, oil: Kyodo 6000h Oil change, gearbox axis 1 on Yushi TMO 150 page 154 Changing...
Page 115 3 Maintenance 3.2.2. Maintenance schedule Continued • If the robot is working in cleanings cells that are not emptied when the robot is switched off, the oil may be replaced more frequently. See also Analysis of water content in oil, gearbox axis 6 (Foundry Prime) on page 127.
Page 116: Expected Component Life
3 Maintenance 3.2.3. Expected component life 3.2.3. Expected component life General The expected life of a component can vary greatly depending on how hard it is run. Expected life Component Expected life Note Cabling for robot, 7th axisand fan 4,000,000 cycles axis 1 ±180º See note 2,000,000 cycles axis 1 ±220º...
Page 117: Inspection Activities
3 Maintenance 3.3.1. Inspection, oil level gearbox axis 1 3.3 Inspection activities 3.3.1. Inspection, oil level gearbox axis 1 Location of gearbox The axis 1 gearbox is located between the frame and base. The oil plugs are shown in the figure below.
Page 118 3 Maintenance 3.3.1. Inspection, oil level gearbox axis 1 Continued Inspection, oil level gearbox, axis 1 The procedure below details how to inspect the oil level in gearbox axis 1. Action Note 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...
Page 119: Inspection, Oil Level Gearbox Axis 2
3 Maintenance 3.3.2. Inspection, oil level gearbox axis 2 3.3.2. Inspection, oil level gearbox axis 2 Location of gearbox The axis 2 gearbox is located in the lower arm rotational center, underneath the motor attachment. xx0600003451 Oil plug, inspection Oil plug, filling Oil plug, draining Required equipment Equipment etc.
Page 120 3 Maintenance 3.3.2. Inspection, oil level gearbox axis 2 Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 3.
Page 121: Inspection, Oil Level Gearbox Axis 3
3 Maintenance 3.3.3. Inspection, oil level gearbox axis 3 3.3.3. Inspection, oil level gearbox axis 3 Location of gearbox The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. xx0200000230 Gearbox axis 3 Oil plug, filling Oil plug, draining Required equipment...
Page 122 3 Maintenance 3.3.3. Inspection, oil level gearbox axis 3 Continued Inspection, oil level gearbox 3 The procedure below details how to inspect the oil level in the gearbox axis 3. Action Note 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...
Page 123: Inspection, Oil Level Gearbox Axis 4
3 Maintenance 3.3.4. Inspection, oil level gearbox axis 4 3.3.4. Inspection, oil level gearbox axis 4 Location of gearbox The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure below. xx0200000231 Oil plug, filling Oil plug, draining Required equipment...
Page 124 3 Maintenance 3.3.4. Inspection, oil level gearbox axis 4 Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 4.
Page 125: Inspection, Oil Level, Gearbox Axis 5
3 Maintenance 3.3.5. Inspection, oil level, gearbox axis 5 3.3.5. Inspection, oil level, gearbox axis 5 Location of gearbox The axis 5 gearbox is located in the wrist unit as shown in the figure below. xx0200000232 Oil plug, filling Oil plug, draining xx0500002013 The figure above shows the wrist unit of IRB 6640ID Wrist unit, axis 5...
Page 126 3 Maintenance 3.3.5. Inspection, oil level, gearbox axis 5 Continued Equipment etc. Art. no. Note Other tools and procedures may These procedures include be required. See references to references to the tools required. these procedures in the step-by- step instructions below. Inspection, oil level gearbox 5 The procedure below details how to inspect the oil level in gearbox axis 5.
Page 127: Inspection, Oil Level Gearbox Axis 6
3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 3.3.6. Inspection, oil level gearbox axis 6 Location of gearbox The axis 6 gearbox is located in the wrist unit as shown in the figure below. xx0400001092 Gearbox, axis 6 Oil plug, filling Oil plug, draining xx0500002017 The figure above shows the wrist unit of IRB 6640ID...
Page 128 3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 Continued Required equipment Equipment Art. no. Note Lubricating oil (IRB 6640) 3HAC032140-001 Kyodo Yushi TMO 150 Note! Do not mix with other oil types! Lubricating oil (IRB 6640ID) 11712016-604 Mobilgear 600 XP 320 Standard toolkit The content is defined in section Standard toolkit on page...
Page 129 3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 Continued Analysis of water content in oil, gearbox axis 6 (Foundry Prime) When changing oil, check for water content in oil. An analysis can be ordered from the oil manufacturer Shell. Then..
Page 130: Inspection, Balancing Device
3 Maintenance 3.3.7. Inspection, balancing device 3.3.7. Inspection, balancing device General Several points are to be checked on the balancing device during the inspection. This section details how to perform the inspection regarding: • dissonance • damage • leakage • contamination / lack of free space.
Page 131 3 Maintenance 3.3.7. Inspection, balancing device Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Maintenance 3HAC029054-001 For maintenance of parts, cradle balancing device 3HAC028470-001. Includes: • bearings, o-rings and seals. Maintenance 3HAC029288-001 For maintenance of parts, shaft balancing device 3HAC028470-001.
Page 132 Check for dissonance If dissonance is detected... from... • cylinder (a tapping ...replace the balancing device or consult ABB Robotics. sound, caused by How to replace the device is detailed in section the springs inside Replacement of balancing device. This section also the cylinder).
Page 133 3 Maintenance 3.3.7. Inspection, balancing device Continued Check for leakage The front ear of the balancing device is lubricated with grease. After filling, excessive grease may normally be forced out between the shaft and the sealing ring in the sealing spacer. This is normal behaviour and must not be confused with incorrect leaks from the ear.
Page 134 3 Maintenance 3.3.7. Inspection, balancing device Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 4. Check the o-rings at the front ear for leakage. The o-rings are included in the Replace the o-rings, if any leaks are detected.
Page 135: Inspection, Cable Harness
3 Maintenance 3.3.8. Inspection, cable harness 3.3.8. Inspection, cable harness Location of cable harness, axes 1-4 The robot cable harness, axes 1-4, is located as shown in the figure below. xx0600003434 IRB 6640 standard Lower arm SMB/BU unit Connectors at base Continues on next page 3HAC026876-001 Revision: C...
Page 136 3 Maintenance 3.3.8. Inspection, cable harness Continued xx0800000044 IRB 6640 Cleanroom variant. Connectors at base Velcro straps Cable harness Side bracket balancing cylinder Gripping clamp (4 pcs) Required equipment Equipment, etc. Art. no. Note Standard toolkit The content is defined in section Standard toolkit on page 394.
Page 137 3 Maintenance 3.3.8. Inspection, cable harness Continued Inspection, cable harness 1-4 The procedure below details how to inspect the cable harness of axes 1-4. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 138 3 Maintenance 3.3.8. Inspection, cable harness Continued Location of cabling axes 5-6 The robot cable harness, axes 5-6, is located as shown in the figure below. xx0600003435 IRB 6640 standard Cable harness axes 5-6 Cable attachment, rear of upper arm Cable attachment, upper arm tube xx0800000045 IRB 6640 Cleanroom variant.
Page 139 3 Maintenance 3.3.8. Inspection, cable harness Continued Cover Connectors at connection plate ax 3 Inspection, cable harness, axes 5-6 The procedure below details how to inspect the cable harness of axes 5-6. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 140: Inspection Of Air Hoses (Foundry Prime)
3 Maintenance 3.3.9. Inspection of air hoses (Foundry Prime) 3.3.9. Inspection of air hoses (Foundry Prime) General The air hoses on Foundry Prime robots must be inspected for leakage every six month. Required equipment Equipment, etc. Art. no. Note Leak detection spray Pressure gauge Cut off valve Procedure...
Page 141: Inspection, Information Labels
3 Maintenance 3.3.10. Inspection, information labels 3.3.10. Inspection, information labels Location of labels The figures below show the location of the information labels to be inspected. xx0600003457 Warning label "High temperature", 3HAC4431-1 (4 pcs) Warning sign, symbol of flash (located on motor cover), 3HAC1589-1 (5 pcs) Instruction label "Safety instruction", 3HAC4591-1 Warning label, tools are not allowed around the balancing device during operation, 3HAC020611-001...
Page 142 3 Maintenance 3.3.10. Inspection, information labels Continued xx0600003456 Instructional label "Lifting the robot", 3HAC026908-001 Warning label "Robot can tip forward...", 3HAC9191-1 Foundry logotype, 3HAC8256-1 Warning label "Stored energy", 3HAC9526-1 Abs-Acc information sign, 3HAC14257-1 Label calibration, 3HAC024307-001 Serial no. from rating label UL-label, 3HAC2763-1 Required equipment Equipment...
Page 143 3 Maintenance 3.3.10. Inspection, information labels Continued Action Note 2. Check the labels, located as shown in the figures Location of labels on page 139. 3. Replace any missing or damaged labels. Art. no. is specified in Required equipment on page 140.
Page 144: Inspection, Mechanical Stop, Axis 1
3 Maintenance 3.3.11. Inspection, mechanical stop, axis 1 3.3.11. Inspection, mechanical stop, axis 1 Location of mechanical stop The mechanical stop axis 1 is located at the base as shown in the figure below. xx0600003436 Mechanical stop pin, axis 1 Fixed stop pin Required equipment Equipment, etc.
Page 145 3 Maintenance 3.3.11. Inspection, mechanical stop, axis 1 Continued Action Note 3. If the stop pin is bent or damaged, it must be Art. no. is specified in Required replaced! equipment on page 142. NOTE! The expected life of gearboxes can be reduced as a result of collissions with the mechanical stop.
Page 146: Inspection, Additional Mechanical Stops
3 Maintenance 3.3.12. Inspection, additional mechanical stops 3.3.12. Inspection, additional mechanical stops Location of mechanical stops The figures below shows the location of the additional mechanical stops on axes 1, 2 and 3 . xx0600002938 Additional stop, axis 1 Attachment screws and washers (2 pcs) Fixed stop Mechanical stop pin, axis 1 xx0600003438...
Page 147 3 Maintenance 3.3.12. Inspection, additional mechanical stops Continued Fixed stop, axis 2 Required equipment Equipment etc. Art. no. Note Mechanical stop set, axis 1 3HAC025204-003 Includes: • Stop +15°/-7.5° • Stop +7.5°/-15° • Attachment screws plus washers • Document for movable mechanical stop Mechanical stop axis 2 3HAC020885-001...
Page 148: Inspection, Damper Axes 2-5
3 Maintenance 3.3.13. Inspection, damper axes 2-5 3.3.13. Inspection, damper axes 2-5 Location of dampers The figure below shows the location of all the dampers to be inspected. xx0600003440 Damper, axis 2 (2 pcs) Damper, axis 3 (2 pcs) Damper, axis 4 (1 pc) Damper, axis 5 (2 pcs) (IRB 6640ID: 4 pcs) Required equipment A damper must be replaced if damaged!
Page 149 3 Maintenance 3.3.13. Inspection, damper axes 2-5 Continued Inspection, dampers The procedure below details how to inspect the dampers, axes 2-5. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 150: Inspection, Signal Lamp (Option)
3 Maintenance 3.3.14. Inspection, signal lamp (option) 3.3.14. Inspection, signal lamp (option) Location of signal lamp The signal lamp is located as shown in the figure below. Note that the position can differ depending on how the customer harness for axis 4-6 is mounted. See assembly drawing on the current harness for alternative positioning.
Page 151 3 Maintenance 3.3.14. Inspection, signal lamp (option) Continued Inspection, signal lamp The procedure below details how to inspect the function of the signal lamp. Action Note 1. Check that the signal lamp is lit, when the motors are put in operation ("MOTORS ON"). DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
Page 152: Replacement / Changing Activities
3 Maintenance 3.4.1. Type of oil in gearboxes 3.4 Replacement / Changing activities 3.4.1. Type of oil in gearboxes Location of gearboxes The figure show the location of the gearboxes on the robot. xx0600003442 Gearbox, axis 1 Gearbox, axis 2 Gearbox, axis 3 Gearbox, axis 4 Gearbox, axis 5...
Page 153 3 Maintenance 3.4.1. Type of oil in gearboxes Continued Type of oil - historically used The gearboxes of the robot have historically been filled with different types of oils. Today only the types of oil specified in the table is recommended. NOTE! When there is a change of oil types in the gearbox, it need to be rinsed.
Page 154 3 Maintenance 3.4.1. Type of oil in gearboxes Continued Labels at robot base Label located at robot base show the types of oil in all gearboxes. xx0600003448 Label at robot base. Currently used types of oil. Mixed types of oil may cause may cause severe damage! When refilling or replacing oil in a gearbox it is important to first check which type of oil is recommended to use in the gearbox.
Page 155 3 Maintenance 3.4.1. Type of oil in gearboxes Continued NOTE! When filling gearbox oil, do not mix different types of oil as this may cause severe damage to the gearbox! Always use the oil recommended by the manufacturer! Rinsing gearbox Depending on which types of oil are mixed and which type of oil shall be filled in the gearbox after rinsing, use the appropiate procedure.
Page 156: Oil Change, Gearbox Axis 1
3 Maintenance 3.4.2. Oil change, gearbox axis 1 3.4.2. Oil change, gearbox axis 1 Location of oil plugs The axis 1 gearbox is located between the frame and base. The oil plugs for filling and inspection are shown in the figure below. xx0600003449 Oil plug, filling Oil plug, inspection...
Page 157 3 Maintenance 3.4.2. Oil change, gearbox axis 1 Continued Draining oil, axis 1 The procedure below details how to drain the oil in gearbox axis 1. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no.
Page 158 3 Maintenance 3.4.2. Oil change, gearbox axis 1 Continued Action Note 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 3. Open the oil plug, filling. Shown in the figure Location of oil plugs on page...
Page 159: Oil Change, Gearbox Axis 2
3 Maintenance 3.4.3. Oil change, gearbox axis 2 3.4.3. Oil change, gearbox axis 2 Location of oil plugs The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment. xx0600003451 Oil plug, inspection Oil plug, filling Oil plug, draining Required equipment Equipment, etc.
Page 160 3 Maintenance 3.4.3. Oil change, gearbox axis 2 Continued Draining, oil The procedure below details how to drain the oil in gearbox axis 2. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 157.
Page 161 3 Maintenance 3.4.3. Oil change, gearbox axis 2 Continued Action Note 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 3. Remove the oil plug, filling and the oil plug, Shown in the figure Location of oil inspection.
Page 162: Oil Change, Gearbox, Axis 3
3 Maintenance 3.4.4. Oil change, gearbox, axis 3 3.4.4. Oil change, gearbox, axis 3 Location of gearbox The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. xx0200000230 Gearbox axis 3 Oil plug, filling Oil plug, draining Required equipment Equipment, etc.
Page 163 3 Maintenance 3.4.4. Oil change, gearbox, axis 3 Continued Draining, oil The procedure below details how to drain oil from the gearbox, axis 3. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 160.
Page 164 3 Maintenance 3.4.4. Oil change, gearbox, axis 3 Continued Action Note 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 3. Remove the oil plug, filling. Shown in the figure Location of gearbox on page...
Page 165: Oil Change, Gearbox, Axis 4
3 Maintenance 3.4.5. Oil change, gearbox, axis 4 3.4.5. Oil change, gearbox, axis 4 Location of gearbox The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure below. xx0200000231 Oil plug, filling Oil plug, draining Required equipment Equipment, etc.
Page 166 3 Maintenance 3.4.5. Oil change, gearbox, axis 4 Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. WARNING! Handling gearbox oil involves several safety risks.
Page 167 3 Maintenance 3.4.5. Oil change, gearbox, axis 4 Continued Action Note 3. Refill the gearbox with lubricating oil through the oil Shown in the figure Location of plug, filling. gearbox on page 163. The amount of oil to be refilled depends on the Art.
Page 168: Oil Change, Gearbox, Axis 5
3 Maintenance 3.4.6. Oil change, gearbox, axis 5 3.4.6. Oil change, gearbox, axis 5 Location of gearbox The axis 5 gearbox is located in the wrist unit as shown in the figure below. xx0200000232 Oil plug, filling Oil plug, draining xx0500002013 Wrist unit of IRB 6640ID Oil plug, filling...
Page 169 3 Maintenance 3.4.6. Oil change, gearbox, axis 5 Continued Equipment, etc. Art. no. Amount Note Oil exchange equipment 3HAC021745-001 The content is defined in section Special tools on page 395. Oil collecting vessel Capacity: 7,000 ml. Standard toolkit The content is defined in section Standard toolkit on page...
Page 170 3 Maintenance 3.4.6. Oil change, gearbox, axis 5 Continued Action Note 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 DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air...
Page 171: Oil Change, Gearbox Axis 6
3 Maintenance 3.4.7. Oil change, gearbox axis 6 3.4.7. Oil change, gearbox axis 6 Location of gearbox The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. xx0400001092 Gearbox, axis 6 Oil plug, filling Oil plug, draining xx0500002017...
Page 172 3 Maintenance 3.4.7. Oil change, gearbox axis 6 Continued Equipment, etc. Art. no. Amount Note Lubricating oil IRB 3HAC032140-001 450 ml Kyodo Yushi TMO 150 6640 Note! Don´t mix with other oil types! Oil exchange 3HAC021745-001 The content is defined in equipment section Special tools on page...
Page 173 3 Maintenance 3.4.7. Oil change, gearbox axis 6 Continued Filling, oil, axis 6 The procedure below details how to fil oil in the gearbox, axis 6. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no.
Page 174: Replacement Of Smb Battery
Required equipment Equipment, etc. Spare part no. Note Battery pack 3HAC16831-1 Battery includes protection circuits. Replace it only with given spare part no. or an ABB approved equivalent. Standard toolkit The content is defined in section Standard toolkit on page 394.
Page 175 Shown in the figure Location of SMB battery on page 172. Battery includes protection circuits. Replace it only with the specified spare part or with an ABB approved equivalent. Refitting, battery The procedure below details how to refit the SMB battery. Action...
Page 176 3 Maintenance 3.4.8. Replacement of SMB battery Continued Action Note 3. Reconnect the battery cable to the SMB battery Art. no. is specified in Required pack and fit it to the frame. equipment on page 172. Shown in the figure Location of SMB battery on page 172.
Page 177: Lubrication Activities
3 Maintenance 3.5.1. Lubrication of spherical roller bearing, balancing device 3.5 Lubrication activities 3.5.1. Lubrication of spherical roller bearing, balancing device Location of bearing The spherical roller bearing is located at the front ear of the balancing device, as shown in the figure below.
Page 178 3 Maintenance 3.5.1. Lubrication of spherical roller bearing, balancing device Continued Lubrication, balancing device bearing The procedure below details how to lubricate the spherical roller bearing. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 179: Rust Preventive Measures, Bearing Axis 1 (Foundry Prime)
3 Maintenance 3.5.2. Rust preventive measures, bearing axis 1 (Foundry Prime) 3.5.2. Rust preventive measures, bearing axis 1 (Foundry Prime) Location of bearing axis 1 The bearing axis 1 is located as shown in the illustration. (View from above). xx0700000445 Plastic ring (cable guide) Required equipment Equipment...
Page 180 3 Maintenance 3.5.2. Rust preventive measures, bearing axis 1 (Foundry Prime) Continued Procedure The following procedure details how to grease the bearing axis 1. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 181 3 Maintenance 3.5.2. Rust preventive measures, bearing axis 1 (Foundry Prime) Continued Action Note 4. Apply rust preventive on the radial sealing with a brush. xx0700000455 Parts: • A: Area where Mercasol 3106 shall be applied 5. Refit the plastic ring. 3HAC026876-001 Revision: C...
Page 182: Rust Preventive Measures, Bearing Axis 4 (Foundry Prime)
3 Maintenance 3.5.3. Rust preventive measures, bearing axis 4 (Foundry Prime) 3.5.3. Rust preventive measures, bearing axis 4 (Foundry Prime) Overview The bearing axis 4 is located as shown in the illustration below. xx0500002869 Plastic cover Plastic ring Required equipment Equipment Art.
Page 183 3 Maintenance 3.5.3. Rust preventive measures, bearing axis 4 (Foundry Prime) Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 184 3 Maintenance 3.5.3. Rust preventive measures, bearing axis 4 (Foundry Prime) Continued Action Note 6. Apply rust preventive on the radial sealing and the rear part of the tube with a brush. xx0600002868 Parts: • A: Radial sealing and rear part of tube •...
Page 185: Rust Preventive Measures, Support Bearing In Wrist (Foundry Prime)
3 Maintenance 3.5.4. Rust preventive measures, support bearing in wrist (Foundry Prime) 3.5.4. Rust preventive measures, support bearing in wrist (Foundry Prime) Location of bearing The support bearing in the wrist is located as shown in the illustration. xx0500002863 Bearing Cable bracket Cover Required equipment...
Page 186 3 Maintenance 3.5.4. Rust preventive measures, support bearing in wrist (Foundry Prime) Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 3.
Page 187: Cleaning Activities
3 Maintenance 3.6.1. Cleaning, robot 3.6 Cleaning activities 3.6.1. Cleaning, robot General The protection class is IP 67, that is the robot is watertight. Activities This instruction specifies how to clean the robot. Periodicity The periodicity of cleaning the robot varies a great deal depending on the actual environment and function of the robot.
Page 188 3 Maintenance 3.6.1. Cleaning, robot Continued Required equipment Equipment, etc. Art. no. Note Steam cleaner • Water pressure at nozzle: max. 2,500 kN/m (25 bar) • Type of nozzle: fan jet, min. 45° spread • Flow: max. 100 litres/min. • Water temperature: max.
Page 189: Repair
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.
Page 190: General Procedures
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 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.
Page 191: Mounting Instructions For Bearings
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. Art. no. Note Grease 3HAB3537-1 Used to grease the bearings, if not specified otherwise.
Page 192 4 Repair 4.2.2. Mounting instructions for bearings Continued 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.
Page 193: Mounting Instructions For Seals
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. Art. no. Note Grease 3HAB3537-1 Used to lubricate the seals. Rotating seals The procedure below details how to fit rotating seals.
Page 194 4.2.3. Mounting instructions for seals Continued Action 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.
Page 195: Complete Robot
4 Repair 4.3.1. Replacement of cable harness, axes 1-6 4.3 Complete robot 4.3.1. Replacement of cable harness, axes 1-6 General This section details how to replace the cable harness that runs undivided from axis 1 to axis 6. Location of cable harness The cable harness of axes 1-6 is run throughout the robot as shown in the figure below.
Page 196 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Cable gland (armhouse) xx0700000107 Required equipment Equipment Spare part no. Note Cable harness, axes 1-6 3HAC027435-001 Brush Option Foundry Prime Rust preventive 3HAC026621-001 Option Foundry Prime Equivalent: • Mercasol 3106 Gasket 3HAC3537-1 Motor axes 1-5...
Page 197 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Cable brackets of the upper arm xx0500002293 Cable bracket, wrist unit Cable bracket, upper arm tube Cable attachment, rear Removal, cable harness - upper arm The procedure below details how to remove the cable harness from the upper arm of the robot. Action Note 1.
Page 198 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note NOTE! Axis 5 must be oriented in the correct position (+90º) to allow the motor 6 cover to open! 5. Remove the cover of motor, axis 6 and disconnect all connectors beneath.
Page 199 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 3. Disconnect connectors R1.MP and R1.SMB. Shown in the figure Location of cable harness on page 193. 4. Remove the cable holder on the frame securing the cable harness. 5.
Page 200 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 9. Remove the cable gland by removing the four attachment screws from inside the SMB recess. xx0700000109 • A: Cable gland • B: Attachment screws, inside SMB recess 10.
Page 201 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 11. Remove the cable gland securing the cables to the arm house. xx0100000143 12. Remove the velcro strap from the harness at Shown in the figure Location of cable the guide plate ax 2 at the lower arm.
Page 202 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 3. Reconnect connectors R1.MP and R1.SMB at Shown in the figure Location of cable the base. harness on page 193. Make a note of the correct positions of the connectors! 4.
Page 203 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 9. Reconnect connectors R2.SMB, R1.SMB1-3, R1.SMB4-6 to the SMB unit. Reconnect X8, X9 and X10 to the brake release unit. Reconnect R1.G if it has been disconnected. xx0700000104 10.
Page 204 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 14. Refit the cable gland securing the cables to the arm house. NOTE! The cable harness is delivered in a pretwisted state. Make sure not to affect this by twisting the cable harness further in any direction.
Page 205 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 2. Refit the cable gland securing the cables in the Shown in the figure Location of cable armhouse. harness on page 193. NOTE! The cable harness is delivered pretwisted. Make sure not to affect this by twisting the cable harness further in any direction.
Page 206 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 9. Fasten the cable bracket, wrist unit with its three attachment screws. Two screws are visible at the rear attachment point of the bracket and the third is located at the bottom of the cable bracket, in the center.
Page 207: Replacement Of Cabling, Axis 5 Motorirb 6640
4 Repair 4.3.2. Replacement of cabling, axis 5 motorIRB 6640 4.3.2. Replacement of cabling, axis 5 motorIRB 6640 Location of cabling The separate cables for the axis 5 motor are located inside the upper arm tube, as shown in the figure below. xx0500002294 Motor axis 5 with connectors R4.FB5 and R4.MP5 Connectors R3.FB5 and R3.MP5...
Page 208 4 Repair 4.3.2. Replacement of cabling, axis 5 motorIRB 6640 Continued Action Note 3. Remove the cover of motor, axis 5. 4. Disconnect all connectors at motor, axis 5. 5. Remove the cable gland cover at the cable exit by unscrewing its two attachment screws. 6.
Page 209: Replacement Of Cable Harness, Cleanroom
4 Repair 4.3.3. Replacement of cable harness, Cleanroom 4.3.3. Replacement of cable harness, Cleanroom General This section details how to replace the cable harness, Cleanroom. Fitting of cable attachments is detailed in section Fitting cable package attachments (Cleanroom). Location of cable harness, Cleanroom The illustration below shows the location of the cable harness, Cleanroom.
Page 210 4 Repair 4.3.3. Replacement of cable harness, Cleanroom Continued Motor axis 1 Connectors at base Required equipment Equipment Spare part no. Note Cable harness, Cleanroom 3HAC029840-001 Gasket 3HAC3537-1 Motor, axes 1.5 Gasket 3HAC12877-1 Motor, axis 6 Standard toolkit The content is defined in section Standard toolkit on page 394.
Page 211 4 Repair 4.3.3. Replacement of cable harness, Cleanroom Continued Action Note 7. Remove the cover on the shelf by removing its attachment screws. xx0800000049 Parts: • A: Cover • B: Shelf • C: Attachment screws M6x16 quality 8.8-A2F (4 pcs) 8.
Page 212 4 Repair 4.3.3. Replacement of cable harness, Cleanroom Continued Action Note 9. Open the gripping clamp and remove the cable harness from the shelf. xx0800000050 Parts: • A: Gripping clamp 10. Pull the cable harness and connectors carefully up through the cable guide in the center of the frame. xx0800000046 Parts: •...
Page 213 4 Repair 4.3.3. Replacement of cable harness, Cleanroom Continued Action Note 12. Disconnect connectors: • R2.SMB, R1.SMB1-3, R1.SMB4-4 to the SMB unit • X8, X9, X10 to the brake release unit xx0700000104 13. Remove the cable gland by removing its attachment screws from inside the SMB recess.
Page 214 4 Repair 4.3.3. Replacement of cable harness, Cleanroom Continued Action Note 14. Open the gripping clamp on the lower bracket and remove the cable harness. xx0800000053 Parts: • A: Gripping clamp 15. Remove the velcro straps on the side bracket, balancing device.
Page 215 4 Repair 4.3.3. Replacement of cable harness, Cleanroom Continued Removal cable harness - upper end The procedure below details how to remove the upper end of the cable harness, Cleanroom. Action Note 1. Remove the cover at the back of the upper arm tube Shown in the figure Location of by removing its attachment screws.
Page 216 4 Repair 4.3.3. Replacement of cable harness, Cleanroom Continued Refitting cable harness - lower end The procedure below details how to refit the lower end of the cable harness, Cleanroom. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 217 4 Repair 4.3.3. Replacement of cable harness, Cleanroom Continued Action Note 7. Fit the bracket on the cable package to the shelf with its attachment screws. xx0800000047 Parts: • A: Cable bracket (part of cable harness) • B: Shelf • C: Attachment screws M6x16 quality 8.8-A2F (2 pcs)
Page 218 4 Repair 4.3.3. Replacement of cable harness, Cleanroom Continued Action Note 10. Refit the cover on the shelf with its attachment screws. xx0800000049 Parts: • A: Cover • B: Shelf • C: Attachment screws M6x16 quality 8.8-A2F (4 pcs) 11. Secure the cable gland with its attachment screws from inside the SMB recess.
Page 219 4 Repair 4.3.3. Replacement of cable harness, Cleanroom Continued Action Note 12. Reconnect connectors: • R2.SMB, R1.SMB1-3, R1.SMB4-6 to the SMB unit • X8, X9, X10 to the brake release unit • R1.G battery cable (if it has been recon- nected) xx0700000104 13.
Page 220 4 R e p a ir 4.3.3. Replacement of cable harness, Cleanroom Continued Action Note 17. Secure the cable harness to the gripping clamps on the lower arm. xx0800000051 Parts: • A: Gripping clamps 18. Continue refitting of the upper end of the cable harness.
Page 221 4 Repair 4.3.3. Replacement of cable harness, Cleanroom Continued Action Note 4. Reconnect all connectors on the connection plate axis 3. xx0800000055 Parts: • A: Connectors (at connection plate axis 3) 5. Reconnect all connectors at motor axis 3 and motor Shown in the figure Location of axis 4.
Page 222: Replacement Of Cable Harness, Axes 1-4- Irb 6640Id
4 Repair 4.3.4. Replacement of cable harness, axes 1-4- IRB 6640ID 4.3.4. Replacement of cable harness, axes 1-4- IRB 6640ID Location of cable harness The cable harness for axes 1-4 is run throughout the base, frame and lower arm as shown in the figure below.
Page 223 4 Repair 4.3.4. Replacement of cable harness, axes 1-4- IRB 6640ID Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Cable harness axes 1-4 3HAC025503-001 Includes a cable protection that must be fitted to the IRB 6640ID - 200/2.55 lower arm, and a velcro strap for the harness going up inside the lower arm!
Page 224 4 Repair 4.3.4. Replacement of cable harness, axes 1-4- IRB 6640ID Continued Action Note 4. Disconnect the earth cable. Attachment point is shown in the figure Location of cable harness on page 220! 5. Disconnect connectors R1.MP and R1.SMB. Attachment points are shown in the figure Location of cable harness on page...
Page 225 4 Repair 4.3.4. Replacement of cable harness, axes 1-4- IRB 6640ID Continued Action Note 10. Remove: • the cable gland by removing the four attachment screws from inside the SMB recess. xx0700000109 • A: Cable gland • B: Attachment screws (inside SMB recess) 11.
Page 226 4 Repair 4.3.4. Replacement of cable harness, axes 1-4- IRB 6640ID Continued Action Note 14. Disconnect connector R2.M5/6 at the cable division Shown in the figure Location of point. cable harness on page 220! 15. Disconnect all connectors at motor 3 and motor 4. Specified and shown in the figure Location of cable harness on page...
Page 227 4 Repair 4.3.4. Replacement of cable harness, axes 1-4- IRB 6640ID Continued Action Note 8. Secure the cable gland with four attachment screws from inside the SMB recess. xx0700000109 • A: Cable gland • B: Attachment screws, inside SMB recess 9.
Page 228 4 Repair 4.3.4. Replacement of cable harness, axes 1-4- IRB 6640ID Continued Action 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 12.
Page 229 4 Repair 4.3.4. Replacement of cable harness, axes 1-4- IRB 6640ID Continued Action Note 18. Fit a cable protection to the lower arm, if not Both the protection and the strap already mounted, with two securing screws (A), are included in the spare part no., M6x16.
Page 230: Replacement Of Cable Harness, Axes 5-6 - Irb 6640Id
4 Repair 4.3.5. Replacement of cable harness, axes 5-6 - IRB 6640ID 4.3.5. Replacement of cable harness, axes 5-6 - IRB 6640ID Location of cable harness, axes 5-6 The cable harness of axes 5-6 is run inside the upper arm, as shown in the figure below. xx0500001896 Cover, upper arm tube Hood, upper arm housing...
Page 231 4 Repair 4.3.5. Replacement of cable harness, axes 5-6 - IRB 6640ID Continued Equipment Spare part no. Art. no. Note Standard toolkit The content is defined in section Standard toolkit on page 394. Product manual - Art. no. is specified in SpotPack/DressPack section References.
Page 232 4 Repair 4.3.5. Replacement of cable harness, axes 5-6 - IRB 6640ID Continued Action Note 7. Remove the cable bracket from the upper arm housing by removing the three attachment screws (B). Leave the cabling fitted to the bracket. xx0500001905 8.
Page 233 4 Repair 4.3.5. Replacement of cable harness, axes 5-6 - IRB 6640ID Continued Cable layout, wrist unit The figure below shows how to run and attach the cabling inside the wrist unit. xx0500002014 Location inside the wrist unit where to strap the cabling, next to the axis 5 motor. Refitting, cable harness axes 5-6 The procedure below details how to refit the cable harness to the upper arm.
Page 234 4 Repair 4.3.5. Replacement of cable harness, axes 5-6 - IRB 6640ID Continued Action Note 4. Secure the cable clamp (C) inside the upper arm tube. xx0500001904 5. Place the cabling inside the wrist unit according Shown in the figure Location of cable to the cable layout shown in the figure Cable...
Page 235 4 Repair 4.3.5. Replacement of cable harness, axes 5-6 - IRB 6640ID Continued Action 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 3HAC026876-001 Revision: C...
Page 236: Replacement Of Complete Arm System
4 Repair 4.3.6. Replacement of complete arm system 4.3.6. Replacement of complete arm system Location of arm system The complete arm system is defined as the complete robot except for the base and gearbox axis 1. This is shown in the figure below. A more detailed view of the component and its position may be found in chapter Upper arm including wrist unit, motors ax.
Page 237 4 Repair 4.3.6. Replacement of complete arm system Continued Required equipment Equipment, etc. Art. no. Note Guide pins M12 x 130 3HAC022637-001 Used to guide the complete arm system when refitting. Always use the guide pins in pairs! In order to make the refitting easier, it is recommended to use two guide pins of different lengths.
Page 238 4 Repair 4.3.6. Replacement of complete arm system Continued Action Note 4. Loosen the cable connectors from the Detailed in section Replacement of cable base and pull up the cabling from the harness, axes 1-6 on page 193. base, through the hole in the center of the Detailed in section Replacement of cable frame.
Page 239 4 Repair 4.3.6. Replacement of complete arm system Continued Action Note NOTE! For Cleanroom robots apply a protection where the lifting equipment and roundslings will rub against the paint of the robot. In order to prevent from particle emission while lifting, put for example a 20 mm thick cellular plastic sheet around the places on the robot where the lifting equipment may rub against the paint.
Page 240 4 Repair 4.3.6. Replacement of complete arm system Continued Action Note 13. Lift the arm system carefully and secure Make sure all hooks and attachments stay in it in a safe area. the correct position while lifting the arm system and that the lifting device does not Always move the robot at very low wear against sharp edges.
Page 241 4 Repair 4.3.6. Replacement of complete arm system Continued Action Note 3. Fit the lifting device as detailed in the figure Art. no. is specified in Required to the right. equipment on page 235. Also fit a hoisting block to the roundsling put Make sure the lift is done completely around the lower arm.
Page 242 4 Repair 4.3.6. Replacement of complete arm system Continued Action Note 6. Fit the two guide pins to the holes in gearbox Dimension is specified in Required axis 1, as shown in the figure to the right. equipment on page 235.
Page 243 4 Repair 4.3.6. Replacement of complete arm system Continued Action Note 10. Refit the calibration plate at the bottom of the frame. xx0700000380 Parts: • A: Calibration plate 11. Refit the motor axis 1. Detailed in section Replacement of motor, axis 1 on page 300.
Page 244: Replacement Of Air Nipple And Hose (Foundry Prime)
4 Repair 4.3.7. Replacement of air nipple and hose (Foundry Prime) 4.3.7. Replacement of air nipple and hose (Foundry Prime) Location The illustration below shows the routing of the Foundry Prime air hose. xx0500002176 Hose lengths xx0700000449 Pos 1A Hose length 40 mm Pos 1B Hose length 40 mm Pos 1C...
Page 245 4 Repair 4.3.7. Replacement of air nipple and hose (Foundry Prime) Continued Pos 1G Hose length 250 mm Pos 1H Hose length 540 mm Pos 1K Hose length 4020 mm Pos 1L Hose length 195 mm Pos 1M Hose length 40 mm Pos 1N Hose length 40 mm Pos 1P...
Page 246 4 Repair 4.3.7. Replacement of air nipple and hose (Foundry Prime) Continued Procedure The following procedures details how to replace the Foundry Prime air nipples and hose. The pos. no. in following procedures correspond to the illustration in Hose lengths on page 242and the table in Required equipment on page 243 Action...
Page 247 4 Repair 4.3.7. Replacement of air nipple and hose (Foundry Prime) Continued Action Note 4. Axis 1 xx0700000458 Items in illustration are detailed in Required equipment on page 243 Hose lengths on page 242. xx0700000459 Item in illustration is detailed in Required equipment on page 243.
Page 248 4 Repair 4.3.7. Replacement of air nipple and hose (Foundry Prime) Continued Action Note 6. Axis 1-2 Items in illustrations are detailed in Hose lengths on page 242 Required equipment on page 243 xx0700000460 xx0700000461 xx0700000462 • A: Air hose beneath velcro strap Continues on next page 3HAC026876-001 Revision: C...
Page 249 4 Repair 4.3.7. Replacement of air nipple and hose (Foundry Prime) Continued Action Note 7. Upper arm housing. xx0600003046 xx0600003047 8. Tube shaft. xx0600003163 • 1P: Lay the hose in a spiral in the tube shaft. Continues on next page 3HAC026876-001 Revision: C...
Page 250 4 Repair 4.3.7. Replacement of air nipple and hose (Foundry Prime) Continued Action Note 9. Wrist. NOTE! Make sure the cable length from 5a to the nipple of axis 6 = S, see Hose lengths on page 242. xx0600003097 3HAC026876-001 Revision: C...
Page 251: Upper And Lower Arm
4 Repair 4.4.1. Replacement of turning disk 4.4 Upper and lower arm 4.4.1. Replacement of turning disk Location of turning disk The turning disk is located in the front of the wrist housing, as shown in the figure below. A more detailed view of the component and its position may be found in chapter Upper arm including wrist unit, motors ax.
Page 252 4 Repair 4.4.1. Replacement of turning disk Continued Removal, turning disk The procedure below details how to remove the turning disk. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 253 4 Repair 4.4.1. Replacement of turning disk Continued Action Note 2. Secure the turning disk with its attachment 12 pcs, M12 x 30, 12.9 quality screws. UNBRAKO, tightening torque: 100 Nm. Reused screws may be used, providing they are lubricated as detailed in section Screw joints on page 390 before fitting.
Page 254: Replacement Of Complete Wrist Unit
4 Repair 4.4.2. Replacement of complete wrist unit 4.4.2. Replacement of complete wrist unit Wrist unit for robot models IRB 6640ID This section is valid for robot models IRB 6640. How to replace the wrist of the models IRB 6640ID is detailed in section Replacement of complete wrist unit, IRB 6640ID on page 257.
Page 255 4 Repair 4.4.2. Replacement of complete wrist unit Continued Required equipment Equipment etc. Spare part no. Art. no. Note Wrist, type 2 3HAC16626-2 Turning disk 3HAC13752-1 Guide pins M12 x 200 3HAC13056-3 Always use guide pins in pairs! Guide pins M12 x 200 3HAC13056-3 Lifting tool, wrist unit 3HAC13605-1...
Page 256 4 Repair 4.4.2. Replacement of complete wrist unit Continued Action Note 7. Loosen the cable bracket, wrist unit on top of the Shown in the figure Location of wrist wrist by undoing the three attachment screws. unit on page 252. Two of the attachment screws are visibly located at the rear of the bracket and the third located at the bottom of the cable bracket, in the center.
Page 257 4 Repair 4.4.2. Replacement of complete wrist unit Continued Action Note 3. Fit the lifting tool to the wrist unit. Art. no. is specified Location of wrist unit on page 252. CAUTION! The complete wrist unit weighs 130 kg! All lifting equipment used must be sized accord- ingly! 5.
Page 258 4 Repair 4.4.2. Replacement of complete wrist unit Continued Action Note 12. Fasten the cable bracket at top of the wrist Shown in the figure Location of wrist unit with three attachment screws. Two of unit on page 252. them are visible at the rear attachment point and the third is located on the bottom of the cable bracket, in the center.
Page 259: Replacement Of Complete Wrist Unit, Irb 6640Id
4 Repair 4.4.3. Replacement of complete wrist unit, IRB 6640ID 4.4.3. Replacement of complete wrist unit, IRB 6640ID Wrist unit for robot models IRB 6640ID This section is only valid for robot models IRB 6640ID. How to replace the wrist unit on the models IRB 6640 is detailed in section Replacement of complete wrist unit on page 252.
Page 260 4 Repair 4.4.3. Replacement of complete wrist unit, IRB 6640ID Continued Removal, wrist unit The procedure below details how to remove the complete wrist unit from the robot. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 261 4 Repair 4.4.3. Replacement of complete wrist unit, IRB 6640ID Continued Action Note CAUTION! The complete wrist unit weighs 187 kg! All lifting equipment used must be sized accordingly! 4. Attach the lifting slings to the wrist unit and lift it to the upper arm tube.
Page 262: Replacement Of Upper Arm
4 Repair 4.4.4. Replacement of upper arm 4.4.4. Replacement of upper arm Location of upper arm The upper arm is located on top of the robot as shown in the following figure. The complete upper arm includes the wrist unit but this section also describes how to remove the upper arm when there is no wrist unit mounted.
Page 263 4 Repair 4.4.4. Replacement of upper arm Continued Required equipment Equipment Art. no. Note Sealing, axis 2/3 3HAC17212-1 Always use a new sealing when refitting the upper arm! Washer, axis 3 (3 pcs) 3HAC12703-1 To be replaced if damaged. Guide pins, sealing axis 2/3 80 mm 3HAC14628-1 For guiding "Sealing, axis 2/3".
Page 264 4 Repair 4.4.4. Replacement of upper arm Continued Action Note 5. Upper arm including wrist unit: Art. no. is specified in Required equipment on page 261. Fit one of the pieces included in lifting device, upper arm to the front attachment for lifting device on the Attachment point is shown in the upper arm.
Page 265 4 Repair 4.4.4. Replacement of upper arm Continued Action Note 14. Carefully remove the attachment screws and Shown in the figure Location of washers, upper arm. upper arm on page 260. 15. Lift the upper arm and place it on a secure surface. Make sure the lift is done completely level! In case of necessary adjustments, use the shortening loops on the lifting tool (chain), but make sure to place the...
Page 266 4 Repair 4.4.4. Replacement of upper arm Continued Action Note 3. Upper arm including wrist unit: Art. no. is specified in Required equipment on page 261. Fit the lifting eye, VLBG M12 to the attachment hole, lifting eye on the wrist unit. Shown in the figure Location of upper arm on page...
Page 267 4 Repair 4.4.4. Replacement of upper arm Continued Action Note 10. Fit in the gearbox attachment holes with the Art. no. is specified in Required attachment holes on the lower arm with the equipment on page 261. guide pins. It may be necessary to turn the gear by rotating the motor pinion with a rotation tool, motor beneath the motor cover.
Page 268 4 Repair 4.4.4. Replacement of upper arm Continued Action Note 21. Recalibrate the robot. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration informa- tion. DANGER! Make sure all safety requirements are met when performing the first test run.
Page 269: Replacement Of Complete Lower Arm
Always use a new sealing when reas- sembling! Puller tool, balancing device 3HAC12475-1 shaft Lifting tool, lower arm 3HAC14691-1 Tool that may be rent from ABB Robotics. Includes: • two guidings, 3HAC 14446-1, must be used for guiding the sealing, axis 2/3. Rotation tool...
Page 270 4 Repair 4.4.5. Replacement of complete lower arm Continued Equipment, etc. Art. no. Note Retaining ring plier Grease 3HAB3537-1 For lubrication of the shaft hole. Isopropanol 11771012-208 For cleaning of the shaft. Standard toolkit The content is defined in section Standard toolkit on page 394.
Page 271 4 Repair 4.4.5. Replacement of complete lower arm Continued Action Note 7. Apply the puller tool, balancing device shaft to the Art. no. is specified in Required shaft of the balancing device, through the hole in equipment on page 267. the frame.
Page 272 4 Repair 4.4.5. Replacement of complete lower arm Continued Action Note 16. Remove the attachment screws and washers that attach the lower arm to the gearbox axis 2. 17. Lift the lower arm and place it on a secure surface. Refitting, lower arm The procedure below details how to refit the lower arm.
Page 273 4 Repair 4.4.5. Replacement of complete lower arm Continued Action Note CAUTION! The lower arm weighs 160 kg! All lifting equipment used must be sized accordingly! 7. Lift the lower arm and move it to its mounting position. 8. In case the hole pattern of the lower arm and Connect power supply to connector the gearbox axis 2 does not match, use power R2.MP2...
Page 274 4 Repair 4.4.5. Replacement of complete lower arm Continued Action Note 17. Refit and reconnect all cables inside the lower Detailed in section Refitting, cable arm. harness, axes 1-4 on page 224. Resecure any cable attachments. Detailed in section Replacement of cable harness, Cleanroom on page 207.
Page 275: Frame And Base
4 Repair 4.5.1. Replacement of SMB unit 4.5 Frame and base 4.5.1. Replacement of SMB unit Location of SMB unit The SMB unit (SMB = serial measurement board) is located on the left hand side of the frame as shown in the figure below. xx0700000121 SMB cover Pins...
Page 276 4 Repair 4.5.1. Replacement of SMB unit Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. WARNING! The unit is sensitive to ESD, before handling the unit please observe the safety information in section WARNING - The unit is sensitive to ESD! on page 35...
Page 277 4 Repair 4.5.1. Replacement of SMB unit Continued Action Note 4. Connect all connectors to the SMB board and fit Art. no. is specified in Required the SMB unit onto the pins. equipment on page 273. Shown in the figure Location of SMB unit on page 273.
Page 278 4 Repair 4.5.1. Replacement of SMB unit Continued Action Note 4. Refit the new SMB unit according to step 3 - 6 in Refitting, SMB unit on page 274 NOTE! Make sure that the gasket under the SMB cover is not damaged! Secure the SMB cover with its attachment screws.
Page 279: Replacement Of Brake Release Unit
4 Repair 4.5.2. Replacement of brake release unit 4.5.2. Replacement of brake release unit Location of brake release unit The brake release unit is located together with the SMB unit on the left hand side of the frame, right next to the gearbox, axis 2, as shown in figure below. xx0700000123 Brake release unit Push button guard...
Page 280 4 Repair 4.5.2. Replacement of brake release unit Continued Removal, brake release unit The procedure below details how to remove the brake release unit. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 281 4 Repair 4.5.2. Replacement of brake release unit Continued Refitting, brake release unit The procedure below details how to refit the brake release unit. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 282 4 Repair 4.5.2. Replacement of brake release unit Continued Action 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 7. Refit the push button guard to the SMB cover. Shown in the figure Location of brake release unit on page 277.
Page 283: Replacement Of Spherical Roller Bearing, Balancing Device (Old And New)
4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device (old and new) 4.5.3. Replacement of spherical roller bearing, balancing device (old and new) Location of bearing The bearing is located at the front ear of the balancing device, as shown in the figure below. xx0700000115 Lower arm 3HAC023627-001 Lower arm 3HAC027033-001...
Page 284 4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device (old and new) Continued Protection plug Lower arm 3HAC031985-001 Lower arm 3HAC032177-001 Washer Radial seal w dustlipp 50x68x8 Spherical roller bearing Radial seal w dustlipp 50x68x8 O-ring End cover Torx pan head screw Shaft Washer Hex socket head cap screw M16x70...
Page 285 4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device (old and new) Continued Mounting tool Press nut Removal, bearing The procedure below details how to remove the bearing from the balancing device front ear. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 286 4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device (old and new) Continued Action Note 3. Insert the threaded bar through the new bearing and place it in the front ear. Also fit the press tool. Secure with the knurled nut and press nut at each end of the threaded bar.
Page 287: Replacement Of Balancing Device (Old And New)
4 Repair 4.5.4. Replacement of balancing device (old and new) 4.5.4. Replacement of balancing device (old and new) Location of balancing device The balancing device is located on rear top of the frame as shown in the figure below. xx0700000094 Washer Radial seal w dustlipp Spherical roller bearing...
Page 288 4 Repair 4.5.4. Replacement of balancing device (old and new) Continued End cover Torx pan head screw M6x10 Shaft VK cover Washer Hex socket head cap screw Retaining ring,bore Washer Radial Sealing V-ring Shaft end Hex socket head cap screw Hydraulic pump Required equipment Spare part...
Page 289 4 Repair 4.5.4. Replacement of balancing device (old and new) Continued Spare part Equipment Art. no. Note Puller tool, 3HAC12475-1 balancing device Press tool, 3HAC17129-1 balancing device shaft Hydraulic cylinder 3HAC11731-1 To be used with the press and puller tools. Hydraulic pump, 3HAC13086-1 To be used with the hydraulic...
Page 290 4 Repair 4.5.4. Replacement of balancing device (old and new) Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 4.
Page 291 4 Repair 4.5.4. Replacement of balancing device (old and new) Continued Action Note 12. Apply the puller tool, balancing Art. no. is specified in Required equipment on page device shaft to the shaft and pull 286. it out. xx0800000250 • A Puller tool, 13.
Page 292 4 Repair 4.5.4. Replacement of balancing device (old and new) Continued Refitting The procedure below details how to refit the balancing device. Action Note 1. Fit the shackle to the balancing Art. no. is specified in Required equipment. device. Where to attach the shackle is shown in the figure Location of balancing device on page 285.
Page 293 4 Repair 4.5.4. Replacement of balancing device (old and new) Continued Action Note 9. Refit the attachment screw Shown in the figure Location of balancing device on securing the shaft. page 285. Attachment screw M16x70 quality 12.9 Gleitmo Tightening torque:300 Nm 10.
Page 294 4 Repair 4.5.4. Replacement of balancing device (old and new) Continued Replacement of balancing device (Foundry prime) old and new. Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level. The repair must be done according to the previous repair procedures with the following additions when refitting the balancing device.
Page 295 4 Repair 4.5.4. Replacement of balancing device (old and new) Continued Action Note 3. Apply Mercasol 3106 on the following machined surfaces on the balancing device: • holes in the lower arm ear • holes in the rod bracket • shaft.
Page 296: Unloading The Balancing Device (Old And New)
4 Repair 4.5.5. Unloading the balancing device (old and new) 4.5.5. Unloading the balancing device (old and new) Prerequisite This section details how to unload the balancing device with the press tool. The lower arm must be secured before unloading the balancing device! How to secure the lower arm is detailed in the current repair activity, for example removal of the balancing device.
Page 297 4 Repair 4.5.5. Unloading the balancing device (old and new) Continued Required equipment Equipment, etc. Art. no. Note Press tool, balancing device 3HAC020902-001 Includes • press device 3HAC15767-2 • press device 3HAC18100-1 Choose the correct device, depending on model of balancing device. Hydraulic cylinder 3HAC11731-1 To be used with the press tool.
Page 298 4 Repair 4.5.5. Unloading the balancing device (old and new) Continued Action Note 2. Fit the correct press device and moving pin to Shown in the figure Press tool and the press tool. Secure with the bolt, press hydraulic cylinder on page 294.
Page 299: Restoring The Balancing Device
4 Repair 4.5.6. Restoring the balancing device 4.5.6. Restoring the balancing device Overview This section details how to restore the balancing device and how to remove the press tool from the device. DANGER! There is a high tensioned spring inside the balancing device, incorrect handling may cause injuries and damage property.
Page 300 4 Repair 4.5.6. Restoring the balancing device Continued Required equipment Equipment, etc. Art. no. Note Hydraulic cylinder 3HAC11731-1 To be used with press tool. Hydraulic pump, 80 MPa 3HAC13086-1 To be used with hydraulic cylinder. Brush Rust preventive 3HAC026621-001 Equivalent: •...
Page 301 4 Repair 4.5.6. Restoring the balancing device Continued Action Note DANGER! The rear cover of the balancing device is a safety device for the piston rod during operation! Make sure the cover is properly secured before commissioning of the robot! 3HAC026876-001 Revision: C...
Page 302: Motors
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 motor axis 1 is located as shown in the figure below. xx0700000085 Motor, axis 1 Required equipment Equipment, etc. Spare part no. Art.
Page 303 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Equipment, etc. Spare part no. Art. no. Note Standard toolkit The content is defined in section Standard toolkit on page 394. Calibration Pendulum 3HAC15716-1 Complete kit that also toolkit includes operating manual.
Page 304 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 8. If required, press the motor out of position by fitting Art. no. is specified in Required removal tool, motor to the motor attachment screw equipment on page 300. holes.
Page 305 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 10. Refit the cable gland cover at the cable exit with its Make sure the cover is tightly two attachment screws. sealed! 11. Refit the motor cover with its four attachment Make sure the cover is tightly screws.
Page 306 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 2. Remove the cover for connector access on top of the motor by unscrewing its four attachment screws. xx0600002874 • A: Attachment screw • B: Air hose • C: Top cover •...
Page 307 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 7. After mounting the motor on the robot, the surface between the motor and the base frame must be protected with Mercasol 3106. xx0600002877 • A: Base frame • B: Motor unit 8.
Page 308: Replacement Of Motor Axis 2
4 Repair 4.6.2. Replacement of motor axis 2 4.6.2. Replacement of motor axis 2 Location of motor The motor, axis 2, is located on the left hand side of the robot as shown in the figure below. xx0700000086 Motor, axis 2 Required equipment Equipment, etc.
Page 309 4 Repair 4.6.2. Replacement of motor axis 2 Continued Equipment, etc. Spare part no. Art. no. Note Power supply 24 VDC, 1.5 A For releasing the brakes. Rotation tool 3HAC17105-1 Used to rotate the motor pinion when mating it to the gear, when brakes are released with 24VDC power supply.
Page 310 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note Use the lock screw to lock the lower arm, as detailed above! 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! 9.
Page 311 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note 4. Fit the lifting tool, motor axis 2, 3, 4 to the Art. no. is specified in Required motor. equipment on page 306. 5. Fit the two guide pins in the two lower motor Art.
Page 312 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note 18. Recalibrate the robot. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration informa- tion. DANGER! Make sure all safety requirements are met when performing the first test run.
Page 313 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note 5. Remove the cover for connector access on top of the motor by unscrewing its four attachment screws. xx0600002874 • A: Attachment screw • B: Air hose • C: Top cover •...
Page 314 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note 10. Fill the four screw recesses on the new motor with Sikaflex. (After hardening, Sikaflex can be formed with a knife) xx0600002875 • A: Motor unit • B: Sikaflex in screw recesses 11.
Page 315: Replacement Of Motor, Axis 3
4 Repair 4.6.3. Replacement of motor, axis 3 4.6.3. Replacement of motor, axis 3 Location of motor The motor axis 3 is located on the left hand side of the robot as shown in the figure below. xx0200000186 Motor axis 3 Cable gland cover, motor axis 3 Motor attachment holes (4 pcs) Required equipment...
Page 316 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Equipment, etc. Spare part no. Art. no. Note Rotation tool 3HAC17105-1 Used to rotate the motor pinion when mating it to the gear, when brakes are released with 24 VDC power supply.
Page 317 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note 4. Remove any equipment hindering access to motor axis 3. 5. Remove the cover on top of the motor by unscrewing its four attachment screws. 6. Remove the cable gland cover at the cable exit by Shown in the figure Location of unscrewing its two securing screws.
Page 318 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Refitting, motor The procedure below details how to refit motor, axis 3. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 319 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note 9. Use the rotation tool in order to rotate the motor Art no. is specified in Required pinion when mating it to the gear! equipment on page 313. Fit the motor, making sure the motor pinion is Make sure the motor pinion does not properly mated to the gear of gearbox, axis 3.
Page 320 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action 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 Replacement of the motor axis 3 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level.
Page 321 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note NOTE! Keep the old top cover with the air nipple mounted. 5. Continue removal of the motor unit, according to step 6 and forwards in section Removal, motor on page 314.
Page 322: Replacement Of Motor, Axis 4
4 Repair 4.6.4. Replacement of motor, axis 4 4.6.4. Replacement of motor, axis 4 Location of motor The motor axis 4 is located on the left hand side of the upper arm as shown in the figure below. xx0200000202 Motor, axis 4 Cable gland cover, motor axis 4 Motor attachment holes (4 pcs) Required equipment...
Page 323 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Equipment, etc. Spare part no. Art. no. Note Calibration 3HAC15716-1 Complete kit that also Pendulum toolkit includes operating manual. Other tools and These procedures include procedures may be references to the tools required.
Page 324 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note 10. Lift the motor to get the pinion away from the gear and disconnect the brake release voltage. 11. Remove the motor by gently lifting it straight Make sure the motor pinion is not out.
Page 325 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note 7. Use the rotation tool in order to rotate the Art. no. is specified in Required motor pinion when mating it to the gear! equipment on page 320. Fit the motor, making sure the motor pinion Make sure the motor pinion does not get is properly mated to the gear, axis 4.
Page 326 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Replacement of the motor axis 4 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level. The repair must be done according to the previous repair procedures with the following additions.
Page 327 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note 5. Fill the four screw recesses on the new motor with Sikaflex. (After hardening, Sikaflex can be formed with a knife) xx0600002875 • A: Motor unit • B: Sikaflex in screw recesses 6.
Page 328: Replacement Of Motor, Axis 5. Irb 6640
4 Repair 4.6.5. Replacement of motor, axis 5. IRB 6640 4.6.5. Replacement of motor, axis 5. IRB 6640 Reused pinion The pinion in the motor, axis 5, is matched with the beveral gear for axis 5. When the motor is replaced the pinion must therefore be removed from the dismounted motor and fitted onto the new motor shaft as detailed in this section.
Page 329 4 Repair 4.6.5. Replacement of motor, axis 5. IRB 6640 Continued Equipment, etc. Spare part no. Art. no. Note Gasket 3HAC3438-1 Option Foundry Prime Must be replaced if the cabling is dismantled from the motor. Grease 3HAC3537-1 For lubricating the o-ring. Isopropanol 11771012-208 For cleaning motor pinion...
Page 330 4 Repair 4.6.5. Replacement of motor, axis 5. IRB 6640 Continued Action Note 4. Place the wrist unit safely on a workbench, in a fixture or similar. 5. Remove the cover on top of the motor by unscrewing its four attachment screws. 6.
Page 331 4 Repair 4.6.5. Replacement of motor, axis 5. IRB 6640 Continued Refitting, motor, axis 5 The procedure below details how to refit motor, axis 5. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 332 4 Repair 4.6.5. Replacement of motor, axis 5. IRB 6640 Continued Action Note 10. Fit the motor, with guidance from the pins, Make sure the motor pinion does not making sure the motor pinion is properly mated get damaged! to the gear of axis 5. 11.
Page 333 4 Repair 4.6.5. Replacement of motor, axis 5. IRB 6640 Continued Action Note 2. Perform step 2 - 4 in Removal, motor, axis 5 on page 327 3. Remove the cover for connector access on top of the motor by unscrewing its four attachment screws.
Page 334 4 Repair 4.6.5. Replacement of motor, axis 5. IRB 6640 Continued Action Note 7. Fill the four screw recesses on the new motor with Sikaflex. (After hardening, Sikaflex can be formed with a knife) xx0600002880 • A: Air hose • B: Motor unit •...
Page 335: Replacement Of Motor, Axis 5, Irb 6640Id
4 Repair 4.6.6. Replacement of motor, axis 5, IRB 6640ID 4.6.6. Replacement of motor, axis 5, IRB 6640ID Location of motor, axis 5 The motor of axis 5 is located on the bottom side of the wrist, when axis 4 is placed in calibration position.
Page 336 4 Repair 4.6.6. Replacement of motor, axis 5, IRB 6640ID Continued Removal tools, motor attachment screws The figure below shows the required dimensions of the tools, in order to access the attachment screws of the motor. xx0500002271 Allen key, Ø 6 mm Socket, Ø...
Page 337 4 Repair 4.6.6. Replacement of motor, axis 5, IRB 6640ID Continued Refitting, motor axis 5 The procedure below details how to refit the motor, axis 5. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
Page 338: Replacement Of Motor, Axis 6, Irb 6640, Irb 6620/Foundry Plus
4 Repair 4.6.7. Replacement of motor, axis 6, IRB 6640, IRB 6620/Foundry Plus 4.6.7. Replacement of motor, axis 6, IRB 6640, IRB 6620/Foundry Plus Location of motor The motor axis 6 is located in the center of the wrist unit as shown in the figure below. A more detailed view of the component and its position may be found in chapter Upper arm including wrist unit, motors ax.
Page 339 4 Repair 4.6.7. Replacement of motor, axis 6, IRB 6640, IRB 6620/Foundry Plus Continued Equipment, etc. Spare part no. Art. no. Note Grease 3HAB3537-1 For lubricating the o-ring. Standard toolkit The content is defined in section Standard toolkit on page 394.
Page 340 4 Repair 4.6.7. Replacement of motor, axis 6, IRB 6640, IRB 6620/Foundry Plus Continued Action Note 6. Remove the motor by unscrewing its four attachment screws and plain washers. xx0600003038 • A: Tilthouse • B: Motor, axis 6 • C: Attachment screws (4 pcs) 7.
Page 341 4 Repair 4.6.7. Replacement of motor, axis 6, IRB 6640, IRB 6620/Foundry Plus Continued Action Note 4. Fit the motor, with guidance from the pins, Make sure the pinion on the motor making sure the motor pinion is properly mated shaft is not damaged! to the gear of gearbox, axis 6.
Page 342 4 Repair 4.6.7. Replacement of motor, axis 6, IRB 6640, IRB 6620/Foundry Plus Continued Action 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 Replacement of the motor axis 6 (Foundry Prime) Robots working with Foundry Prime and that have the special tightness for this application...
Page 343 4 Repair 4.6.7. Replacement of motor, axis 6, IRB 6640, IRB 6620/Foundry Plus Continued Action Note 4. Continue to remove the motor unit, according to step 6 and forwards in Removal, motor on page 337. NOTE! Keep the old rear motor cover with the air nipple.
Page 344: Replacement Of Motor, Axis 6, Irb 6640Id
4 Repair 4.6.8. Replacement of motor, axis 6, IRB 6640ID 4.6.8. Replacement of motor, axis 6, IRB 6640ID Location of motor, axis 6 The motor of axis 6 is located on top of the wrist, when axis 4 is placed in calibration position. xx0500001574 Motor, axis 6 Motor connectors, R3.MP6 and R3.FB6...
Page 345 4 Repair 4.6.8. Replacement of motor, axis 6, IRB 6640ID Continued Equipment Spare part no. Art. no. Note Circuit diagram See chapter Circuit diagram Product manual, reference information. Removal, motor axis 6 The procedure below details how to remove the motor, axis 6. Action Note 1.
Page 346 4 Repair 4.6.8. Replacement of motor, axis 6, IRB 6640ID Continued Action Note 3. In order to release the brakes, connect the 24 Connect to connector R3.MP6: VDC power supply to the motor. • + : pin C • - : pin D 4.
Page 347: Gearboxes
4 Repair 4.7.1. Replacement gearbox axis 1 4.7 Gearboxes 4.7.1. Replacement gearbox axis 1 Location of gearbox axis 1 xx0600003068 Gearbox, axis 1 RV 320C-191.35 Attachment screw, M12x80 quality 12.9 gleitmo (16 pcs) Attachment screw, M16x60 quality 12.9 gleitmo (12 pcs) Base Frame Cable guide...
Page 348 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Equipment, etc. Spare part no. Art. no. Note Lifting tool 3HAC026597-001 Instruction 3HAC026600- 002 is enclosed. Lifting tool 3HAC15556-1 Used to lift gearbox axis 1 and frame. Lifting eye (2 pcs) 3HAC025333-005 Used together with lifting tool 3HAC15556-1.
Page 349 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 4. Remove motor, axis 1. Detailed in section Replacement of motor, axis 1 on page 300. 5. Remove the lower end of thecable harness. Detailed in section Replacement of cable harness, axes 1-6 on page 193.
Page 350 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 14. Fit the support, base and gear axis 1. Make sure the base remains in a stable position before performing any work underneath the base! 15. Unscrew the 12 attachment screws and washers securing the gearbox to the base.
Page 351 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 2. Make sure the o-ring is fitted to the gearbox Art. no. is specified in Required as shown in the figure to the right. equipment on page 345. Lightly lubricate the o-ring with grease. xx0200000055 •...
Page 352 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 8. Refit the gearbox to the base with its Shown in the figure Location of gearbox attachment screws and washers. axis 1 on page 345. M16x60 quality 12.9 (12 pcs) Tightening torque: 300 Nm.
Page 353 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 14. Refit the lower end of thecable harness. Detailed in section Replacement of cable harness, axes 1-6 on page 193. NOTE! For Cleanroom robots the procedure is detailed in section Replacement of cable harness, Cleanroom on page 207.
Page 354 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 2. Apply Mercasol 3106 on sealing surfaces, in the gap and in the tube on gearbox axis 1. xx0700000463 • A: Sealing surfaces • B: Gap • C: Tube • D: Do not apply rust preventive on this surface! 3.
Page 355 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 4. Apply Mercasol 3106 on all machined surfaces and on the radial seals underneath the cable guide. xx0700000465 • A: Machined surfaces DANGER! Make sure all safety requirements are met when performing the first test run.
Page 356: Replacement Gearbox Axis 2
4 Repair 4.7.2. Replacement gearbox axis 2 4.7.2. Replacement gearbox axis 2 Location of gearbox axis 2 The gearbox axis 2 is located in the lower arm rotational center. xx0700000357 Attachment screws, M16x60 quality Gleitmo (12 pcs) Attachment screws, M12x80 quality Gleitmo (16 pcs) Gearbox, axis 2 Motor, axis 2 Required equipment...
Page 357 4 Repair 4.7.2. Replacement gearbox axis 2 Continued Spare part Equipment, etc Art. no. Note Other tools and These procedures include procedures may be references to the tools required. See required. references to these procedures in the step- by-step instructions below.
Page 358 4 Repair 4.7.2. Replacement gearbox axis 2 Continued Action Note 5. Fit the lifting tool on the upper and lower arms as shown in the figure to the right. Secure the robot in an overhead crane. xx0700000350 Parts: • A: Lifting eye (on armhouse) •...
Page 359 4 Repair 4.7.2. Replacement gearbox axis 2 Continued Action Note CAUTION! The gearbox weighs 98 kg! All lifting equipment used must be sized accordingly! 14. Fit the lifting tool for lifting the gearbox, in the Art. no. is specified in Required uppermost hole and secure it with a roundsling.
Page 360 4 Repair 4.7.2. Replacement gearbox axis 2 Continued Action Note CAUTION! The upper and lower arms (incl. gearboxes axes 2 and 3) weighs 455 kg. All lifting equipment used must be sized accordingly! 8. Fit the lifting tool on the upper and lower arms and secure the robot in an overhead crane.
Page 361 4 Repair 4.7.2. Replacement gearbox axis 2 Continued Action Note 14. Recalibrate the robot. Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration infor- mation. DANGER! Make sure all safety requirements are met when performing the first test run.
Page 362 4 Repair 4.7.2. Replacement gearbox axis 2 Continued Action Note 3. Apply Mercasol 3106 on the gear according to the illustration to the right before assembly. xx0600003134 • A: Mercasol 3106 on surfaces 4. Apply Mercasol 3106 on the outer edge around the machined surface where the gear is fitted.
Page 363: Replacement Of Gearbox, Axis 3
4 Repair 4.7.3. Replacement of gearbox, axis 3 4.7.3. Replacement of gearbox, axis 3 Location of gearbox The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
Page 364 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Equipment, etc. Spare part no. Art. no. Note Grease 3HAB3537-1 For lubricating the o-rings. Brush Option Foundry Prime Rust preventive 3HAC026621-001 Option Foundry Prime Equivalent: • Mercasol 3106 Sealing, axis 2/3 3HAC17212-1 A new sealing must be used on each assembly!
Page 365 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note 2. Secure the upper arm in a horizontal position Art. no. is specified in Required using a mechanical stop. equipment on page 361. Fit the mechanical stop to the third and final attachment hole, below the fixed mechanical stop in the upper arm, shown in the figure to the right.
Page 366 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note 9. Fit the lifting eye to the gearbox, in one of the Art. no. is specified in Required attachment screw holes that attaches the gearbox equipment on page 361. to the lower arm (position C in the figure to the right).
Page 367 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note CAUTION! The gearbox weighs 60 kg! All lifting equipment used must be sized accordingly! 5. Fit the lifting eye to the gearbox. Art. no. is specified in Required equipment on page 361.
Page 368 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note 15. Recalibrate the robot! Calibration is detailed in a separate calibration manual, enclosed with the calibration tools. General calibration information is included in section Calibration infor- mation. DANGER! Make sure all safety requirements are met when performing the first test run.
Page 369 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action 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 3HAC026876-001 Revision: C...
Page 370: Replacement Of Gearbox, Axis 6
4 Repair 4.7.4. Replacement of gearbox, axis 6 4.7.4. Replacement of gearbox, axis 6 Location of gearbox The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. xx0200000219 Gearbox, axis 6 Attachment screws and washers, gearbox (18 pcs) Oil plug, draining Oil plug, filling...
Page 371 4 Repair 4.7.4. Replacement of gearbox, axis 6 Continued Attachment screws and washers Oil plug, draining Oil plug, filling Required equipment Equipment, etc. Spare part no. Art. no. Note Gearbox 3HAC10828-13 Includes o-ring 3HAB3772- Washers 3HAA1001-172 Not included in gearbox! Replace only when damaged! O-ring 3HAB3772-58...
Page 372 4 Repair 4.7.4. Replacement of gearbox, axis 6 Continued Action Note 5. If required, apply M8 screws to the holes shown in the figure beside to press the gearbox out. xx0200000220 • A: M8 holes for pressing out the gearbox 6.
Page 373 4 Repair 4.7.4. Replacement of gearbox, axis 6 Continued Action Note 2. Make sure the o-ring is fitted to the rear of Art. no. is specified in Required equipment the gearbox. Lubricate the o-ring with on page 369. grease. xx0100000132 •...
Page 374 4 Repair 4.7.4. Replacement of gearbox, axis 6 Continued Action Note 7. If the robot is going to work in a water jet application cell: • apply Mercasol 3106 on unpainted surfaces between gearbox and turning disk • apply Mercasol 3106 on the screw heads in the front of the turning disk.
Page 375: Calibration Information
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 374, and further detailed in separate Calibration manuals.
Page 376: Calibration Methods
5 Calibration information 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 calibra- Description Calibration method tion Standard The calibrated robot is positioned at home...
Page 377 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.
Page 378: Calibration Scales And Correct Axis Position
5 Calibration information 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 scales/marks, IRB 6640 and IRB 6640ID The figure below shows the positions of the calibration marks on the robot.
Page 379: Calibration Movement Directions For All Axes
5 Calibration information 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.
Page 380: Updating Revolution Counters
5 Calibration information 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;...
Page 381 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.
Page 382 5 Calibration information 5.5. Updating revolution counters Continued Action 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 381.
Page 383: Checking The Calibration Position
This section describes how to create a program, which runs all the robot axes to their zero position. Action Note 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...
Page 384 5 Calibration information 5.6. Checking the calibration position 3HAC026876-001 Revision: C...
Page 385: Decommissioning
6 Decommissioning 6.1. Introduction 6 Decommissioning 6.1. Introduction Introduction This section contains information to consider when taking a product, robot or controller, out of operation. It deals with how to handle potentially dangerous components and potentially hazardous manterials. General All used grease/oils and dead batteries must be disposed of in accordance with the current legislation of the country in which the robot and the control unit is installed.
Page 386: Environmental Information
6 Decommissioning 6.2. Environmental information 6.2. Environmental information Hazardous material The table specifies some of the materials in the robot and their respective use throughout the product. Dispose the components properly to prevent health or environmental hazards. Material Example application Batteries, NiCad or Lithium Serial measurement board Copper...
Page 387: Decommissioning Of Balancing Device
6 Decommissioning 6.3. Decommissioning of balancing device 6.3. Decommissioning of balancing device General There is much energy stored in the balancing device. Therefore a special procedure is required to dismantle it. The coil springs inside the balancing device exert a potentially lethal force unless dismantled properly.
Page 388 6 Decommissioning 6.3. Decommissioning of balancing device Continued Decommissioning at decommissioning company, balancing device The instruction below details how to decommission the balancing device. Contact ABB Robotics for further consultation. Action Note DANGER! There is stored energy built up by high...
Page 389: Reference Information
7 Reference information 7.1. Introduction 7 Reference information 7.1. Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. 3HAC026876-001 Revision: C...
Page 390: Applicable Safety Standards
7 Reference information 7.2. Applicable Safety Standards 7.2. Applicable Safety Standards Standards, general The robot is designed in accordance with the requirements of: • EN ISO 10218-1: 2006 Robots for industrial environments - Safety requirements - Part 1 Robot. • EN 292-1 - Basic terminology.
Page 391: Unit Conversion
7 Reference information 7.3. Unit conversion 7.3. Unit conversion Converter table Use the table below to convert units used in this manual. Quantity Units Length 3.28 ft 39.37 in Weight 1 kg 2.21 lb Pressure 1 bar 100 kPa 14.5 psi Force 0.738 lbf Moment...
Page 392: Screw Joints
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.
Page 393 7 Reference information 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 descriptions.
Page 394 7 Reference information 7.4. Screw joints Continued Tightening torque (Nm) Tightening torque (Nm) Dimension Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass. Tightening torque Tightening torque Tightening torque...
Page 395: Weight Specifications
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.
Page 396: Standard Toolkit
7 Reference information 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.
Page 397: Special Tools
7 Reference information 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 394, and of special tools, listed directly in the instructions and also gathered in this section.
Page 398 7 Reference information 7.7. Special tools Continued Description Art. no. Guide pins, sealing ax 2/3, 100mm 3HAC14628-2 Guide pins, sealing ax 2/3, 80mm 3HAC14628-1 Hydraulic cylinder 3HAC11731-1 Hydraulic pump, 80 MPa 3HAC13086-1 Hydraulic pump, 150 MPa (Glycerin) 3HAC021563-012 Lifting device, base 3HAC15560-1 Lifting device, upper arm 3HAC15994-1...
Page 399 7 Reference information 7.7. Special tools Continued Calibration equipment, Calibration Pendulum The table below specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method. Description Art. no. Note Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating manual.
Page 400: Lifting Equipment And Lifting Instructions
7 Reference information 7.8. Lifting equipment and lifting instructions 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.
Page 401: Spare Part List Irb 6640
8.1. Base frame Spare parts Item Part. Spare part no. Description 3HAC027851-001 Gearbox axis 1 RV 320C - 191.35 (IRB 6640 - 180/2.55, 235/2.55, 185/2.8, 205/2.75, 130/3.2) (IRB 6640ID - 200/2.55, 170/2.75) 3HAC026393-001 Frame 3HAC026771-001 Base 9ADA205-75 Set screw, cup point...
Page 402 8 Spare Part List IRB 6640 8.1. Base frame Continued Illustration xx0700000346 3HAC026876-001 Revision: C...
Page 403: Spare Parts - Balancing Device
8 Spare Part List IRB 6640 8.2. Spare parts - Balancing device 8.2. Spare parts - Balancing device Spare Parts, balancing device 3HAC028470-001 and 3HAC030868-001 Item Part Spare part no. Description 3HAC028470-001 Balancing device, standard 3HAC030868-001 Balancing device, Cleanroom 3HAB3409-84 Hex socket head cap screw 3HAC026582-001 Cradle...
Page 404 8 Spare Part List IRB 6640 8.2. Spare parts - Balancing device Continued Illustration xx0700000341 Continues on next page 3HAC026876-001 Revision: C...
Page 405 8 Spare Part List IRB 6640 8.2. Spare parts - Balancing device Continued Spare Parts, balancing device 3HAC026268-003/3HAC027987-003 Item Part Spare part no. Description 3HAB3409-88 Hex socket head cap screw 3HAA1001-186 Washer 3HAC032228-001 Shaft 9ADA618-54 Torx pan head screw 3HAC031955-001 End cover 3HAB3772-121 O-ring...
Page 406 8 Spare Part List IRB 6640 8.2. Spare parts - Balancing device Continued xx0800000253 3HAC026876-001 Revision: C...
Page 407: Frame To Lower Arm
Part Spare part no. Description 3HAB3772-91 O-ring 3HAC025819-001 Rot. AC motor incl. pinion axis 2, standard (IRB 6640 - 180/2.55, 235/2.55, 185/2.8, 205/2.75, 130/3.2) (IRB 6640ID - 200/2.55, 170/2.75) 3HAC029784-001 Rot. AC motor incl. pinion, axis 2 (Foundry Prime) 3HAC030800-001 Rot.
Page 408 8 Spare Part List IRB 6640 8.3. Frame to lower arm Continued Illustration xx0700000344 3HAC026876-001 Revision: C...
Page 409: Lower Arm To Upper Arm
8.4. Lower arm to upper arm Part list Item Parts Spare part no. Description 3HAC021127-001 RV410F-270,176 assembly Gearbox axis 3 (IRB 6640 - 180/2.55, 235/2.55, 185/2.8, 205/2.75, 130/3.2) (IRB 6640ID - 200/2.55, 170/2.75) 3HAB3409-71 Hex socket head cap screw 3HAA1001-134 Washer 3HAC023627-001 Lower arm, Short...
Page 410 8 Spare Part List IRB 6640 8.4. Lower arm to upper arm Continued Illustration xx0700000377 3HAC026876-001 Revision: C...
Page 411: Upper Arm Including Wrist Unit, Motors Ax. 3- 6 (Irb 6640 And Irb 6640Id)
3HAC026982-001 Rotational AC motor, axis 5 (Fitted inside upper arm tube) (Foundry Prime) 103.4.4 3HAC15990-4 Rotational AC motor M10, axis 6 (Standard, IRB 6640 - 180/2.55) 103.4.4 3HAC030828-001 Rotational AC motor, axis 6 (Cleanroom, IRB 6640 - 180/2.55) 103.4.4 3HAC15991-4 Rotational AC motor M10, axis 6 (Standard, IRB 6640 - 235/2.55, 185/2.8, 205/2.75, 130/3.2)
Page 412 3HAC030825-001 Rot. AC motor incl. pinion, axis 3 (Cleanroom) 102.4 3HAC15887-2 Rot. AC motor incl. pinion, axis 4 (Standard, IRB 6640 - 180/2.55) 102.4 3HAC15889-2 Rot. AC motor incl. pinion, axis 4 (Standard, IRB 6640 - 235/2.55, 185/2.8, 205/2.75, 130/3.2) (IRB 6640ID - 200/2.55, 170/2.75)
Page 413 8 Spare Part List IRB 6640 8.5. Upper arm including wrist unit, motors ax. 3- 6 (IRB 6640 and IRB 6640ID) Continued Illustration xx0700000383 3HAC026876-001 Revision: C...
Page 414: Cable Harness And Smb Unit
8.6. Cable harness and SMB unit Part list Item Part Spare part no. Description 3HAC024385-001 Manipulator harness, axis 1-6 (Standard, IRB 6640 - 180/2.55, 235/ 2.55, 185/2.8) 3HAC024386-001 Manipulator harness, axis 1-6 (Standard, IRB 6640 - 205/2.75, 130/3.2) 3HAC14139-1 Manipulator harness axis 5 (Standard, IRB 6640 - 180/2.55, 235/...
Page 415 8 Spare Part List IRB 6640 8.6. Cable harness and SMB unit Continued Illustrations xx0700000384 3HAC026876-001 Revision: C...
Page 416 8 Spare Part List IRB 6640 8.6. Cable harness and SMB unit 3HAC026876-001 Revision: C...
Page 417: Circuitdiagrams
9 Circuitdiagrams 9.1. Introduction 9 Circuitdiagrams 9.1. Introduction Overview This chapter includes the circuit diagram for the robot. 3HAC026876-001 Revision: C...
Page 418 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.
Page 419: Índice
Table of contents ABB Contents1 Page Page description Comment COPYRIGHT page Table of contents: (1 - 150) Valid For Connection point location IRB 6600 / 6640 / 6650 / 7600 Connection point location IRB 6660 Legend IRB 66XX / 7600...
Page 420 Valid For: This circuit diagram is valid for the following cable harness assemblies: 3HAC 024385-001 Manipulator harness axis 1-6 (IRB 6600 / 6640) 3HAC 024386-001 Manipulator harness axis 1-6 (IRB 6640 / 6650 / 6650S) 3HAC14940-1 rev 3 and later. Manipulator harness axis 1-4 (IRB 6600 ID / 6640 ID / 7600) 3HAC16331-1 rev 1 and later.
Page 421 R3.FB5 (IRB 7600, 6600 ID, 6640 ID, 6650 ID) R3.MP5 (IRB 7600, 6600 ID, 6640 ID, 6650 ID) R1.MP R2.M5/6 R3.MP6 R3.MP5 (IRB 6600, 6640, 6650, 6650S) (On IRB7600, 6600 ID, R3.FB6 R3.FB5 (IRB 6600, 6640, 6650, 6650S) 6640 ID, 6650 ID) R4.MP5 (IRB 6600, 6640, 6650, 6650S) R4.FB5 (IRB 6600, 6640, 6650, 6650S) R2.MP4...
Page 422 R3.MP6 R3.FB6 R3.MP5 R3.FB5 R2.CP/CS R2.MP4 R2.FB4 R2.MP3 R2.FB3 R2.H1 R2.H2 R2.MP2 R2.FB2 R2.MP1 R2.FB1 R1.SMB1-3 R1.SMB4-6 R2.SMB R1.MP R1.SMB R1.CP/CS Lab/Office: Latest revision: Status: Plant: IRB6660 Location: Manipulator APPROVED Connection point location Sublocation: Document no. Rev. Ind Page 5 Next 3HAC025744-001 IRB 6660...
Page 423 Motor Protective Earth Brake Twisted wires Temp sensor (PTC- resistor) Screened wires Resolver Any number i.e. 66XX can be 6600, 6640, 6660 or 6650 Battery Pack Brake Release Unit Feedback unit Serial Measurment Board Position switch Keypin Location pin to avoid mismatch Lab/Office: Latest revision: Status:...
Page 424 BU Brake Release (Simplified) -R1.MP Brake Release -X10 -X10 R1.MP -BU M1 / +Axis 1/30;2 Brake PB Brake Bleed Circuit -BU 0V M1 / +Axis 1/30;2 R1.MP -BU M2 / +Axis 2/40;2 -BU 0V M2 / +Axis 2/40;2 -BU 0V M3 / +Axis 3/50;2 Brake Bleed Circuit -BU 0V M4 / +Axis 4/60;2 R1.MP...
Page 425 +Axis 3/50;3 / -0V EXT.LAMP R1.SMB R2.SMB R2.SMB SDI-N WHBK SDO-N WHBN WHRD KEYPIN +Axis 3/50;3 / -24V EXT.LAMP R2.G R1.G(X3) R1.G(X3) Lab/Office: Latest revision: Status: 2005-10-17 Plant: 66XX/7600 Location: APPROVED Serial Measuring Board Sublocation: Document no. Rev. Ind Page 20 Next 3HAC025744-001 IRB 66XX / 7600...
Page 426 R1.MP -R2.MP1 -R2.MP1 R (U) T (W) S (V) GNYE GNYE GNYE GNYE +BU/10;7 / -BU M1 BU M1 BU + Brake +BU/10;2 / -BU 0V M1 BU 0V M1 BU - -PTC1 PTC M +Axis 2/40;2 / -PTC M2 PTC M2 R1.SMB1-3 R1.SMB1-3...
Page 427 R1.MP -R2.MP2 -R2.MP2 R (U) T (W) S (V) GNYE GNYE GNYE GNYE +BU/10;7 / -BU M2 BU M2 BU + Brake +BU/10;2 / -BU 0V M2 BU 0V M2 BU - -PTC2 +Axis 1/30;2 / -PTC M2 PTC M2 +Axis 3/50;2 / -PTC M3 PTC M3 R1.SMB1-3...
Page 428 R1.MP -R2.MP3 -R2.MP3 R (U) T (W) S (V) GNYE GNYE GNYE GNYE +BU/10;7 / -BU M3 BU M3 BU + Brake +BU/10;2 / -BU 0V M3 BU 0V M3 BU - -PTC3 +Axis 2/40;2 / -PTC M3 PTC M3 +Axis 4/60;2 / -PTC M4 PTC M4 KEYPIN...
Page 429 R1.MP -R2.MP4- -R2.MP4- R (U) T (W) S (V) GNYE GNYE +BU/10;7 / -BU M4 BU M4 BU + Brake +BU/10;2 / -BU 0V M4 BU 0V M4 BU - -PTC4 +Axis 3/50;2 / -PTC M4 PTC M4 =7600+Axis 5/70;2 PTC M5 =66XX+Axis 5/80;2 A Keypin...
Page 430 R1.MP R2.M5/6 -R3.MP5 -R3.MP5- R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M5 BU M5 BU M5 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M5 BU 0V M5 BU 0V M5 BU - -PTC5 =66XX/7600+Axis 4/60;2 / -PTC M5 PTC M5 PTC M5 PTC 0V...
Page 431 R1.MP R3.MP5 -R4.MP5- -R4.MP5- R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M5 BU M5 BU M5 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M5 BU 0V M5 BU 0V M5 BU - -PTC5 =66XX/7600+Axis 4/60;2 / -PTC M5 PTC M5 PTC M5 +Axis 6/110;2 / -PTC M6.1...
Page 432 R1.MP R2.M5/6 -R3.MP5 -R3.MP5- R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M5 BU M5 BU M5 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M5 BU 0V M5 BU 0V M5 BU - -PTC5 =66XX/7600+Axis 4/60;2 / -PTC M5 PTC M5 PTC M5 PTC 0V...
Page 433 R1.MP -R2.M5/6- -R3.MP6 -R3.MP6 R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M6 BU M6 BU M6 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M6 BU 0V M6 BU 0V M6 BU - -PTC6 +Axis 5/70;5 / -PTC M6 PTC M6 +Axis 5/70;3 / -PTC 0V PTC 0V...
Page 434 R1.MP -R3.MP6- -R3.MP6- R (U) T (W) S (V) GNYE GNYE =66XX/7600+BU/10;7 / -BU M6 BU M6 BU + Brake =66XX/7600+BU/10;2 / -BU 0V M6 BU 0V M6 BU - -PTC6 +Axis 5/80;2 / -PTC M6.1 PTC M6 PTC 0V R1.SMB4-6 R1.SMB4-6 -R3.FB6...
Page 435 R1.MP -R2.M5/6- -R3.MP6 -R3.MP6 R (U) T (W) S (V) GNYE GNYE GNYE =66XX/7600+BU/10;7 / -BU M6 BU M6 BU M6 BU + Brake +Axis 5/90;5 / -BU 0V M6.1 BU 0V M6 BU - -PTC6 +Axis 5/90;5 / -PTC M6.2 PTC M6 +Axis 5/90;3 / -PTC 0V.1 PTC 0V...
Page 436 -SW1.1 Power 1.1.1 Location of position switches Power 1.1.2 Signal 1.1.2 Signal 1.1.1 SW1.6 -SW1.2 SW1.5 Power 1.2.1 Power 1.2.2 SW1.4 Signal 1.2.2 SW1.3 Signal 1.2.1 -SW1.3 SW1.2 Power 1.3.1 SW1.1 Power 1.3.2 Signal 1.3.2 Signal 1.3.1 Position switches -SW1.4 Axis 1 Power 1.4.1 Power 1.4.2...
Page 437 Location of position switches -SW2.1 R1.SW2/3 R2.SW2 Power 2.1.1 Power 2.1.1 Power 2.1.2 Power 2.1.2 Signal 2.1.2 Signal 2.1.2 Signal 2.1.1 Signal 2.1.1 -SW2.2 Power 2.2.1 Power 2.2.1 Power 2.2.2 Power 2.2.2 Signal 2.2.2 Signal 2.2.2 Signal 2.2.1 Signal 2.2.1 Position switches -SW2.3 Axis 2...
Page 438 Location of Position switches -SW3.1 R1.SW2/3 R2.SW3 Power 3.1.1 Power 3.1.1 Power 3.1.2 Power 3.1.2 Signal 3.1.2 Signal 3.1.2 Signal 3.1.1 Signal 3.1.1 -SW3.2 Power 3.2.1 Power 3.2.1 Power 3.2.2 Power 3.2.2 Signal 3.2.2 Signal 3.2.2 Signal 3.2.1 Signal 3.2.1 Position switches -SW3.3 Axis 3...
Page 440 Index Absolute Accuracy, calibration 375 installation mechanical stop axis 1 93 mechanical stop axis 2 95 balancing device bearing, replacement 281 mechanical stop axis 3 97 brake release unit, replacement 277 brakes testing function 24 lifting equipment 393 lifting upper arm attachment points for lifting device 260 cable harness axes 1-4, replacement 220 loads on foundation 48...
Page 441 Index wrist unit 252 base plate 63 requirements on foundation 48 complete arm system 237 restricting gearbox 364 working range axis 1 93 lower arm 269 working range axis 2 95 motor 302 working range axis 3 97 upper arm 262 revolution counters wrist unit 254 storing on FlexPendant 379...
Page 443 ABB Robotics S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000 Telefax: +46 (0) 21 132592...

This manual is also suitable for:

Irb 6640 - 235/2.55 Irb 6640 - 185/2.8 Irb 6640 - 205/2.75 Irb 6640id - 200/2.55 Irb 6640 - 130/3.2 Irb 6640id - 170/2.75 ... Show all

ABB IRB 6640 - 180/2.55 Product Manual

1 Safety

2 Installation and Commissioning

3 Maintenance

4 Repair

5 Calibration Information

6 Decommissioning

7 Reference Information

8 Spare Part List IRB 6640

9 Circuitdiagrams

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