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ABB IRB 6640, Product Manual

The ABB IRB 6640, a powerful industrial robot designed for efficiency and precision, comes with a comprehensive product manual. This manual is available for free download on our website, allowing users to access valuable information and instructions to maximize the performance of their robot.

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Table of Contents

3

3HAC026876-001  Revision: F     

© Copyri

ght 

200

7-2010 ABB.

 All rights reserved.

Overview of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1 Safety

15

1.1 Introduction to safety information  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.2.1 Safety in the manipulator system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

1.2.2 Safety risks  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.2.2.1 Safety risks during installation and service work on manipulators. . . . . . . . . . . . . . . . . . 17
1.2.2.2 CAUTION - Hot parts may cause burns! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.2.3 Safety risks related to tools/workpieces  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.2.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.2.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.2.6 Risks associated with live electric parts  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

1.2.3 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.3.3 Emergency release of the manipulator’s arm  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s"  . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2.3.6 Safe use of the FlexPendant  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  . 29
1.2.3.7 Work inside the manipulator's working range  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2.3.8 Signal lamp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

1.2.4 Safety stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.2.4.1 What is an emergency stop? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

1.3 Safety related instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.3.1 Safety signals in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3.2 Safety symbols on the manipulator labels  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3.3 DANGER - Moving manipulators are potentially lethal!  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3.4 DANGER - First test run may cause injury or damage!  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.3.5 WARNING - The brake release buttons may be jammed after service work  . . . . . . . . . . . . . . . . 42
1.3.6 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
1.3.7 WARNING - Safety risks during work with gearbox lubricants (oil or grease) . . . . . . . . . . . . . . 44

2 Installation and commissioning

47

2.1 Introduction  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2 Design 1 and Design 2 of IRB 6640. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3 Robot transportation precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.4 Securing the robot  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

2.5 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

2.5.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.5.2 Working range and type of motion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.5.3 Risk of tipping/stability  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

2.6 On-site installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

2.6.1 Lifting the robot with fork lift  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.6.2 Lifting robot with roundslings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.6.3 Manually releasing the brakes  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.6.4 Lifting the base plate  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.6.5 Securing the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.6.6 Orienting and securing the robot  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.6.7 Fitting equipment on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.6.8 Installation of cooling fan for motors, axes 1 and 2 (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.6.9 Installation of Foundry Plus Cable guard (option no. 908-1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Summary of Contents for IRB 6640

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 2: ......

Page 3: ... 2010 ABB All rights reserved 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 F ...

Page 4: ...sons 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 manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose Contravent...

Page 5: ...onal 31 1 2 4 Safety stops 32 1 2 4 1 What is an emergency stop 32 1 3 Safety related instructions 34 1 3 1 Safety signals in the manual 34 1 3 2 Safety symbols on the manipulator labels 36 1 3 3 DANGER Moving manipulators are potentially lethal 40 1 3 4 DANGER First test run may cause injury or damage 41 1 3 5 WARNING The brake release buttons may be jammed after service work 42 1 3 6 WARNING The...

Page 6: ... 124 3 3 3 Inspection oil level gearbox axis 3 126 3 3 4 Inspection oil level gearbox axis 4 128 3 3 5 Inspection oil level gearbox axis 5 130 3 3 6 Inspection oil level gearbox axis 6 132 3 3 7 Inspection balancing device 137 3 3 8 Inspection cable harness 142 3 3 9 Inspection of air hoses Foundry Prime 147 3 3 10 Inspection of surface treatment Foundry Prime 148 3 3 11 Inspection information lab...

Page 7: ...release unit 288 4 5 3 Replacement of spherical roller bearing balancing device 292 4 5 4 Replacement of balancing device design 1 297 4 5 5 Replacement of balancing device design 2 306 4 5 6 Unloading the balancing device using distance tool 317 4 5 7 Restoring the balancing device using distance tool 320 4 5 8 Unloading the balancing device using hydraulic press tool 322 4 5 9 Restoring the bala...

Page 8: ...ce information 401 7 1 Introduction 401 7 2 Applicable safety standards 402 7 3 Unit conversion 404 7 4 Screw joints 405 7 5 Weight specifications 408 7 6 Standard toolkit 409 7 7 Special tools 410 7 8 Dismounting and mounting tool 3HAC028920 001 413 7 9 Lifting equipment and lifting instructions 428 8 Spare parts 429 8 1 Spare parts and exploded views 429 9 Circuit diagrams 431 9 1 About circuit ...

Page 9: ...al installation repair maintenance work Organization of chapters The manual is organized in the following chapters Chapter Contents Safety Safety information that must be read through before performing any installation or service work on the robot Contains general safety aspects as well as more specific information on how to avoid personal injuries and damage to the product Installation and commis...

Page 10: ... Operating manual Calibration Pendulum 3HAC16578 1 Operating manual Service Information System 3HAC025709 001 Application manual Additional axes and stand alone controller 3HAC021395 001 Technical reference manual System parameters 3HAC17076 1 Application manual Electronic Position Switches 3HAC027709 001 Application manual CalibWare Field 5 0 3HAC030421 001 Reference Document ID Replacement gearb...

Page 11: ...dule in chapter Maintenance Intervals for inspection activities and oilchanges has been revised Section Maintenance schedule in chapter Maintenance Overhaul of robot is new Section Maintenance schedule in chapter Maintenance The information about Service Information System SIS has been updated Section Maintenance schedule in chapter Maintenance Interval for replacement of battery pack changed Sect...

Page 12: ...tion Working range and type of motion on page 60 Lifting equipment and tools for the robot throughout the manual updated Section Fitting cable package attachments Cleanroom moved from Installation chapter to Repair chapter Wrist type 1 added throughout the manual where it has been missing Updates in section Maintenance schedule on page 115 Interval updated for inspection of balancing device Foundr...

Page 13: ...e numbers for documentation referred to in Product manual procedures lists of tools safety standards Parts list Foldouts or exploded views Circuit diagrams or references to circuit diagrams Technical reference manuals The technical reference manuals describe the manipulator software in general and contain relevant reference information RAPID Overview An overview of the RAPID programming language R...

Page 14: ...manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and trouble shooters The group of manuals includes Emergency safety information General safety information Getting started IRC5 and RobotStudio IRC5 with FlexPendant RobotStudio Introduction to RAPID Trouble shooting for the controller and manipulator Continued ...

Page 15: ...e references to equipment spare parts tools etc required for the different actions in the procedure The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information that is article number and dimensions The designation in the procedure for the component or attachment point corresponds to the designation ...

Page 16: ...How to read the product manual 3HAC026876 001 Revision F 14 Copyright 2007 2010 ABB All rights reserved ...

Page 17: ... 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 General safety information on page 16 Specific safety information pointed out in the procedures How to avoid and eliminate the danger is either described directly in the procedure or in specific instructions in the section Safety r...

Page 18: ...he operation and handling of the industrial manipulator as described in the applicable documents for example Operating manual IRC5 with FlexPendant Product manual Connection of external safety devices Apart from the built in safety functions the manipulator is also supplied with an interface for the connection of external safety devices Via this interface an external safety function can interact w...

Page 19: ...fore admittance must be set up in front of the manipulator s working space Light beams or sensitive mats are suitable devices Turntables or the like should be used to keep the operator out of the manipulator s working space The axes are affected by the force of gravity when the brakes are released In addition to the risk of being hit by moving manipulator parts there is a risk of being crushed by ...

Page 20: ...hat the manipulator does not collapse as parts are removed e g secure the lower arm with fixtures if removing motor axis 2 Safety risk Description Cable packs are sensitive to mechanical damage CAUTION The cable packs are sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging them Safety risk Description Gears may be damaged if excessive ...

Page 21: ...s also become hot Touching these may cause burns of various severity Because of a higher environment temperature more surfaces on the manipulator get hot and may result in burns Elimination The instructions below detail how to avoid the dangers specified above Action Info 1 Always use your hand at some distance to feel if heat is radiating from the potentially hot component before actually touchin...

Page 22: ...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 Safe design Grippers end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance to the controller CAUTION Ensure that a gripper is prevented from dropping a workpie...

Page 23: ... to pneumatic and hydraulic systems Residual energy Residual energy can be present in these systems After shutdown particular care must be taken The pressure in pneumatic and hydraulic systems must be released before starting to repair them Safe design Gravity may cause any parts or objects held by these systems to drop Dump valves should be used in case of emergency Shot bolts should be used to p...

Page 24: ...carried out professionally and in accordance with the applicable safety regulations Care must be taken at all times Qualified personnel Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts Extraordinary risks If the working process is interrupted extra care must be taken...

Page 25: ...external source The mains supply mains switch The transformers The power unit The control power supply 230 VAC The rectifier unit 400 480 VAC and 700 VDC Note Capacitors The drive unit 700 VDC The drive system power supply 230 VAC The service outlets 115 230 VAC The customer power supply 230 VAC The power supply unit for additional tools or special power supply units for the machining process The ...

Page 26: ...he fence or enclosure to enable it to withstand the force created if the load being handled by the manipulator is dropped or released at maximum speed Determine the maximum speed from the maximum velocities of the manipulator axes and from the position at which the manipulator is working in the work cell see the section Robot motion in the Product specification Also consider the maximum possible i...

Page 27: ...nguishing 25 3HAC026876 001 Revision F Copyright 2007 2010 ABB All rights reserved 1 2 3 2 Fire extinguishing NOTE Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator system manipulator or controller ...

Page 28: ...anually by pushing the brake release buttons on the manipulator How to release the brakes is detailed in the section Manually releasing the brakes on page 71 The manipulator arm may be moved manually on smaller manipulator models but larger models may require using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the arms does not inc...

Page 29: ... function How to test The function of the holding brake of each axis motor may be checked as detailed below 1 Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized max static load 2 Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller 3 Check that the axis maintains its position If the manipulato...

Page 30: ...01 Revision F 28 Copyright 2007 2010 ABB All rights reserved 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 ...

Page 31: ... her when entering the manipulator s working space This is to prevent anyone else taking control of the manipulator without the programmer s knowledge Enabling device The enabling device is a manually operated constant pressure push button which when continuously activated in one position only allows potentially hazardous functions but does not initiate them In any other position hazardous functio...

Page 32: ...ced speed This should be the normal position when entering the working space The position Manual mode with full speed 100 may only be used by trained personnel who are aware of the risks that this entails Pay attention to the rotating axes of the manipulator Keep a distance to the axes in order not to get entangled with hair or clothing Also be aware of any danger that may be caused by rotating to...

Page 33: ...d 1 2 3 8 Signal lamp optional Description A signal lamp with a yellow fixed light can be mounted on the manipulator 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 product manual for the controller ...

Page 34: ...tions with power available to the motors so that the manipulator path can be maintained When completed power is disconnected The default setting is uncontrolled stop However controlled stops are preferred since they minimize extra unnecessary wear on the manipulator and the actions needed to return the manipulator system back to production Please consult your plant or cell documentation to see how...

Page 35: ...ency stop devices that can be operated in order to achieve an emergency stop There are emergency stop buttons available on the FlexPendant and on the controller cabinet on the Control Module on a Dual Cabinet Controller There can also be other types of emergency stops on your manipulator Consult your plant or cell documentation to see how your manipulator system is configured Continued ...

Page 36: ...o danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc warning WARNING Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact wi...

Page 37: ...rostatic discharge ESD ELECTROSTATIC DISCHARGE ESD Warns for electrostatic hazards which could result in severe damage to the product Note NOTE Describes important facts and conditions Tip TIP Describes where to find additional information or how to do an operation in an easier way Symbol Designation Significance Continued ...

Page 38: ... 36 The information labels can contain information in text English German and French Symbols on safety labels Symbol Description xx0900000812 Warning Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical ...

Page 39: ...antle Dismantling this part can cause injury xx0900000814 Extended rotation This axis has extended rotation working area compared to standard xx0900000808 Brake release Pressing this button will release the brakes This means that the manipulator arm can fall down xx0900000810 Tip risk when loosening bolts The manipulator can tip over if the bolts are not securely fastened xx0900000817 Crush Risk f...

Page 40: ...0900000818 Heat Risk of heat that can cause burns xx0900000819 Moving robot The robot can move unexpectedly xx0900000820 Brake release buttons xx0900000821 Lifting bolt xx0900000822 Lifting of robot xx0900000823 Oil Can be used in combination with prohibition if oil is not allowed Symbol Description Continued Continues on next page ...

Page 41: ...anical stop xx0900000825 Stored energy Warns that this part contains stored energy Used in combination with Do not dismantle symbol xx0900000826 Pressure Warns that this part is pressurized Usually contains additional text with the pressure level xx0900000827 Shut off with handle Use the power switch on the controller Symbol Description Continued ...

Page 42: ...or Elimination Action Note 1 Before attempting to run the manipulator make sure all emergency stop equipment is correctly installed and connected Emergency stop equipment such as gates tread mats light curtains etc 2 Usually the hold to run function is active only in manual full speed mode To increase safety it is also possible to activate hold to run for manual reduced speed with a system paramet...

Page 43: ...he procedure below when performing the first test run after a service activity such as repair installation or maintenance Collision risks CAUTION When programming the movements of the manipulator always check potential collision risks before the first test run Action 1 Remove all service tools and foreign objects from the robot and its working area 2 Install all safety equipment properly 3 Make su...

Page 44: ...If the power is turned on while a brake release button is jammed in depressed position the affected motor brake is released This may cause serious personal injuries and damage to the manipulator Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action 1 Make sure the power is turned off 2 Remove the push button guard if neces...

Page 45: ...y transfer high static charges This discharge may destroy sensitive electronics Elimination Location of wrist strap button The location of the wrist strap button is shown in the following illustration IRC5 The wrist strap button is located in the top right corner xx0500002171 Action Note 1 Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operatin...

Page 46: ...that protective gear like goggles and gloves are always worn Possible pressure build up in gearbox When opening the oil or grease plug there may be pressure present in the gearbox causing lubricant to spray from the opening Open the plug carefully and keep away from the opening Do not overfill the gearbox when filling Do not overfill Overfilling of gearbox lubricant can lead to internal over press...

Page 47: ...cified amount depends on drained volume The specified amount of oil or grease is based on the total volume of the gearbox When changing the lubricant the amount refilled may differ from the specified amount depending on how much has previously been drained from the gearbox After refilling check the lubricant level Warning Description Elimination Action Continued ...

Page 48: ...1 Safety 1 3 7 WARNING Safety risks during work with gearbox lubricants oil or grease 3HAC026876 001 Revision F 46 Copyright 2007 2010 ABB All rights reserved ...

Page 49: ...ment Safety information Before any installation work is commenced it is extremely important that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 15 before performing any installation work NOTE If the robo...

Page 50: ...hts reserved 2 2 Design 1 and Design 2 of IRB 6640 Differences in design There are some differences in the two designs of the robot IRB 6640 design 1 has one ear on the lower arm as shown in the figure for design 1 Design 2 has two ears on the lower arm as shown in the figure for design 2 Design 1 xx0800000401 Design 2 xx0800000402 ...

Page 51: ... 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 xx0800000030 Always follow these instructions when transporting an ABB robot according to method 1 Always remov...

Page 52: ...o method 2 Always read and follow the instructions in section Securing the robot on page 56 Always place the robot in the ABB recommended transport position for robot with tool detailed in sub section Transport position with a transport support on page 52 Always use the recommended transport support detailed in sub section Recommended transport support on page 54 IRB7600 IRB66XX xx0800000037 A Tra...

Page 53: ...rtation precautions 51 3HAC026876 001 Revision F Copyright 2007 2010 ABB All rights reserved IRB6620 Foundry Plus xx0800000036 A Transport Support B Hexagon socket head cap screw M10x50 C Threaded bar M10x280 D Nut M10 Continued Continues on next page ...

Page 54: ...cautions 3HAC026876 001 Revision F 52 Copyright 2007 2010 ABB All rights reserved Transport position with a transport support All transportation of the robot with tool must follow these instructions IRB 7600 IRB 66XX xx0800000040 Continued Continues on next page ...

Page 55: ...stallation and commissioning 2 3 Robot transportation precautions 53 3HAC026876 001 Revision F Copyright 2007 2010 ABB All rights reserved IRB 6620 Foundy Plus xx0800000041 Continued Continues on next page ...

Page 56: ...precautions 3HAC026876 001 Revision F 54 Copyright 2007 2010 ABB All rights reserved Recommended transport support Always use the recommended transport support when transporting a robot with tool IRB 7600 IRB 66XX xx0800000039 Continued Continues on next page ...

Page 57: ...2 Installation and commissioning 2 3 Robot transportation precautions 55 3HAC026876 001 Revision F Copyright 2007 2010 ABB All rights reserved IRB 6620 xx0800000038 Continued ...

Page 58: ...ng 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 Securing the robot xx0800000062 Action Note 1 Mount the transport support s lower end to the robot using the recommended screw joint A in figure Do not tighten the screw See attachment point for the specific robot in the section Transport position with a ...

Page 59: ...resting position on the transport support see the section Manually releasing the brakes on page 71 See attachment point for the specific robot in the section Transport position with a transport support on page 52 4 Tighten all the attachment screws A and B in the figure with the brake release for axis 3 still activated starting with the lower attachment screw CAUTION Do not attempt to tighten any ...

Page 60: ... Make sure the lifting device used is suitable to handle the weight of the robot as specified in Weight robot on page 58 4 If the robot is not installed directly it must be stored as described in Storage conditions robot on page 59 5 Make sure the expected operating environment of the robot conforms to the specifica tions as described in Operating conditions robot on page 59 6 Before taking the ro...

Page 61: ...ions robot The table below shows the allowed operating conditions for the robot Protection classes robot The table below shows the protection class of the robot Force Endurance load operation Max load emergency stop Force xy 8 5 kN 20 4 kN Force z 15 0 9 0 kN 15 0 20 0 kN Torque xy 20 1 kNm 45 2 kNm Torque z 5 1 kNm 10 6 kNm Requirement Value Note Min levelity 0 5 mm Max tilt 5 The limit for the m...

Page 62: ...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 xx0600003396 Robot model A B C D E F IRB 6640 2 55 3015 mm 286 mm 2550 mm 903 mm 1119 mm 1814 mm IRB 6640 2 75 3219 mm 268 mm 2755 mm 961 mm 1252 mm 1999 mm IRB 6640 2 8 3261 mm 533 mm 2800 mm 1004 mm 1324 mm 2061 mm ...

Page 63: ...640 2 55 2550 mm IRB 6640 2 75 2755 mm IRB 6640 2 8 2800 mm IRB 6640 3 2 3200 mm IRB 6640ID 2 55 2550 mm IRB 6640ID 2 75 2755 mm Axis Type of motion Range of movement Note 1 Rotation motion 170 to 170 Movement range can be set to 220º to 220º option 561 1 2 Arm motion 85º to 65º 3 Arm motion 70º to 180º 4 Wrist motion 300º to 300º IRB 6640ID the range of movement is the combined value for axis 4 a...

Page 64: ...imitations of the range of movement with a DressPack SpotPack application fitted to the robot See product manual SpotPack DressPack IRB 6640 chapter Installation section DressPack cable package Art no can be found in section Overview of this manual on page 7 6 Turn motion IRB 6640 360º to 360º default 96 revolutions IRB 6640ID 300º to 300º 300º max 1 Axis Type of motion Range of movement Note Cont...

Page 65: ...nd 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 Do not change the robot position before securing it to the foundation Stabililty The figure below shows the robot in its shipping position which also is its most stable position xx0600003400 WARNING The robot is likely to be mechanically unst...

Page 66: ...at 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 xx0600002910 Required equipment A Fork lift pocket B Attachment screw M20x60 quality 8 8 2 pcs x 4 Equipment Art no Note Fork lift device set 3HAC025040 003 Standard toolkit The content is defi...

Page 67: ...ustration below shows the position of the robot when lifting it with a fork lift xx0600003401 Action Note 1 Move the robot to the position as shown in the figure above NOTE No load is permitted on the robot Release the brakes if required as detailed in the section Manually releasing the brakes on page 71 2 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot Fo...

Page 68: ...are always used or replacements of equivalent quality M20x60 quality 8 8 Attachment points on the robot are shown in the figure below xx0600002927 A Attachment holes for fork lift 4 NOTE For Cleanroom robots protective plates are applied between the fork lifting pocket and the robot base in order to prevent from particle emission when lifting xx0800000042 Parts A Fork lifting pocket B Protective p...

Page 69: ...ng torque 300 Nm 6 Insert the fork lift forks into the pockets 7 CAUTION The robot weighs up to 1450 kg depending on variant See lifting instruction for details All lifting equipment used must be sized accordingly NOTE When the robot is equipped with forklift pockets an extra weight of 90 kg must be added 8 Carefully lift the robot and move it to its installation site NOTE Move the robot with low ...

Page 70: ...bel attached to the robot s lower arm Attachment points The figure below shows how to attach the roundslings to the robot xx0600003455 IRB 6640 standard Lifting instruction 3HAC027647 001 A Roundsling robot 2 5 m 4 pcs Capacity 2 000 kg B Roundsling upper arm 2 m Note Make a loop around the upper arm and wrap the roundsling twice around the upper arm Do not stretch C Lifting eye M20 4 pcs Note Fit...

Page 71: ...aged B Roundsling upper arm 2 m NOTE Make a loop around the upper arm and wrap the roundsling twice around the upper arm Do not stretch C Lifting eye M20 4 pcs NOTE Fit lifting eyes in the rear holes D Positions for cellular plastic NOTE Do not lift without See procedure below for more specific information where to apply the cellular plastic Sling type Qty Lifting capacity Length Note Roundsling r...

Page 72: ...mission 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 Put the 20 mm cellular plastic sheet as extra protection in the following places Around the upper arm Lower arm Balancing device Around motor axis 2 Not shown in figure xx0800000060 Protective cellular plastic sheets at A Upper arm B Lower ...

Page 73: ...on Note 1 The internal brake release unit is located on the frame beside motor axis 1 The internal brake release unit is equipped with six buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes If the robot is not connected to the controller power must be supplied to the connector R1 MP according to the section Supplying power to connector R1 MP on pa...

Page 74: ... connector R1 MP If the robot is not connected to the controller power must be supplied to connector R1 MP on the robot in order to enable the brake release buttons Action Note 1 DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 2 Supply 0V on pin 12 and 24V on pin 11 xx0600002937 Continued ...

Page 75: ...Lifting base plate Equipment Art no Note Lifting eye M16 3HAC14457 4 3 pcs Lifting slings 3 pcs Length approx 2 m A Attachment holes for lifting eyes x3 Action Note 1 CAUTION The base plate weighs 353 kg All lifting equipment used must be sized accordingly 2 Fit the lifting eyes in the specified holes Shown in the figure Hole con figuration on page 73 3 Fit the lifting slings to the eyes and to th...

Page 76: ...ecuring the base plate 3HAC026876 001 Revision F 74 Copyright 2007 2010 ABB All rights reserved 2 6 5 Securing the base plate General This section details how to secure the base plate Base plate dimensions xx0100000105 Continues on next page ...

Page 77: ...on and commissioning 2 6 5 Securing the base plate 75 3HAC026876 001 Revision F Copyright 2007 2010 ABB All rights reserved xx0400000715 A Four holes for alternative clamping 4x Ø18 Continued Continues on next page ...

Page 78: ...attachment holes 4 pcs Equipment Art no Note Base plate 3HAC12937 9 Includes guide sleeves 3HAC12937 3 levelling screws 9ADA120 79 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 the section Standard toolkit on page 409 Other tools and procedures may be required See...

Page 79: ...tion to the robot work location using the three grooves in the base plate Shown in the figure Base plate grooves and holes on page 76 4 Lift the base plate to its mounting position Detailed in section Lifting the base plate on page 73 5 Use the base plate as a template and drill 16 attachment holes as required by the selected bolt dimension If possible observe the recommenda tions specified in sec...

Page 80: ...te The illustration below shows the robot base fitted to the base plate xx0600002933 Attachment screws The table below specifies the type of securing screws and washers to be used for securing the robot to the base plate foundation A Robot attachment bolts and washers 8 pcs M24 x 100 B Orienting grooves in the robot base and in the base plate C Levelling screws Note Remove before the robot base is...

Page 81: ...ion 3 Fit two guide sleeves to the guide sleeve holes in the base plate NOTE One of the guide sleeve holes is elongated 4 Guide the robot gently using two M24 screws while lowering it into its mounting position Make sure the robot base is correctly fitted onto the guide sleeves 5 Fit the bolts and washers in the base attachment holes Specified inAttachment screws on page 78 Shown in the figure Ill...

Page 82: ...n F 80 Copyright 2007 2010 ABB All rights reserved 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 Continued ...

Page 83: ...ere may not be any additional equipment fitted to the robot except in the following places turning disk armhouse frame Additional cables from base to upper arm may not be fitted to Cleanroom robots Illustration fitting of extra equipment on lower arm The illustrations below shows the mounting holes available for fitting extra equipment on the lower arm Make sure not to damage the robot cabling on ...

Page 84: ...2445 mm 725 mm 1280 mm IRB 6640 2 8 2240 mm 520 mm 1075 mm IRB 6640 3 2 2445 mm 725 mm 1280 mm IRB 6640ID 2 55 2240 mm 520 mm 1075 mm IRB 6640ID 2 75 2445 mm 725 mm 1280 mm Robot variant A B C 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 13 mm 30 mm IRB 6640ID 2 55 400 mm 13 mm 40 mm IRB 6640ID 2 75 500 mm 13 mm 30 mm Continu...

Page 85: ...w shows the mounting holes available for fitting extra equipment on the upper arm Note Extra equipment may not be fitted on the upper arm of IRB 6640ID and Cleanroom robots xx0600003414 xx1000000158 Robot variant A B IRB 6640 2 55 1142 mm 200 mm IRB 6640 2 75 1142 mm 200 mm IRB 6640 2 8 1392 mm 200 mm IRB 6640 3 2 1592 mm 200 mm IRB 6640ID 1142 mm 290 mm IRB 6640ID 1142 mm 290 mm Continued Continu...

Page 86: ... 3HAC026876 001 Revision F 84 Copyright 2007 2010 ABB All rights reserved Illustration fitting of extra equipment on frame The illustration below shows the mounting holes available for fitting extra equipment on the frame xx0600003416 Continued Continues on next page ...

Page 87: ... ABB All rights reserved Illustration fitting on turning disk The illustration below shows the mounting holes available for fitting equipment on the turning disk There are two different versions of the turning disk as shown in the illustrations below xx0200000397 Turning disk type 1 Continued Continues on next page ...

Page 88: ... Installation and commissioning 2 6 7 Fitting equipment on robot 3HAC026876 001 Revision F 86 Copyright 2007 2010 ABB All rights reserved xx0200000197 Turning disk type 2 Continued Continues on next page ...

Page 89: ...opyright 2007 2010 ABB All rights reserved xx0500001580 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 Turning disk unit for robot versionIRB 6640ID Continued ...

Page 90: ... 2 However cooling fans for axes 1 and 2 can not be combined The cabling for the fans is available as separate cabling for axis 1 or 2 including only connections for the cooling fans on axes 1 or 2 Installation of this cabling is detailed in section Installation separate fan cabling axis 1 or 2 on page 92 Location of cooling fans The fans are installed on the motors axes 1 2 as shown in the figure...

Page 91: ... rights reserved Cooling fan The details of the cooling fan are shown in the figure below xx0500002158 xx0900000137 A Fanbox B Attachment screws fanbox plates 9 pcs C Groove in the connector D Tightening screws fanbox 3 pcs A Fanbox B Groove in the connector C Back plate D Part of the fanbox that can be removed if needed Continued Continues on next page ...

Page 92: ...own in the figure Plate for customer connections at base on page 91 Additional cabling to and inside the controller Material set fan axes 1 and 2 3HAC023999 001 The set includes fan axes 1 2 cable harness plate customer attachment screws and nuts Cable harness inside controller 3HAC025488 001 Locking liquid Loctite 243 Used for the three tightening screws Standard toolkit The content is defined in...

Page 93: ...tic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Prepare the fanbox for installation disassemble the two parts of the box by removing the nine attachment screws loosen the three tightening screws to avoid damaging the surfaces of the motor when fitting the fanbox turn the connector to the correct position axis 1 groove pointing inward...

Page 94: ...sing locking liquid Tighten them properly so that the box is firmly attached to the motor 6 Install the cabling and make adjustments in RobotWare as described in the following procedures Action Note A Cable bracket B Connector R1 SW2 3 connected to the robot base C Connector R3 FAN2 connected to the fan of axis 1or 2 Action Note 1 Move the robot to its calibration position Shown in section Calibra...

Page 95: ...ect cable run is shown in the figure to the right NOTE There is a risk of the balancing device damaging the cable if it is not protected by the robot cabling xx0500002174 A Cable bracket Also shown in the figure Separate cabling for axis 1 or 2 on page 92 8 Connect the connector R3 FAN2 to the fan of axis 1or 2 NOTE Fans on both axis 1 and 2 can not be used at the same time 9 Connect the connector...

Page 96: ...B All rights reserved Adjustments in RobotWare Action Note 1 Modify the settings in RobotWare to include the cooling fans RobotWare 5 0 change the settings in the Modifying options dialogue by using the Modify Controller System Wizard in the System Builder of RobotStudio Read more about modifying the system in Operating manual RobotStudio Continued ...

Page 97: ...tion of Foundry Plus Cable guard option no 908 1 Introduction How to install the Foundry Plus Cable guard is described in the instruction delivered with the cable guard Separate instructions for IRB 140 1600 6620 6640 6650S 6660 and 7600 are available in English German French Spanish and Italian and can be found on the DVD delivered with the Cable guard article number 3HAC035933 001 ...

Page 98: ...d overloading motors gears and structure CAUTION Incorrectly defined loads may result in operational stops or major damage to the robot References Load diagrams permitted extra loads equipment and their positions are specified in the Product 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...

Page 99: ...t may collide with other objects its working space should be limited The working range of the following axis may be restricted Axis 1 hardware mechanical stop and software Axis 2 hardware mechanical stop and software Axis 3 hardware mechanical stop and software This section describes how to install hardware that restricts the working range Note Adjustments must also be made in the robot configurat...

Page 100: ...15 graduation between 22 5 and 135 in both directions Mechanical stops axis 1 The illustration below shows the mounting position of the stop pin and one of the additional mechanical stops available for axis 1 xx0600002938 Required equipment A Movable mechanical stop B Attachment screw plus washer M12 x 40 quality 12 9 2 pcs C Fixed mechanical stop D Mechanical stop pin axis 1 Equipment etc Art no ...

Page 101: ...not turn off the air pressure to motors and SMB 2 Fit the additional mechanical stop to the frame according to the figure Mechanical stops axis 1 on page 98 Tightening torque 120 Nm 3 NOTE To use the option 561 1 Extended working range axis 1 the software working range limitations must be redefined in the system parameters topic Motion The Arm parameters Upper Joint Boundand Lower Joint Bound must...

Page 102: ...l stops axis 2 The illustration below shows the mounting position of the mechanical stops on axis 2 xx1000000163 The figure shows IRB 7600 but the principle is the same Required equipment A Additional stops axis 2 B Fixed stop axis 2 C Attachment screw washer M16x50 quality 12 9 Equipment etc Art no Note Mechanical stop set axis 2 3HAC020885 001 Includes six stops attachment screws washers and ass...

Page 103: ...essure to motors and SMB 2 Fit and tighten the additional stops in a row starting from the fixed stop Tightening torque 115 Nm Shown in the figure Mechanical stops axis 2 on page 100 3 The software working range limitations must be redefined to correspond to the changes in the mechanical limitations of the working range The system parameters that must be changed Upper joint bound and Lower joint b...

Page 104: ...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 Mechanical stops axis 3 The illustration below shows the mounting position of the mechanical stops on axis 3 xx0300000048 The figure shows IRB 7600 but the principle is the same A Additional mechanical stops B Fixed mechanical stop C Attachment sc...

Page 105: ...chment screw and washer Equipment etc Art no Note Mechanical stop set axis 3 3HAC13128 1 Includes six stops one with 80 restric tion 3HAC12708 3 use when limitation angle 80 and five with 20 3HAC12708 1 attachment screws Standard toolkit The content is defined in the section Standard toolkit on page 409 Technical reference manual System parameters Art no is specified in section References on page ...

Page 106: ...tors and SMB 2 Fit and tighten the additional stops in a row starting from the fixed stop Tightening torque 115 Nm Shown in the figure Mechanical stops axis 3 on page 102 3 NOTE The software working range limitations system parameters must be redefined to correspond to the changes in the mechanical limitations of the working range The system parameters that must be changed Upper joint bound and Lo...

Page 107: ...Specified in the table Robot cables on page 105 Fan cables option Handles supply to and feedback from any cooling fan on the robot Specified in the table Fan cables robot base to control cabinet option on page 106 Customer cables option Handles communication with equipment fitted on the robot by the customer including databus communication low voltage signals and high voltage power supply protecti...

Page 108: ...nside of the cabinet If equipping the robot with cooling fans use the cabling specified below The cables for cooling fans listed below are used together with a distributing cable also specified below Cable Art no Robot cable power 7 m 3HAC11818 1 Robot cable power 15 m 3HAC11818 2 Robot cable power 22 m 3HAC11818 3 Robot cable power 30 m 3HAC11818 4 Cable Art no Robot cable signal shielded 7 m 3HA...

Page 109: ...f robot after it has been switched off When turning off a cleaning cell we recommend that the humid air inside a cell is ventilated out to avoid that the humid air is sucked into gearboxes for example due to the raised vacuum when cooled down Environmental conditions The table below details the environmental conditions Air specification for pressurizing of robot The air must be dry and clean such ...

Page 110: ...lso when it is switch off to avoid that the humid environmental air is sucked into the motors when cooling down 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 Action Note 1 Connect a compressed air...

Page 111: ... Revision F Copyright 2007 2010 ABB All rights reserved Protection points at the wrist joints The illustration below shows points that are particularly sensitive to water spray xx0600002792 A Axis 5 bearing support side B Axis 5 bearing gear side C Axis 6 mounting flange gear house Continued ...

Page 112: ...tors and serial measurement compartment during cooling down of robot after it has been switched off NOTE To reduce the risk for corrosion due to condensation in gearboxes it is recommendable that the robot is running with high speed on each axes at least on one occasion each hour This is to lubricate the gearbox cavities NOTE When turning off a cleaning cell we recommend that the humid air is vent...

Page 113: ...work possible to perform without cracking the paint The robot is painted with four layers of polyurethane paint The last layer being a varnish over labels in order to simlify cleaning Clean room parts being replaced must be replaced with parts designed for use in Clean room environments Clean room class 5 Particle emission from the robot fulfill Clean room class 5 standard according to DIN EN ISO ...

Page 114: ...2 Installation and commissioning 2 10 1 Additional installation procedure Clean room 3HAC026876 001 Revision F 112 Copyright 2007 2010 ABB All rights reserved ...

Page 115: ...s required tools and materials The procedures are gathered in different sections and divided according to the maintenance activity Safety information Before any service work is commenced it is extremely important that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks w...

Page 116: ...working conditions of the manipulator Calendar time specified in months regardless of whether the manipulator system is run or not Operating time specified in operating hours More frequent running of the manipulator means more frequent maintenance activities SIS specified by the robot s SIS Service Information System A typical value is given for a typical work cycle but the value will differ depen...

Page 117: ...ry 12 months 2 Inspection oil level gearbox axis 1 on page 122 Inspection Axis 2 gearbox oil level Every 12 months2 Inspection oil level gearbox axis 2 on page 124 Inspection Axis 3 gearbox oil level Every 12 months2 Inspection oil level gearbox axis 3 on page 126 Inspection Axis 4 gearbox oil level Every 12 months2 Inspection oil level gearbox axis 4 on page 128 Inspection Axis 5 gearbox oil leve...

Page 118: ...urs Following changes Every 24 000 hours Do not mix with other oils Oil change gearbox axis 3 on page 171 Changing Axis 4 gearbox oil Mobilgear 600 XP320 Every 24 000 hours 2 Oil change gearbox axis 4 on page 174 Changing Axis 5 gearbox oil Mobilgear 600 XP320 Every 24 000 hours 2 Oil change gearbox axis 5 on page 177 Changing Axis 6 gear oil Kyodo Yushi TMO 150 First change when DTC 1 reads 6 000...

Page 119: ...ctions 4 Replace when damage or cracks is detected or life limit is approaching as specified in section Expected component life on page 120 5 Always lubricate the front eye bearing after refitting the shaft of the balancing device Activities and intervals optional equipment The table below specifies the required maintenance activities and intervals for common optional equipment The maintenance of ...

Page 120: ...nths Inspection mechanical stop pin axis 1 on page 152 Analysis Oil gearbox axis 6 Every 3 000h or 6 months 2 Inspection oil level gearbox axis 6 on page 132 Changing Axis 1 gearbox oil Kyodo Yushi TMO 150 Every 6 000 hours Oil change gearbox axis 1 on page 165 Changing Axis 2 gearbox oil Kyodo Yushi TMO 150 Every 6 000 hours Oil change gearbox axis 2 on page 168 Changing Axis 3 gearbox oil Kyodo ...

Page 121: ... robot powered off is less than 2 months Typical lifetime of a new battery is 36 months if the robot is powered off 2 days week or 18 months if the robot is powered off 16 hours day The lifetime can be extended approx 3 times for longer production breaks by a battery shutdown service routine See Operating manual IRC5 with FlexPendant for instructions 5 Damage to painted surfaces must be repaired a...

Page 122: ... service of gearbox for the individual robot This applies to gearboxes on axes 1 2 3 and 6 The lifetime of gearbox axes 4 and 5 is not calculated by SIS See the Operating manual Service Information System In some applications such as Foundry or Washing the robot can be exposed to chemicals high temperature or humidity which can have an effect on the lifetime of the gearboxes Contact the local ABB ...

Page 123: ...d to that of standard robots in a typical robotic application See Expected component life on page 120for standard robots Depending on the actual washing application the life of an individual robot can vary or being redused The life of Foundry Prime robots in washing applications will depend on a number of factors The most important factors are the washing detergent used the ambient environment ins...

Page 124: ... in the figure below xx0600003449 Required equipment A Oil plug filling B Oil plug inspection C Oil plug draining Equipment Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 Note Do not mix with other oils Standard toolkit The content is defined in the section Standard toolkit on page 409 Other tools and procedures may be required See references to these procedures in the step by step...

Page 125: ...during work with gearbox lubricants oil or grease on page 44 2 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 Open the filler plug Shown in the figure Location of gearbox on page 122 4 Required oil level max 5 mm below the oil plug hole 5 Add oil if required Art no is specified ...

Page 126: ...ent xx0600003451 Required equipment A Oil plug inspection B Oil plug filling C Oil plug draining Equipment etc Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 Note Do not mix with other oils Standard toolkit The content is defined in the section Standard toolkit on page 409 Other tools and procedures may be required See references to these procedures in the step by step instructions...

Page 127: ...il or grease on page 44 2 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 Open the oil plug filling Shown in the figure Location of gearbox on page 124 4 Measure the oil level at the oil plug filling Required oil level max 5 mm below the oil plug hole Shown in the figure Location...

Page 128: ...elow xx0200000230 Required equipment A Gearbox axis 3 B Oil plug filling C Oil plug draining Equipment etc Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 Note Do not mix with other oils Standard toolkit The content is defined in the section Standard toolkit on page 409 Other tools and procedures may be required See references to these procedures in the step by step instructions bel...

Page 129: ... 2 Move the robot to the calibration position Detailed in the section Calibration scale and correct axis position on page 390 3 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 Open the oil plug filling Shown in the figure Location of gearbox on page 126 5 Required oil level max 5...

Page 130: ...rm as shown in the figure below xx0200000231 Required equipment A Oil plug filling B Oil plug draining Equipment etc Art no Note Lubricating oil 11712016 604 Mobilgear 600 XP320 Standard toolkit The content is defined in the section Standard toolkit on page 409 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures incl...

Page 131: ...4 2 Move the robot to the calibration position Shown in the section Calibration scale and correct axis position on page 390 3 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 Open the oil plug filling Shown in the figure Location of gearbox on page 128 5 Required oil level maximum...

Page 132: ... 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 xx0500002013 A Oil plug filling B Oil plug draining The figure above shows the wrist unit of IRB 6640ID A Wrist unit axis 5 B Oil plug filling C Oil plugs draining Continues on next page ...

Page 133: ...ks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 44 2 Move the robot upper arm to a horizontal position 3 Turn the wrist unit in a way that both oil plugs are facing upwards 4 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not t...

Page 134: ...rights reserved 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 xx0600002964 xx0400001092 A Gearbox axis 6 B Oil plug filling C Oil plug draining A Gearbox axis 6 B Oil plug filling C Oil plug draining Continues on next page ...

Page 135: ...ent The figure above shows the wrist unit of IRB 6640ID A Gearbox axis 6 B Oil plugs draining C Oil plug filling Equipment Art no Note Lubricating oil 3HAC032140 001 Kyodo Yushi TMO 150 Note Do not mix with other oils Lubricating oil IRB 6640ID 11712016 604 Mobilgear 600 XP320 Standard toolkit The content is defined in the section Standard toolkit on page 409 Other tools and procedures may be requ...

Page 136: ...t For Foundry Prime robots Do not turn off the air pressure to motors and SMB 3 Make sure the oil plug filling is facing upwards and open it Shown in the figure Location of gearbox on page 132 4 Turn axis to 85 degrees Oil should now start to run over To much oil will give overrun before 85 degrees to little oil in axis means oil will not spill over until after 85 degrees 5 Add oil if required Art...

Page 137: ...icants oil or grease on page 44 2 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 Make sure the oil plug filling is facing upwards and open it Shown in the figure Location of gearbox on page 132 4 Measure the oil level 55 mm 5 mm 15 mm IRB 6640ID xx0500002222 5 Add oil if require...

Page 138: ...nt there is a risk for corrosion in the gearbox and reduced viscosity in the oil Replacement of gearbox axis 6 is required every two years xx0600003155 A Water content in oil from gearbox axis 6 B Months or hours in operation C Replacement of gearbox axis 6 2 Less than 2 water in oil Normal replacement interval is required for gearbox axis 6 as specified by SIS or typically 96 months as on a stand...

Page 139: ...perform the inspection regarding dissonance damage leakage contamination lack of free space Inspection points balancing device The balancing device is located at the top rear of the frame as shown in the figure below The figure also shows the inspection points further detailed in the instructions xx0600003431 A Balancing device B Piston rod inside balancing device C Fork Link ear D Shaft E Retaini...

Page 140: ...029288 001 For maintenance of balancing device Includes bearing o ring and sealing Rear bearing Design 2 Maintenance parts cradle 3HAC033413 001 For maintenance of balancing device Includes bearing o ring and sealing Rear bearing Securing screw Securing screw in the shaft M16 x 180 Locking liquid must be used when fitting the screw Loctite 243 Toolkit for maintenance 3HAC028920 001 Standard toolki...

Page 141: ...no for the kit and the documentation are specified in section Required equipment on page 138 2 balancing device a tapping sound caused by the springs inside the cylinder replace the balancing device or consult ABB Robotics How to replace the device is detailed in section Replacement of balancing device This section also specifies the spare part number 3 piston rod squeaking may indicate worn plain...

Page 142: ... for leaks as shown and detailed below xx0700000111 A Shaft B Sealing ring radial 2 pcs C O ring D Sealing spacer Action Note 1 Clean the area at the front ear from old grease 2 Run the robot for some minutes in order to move the balancing device piston 3 Check the o rings at the front ear for leakage Replace the o rings if any leaks are detected Excessive grease from between the shaft and the sea...

Page 143: ... robots Do not turn off the air pressure to motors and SMB 4 Check the o rings at the front ear for leakage 5 Replace o rings if leaks are detected The o rings are included in the Maintenance kit bearings and seals already assembled with sealing spacers and sealing rings Art no for the kit is specified in Required equipment on page 138 Replement of the complete bearing is also described in section...

Page 144: ...ction of axes 1 4 is described in Location of cable harness axes 1 4 on page 142 and Inspection cable harness 1 4 on page 144 Inspection of axes 5 6 is described in Location of cabling axes 5 6 on page 145 and Inspection cable harness axes 5 6 on page 146 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 A Low...

Page 145: ...Side bracket balancing cylinder E Gripping clamp 4 pcs Equipment etc Art no Note Standard toolkit The content is defined in the section Standard toolkit on page 409 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include references to the tools required Circuit diagram 3HAC025744 001 See the chapter Circuit diagr...

Page 146: ...Shown in the figure Location of cable harness axes 1 4 on page 142 4 NOTE If the robot is used in a Foundry Prime appli cation check the cables for cracks in insulation 5 Check that velcro straps are properly attached to the side bracket balancing cylinder NOTE For Cleanroom robots check all cable attachments as well as velcro straps Make sure the cable harness is properly attached to the robot an...

Page 147: ...The robot cable harness axes 5 6 is located as shown in the figure below xx0600003435 IRB 6640 standard xx0800000045 IRB 6640 Cleanroom variant A Cable harness axes 5 6 B Cable attachment rear of upper arm C Cable attachment upper arm tube A Gripping clamp B Cable guide C Cover D Connectors at connection plate ax 3 Continued Continues on next page ...

Page 148: ...axis 3 is not bent or in any other way damaged Shown in the figure Location of cabling axes 5 6 on page 145 4 NOTE For Cleanroom robots check all cable attachments as well as velcro straps Also check that the cable harness is fitted correctly at the cable guide on the armhouse Make sure the cable harness is properly attached to the robot and isn t damaged Shown in the figure Location of cabling ax...

Page 149: ...Action Note 1 Apply compressed air to the air connector on robot base and raise the pressure with the knob until the correct value is shown on the pressure gauge Recommended pressure 0 2 0 3 bar xx0600002794 A Air Connection B Cut off valve C Pressure gauge 2 Close the cut off valve It should take at least 5 seconds for the pressure to reach 0 bar 3 The time is 5 seconds If the answer is YES Local...

Page 150: ...soon as possible to avoid corrosion All painted surfaces on the robot must be inspected Required equipment Inspection and repair of surface treatment Use this procedure to inspect the surface treatment on Foundry Prime robots Equipment etc Spare part no Touch up paint Foundry Prime orange 3HAC037052 001 Touch up paint Foundry Prime 2 grey 3HAC035355 001 Action Info 1 Inspect all painted surfaces f...

Page 151: ...nformation labels to be inspected xx0600003457 A Warning label concerning high temperature 4 pcs B Warning sign symbol of flash located on motor cover 5 pcs C Instruction label I Warning label tools are not allowed around the balancing device during operation J Warning label concerning shutting off power M Serial no from rating label Information labels about type of oil at gearboxes and at robot b...

Page 152: ...Warning label concerning stored energy K Abs Acc information sign N Label calibration M Serial no from rating label L UL label Equipment Art no Note Labels and plate set See the chapter Spare parts Includes all labels specified in the two previous figures Label set oil labels See the chapter Spare parts Includes only the oil labels at the gearboxes and at the robot base Are fitted to the robot if ...

Page 153: ...bels Action Note 1 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 2 Check the labels located as shown in the figures 3 Replace any missing or damaged labels Art no is specified in Required equipment on page 150 Continued ...

Page 154: ...of mechanical stop pin The mechanical stop axis 1 is located at the base as shown in the figure below xx0600003436 Required equipment A Mechanical stop pin axis 1 B Fixed mechanical stop Equipment etc Art no Note Mechanical stop pin axis 1 3HAC024014 001 To be replaced when damaged Standard toolkit The content is defined in the section Standard toolkit on page 409 Continues on next page ...

Page 155: ...ric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Inspect the mechanical stop pin axis 1 Shown in the figure Location of mechanical stop pin on page 152 3 If the mechanical stop pin is bent or damaged it must be replaced NOTE The expected life of gearboxes can be reduced as a result of collisions with the ...

Page 156: ...ights reserved 3 3 13 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 A Additional stop axis 1 B Attachment screws and washers 2 pcs C Fixed stop D Mechanical stop pin axis 1 Continues on next page ...

Page 157: ...et 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 Includes Mechanical stop pin Attachment screw and washer Document for mechanical stop pin Mechanical stop set axis 3 3HAC025290 003 Includes Mechanical stop pin Attachment screw and washer Document for mechanical stop pin Standard toolk...

Page 158: ...es to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Check the additional stops on axes 1 2 and 3 for damage Shown in the figure Location of mechanical stops on page 154 3 Make sure the stops are properly attached Correct tightening torque mechanical stop axis 1 120 Nm 4 If any damage is detected the mechanical stops must be replaced Correct attachment scre...

Page 159: ...per must be replaced if damaged A Damper axis 2 2 pcs B Damper axis 3 2 pcs C Damper axis 4 1 pc D Damper axis 5 2 pcs IRB 6640ID 4 pcs Equipment Spare part art no Note Damper axis 2 3HAC12991 1 Damper axis 3 3HAC12320 1 Damper axis 4 3HAC13564 1 Damper axis 5 3HAB4337 2 Damper 1 axis 5 3HAC021325 001 IRB 6640ID 2 pcs Damper 2 axis 5 3HAC021675 001 IRB 6640ID 2 pcs Standard toolkit 3HAC15571 1 The...

Page 160: ...supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Check all dampers for damage and for cracks or existing impressions larger than 1 mm To inspect the damper axis 4 remove the two covers on top of the upper arm Shown in the figure Location of dampers on page 157 3 Check attachment screws for deformation 4 If any damage is detected the damper must be...

Page 161: ...n the current harness for alternative positioning xx0600003071 Required equipment A UL signal lamp B Clamp C Cable strap outdoor D Motor axis 3 E Attachment screw M6x8 quality 8 A2F 2 pcs Equipment etc Art no Note Signal lamp 3HAC10830 1 To be replaced in case of detected damage Standard toolkit The content is defined in the section Standard toolkit on page 409 Other tools and procedures may be re...

Page 162: ...operation MOTORS ON 2 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 If the lamp is not lit trace the fault by Checking whether the signal lamp is broken If so replace it Checking the cable connections Measuring the voltage in connectors motor axis 3 24V Checking the cabling Rep...

Page 163: ...hanging activities 3 4 1 Type of oil in gearboxes Location of gearboxes The figure shows the location of the gearboxes on the robot xx0600003442 xx0500002226 A Gearbox axis 1 B Gearbox axis 2 C Gearbox axis 3 D Gearbox axis 4 E Gearbox axis 5 F Gearbox axis 6 E Axis 5 gearbox IRB 6640ID F Axis 6 gearbox IRB 6640ID Continues on next page ...

Page 164: ...ly rinsed See Rinsing the gearbox on page 164 Type of oil currently used The table show which types of oil are used in gearboxes Labels next to oil plugs Labels located next to the oil plugs of each gearbox show which type of oil it contains All gearboxes must have the correct label clearly visible xx0800000230 xx0800000241 Gearbox Type of oil Art no Amount Axis 1 Kyodo Yushi TMO 150 3HAC032140 00...

Page 165: ... As Kyodo Yushi TMO 150 as well as Shell Tivela S 150 is not compatible with mineral oil contamination with other types of oil in the gearboxes is not accepted Equipment used in handling Kyodo Yushi as well as Shell Tivela S 150 must be carefully cleaned before use If the type of oil needs to be changed the gearbox must be thoroughly rinsed See Rinsing the gearbox on page 164 NOTE When filling gea...

Page 166: ...i TMO 150 and Optimol Optigear RMO 150 Optigear RO 150 are mixed Flush the gearbox properly three times with the correct type of oil Use a service program when flushing Refill the gearbox with the correct type of oil Kyodo Yushi TMO 150 mixed with Mobilgear 600 XP320 Use this procedure to rinse the contaminated gearbox if the gearbox shall contain Kyodo Yushi TMO 150 and it is mixed with Mobilgear...

Page 167: ...he figure below xx0600003449 Required equipment A Oil plug filling B Oil plug inspection C Oil plug draining Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 6 000 ml Kyodo Yushi TMO 150 Note Do not mix with other oil types Oil collecting vessel Capacity 8 000 ml Oil exchange equipment 3HAC021745 001 The content is defined in the section Special tools on page 410 Standard toolkit Th...

Page 168: ...t turn off the air pressure to motors and SMB 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 44 3 Collect the drained oil in an oil vessel Vessel capacity is specified in Required equipment on page 165 4 Remove the oil plug filling in orde...

Page 169: ...ad the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 44 3 Open the oil plug filling Shown in the figure Location of oil plugs on page 165 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously being drained The correct oil level is detailed in section Inspection oil level gearbox...

Page 170: ... xx0600003451 Required equipment A Oil plug inspection B Oil plug filling C Oil plug draining Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 5 800 ml Kyodo Yushi TMO 150 Note Do not mix with other oil types Oil collecting vessel Capacity 6 000 ml Oil exchange equipment 3HAC021745 001 The content is defined in the section Special tools on page 410 Standard toolkit The content is de...

Page 171: ...air pressure to motors and SMB 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 44 3 Remove the oil plug draining and drain the gearbox oil using a hose with nipple and an oil collecting vessel Remove the oil plug filling in order to drain t...

Page 172: ...ox oil involves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 44 3 Remove the oil plug filling and the oil plug inspection Shown in the figure Location of oil plugs on page 168 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount prev...

Page 173: ... xx0200000230 Required equipment A Gearbox axis 3 B Oil plug filling C Oil plug draining Equipment etc Art no Amount Note Lubricating oil 3HAC032140 001 2 500 ml Kyodo Yushi TMO 150 Note Do not mix with other oil types Oil exchange equipment 3HAC021745 001 The content is defined in the section Special tools on page 410 Oil collecting vessel Capacity 3 000 ml Standard toolkit The content is defined...

Page 174: ...e air pressure to motors and SMB 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 44 3 Remove the oil plug draining and drain the gearbox oil using a hose with nipple and an oil collecting vessel Remove the oil plug filling in order to drain...

Page 175: ...Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 44 3 Remove the oil plug filling Shown in the figure Location of gearbox on page 171 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously drained T...

Page 176: ... as shown in the figure below xx0200000231 Required equipment A Oil plug filling B Oil plug draining Equipment etc Art no Amount Note Lubricating oil 11712016 604 8 100 ml Mobilgear 600 XP 320 Oil exchange equipment 3HAC021745 001 The content is defined in the section Special tools on page 410 Oil collecting vessel Capacity 9 000 ml Standard toolkit The content is defined in the section Standard t...

Page 177: ...rn off the air pressure to motors and SMB 3 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 44 4 Drain the oil from the gearbox into a vessel by opening the oil plug draining Remove the oil plug filling in order to drain the oil quicker Shown...

Page 178: ...turn off the air pressure to motors and SMB 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 44 3 Refill the gearbox with lubricating oil through the oil plug filling The amount of oil to be refilled depends on the amount previously being dr...

Page 179: ...All rights reserved 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 xx0500002013 A Oil plug filling B Oil plug draining A Wrist unit of IRB 6640ID B Oil plug filling C Oil plug draining Continues on next page ...

Page 180: ...e content is defined in the section Standard toolkit on page 409 Action Note 1 Run axis 4 to a position where the oil plug draining is facing downwards 2 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 WARNING Handling gearbox oil involves several safety risks Before proceeding p...

Page 181: ... read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 44 3 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 Refill the gearbox with lubricating oil through the oil plug filling The amount of oil to be refilled de...

Page 182: ...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 xx0500002017 A Gearbox axis 6 B Oil plug filling C Oil plug draining The figure above shows the wrist unit of IRB 6640ID A Gearbox axis 6 B Oil plug draining C Oil plug filling Continues on next page ...

Page 183: ... The content is defined in the section Standard toolkit on page 409 Action Note 1 IRB 6640 Run the robot to a position where the oil plug draining of axis 6 gearbox is facing downwards and the oil plug filling is facing upwards IRB 6640ID Run the robot to a position where the oil plug draining is facing downwards Shown in the figure Location of gearbox on page 180 2 DANGER Turn off all electric po...

Page 184: ... Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 44 3 Remove the oil plug filling Shown in the figure Location of gearbox on page 180 4 Refill the gearbox with lubricating oil The amount of oil to be refilled depends on the amount previously drained ...

Page 185: ...outine Location of SMB battery The SMB battery SMB serial measurement board is located on the left hand side of the frame as shown in the figure below xx0600003444 Required equipment A Cover battery box B Battery pack C Cable battery D Battery holder Equipment etc Spare part no Note Battery pack 3HAC16831 1 Battery includes protection circuits Replace it only with a given spare part number or an A...

Page 186: ... air pressure to motors and SMB 3 esd WARNING The unit is sensitive to ESD Before handling the unit please read the safety information in the section WARNING The unit is sensitive to ESD on page 43 4 Remove the SMB battery cover by unscrewing its attachment screws Shown in the figure Location of SMB battery on page 183 5 Pull out the battery and disconnect the battery cable Shown in the figure Loc...

Page 187: ... in the section WARNING The unit is sensitive to ESD on page 43 3 Reconnect the battery cable to the SMB battery pack and fit it to the frame Art no is specified in Required equipment on page 183 Shown in the figure Location of SMB battery on page 183 4 Secure the SMB battery cover with its attachment screws Shown in the figure Location of SMB battery on page 183 5 Update the revolution counter De...

Page 188: ...es 3 5 1 Lubrication of spherical roller bearing balancing device Location of bearing Design 1 The spherical roller bearing is located at the front ear of the balancing device as shown in the figure below Note The balancing device must be mounted on the robot when lubricating the bearing xx0700000361 A Lubrication hole on ear B Spherical roller bearing Continues on next page ...

Page 189: ...to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Lubricate the spherical roller bearing through the lubrication nipple in the ear with grease Fill until excessive grease is forced out between the shaft and the sealing spacer Art no and amount is specified in Required equipment on page 187 Shown in the figure Location of bearing Design 1 on page 186 The bal...

Page 190: ...as shown in the illustration xx0500002869 Required equipment A Cover B Cable guide Equipment Art no Note Brush Rust preventive 3HAC026621 001 Equivalent Mercasol 3106 Standard toolkit The content is defined in the section Standard toolkit on page 409 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures include referen...

Page 191: ...the robot in a suitable position 2 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 Remove the cover at the rear end of the upper arm xx0600002872 Parts A Cover B Cable guide 4 Remove the cable guide that covers the sealing xx0600002871 Parts A Cable guide 5 Wipe the surface under...

Page 192: ...01 Revision F 190 Copyright 2007 2010 ABB All rights reserved 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 B Cable guide 7 Refit the radial sealing and cable guide Action Note Continued ...

Page 193: ...wrist is located as shown in the illustration xx0500002863 Required equipment A Bearing B Cable bracket C Cover Equipment Art no Note Brush Rust preventive 3HAC026621 001 Equivalent Mercasol 3106 Standard toolkit The content is defined in the section Standard toolkit on page 409 Other tools and procedures may be required See references to these procedures in the step by step instructions below The...

Page 194: ...GER 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 Dismantle the air hose from motor axis 6 4 Tighten the hose clamp on motor axis 6 and remove the air hose 5 Remove the cover xx0600002864 A Cover 6 Apply rust preventive on the bearing and cable bracket with the brush See Location of b...

Page 195: ...ch protection class Cleaning method Standard Foundry Plus Foundry Prime Clean Room Vacuum cleaner Yes Yes Yes Yes Wipe with cloth Yes With light cleaning detergent Yes With light cleaning detergent or spirit Yes With cleaning detergentapproved by ABB spirit or isopropyl alcohol Yes Withlight cleaning detergent spirit or isopropyl alcohol Rinse with water Yes It is highly recommended that water con...

Page 196: ...cleaning equipment may shorten the life of the robot Always check that all protective covers are fitted to the robot before cleaning Never Never point the water jet at connectors joints sealings or gaskets Never use compressed air to clean the robot Never use solvents that are not approved by ABB to clean the robot Never spray from a distance closer then 0 4m Never remove any covers or other prote...

Page 197: ...Required equipment All equipment required to perform a specific repair activity is listed together with the current procedure The equipment is also gathered in different lists in chapter Reference information Safety information Before any service work is commenced it is extremely important that all safety information is read There are general safety aspects that must be read through as well as mor...

Page 198: ...included in the leakdown tester kit may be required Art no is specified in Required equipment on page 196 3 Apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer Recommended value 0 2 0 25 bar 20 25 kPa 4 Disconnect the compressed air supply 5 Wait for approx 8 10 minutes No pressure loss may be detected If the compressed air is signifi cantly ...

Page 199: ...37 1 Used to grease the bearings if not specified otherwise Action Note 1 To avoid contamination let a new bearing remain in its wrapping until it is time for fitting 2 Ensure that all parts included in the bearing fitting are free from burrs grinding waste and other contamination Cast components must be free from foundry sand 3 Bearing rings inner rings and roller elements must under no cir cumst...

Page 200: ...aring 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 During operation the bearing should be filled to 70 80 of the available volume Ensure that grease is handled and stored properly to avoid contamination Grease the different types of bearings as detailed below Grooved ball bearings must be fille...

Page 201: ...ing over threads keyways etc Equipment etc Art no Note Grease 3HAB3537 1 Used to lubricate the seals Action Note 1 Check the seal to ensure that the seal is of the correct type provided with cutting edge there is no damage to the sealing edge feel with a fingernail 2 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced since it may result in future...

Page 202: ... defective the parts may not be used because leakage could occur 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 Action Note 1 Ensure that the correct o ring size is used 2 Check the o ring for surface defects burrs shape accuracy et...

Page 203: ...asy cleaned surface is retained Required equipment Disassemble Use this procedure when dismantling a part for exchanges on a Clean room robot Equipment Spare parts Note Sealing compound See the chapter Spare parts Sikaflex 521 FC Color white Tooling pin Width 6 9 mm made of wood Spirit Etanol Knife Lint free cloth Action Description 1 Cut the paint with a knife in the joint between the part that w...

Page 204: ...ble NOTE After all repair work wipe the robot free from particles with spirit on a cloth Action Description 1 After the parts is mounted clean the joint free from oil and grease 2 Seal the joint with Sikaflex 521FC xx0900000122 3 Smooth the joint with a tooling pint that has been placed in hot water before use xx0900000125 Continued ...

Page 205: ... Prime For replacement of cable harness on robots with option Foundry Prime see Replacement of cable harness axis 1 6 Option Foundry Prime 3HAC037959 005 available on ABB Library Location of cable harness The cable harness of axes 1 6 is run throughout the robot as shown in the figure below xx0700000102 A Connectors at motor axis 2 R2 FB2 R2 MP2 B Connectors at motor axis 1 R2 FB1 R2 MP1 C Rear co...

Page 206: ...y view P Velcro strap inside lower arm on metal clamp R Cable gland armhouse Equipment Spare part no Note Cable harness axes 1 6 See Spare parts chapter Gasket 3HAC033489 001 Motor axis 6 Standard toolkit The content is defined in the section Standard toolkit on page 409 Other tools and procedures may be required See references to these procedures in the step by step instructions below These proce...

Page 207: ...le attachment rear Action Note 1 In order to facilitate refitting of cable harness run the robot to the specified position Axis 1 0 Axis 2 0 Axis 3 0 Axis 4 0 Axis 5 90 Axis 6 no significance Axes 2 and 3 may be tilted slightly to improve access 2 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 m...

Page 208: ...ottom of cable bracket 7 Pick out the cabling from motor axis 6 8 Loosen the cable bracket upper arm tube by undoing the two screws on top of the tube Shown in the figure Cable brackets of the upper arm on page 205 9 Disconnect the two connectors R3 FB5 and R3 MP5 inside the tube Shown in the figure Location of cable harness on page 203 10 Remove eventual cable straps from the harness 11 Remove th...

Page 209: ...SMB Shown in the figure Location of cable harness on page 203 4 Remove the cable holder on the frame securing the cable harness 5 Pull the cable and connectors up through the cable guide in the center of the frame 6 Disconnect all connectors at motors 1 and 2 7 Open the SMB cover carefully The cable between the battery and the SMB unit may stay connected in order to avoid an update of the revoluti...

Page 210: ...nside SMB recess 10 Remove the velcro strap and cable gland 11 Remove the cable gland securing the cables to the arm house xx0100000143 12 Remove the velcro strap from the harness at the guide plate ax 2 at the lower arm Shown in the figure Location of cable harness on page 203 13 Remove the cable harness from the cable guide plate ax 2 14 Disconnect all connectors at motors 3 and 4 15 Gently pull...

Page 211: ...ith eventual customer harnesses Make a note of the correct positions of the connectors 2 Reconnect connectors R1 MP and R1 SMB at the base Shown in the figure Location of cable harness on page 203 Make a note of the correct positions of the connectors 3 Reconnect the earth cable Position shown in the figure Location of cable harness on page 203 4 Refit the rear cover plate to the robot with its at...

Page 212: ...cure the SMB cover with its attachment screws 9 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 42 10 Pull the cable harness through the lower arm 11 Refit the metal clamp on the inside of the lower arm Then refit the cable harness to the metal clamp with the velcro strap and cabl...

Page 213: ...y twisting the cable harness further in any direction xx0100000143 Action Note Action Note 1 Before refitting the upper end of the cable harness the lower end must first be refitted Detailed in section Refitting cable harness lower arm frame and base on page 209 2 Refit the cable gland securing the cables in the armhouse NOTE The cable harness is delivered pretwisted Make sure not to affect this b...

Page 214: ...ace the cabling to motor axis 6 correctly on the upper arm and gently pull the connectors through the hole on top of the wrist unit to motor axis 6 In case of excess of cable length put the excess cable in a loop in the area shown in the figure and secure with cable straps Cables are longer in order to fit different upper arm lengths xx0200000185 A Cable straps 10 Fasten the cable bracket wrist un...

Page 215: ... cable straps have been removed refit them to the harness 14 Refit the cable attachment rear Shown in the figure Cable brackets of the upper arm on page 205 15 If the connection between the SMB battery and the SMB unit has been broken the revolution counters now must be updated Detailed in section Updating revolution counters on page 392 16 DANGER Make sure all safety requirements are met when per...

Page 216: ...r axis 5 with connectors R4 FB5 and R4 MP5 B Connectors R3 FB5 and R3 MP5 Equipment Spare part no Note Cable harness axis 5 See Spare parts chapter Circuit diagram 3HAC025744 001 Standard toolkit The content is defined in the section Standard toolkit on page 409 Other tools and procedures may be required See references to these procedures in the step by step instructions below These procedures inc...

Page 217: ... hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the air pressure to motors and SMB 2 Reconnect all connectors at motor axis 5 3 Refit the cable gland cover at the cable exit with its two attachment screws 4 Refit the cover of motor axis 5 5 Refit the complete wrist unit Detailed in section IRB 6640 Refitting wrist unit on page 266 IRB 6640ID Refitti...

Page 218: ...able harness attachments are located as shown in the figure below xx0800000022 Required equipment A Shelf B Gripping clamp C Side bracket balancing cylinder D Lower bracket E Gripping clamp F Bracket for cable clamp G Gripping clamp H Gripping clamp J Bracket for cable clamp K Cable guide L Connection plate axis 3 Equipment Part no Note Locking liquid Loctite 243 Standard toolkit The content is de...

Page 219: ... cable harness Cleanroom Action Note 1 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 2 Fit the shelf to the frame with its attachment screws Lock screws with locking liquid Locking liquid is specified in Required equipment on page 216 xx0800000006 Parts A Shelf B Attachment screw...

Page 220: ...nt on page 216 xx0800000008 Parts A Shelf B Cover C Attachment screws M8x16 quality 8 8 A2F 2 pcs D Washer 2 holes E Gripping clamp 4 Fit the side bracket balancing cylinder with its attachment screws Lock screws with locking liquid The screws are supplied with the kit Locking liquid is specified in Required equipment on page 216 xx0800000010 Parts A Side bracket balancing cylinder B Attachment sc...

Page 221: ...800000010 Parts A Lower bracket B Gripping clamp C Washer 2 holes D Attachment screws M8x16 quality 8 8 A2F 2 pcs 6 Then attach the lower bracket with the gripping clamp already fitted to the side bracket balancing cylinder with its attachment screws Lock screws with locking liquid The screws are supplied with the kit Locking liquid is specified in Required equipment on page 216 xx0800000013 Parts...

Page 222: ...ing 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 arm with its attachment screws Lock screws with locking liquid Locking liquid is specified in Required equipment on page 216 xx0800000019 Parts A Bracket for cable clamp B Attachment screws M12x25 quality 8 8 A3F 2 2 pcs Action Note Continued Continues on next page ...

Page 223: ...th the kit Locking liquid is specified in Required equipment on page 216 xx0800000021 Parts A Gripping clamp B Bracket for gripping clamp Action Note Action Note 1 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 2 Fit the bracket for cable clamp on top of the armhouse with its atta...

Page 224: ...quid is specified in Required equipment on page 216 xx0800000023 Parts A Armhouse B Locking nut M8 C Washer D Bracket for cable clamp E Gripping clamp F Washer 2 holes G Attachment screws M8x25 quality 8 8 A2F 2 pcs 4 Fit the cable guide on the side of the armhouse with its attachment screws Lock screws with locking liquid The screws are supplied with the kit Locking liquid is specified in Require...

Page 225: ...ghts reserved 5 Fit the connection plate axis 3 with its attachment screws Lock screws with locking liquid The screws are supplied with the kit Locking liquid is specified in Required equipment on page 216 xx0800000026 Parts A Connection plate axis3 B Attachment screws M10x16 quality 8 8 A3F 2 pcs Action Note Continued ...

Page 226: ... on page 216 Location of cable harness Cleanroom The illustration below shows the location of the cable harness Cleanroom xx0800000054 A Earth placed under rear cover plate B Rear cover plate C Velcro straps D Gripping clamp shelf E Cover shelf F Cover armhouse G Bracket for metal clamp H Gripping clamp armhouse J Cable harness Cleanroom K Gripping clamps lower arm L Gripping clamp lower bracket M...

Page 227: ...s required Circuit diagram 3HAC025744 001 See the chapter Circuit diagram Action Note 1 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 2 CAUTION The cable package is sensitive to mechanical damage They must be handled with care especially the connectors in order to avoid damaging ...

Page 228: ... removing its attachment screws xx0800000049 Parts A Cover B Shelf C Attachment screws M6x16 quality 8 8 A2F 4 pcs 8 Remove the bracket on the cable harness from the shelf by removing its attachment screws xx0800000047 Parts A Cable bracket part of cable harness B Shelf C Attachment screws M6x16 quality 8 8 A2F 2 pcs Action Note Continued Continues on next page ...

Page 229: ...e guide in the center of the frame xx0800000046 Parts A Cable harness 11 Open the SMB cover by removing its attachment screws The cable between the battery and the SMB unit may stay connected in order to avoid an update of the revolution counter NOTE Be careful not to let the weight of the cover strain the cable NOTE In order to remove the SMB cover completely the connector R1 G must be disconnect...

Page 230: ...d 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 xx0700000109 Parts A Cable gland B Attachment screws inside SMB recess 4 pcs Action Note Continued Continues on next page ...

Page 231: ...ve the cable harness xx0800000053 Parts A Gripping clamp 15 Remove the velcro straps on the side bracket balancing device xx0800000052 Parts A Velcro starps B Cable harness 16 Open the gripping clamp on the lower arm and remove the cable harness xx0800000051 Parts A Gripping clamps 17 Continue removal of the upper end of the cable harness Action Note Continued Continues on next page ...

Page 232: ...le harness of the robot Detailed in section Removal cable harness upper arm on page 205 3 Remove the cable clamp on the armhouse by removing its attachment screws Shown in the figure Location of cable harness Cleanroom on page 224 4 Disconnect all connectors at motor axis 3 and motor axis 4 Shown in the figure Location of cable harness Cleanroom on page 224 5 Carefully pull out the cable harness f...

Page 233: ...chanical damage They must be handled with care especially the connectors in order to avoid damaging them 3 Push the cable harness and connectors carefully down through the cable guide in the center of the frame Make sure that the cables are not twisted with each other xx0800000046 Parts A Cable harness 4 Reconnect the earth cable Shown in the figure Location of cable harness Cleanroom on page 224 ...

Page 234: ...hment screws xx0800000047 Parts A Cable bracket part of cable harness B Shelf C Attachment screws M6x16 quality 8 8 A2F 2 pcs 8 Secure the cable harness to the gripping clamp on the shelf xx0800000050 Parts A Gripping clamp 9 Reconnect all connectors at motor axis 1 and motor axis 2 Shown in the figure Location of cable harness Cleanroom on page 224 Action Note Continued Continues on next page ...

Page 235: ...t 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 xx0700000104 Parts A Cable gland B Attachment screws inside SMB recess 4 pcs Action Note Continued Continues on next page ...

Page 236: ...e SMB cover with its attachment screws 14 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 42 15 Secure the cable harness to the gripping clamp on the lower bracket xx0800000053 Parts A Gripping clamp 16 Secure the cable harness with the velcro straps to the side bracket balancing ...

Page 237: ...mps 18 Continue refitting of the upper end of the cable harness Action Note Action Note 1 Start refitting of the cable harness by refitting the lower end Detailed in section Refitting cable harness lower end on page 231 above 2 Secure the cable harness to the gripping clamp on the bracket for cable clamp xx0800000056 Parts A Gripping clamp B Cable harness C Bracket for cable clamp 3 Place the cabl...

Page 238: ...mp 7 Carefully insert the cable harness from the rear into the upper arm tube 8 Continue refitting the cable harness to motor axis 5 and motor axis 6 as well as to the wrist This procedure is the same as for the standard cable harness of the robot Detailed in section Refitting cable harness upper arm on page 211 9 Fit the cover at the back of the upper arm tube with its attachment screws Shown in ...

Page 239: ... FB2 R2 MP2 B Connectors at motor axis 1 R2 FB1 R2 MP1 C Rear cover plate D Earth attachment point is placed under the cover plate E Cable harness F Cable holder G Velcro strap H Guide plate axis 2 J Cable guide K Connector R1 MP L Connector R1 SMB M Cable protector placed inside the lower arm N Position for SMB and brake release units O Cable harness cut away view P Velcro strap inside lower arm ...

Page 240: ...quired See references to these procedures in the step by step instructions below These procedures include references to the tools required Circuit Diagram See the chapter Circuit diagram Action Note 1 In order to facilitate refitting of cable harness run the robot to the specified position Axis 1 0 Axis 2 0 Axis 3 0 Axis 4 0 Axis 5 90 Axis 6 no significance Axes 2 and 3 may be tilted slightly to i...

Page 241: ...fied and shown in the figure Location of cable harness on page 237 8 Open the SMB cover carefully The cable between the battery and the SMB unit may stay connected in order to avoid an update of the revolution counter Be careful not to let the weight of the cover strain the cable In order to remove the cover completely the connector R1 G must be disconnected This causes a necessary updating of the...

Page 242: ...he SMB recess xx0700000109 A Cable gland B Attachment screws inside SMB recess 11 Remove the cable gland securing the cables inside the lower arm 12 Remove the cable gland securing the cables to the arm house xx0100000143 wmf 13 Remove the velcro strap from the harness at the cable fixing bracket at the arm house Shown in the figure Location of cable harness on page 237 Action Note Continued Conti...

Page 243: ...ified position Axis 1 0 degrees Axis 2 0 degrees Axis 3 0 degrees Axis 4 0 degrees Axis 5 90 degrees Axis 6 no significance Axes 2 and 3 may be tilted slightly to improve access 3 Pull the cable and connectors down through the cable guide in the center of the frame Make sure the cables are not twisted with each other or with eventual customer harnesses Make a note of the correct positions of the c...

Page 244: ...ttachment screws from inside the SMB recess xx0700000109 A Cable gland B Attachment screws inside SMB recess 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 Secure the SMB cover with its attachment screws Action Note Continued Continues on next page ...

Page 245: ...ll connectors at motor 3 and motor 4 Specified and shown in the figure Location of cable harness on page 237 16 Reconnect the connector R2 M5 6 gently at the cable division point Be careful not to bend the attachment plate when fastening the screws Shown in the figure Location of cable harness on page 237 M6 2 pcs 17 Secure the cable harness to the upper arm house by refitting the velcro strap to ...

Page 246: ...ttery and the SMB unit has been broken the revolution counters must now be updated Detailed in the Calibration chapter section Updating revolution counters on page 392 21 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 41 Action Note Continued ...

Page 247: ...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 A Cover upper arm tube B Hood upper arm housing C Attachment screws and washers 3 pcs hood upper arm housing D Connectors at motor axis 5 R3 FB5 and R3 MP5 E Connectors at motor axis 6 R3 FB6 and R3 MP6 F Connector at cable harness division point R2 M5 6 Continues on next p...

Page 248: ...f 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 Remove the process cabling from the upper arm if any How to remove the DressPack harness from the upper arm and wrist unit is detailed in the Product manual SpotPack DressPack 4 Remove the cover from the upper arm tube and the hood from the upper...

Page 249: ...removing the three attachment screws B Leave the cabling fitted to the bracket xx0500001905 8 Loosen the cable clamp C inside of the upper arm tube xx0500001904 9 Remove all velcro straps and cable ties holding the cabling inside the wrist unit 10 Pull out the cabling from the wrist unit and the upper arm tube Be careful not to damage the connectors Action Note Continued Continues on next page ...

Page 250: ...nit where to strap the cabling next to the axis 5 motor Action Note 1 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 2 Make sure all the cable clamps and brackets are attached properly to the new cable harness Spare part no is specified in Required equipment on page 246 3 Insert t...

Page 251: ...d of the fifth turn equal with the others creating a symmetrical spiral xx0500001909 A Attachment point for the power cable R3 MP B Attachment point for the signal cable R3 FB 7 Grease the cabling with cable grease Art no is specified in Required equipment on page 246 8 Refit the cover to the upper arm tube and the hood to the upper arm housing Shown in the figure Location of cable harness axes 5 ...

Page 252: ...e 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 3 6 IRB 6640 and IRB 6640ID Detailed in section Lower arm to upper arm xx0700000352 A Upper arm B Lower arm C Frame D Base E Gearbox axis 1 F Attachment screws base M12x80 quality 12 9 Gleitmo 16 pcs...

Page 253: ... 000 kg Roundsling 1 5 m Lifting capacity 1 000 kg Hoisting block Lifting capacity 500 kg Used to adjust the length of the lifting chain Lifting chain Used together with the hoisting block Standard toolkit The content is defined in the section Standard toolkit on page 409 Other tools and procedures may be required See references to these procedures in the step by step instructions below These proc...

Page 254: ...Lifting chain E Roundsling put in a loop around the wrist on the inside F Roundsling used to eliminate any load through the brake on motor axis 3 G Position for roundsling F put behind the mechanical stop pin H Roundsling put in a loop around the lower arm 4 NOTE For Cleanroom robots apply a protection where the lifting equipment and roundslings will rub against the paint of the robot In order to ...

Page 255: ...ng from the base through the hole in the center of the frame Detailed in section Replacement of cable harness axes 1 6 on page 203 Detailed in section Replacement of cable harness Cleanroom on page 224 8 Remove the motor axis 1 Detailed in section Replacement of motor axis 1 on page 328 9 Remove the calibration plate from the bottom of the frame xx0700000380 Parts A Calibration plate 10 Unfasten t...

Page 256: ...ecure it in a safe area Always move the robot at very low speeds making sure it does not tip Continue lifting even if the arm system turns out to be unbalanced despite earlier adjustments The risk of damaging the interfaces is bigger if the load is lowered unbalanced Make sure all hooks and attachments stay in the correct position while lifting the arm system and that the lifting device does not w...

Page 257: ...nd SMB 2 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 Put the 20 mm cellular plastic sheet as extra protection in the fol...

Page 258: ... the brakes on page 71 xx0700000349 Parts A Lifting eye on armhouse B Lifting chain C Hoisting block D Lifting chain E Roundsling put in a loop around the wrist on the inside F Roundsling used to eliminate any load through the brake on motor axis 3 G Position for roundsling F put behind the mechanical stop pin H Roundsling put in a loop around the lower arm 4 CAUTION The complete arm system weighs...

Page 259: ...e arm system Lower the arm system with guidance from the guide pins previously fitted to the gearbox axis 1 Fit the guide pins in the cor responding holes in the frame as shown in the figure to the right NOTE The refitting must be made completely level Make sure the lifting device is adjusted prior to refitting of arm system This is a complex task to be performed with utmost care in order to avoid...

Page 260: ... fitting 11 Refit the calibration plate at the bottom of the frame xx0700000380 Parts A Calibration plate 12 Refit the motor axis 1 Detailed in section Replacement of motor axis 1 on page 328 13 Refit the cabling in the base Detailed in section Replacement of cable harness axes 1 6 on page 203 Detailed in section Replacement of cable harness Cleanroom on page 224 14 Perform a leak down test of the...

Page 261: ...01 Revision F Copyright 2007 2010 ABB All rights reserved 17 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 41 Action Note Continued ...

Page 262: ... 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 3 6 IRB 6640 and IRB 6640ID xx0300000473 xx0200000217 A Turning disk type 1 B Wrist unit E Attachment screws 6 pcs turning disk A Turning disk type 2 B Wrist unit C Oil plug draining D Oil plug filling F Attachment scre...

Page 263: ...olkit The content is defined in the section Standard toolkit on page 409 Other tools and procedures may be required See references to these procedures in the step by step instruc tions below These procedures include references to the tools required Action Note 1 DANGER Turn off all electric power hydraulic and pneumatic pressure supplies to the robot For Foundry Prime robots Do not turn off the ai...

Page 264: ...ng 2 Secure the turning disk with its attachment screws The number of attachment screws depends on which wrist type is used 6 pcs M14 x 25 Tightening torque 174 Nm 12 pcs M12 x 30 12 9 quality Gleitmo Tightening torque 100 Nm Reused screws may be used providing they are lubricated as detailed in the section Screw joints on page 405 before fitting 3 Perform a leak down test of the gearbox axis 6 De...

Page 265: ...Revision F Copyright 2007 2010 ABB All rights reserved 6 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 41 Action Note Continued ...

Page 266: ...tion of wrist unit The wrist unit is located in the frontmost part of the upper arm 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 3 6 IRB 6640 and IRB 6640ID Upper arm inc wrist unit motors ax 3 6 xx0700000343 A Wrist unit B Turning disk C Cover wrist unit D Cover upper arm tube E Connectors uppe...

Page 267: ...y step instructions below These procedures include references to the tools required Circuit diagram 3HAC025744 001 See the chapter Circuit diagram Action Note 1 Remove all equipment fitted to the turning disk 2 Turn axis 4 to a position where the cover upper arm tube and wrist unit faces upwards Turn axis 5 to 90 xx0200000185 3 DANGER Turn off all electric power hydraulic and pneumatic pressure su...

Page 268: ...10 CAUTION The complete wrist unit weighs 130 kg All lifting equipment used must be sized accordingly 11 Slightly raise the wrist unit to unload the screw joint facilitating removing the attachment screws 12 Remove the wrist unit attachment screws and washers Shown in the figure Location of wrist unit on page 264 13 Pull the wrist unit out lift it away and place it on a secure surface 14 Disconnec...

Page 269: ...64 7 Secure the wrist unit with 10 of the 12 attachment screws and washers Shown in the figure Location of wrist unit on page 264 12 pcs M12 x 50 12 9 quality Gleitmo Tightening torque 115 Nm Reused screws may be used providing they are lubricated as detailed in the section Screw joints on page 405 before fitting 8 Remove the guide pins and secure the two remaining attachment screws as detailed ab...

Page 270: ...connect the connectors to motor axis 6 and refit the motor cover 14 Refit the cover upper arm tube Shown in the figure Location of wrist unit on page 264 15 Refit the cover wrist unit Shown in the figure Location of wrist unit on page 264 16 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included...

Page 271: ...be found in chapter Upper arm including wrist unit motors ax 3 6 IRB 6640 and IRB 6640ID xx0500001567 Required equipment A Wrist unit B Attachment screws and washers wrist unit C Upper arm tube Equipment Spare part no Art no Note Wrist process See Spare parts chapter Guide pins M12 x 200 Guide pins M12 x 200 3HAC13056 3 3HAC13056 3 Always use guide pins in pairs Roundslings Standard toolkit The co...

Page 272: ...from motors axes 5 and 6 Loosen the cabling from the wrist unit 5 Support the weight of the wrist unit with lifting slings 6 CAUTION The complete wrist unit weighs 187 kg All lifting equipment used must be sized accordingly 7 Slightly raise the wrist unit to unload the screw joint facilitating removal of the attachment screws 8 Remove the attachment screws and washer from the wrist unit 9 Lift awa...

Page 273: ...ing torque 115 Nm Reused screws may be used providing they are lubricated as detailed in the section Screw joints on page 405 before fitting 7 Remove the guide pins and secure the two remaining attachment screws as detailed above 8 Reconnect the motor connectors to the motors axes 5 and 6 Fasten the cabling as shown in the cable layout in the figure Cable layout wrist unit on page 248 9 Recalibrat...

Page 274: ... differently depending on whether the wrist unit is mounted on the upper arm or not The attachment points are shown in the following figure A more detailed view of the component and its position may be found in chapter Exploded views in the Product manual reference information xx0700000345 A Attachment hole for lifting eye M12 if the wrist unit is mounted B Attachment for lifting device upper arm ...

Page 275: ...ed together with lifting eye M12 and lifting device upper arm Standard toolkit The content is defined in the section Standard toolkit on page 409 Other tools and procedures may be required See references to these procedures in the step by step instruc tions below These procedures include references to the tools required Action Note 1 Remove all equipment fitted to turning disk 2 Move the upper arm...

Page 276: ...the motors 10 Remove the cable harness upper arm and place it in a way that it will not be damaged in the proceeding procedure of removing the upper arm Detailed in section Removal cable harness upper arm on page 205 Detailed in section Replacement of cable harness Cleanroom on page 224 11 CAUTION The complete upper arm weighs 380 kg without any additional equipment fitted Use a suitable lifting d...

Page 277: ...is 2 3 from the lower arm Shown in the figure Location of upper arm on page 272 Action Note Action Note 1 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 2 Fit the two guide pins sealing axis 2 3 in two of the attachment screw holes on gearbox 3 see figure to the right Guide the ne...

Page 278: ...ent points depends on whether the wrist unit is mounted or not 5 In order to release the brake of the axis 3 motor connect the 24 VDC power supply after removing the motor cover Connect to connector R2 MP3 pin 2 pin 5 6 Fasten the lifting tool chain onto the lifting eye the lifting device and an overhead crane Art no is specified in Required equipment on page 273 7 CAUTION The complete upper arm w...

Page 279: ...ion of upper arm on page 272 Removing the plastic mechanical stops may be required before fitting the upper arm If guide pins are removed before the screws are tightened the sealing can be involuntarily moved into wrong position 13 Secure the lower arm to gearbox axis 3 with the attachment screws 33 pcs M12 x 50 12 9 quality UNBRAKO tightening torque 120 Nm Reused screws may be used providing they...

Page 280: ... in a separate calibration manual enclosed with the calibration tools General calibration information is included in the section Calibration infor mation 22 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 41 Action Note Continued ...

Page 281: ...s 2 C Front shaft balancing device D Attachment for lifting equipment balancing device Equipment etc Art no Note Lifting tool lower arm 3HAC027794 001 Rotation tool 3HAC17105 1 Used to rotate the motor pinion and gear if necessary when brakes are released Grease 3HAB3537 1 For lubrication of the shaft hole Isopropanol 11771012 208 For cleaning of the shaft Standard toolkit The content is defined i...

Page 282: ... the device Art no is specified in Required equipment on page 279 Attachment is shown in the figure Location of lower arm on page 279 5 Unload the balancing device in order to make the piston rod and front ear adjustable when pulling the front shaft out Method 1 detailed in section Unloading the balancing device using hydraulic press tool on page 322 Method 2 detailed in section Unloading the bala...

Page 283: ...c sheet around the places on the robot where the lifting equipment may rub against the paint 11 Apply the lifting tool to the lower arm Art no is specified in Required equipment on page 279 12 Drain the oil from gearbox 2 Detailed in section Oil change gearbox axis 2 on page 168 13 CAUTION The lower arm weighs 160 kg All lifting equipment used must be sized accordingly 14 Raise the tool to unload ...

Page 284: ...s of the lower arm xx0700000348 3 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 4 Apply the lifting tool to the lower arm ...

Page 285: ...section Screw joints on page 405 before fitting 10 Remove the guidings and secure the two remaining screws as detailed above 11 Remove the lifting tool from the lower arm 12 Refit and restore the balancing device Detailed in section Refitting of balancing device 13 Refit the upper arm Detailed in section Refitting upper arm on page 275 14 Perform a leak down test Detailed in section Performing a l...

Page 286: ...vision F 284 Copyright 2007 2010 ABB All rights reserved 18 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 41 Action Note Continued ...

Page 287: ... Foundry Prime 3HAC037959 014 available on ABB Library 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 Required equipment A SMB cover B Pins C Battery cable D SMB unit Equipment etc Spare part no Art no Note SMB unit 3HAC022286 001 Standard toolkit The content is defined in the section Standard t...

Page 288: ...nit please read the safety information in the section WARNING The unit is sensitive to ESD on page 43 4 Remove the SMB cover by unscrewing its attachment screws Shown in the figure Location of SMB unit on page 285 5 Remove the connectors X8 X9 and X10 from the brake release board if need of more space 6 Remove the nuts and washers from the pins securing the board Shown in the figure Location of SM...

Page 289: ...tion of SMB unit on page 285 4 Connect all connectors to the SMB board and fit the SMB unit onto the pins Art no is specified in Required equipment on page 285 Shown in the figure Location of SMB unit on page 285 R1 SMB1 3 R1 SMB4 6 and R2 SMB 5 Secure the SMB unit to the pins with the nuts and washers 6 If disconnected reconnect the connectors X8 X9 and X10 to the brake release board 7 Secure the...

Page 290: ... xx0700000123 Required equipment A Brake release unit B Push button guard C Battery cover D Battery E SMB cover F Battery cable Equipment etc Art no Note Brake release unit with buttons 3HAC16035 1 Located together with the SMB unit at the left hand side of the frame Standard toolkit The content is defined in the section Standard toolkit on page 409 Other tools and procedures may be required See r...

Page 291: ...sensitive to ESD on page 43 3 Remove the push button guard from the SMB cover Shown in the figure Location of brake release unit on page 288 The guard must be removed to ensure a correct refitting of the brake release unit 4 Let the battery stay connected to avoid the need of synchronization of the robot Shown in the figure Location of brake release unit on page 288 5 Disconnect the connectors X8 ...

Page 292: ...itive to ESD on page 43 3 Fasten the brake release unit on the bracket with the attachment screws Make sure the unit is positioned as straight as possible on the bracket The push buttons can otherwise get jammed when the SMB cover is refitted Shown in the figure Location of brake release unit on page 288 Art no is specified in Required equipment on page 288 4 Connect the connectors X8 X9 and X10 t...

Page 293: ...age 42 7 Refit the push button guard to the SMB cover Shown in the figure Location of brake release unit on page 288 8 If the battery has been disconnected the revolution counter must be updated Detailed in the Calibration chapter section Updating revolution counters on page 392 9 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the ...

Page 294: ... the robot IRB 6640 design 1 has one ear on the lower arm as shown in the figure for design 1 Design 2 has two ears on the lower arm as shown in the figure for design 2 The difference is described in section Design 1 and Design 2 of IRB 6640 on page 48 Location of bearing Design 1 The bearings are located in the balancing device as shown in the figure below xx0900000072 A Washer B Sealing ring rad...

Page 295: ...n 2 xx0900000066 E Shaft F Retaining ring bore H VK cover J VK cover K Retaining ring bore L Cradle bearing kit M Hex socket head cap screw M16x70 N Sealing washer A Shaft B Washer C Hex socket head cap screw M16x70 D VK cover E Washer F Radial sealing with dust lip 50x68x8 G Spherical roller bearing H Radial sealing with dust lip 50x68x8 Continued Continues on next page ...

Page 296: ...n room applications M Cradle bearing kit N Retaining ring bore O Washer P Hex socket head cap screw M16x70 Q VK cover Equipment Spare part no Art no Note Maintenance parts shaft See Spare parts Includes the parts shown in the figure above Grease 3HAB3537 1 For lubrication of the components Toolkit 3HAC028920 001 The tools in the set are shown in the section Dismounting and mounting tool 3HAC028920...

Page 297: ...Detailed in section Replacement of balancing device design 1 on page 297 or in Replacement of balancing device design 2 on page 306 3 Remove the both sealing spacers with a screwdriver or any equal tool Shown in the figure Location of bearing Design 1 on page 292 and Location of bearing Design 2 on page 293 4 Remove the sperical roller bearing using the dismounting and mounting tool 3HAC028920 001...

Page 298: ...2 or Location of bearing Design 2 on page 293 7 Refit the balancing device to the robot Detailed in section Replacement of balancing device design 1 on page 297orReplacement of balancing device design 2 on page 306 8 Lubricate the spherical roller bearing in the ear NOTE The balancing device must be mounted on the robot when lubrication is performed Detailed in section Lubrication of spherical rol...

Page 299: ...or Foundry Prime For replacement of balancing device on robots with option Foundry Prime see Replacement of balancing device design 1 Option Foundry Prime 3HAC037959 006 available on ABB Library Location of balancing device The balancing device is located on rear top of the frame as shown in the figure below xx0800000477 A Balancing device B Cradle bearing C Spherical roller bearing Continues on n...

Page 300: ...p To lubricate spherical roller bearing Lifting tool chain 3HAC15556 1 Shackle 3HAC020997 001 Press tool balancing device 3HAC020902 001 For unloading and restoring the balancing device Distance tool 3HAC030662 001 Dismantle and mounting tool 3HAC028920 001 For dismantle and mounting of shaft and bearings Hydraulic cylinder 3HAC11731 1 To be used with these tools 3HAC028920 001 3HAC020902 001 Hydr...

Page 301: ...lancing device weights 210 kg All lifting equipment used must be sized accordingly xx0900000092 4 Secure the upper arm using a lifting sling or using the locking screw A in the frame xx0800000249 5 Method 1 Unload the balancing device with the press tool in order to make the piston rod and front ear adjustable when pulling the shaft out Method 2 Unload the balancing device with the distance tool i...

Page 302: ...with a plastic hammer or similar and tilt it out 8 Remove the retaining ring bore 9 Remove the front shaft using the Dismantle and mounting tool 3HAC028920 001 Described in section Dismounting and mounting tool 3HAC028920 001 on page 413 xx0900000095 10 Remove the VK cover in order to reach the shaft holding the balancing device Hit the VK cover gently at the bottom part of it with a plastic hamme...

Page 303: ... A securing the shaft xx0900000079 14 Remove both the cradle bearings and the balancing device shafts using the dismounting and mounting tool 3HAC028920 00 xx0900000074 15 Perform the following procedure of pulling out the shafts on both sides of the cradle 16 Lift the balancing device gently backwards to a secure area Action Note Continued Continues on next page ...

Page 304: ... 1 Fit the shackle 3HAC020540 001 to the balancing device Where to attach the shackle is shown in the figure xx0900000094 2 CAUTION The balancing device weighs 210 kg All lifting equipment used must be sized accordingly 3 Refit one of the two retaining rings 4 Grease the cradle 5 Use the tool 3HAC028920 001 to refit the cradle bearings and the balancing device shafts xx0900000060 Continued Continu...

Page 305: ...e cradle bearings and the balancing device shafts to the retaining ring bore 7 On the side where the retaining ring bore is not mounted refit the cradle bearings and the balancing device shafts completely 8 It should look like this xx0900000083 9 Mount new radial sealings NOTE The radial sealings is not used in Clean room appli cations xx0900000093 Action Note Continued Continues on next page ...

Page 306: ...ides of the cradle before refitting of the shaft at the piston rod shaft front eye 12 Lift the balancing device to the back of the robot 13 Fit the balancing device on the side where the shaft is in final position and fix it lightly using the Hex socket head cap screw M16x70 14 On the other side use the Hex socket head cap screw M16x70 to refit the cradle bearings and the balancing device shafts t...

Page 307: ...ew M16x70 quality 12 9 Gleitmo Tightening torque 300 Nm 21 Refit the retaining ring bore 22 Refit the VK cover 23 Lubricate the bearing in the ear with grease through the lubricating nipple with a grease pump Fill until excessive grease pierces between the shaft and the sealing spacer 20ml 24 For Clean Room robots refit the lower end of the cable harness Detailed in section Replacement of cable ha...

Page 308: ...me 3HAC037959 007 available on ABB Library Location of balancing device The balancing device is located on rear top of the frame as shown in the figure below xx0900000075 Required equipment A Balancing device B Cradle bearing C Spherical roller bearing Equipment Spare part no Art no Note Balancing device See Spare parts Maintenance parts shaft See Spare parts Maintenance parts cradle See Spare par...

Page 309: ... tool 3HAC028920 001 For dismantle and mounting of shaft and bearings Hydraulic cylinder 3HAC11731 1 To be used with these tools 3HAC028920 001 3HAC020902 001 Hydraulic pump 80 MPa 3HAC13086 1 To be used with the hydraulic cylinder 3HAC11731 1 Standard toolkit Described in section Standard toolkit on page 409 Loctite 577 Sikaflex 521FC Equipment Spare part no Art no Note Action Note 1 Remove all e...

Page 310: ...istance tool in order to make the piston rod and front ear adjustable when pulling the shaft out Described in section Unloading the balancing device using distance tool on page 317 7 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 8 Remove the protection plug covering the shaft in ...

Page 311: ...nly Clean Room B Hex socket head cap screw M16x70 C Washer D Shaft E Distance tool 11 Remove the VK cover in order to reach the shafts holding the balancing device Hit the VK cover at the bottom part of it with a hammer or similar and tilt it out NOTE It is almost impossible to remove the VK cover without damage new VK covers are needed 12 Remove the hex socket head cap screw M16x70 securing the s...

Page 312: ...aining ring bore A securing the shaft and bearing xx0900000079 15 Remove both the cradle bearings and the balancing device shafts using the dismounting and mounting tool 3HAC028920 00 Tool configuration in section Removal rear shafts Design 1 and 2 on page 425 xx0900000074 16 Remove the balancing device Action Note Continued Continues on next page ...

Page 313: ...efit one of the two retaining rings 3 Use the tool 3HAC028920 001 to refit the cradle bearings and the balancing device shafts Described in section Dismounting and mounting tool 3HAC028920 001 on page 413 xx0900000061 4 On the side where the retaining ring bore is mounted Refit the cradle bearings and the balancing device shafts to the retaining ring bore xx0900000084 Continued Continues on next p...

Page 314: ...5 On the side where the retaining ring bore is not mounted refit the cradle bearings and the balancing device shafts completely xx0900000085 6 It should look like this xx0900000083 7 Mount new radial sealings NOTE The radial sealings is not used in Clean room appli cations xx0900000093 Action Note Continued Continues on next page ...

Page 315: ...l lifting equipment used must be sized accordingly 9 Use Loctite on the threads on the balancing device NOTE Do not use Loctite on the threads of the Hex socket head cap screw M16x70 xx0900000088 10 Perform the following procedure of refitting the shafts on both sides of the cradle before refitting of the shaft at the piston rod shaft front eye 11 Lift the balancing device in to the cradle Action ...

Page 316: ...al position and fix it lightly using the Hex socket head cap screw M16x70 13 On the other side use the Hex socket head cap screw M16x70 to refit the cradle bearings and the balancing device shafts to the final position Tightening torque 300Nm 14 Lock the cradle bearings using the retaining ring bore A xx0900000089 15 Mount new VK covers on both sides Action Note Continued Continues on next page ...

Page 317: ...t head cap screw M16x70 C Washer D Shaft E Distance tool 17 Refit the Hex socket head cap screw M16x70 use Loctite Tightening torque 50Nm 18 Restore the balancing device Method 1 Described in section Restoring the balancing device using a hydraulic press tool on page 325 Method 2 Described in section Restoring the balancing device using distance tool on page 320 19 Fill the cradle bearings with 70...

Page 318: ...5 5 Replacement of balancing device design 2 3HAC026876 001 Revision F 316 Copyright 2007 2010 ABB All rights reserved 20 Fill the spherical roller bearing with 20 ml Optimol PDO xx0900000102 Action Note Continued ...

Page 319: ...on details how to unload the balancing device using a distance tool 3HAC030662 001 This method is used when the balancing device is reusable DANGER There is a high tensioned spring inside the balancing device incorrect handling may cause injuries and damage property DANGER Do not remove the press tool from a dismounted balancing device Distance tool xx0800000478 A Distance tool 3HAC030662 001 Cont...

Page 320: ...ghts reserved Unloading procedure Action Note Illustration 1 Jog the robot lower arm to a maximal forward position xx0800000479 2 Remove the cover plate on the back of the balancing device 3 Mount the press tool on the back of the balancing device using the four screws xx0800000480 A Press tool Continued Continues on next page ...

Page 321: ... 319 3HAC026876 001 Revision F Copyright 2007 2010 ABB All rights reserved 4 Jog the robot lower arm backward until the pressure from the balancing device release xx0800000481 5 CAUTION Secure the upper arm before removing the shaft Action Note Illustration Continued ...

Page 322: ...t remove the press tool 3HAC030662 001 from a dismounted balancing device Required equipment Restoring procedure Equipment Spare part no Art no Note End Cover Gasket See Spare parts To be replaced if damaged Distance tool 3HAC030662 001 For unloading and restoring the balancing device Method 2 Standard toolkit Loctite 577 Sikaflex 521FC Action Note Illustration 1 Jog the lower arm forward to relea...

Page 323: ...6 001 Revision F Copyright 2007 2010 ABB All rights reserved 4 Mount the cover on the back of the cylinder using the four screws Apply Sikaflex 521FC on the end cover gasket xx0900000104 5 Use Loctite 577 on the four screws Tightening torque 47Nm Action Note Illustration Continued ...

Page 324: ...er arm is detailed in the current repair activity for example removal of the balancing device DANGER There is a high tensioned spring inside the balancing device incorrect handling may cause injuries and damage property Press tool and hydraulic cylinder The figure below shows the hydraulic cylinder mounted on the press tool The press tool includes two press devices that are used to different model...

Page 325: ...ol is detailed in section Restoring the balancing device using a hydraulic press tool on page 325 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 Hydraulic pump 80 MPa 3HAC13086 1 To be used wi...

Page 326: ...pment on page 323 See the figure Press tool and hydraulic cylinder on page 322 5 Fit the hydraulic cylinder to the press tool Art no is specified in Required equipment on page 323 See the figure Press tool and hydraulic cylinder on page 322 6 Connect the hydraulic pump to the cylinder Art no is specified in Required equipment on page 323 7 Increase the pressure and press until the marking on the m...

Page 327: ... the device DANGER There is a high tensioned spring inside the balancing device incorrect handling may cause injuries and damage property Press tool and hydraulic cylinder The figure below shows the hydraulic cylinder mounted on the press tool The press tool includes two press devices that are used to different models of the balancing device xx0200000174 A Press block B Hydraulic cylinder C Press ...

Page 328: ...ss tool and hydraulic cylinder on page 325 2 Press with the cylinder and the hydraulic pump until the fix plate is movable again Turn the pin on the fix plate to position Open Shown in the figure Press tool and hydraulic cylinder on page 325 Do not apply more pressure than necessary it could damage bearings and sealings at the shaft 3 Unload the cylinder and make sure the moving pin indicates that...

Page 329: ...l 327 3HAC026876 001 Revision F Copyright 2007 2010 ABB All rights reserved 8 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 Action Note Continued ...

Page 330: ...e see Replacement of motor axis 1 Option Foundry Prime 3HAC037959 008 available on ABB Library Location of motor The motor axis 1 is located as shown in the figure below xx0700000085 Required equipment A Motor axis 1 Equipment etc Spare part no Art no Note Motor axis 1 See Spare parts Includes motor pinion o ring 21522012 430 O ring 21522012 430 Must be replaced when reassemling the motor Grease 3...

Page 331: ...w These procedures include references to the tools required Circuit Diagram See the chapter Circuit diagram Equipment etc Spare part no Art no Note Action Note 1 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 2 Remove the cover for connector access on top of the motor by unscrewin...

Page 332: ...oundry Prime robots Do not turn off the air pressure to motors and SMB 2 Make sure the o ring on the circumference of the motor is seated properly Lightly lubricate the o ring with grease Art no is specified in Required equipment on page 328 3 CAUTION The motor weighs 25 kg All lifting equipment used must be sized accordingly 4 Apply the lifting tool motor axis 1 4 5 to the motor Art no is specifi...

Page 333: ...tly sealed 12 Refit the motor cover with its four attachment screws Make sure the cover is tightly sealed 13 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in the section Calibration information 14 DANGER Make sure all safety requirements are met when performing the first test run These ...

Page 334: ... xx0700000086 Required equipment A Motor axis 2 Equipment etc Spare part no Art no Note Motor including pinion See Spare parts chapter Includes motor pinion o ring 2152 2012 430 O ring 21522012 430 21522012 430 Must be replaced when reassembling motor Mercasol 3106 3HAC026621 001 Option Foundry Prime Loctite 574 Option Foundry Prime Grease 3HAB3537 1 For lubricating the o ring Locking screw 3HAA10...

Page 335: ... by step instruc tions below These procedures include references to the tools required Circuit diagram See the chapter Circuit diagram Equipment etc Spare part no Art no Note Action Note 1 Move the robot to a position close enough to its calibration position to allow the lock screw to be inserted into thehole for lock screw Shown in the figure Location of motor on page 332 2 DANGER Turn off all el...

Page 336: ...e the motor by unscrewing its four attachment screws and plain washers 11 Fit the two guide pins in two of the motor attachment holes Art no is specified in Required equipment on page 332 Shown in the figure Location of motor on page 332 12 If required press the motor out of position by fitting the removal tool motor to the remaining motor attachment holes Art no is specified in Required equipment...

Page 337: ...pment on page 332 5 Fit the two guide pins in the two lower motor attachment holes Art no is specified in Required equipment on page 332 Shown in the figure Location of motor on page 332 6 Lift the motor and guide it onto the guide pins as close to the correct position as possible without pushing the motor pinion into the gear Make sure that the motor is turned the right direction that is the cabl...

Page 338: ...ge 332 14 Refit the cover on top of the motor with its four attachment screws Make sure the cover is tightly sealed 15 Remove the lock screw from the hole for lock screw Shown in the figure Location of motor on page 332 16 Perform a leak down test Detailed in Performing a leak down test on page 196 17 Refill the gearbox with oil Detailed in the section Oil change gearbox axis 2 on page 168 18 Reca...

Page 339: ...eft hand side of the robot as shown in the figure below xx0200000186 Required equipment A Motor axis 3 B Cable gland cover motor axis 3 C Motor attachment holes 4 pcs Equipment etc Spare part no Art no Note Motor including pinion See Spare parts chapter Includes motor pinion o ring 21522012 430 O ring 21522012 430 Must be replaced when reas sembling motor Mercasol 3106 3HAC0266621 001 Option Found...

Page 340: ...342 1 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 Power supply 24 VDC max 1 5 A For releasing the brakes Standard toolkit The content is defined in the section Standard toolkit on page 409 Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Other tools and procedures may...

Page 341: ...ox axis 3 Detailed in section Oil change gearbox axis 3 on page 171 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 unscrewing its two securing screws Shown in the figure Location of motor on page 337 Make sure the gasket is not damaged 7 Disconnect all connec...

Page 342: ...ure the o ring on the circumference of the motor is seated properly Lightly lubricate it with grease Art no is specified in Required equipment on page 337 3 Fit the lifting tool motor axis 2 3 4 to the motor Art no is specified in Required equipment on page 337 4 Fit the two guide pins in the two lower motor attachment holes Art no is specified in Required equipment on page 337 Shown in the figure...

Page 343: ...ectors beneath the motor cover Connect in accordance with markings on connectors 14 Refit the cable gland cover at the cable exit with its two attachment screws Make sure the cover is tightly sealed Shown in the figure Location of motor on page 337 15 Refit the cover on top of the motor with its four attachment screws Make sure the cover is tightly sealed 16 Remove the equipment used to unload the...

Page 344: ...wn in the figure below xx0200000202 Required equipment A Motor axis 4 B Cable gland cover motor axis 4 C Motor attachment holes 4 pcs Equipment etc Spare part no Art no Note Motor including pinion See Spare parts Includes motor pinion o ring 21522012 430 O ring 21522012 430 Must be replaced when reas sembling motor Mercasol 3106 3HAC026621 001 Option Foundry Prime Loctite 574 Option Foundry Prime ...

Page 345: ...eferences to the tools required Circuit Diagram 3HAC025744 001 See the chapter Circuit diagram Equipment etc Spare part no Art no Note Action Note 1 Move the robot to a position where the upper arm is pointed straight up This position enables the motor to be replaced without draining the gear oil which in turn saves time Any other position of the upper arm requires a draining of oil from the gearb...

Page 346: ...rom the gear and disconnect the brake release voltage 11 Remove the motor by gently lifting it straight out Make sure the motor pinion is not damaged Action Note Action Note 1 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 2 Make sure the o ring on the circumference of the motor i...

Page 347: ... the brake release voltage 10 Reconnect all connectors beneath the motor cover 11 Refit the cover on top of the motor with its four attachment screws Make sure the cover is tightly sealed 12 Refit the cable gland cover at the cable exit with its two attachment screws Shown in the figure Location of motor on page 342 13 Perform a leak down test if the gearbox has been drained Detailed in the sectio...

Page 348: ...ismounted motor and fitted onto the new motor shaft as detailed in this section Location of motor The motor axis 5 is located inside the upper arm tube but attached to 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 3 6 IRB 6640 and IRB 6640ID xx0200000204 Required equipment A Motor ...

Page 349: ... 001 For pressing the pinion on to the new motor Measuring tool 6896134 GN Guide pins M8 x 100 3HAC15520 1 For guiding the motor Guide pins M8 x 150 3HAC15520 2 For guiding the motor Power supply 24 VDC 1 5 A For releasing the brakes Standard toolkit The content is defined in the section Standard toolkit on page 409 Other tools and procedures may be required See references to these procedures in t...

Page 350: ... Required equipment on page 346 11 If required press the motor out of position by fitting removal tool motor M10 to the motor attachment screw holes Art no is specified in Required equipment on page 346 Always use the removal tools in pairs and diagonally 12 Lift the motor to get the pinion away from the gear and disconnect the brake release voltage Make sure the motor pinion is not damaged 13 Rem...

Page 351: ...d to achieve an even friction torque when assembling the pinion Art no is specified in Required equipment on page 346 5 Place the motor and pinion in the press fixture Art no is specified in Required equipment on page 346 6 Press the pinion onto the new motor and check the pressing force For an axis diameter of 15 5 mm use min pressing force 18 5 kN and max pressing force 39 5 kN If the pressing f...

Page 352: ...achment screws 15 Refit the cover on top of the motor with its four attachment screws Make sure the cover is tightly sealed 16 Perform a leak down test Detailed in the section Performing a leak down test on page 196 17 Refit the wrist unit Detailed in the section Refitting wrist unit on page 266 18 Refill the gear with oil Detailed in the section Oil change gearbox axis 5 on page 177 19 Recalibrat...

Page 353: ...nion See Spare parts Includes o ring 3HAB 3772 22 O ring 3HAB3772 22 Grease 3HAB 3537 1 For lubricating the o ring Power supply 24 VDC 1 5A For releasing the brakes Allen key and socket A specific length is required for accessing the attachment screws of the motor The dimensions are shown in the figure Removal tools motor attachment screws on page 352 Standard toolkit The content is defined in the...

Page 354: ...s Do not turn off the air pressure to motors and SMB 2 Move axis 4 90º so that the gearbox of axis 5 is faced downwards This makes it possible to remove the motor without draining the gearbox oil 3 Disconnect the motor connectors from the axis 5 motor Shown in the figure Location of motor axis 5 on page 351 4 In order to release the brakes connect the 24 VDC power supply to the motor Connect to co...

Page 355: ...erly mated to the gear of axis 5 5 Secure the motor with the three attachment screws and washers 3 pcs M8x25 Tightening torque 24 Nm Dimensions of the tools are specified in the figure Removal tools motor attachment screws on page 352 6 Disconnect the brake release and reconnect the motor connectors Shown in the figure Location of motor axis 5 on page 351 7 Perform a leak down test Detailed in sec...

Page 356: ...n may be found in chapter Upper arm including wrist unit motors ax 3 6 IRB 6640 and IRB 6640ID xx0700000126 Required equipment A Gearbox axis 6 B Motor axis 6 C Attachment screws 4 pcs Equipment etc Spare part no Art no Note Motor including pinion See Spare parts Includes motor pinion o ring 21522012 430 O ring 21522012 430 Must be replaced when reas sembling motor Gasket 3HAC033206 001 Must be re...

Page 357: ...clude references to the tools required Circuit Diagram 3HAC025744 001 See the chapter Circuit diagram Equipment etc Spare part no Art no Note Action Note 1 Move the robot to a position where the motor in axis 6 is pointed straight up This position enables the motor to be replaced without draining the gear oil which in turn saves time Shown in the figure Location of motor on page 354 2 DANGER Turn ...

Page 358: ...n page 354 Always use the removal tools in pairs 8 Lift the motor carefully to get the pinion away from the gear and disconnect the brake release voltage Make sure the motor pinion is not damaged 9 Remove the motor by gently lifting it straight out Action Note Action Note 1 Make sure the o ring on the circumference of the motor is seated properly Lightly lubricate the o ring with grease Art no is ...

Page 359: ...hers 4 pcs M8 x 25 tightening torque 24 Nm 7 Disconnect the brake release voltage 8 Reconnect all connectors beneath the motor cover 9 Refit the cover on top of the motor with its five attachment screws Make sure the cover is tightly sealed 10 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is includ...

Page 360: ...placed in calibration position xx0500001574 Required equipment A Motor axis 6 B Motor connectors R3 MP6 and R3 FB6 C Wrist side with axis 6 gearbox inside Equipment Spare part no Art no Note Motor including pinion See Spare parts Includes o ring 3HAB3772 22 Grease 3HAB 3537 1 For lubricating the o ring O ring 3HAB3772 22 Power supply 24 VDC 1 5 A For releasing the brakes Allen key and socket A spe...

Page 361: ...he motor to be replaced without draining the gearbox oil from axis 6 2 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 Disconnect the motor connectors Shown in the figure Location of motor axis 6 on page 358 4 In order to release the brakes connect the 24 VDC power supply to the ...

Page 362: ...o the gear of axis 6 5 Secure the motor with its three attachment screws and washers 3 pcs M8x25 Tightening torque 24 Nm Dimensions of the tools are specified in the figure Removal tools motor attachment screws on page 352 6 Disconnect the brake release voltage 7 Reconnect the motor connectors Shown in the figure Location of motor axis 6 on page 358 8 Perform a leak down test Detailed in section P...

Page 363: ...acement of gearbox axis 1 on robots with option Foundry Prime see Replacement gearbox axis 1 on IRB 6640 Option Foundry Prime 3HAC037959 001 available on ABB Library Location of gearbox axis 1 xx0600003068 A Gearbox axis 1 RV 320C 191 35 B Attachment screw M12x80 quality 12 9 gleitmo 16 pcs C Attachment screw M16x60 quality 12 9 gleitmo 12 pcs D Base E Frame F Protection pipe axis 1 G O ring Conti...

Page 364: ...M16x300 3HAC13120 5 Always use guiding pins in pairs Guide pins M16x250 3HAC13120 4 Always use guiding pins in pairs 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 Grease 3HAB3537 1 For lubricating o rings Standard tools The content is defined in the section Standard toolkit on page 409 Other tools and pro...

Page 365: ...Detailed in section Replacement of complete arm system on page 250 5 Lift the robot without the base and put it safely on its side on the floor 6 Remove the robot s attachments screws in order to unfasten the base from the foundation Detailed in section Orienting and securing the robot on page 78 7 Fit two lifting eyes on each side of the gearbox and secure it with a roundsling Art no is specified...

Page 366: ...ts reserved 12 Unscrew the 12 attachment screws and washers securing the gearbox to the base xx0600003069 A Gearbox axis 1 B Attachment screw M16x60 13 CAUTION The gearbox weighs 108 kg All lifting equipment used must be sized accordingly 14 Remove the gearbox Action Note Continued Continues on next page ...

Page 367: ...pecified in Required equipment on page 362 xx0200000055 A O ring Gearbox shown from the side 3 Fit the three o rings 23x3 6 Use some grease to attach them 4 Refit the protection pipe axis 1 in the center of gearbox 1 with its attachment screws Shown in the figure Location of gearbox axis 1 on page 361 5 Fit two lifting eyes on each side of the gearbox and secure it with a roundsling Art no is spec...

Page 368: ...y 11 Lift the robot base and gearbox 1 to allow removing the support base and gear 12 Secure the base to the mounting site Detailed in section Orienting and securing the robot on page 78 13 Refit the complete armsystem Detailed in section Replacement of complete arm system on page 250 14 Refit the robot to the base with its attachment screws and serrated lock washers NOTE The orientation of the se...

Page 369: ... 1 Detailed in section Replacement of motor axis 1 on page 328 17 Fill oil in gearbox axis 1 Detailed in section Oil change gearbox axis 1 on page 165 18 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in the section Calibration infor mation 19 DANGER Make sure all safety requirements are...

Page 370: ...ment screws M16x50 quality Gleitmo 20 pcs B Attachment screws M12x60 quality Gleitmo 32 pcs C Gearbox axis 2 D Motor axis 2 Equipment etc Spare part no Art no Note Gearbox axis 2 See Spare parts Includes gearbox o ring O ring 339 3x5 7 3HAB3772 91 Option Foundry Prime 3HAC026621 001 Option Foundry Prime Equivalent Mercasol 3106 Grease 3HAB3537 1 For lubricating o rings Lifting tool 3HAC025214 001 ...

Page 371: ...od 1 described in section Unloading the balancing device using hydraulic press tool on page 322 Method 2 described in section Unloading the balancing device using distance tool on page 317 2 Remove the front shaft using the tool 3HAC028920 001 Described in section Replacement of balancing device design 1 on page 297 for design 1 Described in section Replacement of balancing device design 2 on page...

Page 372: ... xx0700000350 Parts A Lifting eye on armhouse B Lifting chain C Hoisting block D Lifting chain E Lifting chain F Roundsling put in a loop around the wrist on the inside G Roundsling put in a loop around the lower arm 6 Jog ax 3 to reach lifting center and straighten the lifting slings xx0900000112 7 Drain the oil from gearbox axis 2 Detailed in the section Oil change gearbox axis 2 on page 168 Act...

Page 373: ...ness axes 1 6 on page 203 10 Let the removed part of the cable harness hang loose and take care not to damage it during the removal process 11 Remove the attachment screws M16x60 12 pcs securing the lower arm to gearbox axis 2 Shown in the figure Location of gearbox axis 2 on page 368 12 Remove the upper and lower arms and put them down on the floor 13 Remove motor axis 2 Detailed in the section R...

Page 374: ... a roundsling Art no is specified in Required equipment on page 368 xx0900000114 The figure shows IRB6640 18 Remove the attachment screws M12x60 32 pcs securing the gearbox to the frame Shown in the figure Location of gearbox axis 2 on page 368 19 Remove the gearbox and put it in a place where it will not cannot be damaged 20 Wipe away residual oil and paint Action Note Continued Continues on next...

Page 375: ...s fitted to the gearbox Lightly lubricate it with grease xx0600003128 A O ring 3HAB3772 91 2 CAUTION The gearbox weighs 98 kg All lifting equipment used must be sized accordingly 3 Fit the lifting tool for lifting the gearbox in the uppermost hole of the gearbox and secure it with a roundsling Art no is specified in Required equipment on page 368 xx0900000114 The figure shows IRB6640 Continued Con...

Page 376: ...ON 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 xx0700000350 Parts A Lifting eye on armhouse B Lifting chain C Hoisting block D Lifting chain E Lifting chain F Roundsling put in a loop around the wrist on the inside G Roundsling put...

Page 377: ...ment of cable harness Cleanroom on page 224 Detailed in the section Replacement of cable harness axes 1 6 on page 203 13 Fill the gearbox axis 2 with oil Detailed in the section Oil change gearbox axis 2 on page 168 14 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in the section Calibra...

Page 378: ...lacement gearbox axis 3 on IRB 6640 Option Foundry Prime 3HAC037959 003 available on ABB Library 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 Product manual reference information xx0200000194 A Gearbox axis 3 B Motor axis 3 C Uppe...

Page 379: ...t M16x60 for mechanical stop axis 3 3HAB3409 86 Lifting eye M12 3HAC025333 005 Guide pins M12 x 200 3HAC13056 3 For guiding the gearbox Use guides in pairs Guide pins M12 x 250 3HAC13056 4 For guiding the gearbox Use guides in pairs Guide pins sealing ax 2 3 80mm 3HAC14628 1 For guiding the sealing axis 2 3 Use guides in pairs Guide pins sealing ax 2 3 100mm 3HAC14628 2 For guiding the sealing axi...

Page 380: ...ed in section Removal motor on page 339 NOTE When removing the motor axis 3 the brake on axis 3 is released Make sure the upper arm is secured and disabled to move 4 Remove the upper arm Detailed in section Removal upper arm on page 273 5 Remove the sealing axis 2 3 between the gearbox and lower arm On reassembly a new sealing must be used Art no is specified in Required equipment on page 377 6 Pl...

Page 381: ... Art no is specified in Required equipment on page 377 xx0200000201 A M12 holes for pressing the gearbox out B Attachment screw holes gearbox upper arm C Attachment screw holes gearbox lower arm 10 CAUTION The gearbox weighs 60 kg All lifting equipment used must be sized accordingly 11 Remove the gearbox with guidance from the guide pins using an overhead crane or similar Action Note Continued Con...

Page 382: ... Fit two guide pins in 180 relation to each other in the holes in the upper arm used for the gearbox attachment screws Art no is specified in Required equipment on page 377 4 CAUTION The gearbox weighs 60 kg All lifting equipment used must be sized accordingly 5 Make sure the o rings are fitted to the gearbox Apply grease to the o rings to make sure they stick in their grooves during assembly Repl...

Page 383: ...ted as detailed in the section Screw joints on page 405 before fitting 11 Refit the upper arm with a new sealing axis 2 3 Art no is specified in Required equipment on page 377 Detailed in section Refitting upper arm on page 275 12 Refit the motor Detailed in section Refitting motor on page 340 13 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calib...

Page 384: ...ox axis 6 on robots with option Foundry Prime see Replacement gearbox axis 6 on IRB 6640 Option Foundry Prime 3HAC037959 004 available on ABB Library Location of gearbox The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below xx0200000219 A Gearbox axis 6 B Attachment screws and washers gearbox 18 pcs C Oil plug draining D Oil plug filling O ring not shown in fig...

Page 385: ...ng type 1 6 pcs 15 5x1 5 21520431 20 Must be replaced when reas sembling gearbox O ring type 2 164 7x3 53 3HAB3772 57 Must be replaced when reas sembling gearbox O ring type 2 150 0x2 0 3HAB3772 64 Must be replaced when reas sembling gearbox O ring type 2 12 pcs 13 1x1 6 3HAB3772 61 Must be replaced when reas sembling gearbox Grease 3HAB3537 1 For lubricating the o ring Standard toolkit The conten...

Page 386: ... 2 Drain the oil from gearbox axis 6 Detailed in the section Oil change gearbox axis 6 on page 180 3 Remove the turning disk Detailed in the section Removal turning disk on page 261 4 Remove the gearbox by unscrewing its 18 attachment screws Shown in the figure Location of gearbox on page 382 5 If required apply M8 screws to the holes shown in the figure beside to press the gearbox out xx020000022...

Page 387: ...the holding brake of motor axis 6 Detailed in the section Manually releasing the brakes on page 71 4 Insert the gearbox axis 6 into the wrist unit Art no is specified in Required equipment on page 383 Shown in the figure Location of gearbox on page 382 Make sure the gears of the gearbox mate with the gears of the motor 5 Secure the gearbox with the attachment screws and washers Shown in the figure...

Page 388: ... section Oil change gearbox axis 6 on page 180 9 Recalibrate the robot Calibration is detailed in a separate calibration manual enclosed with the calibration tools General calibration information is included in the section Calibration information 10 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run ma...

Page 389: ...arate calibration manuals If the robot has Absolute Accuracy calibration it is also recommended but not always necessary to calibrate for new absolute accuracy The resolver values will change when parts affecting the calibration position are replaced on the robot for example motors or parts of the transmission The revolution counter memory is lost If the revolution counter memory is lost the count...

Page 390: ...tion Pendulum standard method Absolute Accuracy calibration optional Based on standard calibration and besides positioning the robot at home position the Absolute Accuracy calibration also compensates for mechanical tolerances in the robot structure deflection due to load Absolute Accuracy calibration focuses on positioning accuracy in the Cartesian coordinate system for the robot Absolute Accurac...

Page 391: ...method and the different routines further CalibWare Absolute Accuracy calibration To achieve a good positioning in the Cartesian coordinate system Absolute Accuracy calibration is used as a TCP calibration The CalibWare tool guides through the calibration process and calculates new compensation parameters This is further detailed in the application manual Absolute Accuracy Calibware Field 5 0 If a...

Page 392: ...uction 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 xx0700000340 A Calibration mark axis 1 B Calibration mark axis 2 C Calibration mark axis 3 D Calibration mark axis 4 E Calibration mark axis 5 F Calibration mark ax...

Page 393: ...ds the calibration position in the same direction in order to avoid position errors caused by backlash in gears and so on Positive directions are shown in the graphic below This is normally handled by the robot calibration software Calibration movement directions 6 axes Note The graphic shows an IRB 7600 The positive direction is the same for all 6 axis robots except the positive direction of axis...

Page 394: ...late on the base At delivery the robot is in the correct position do NOT rotate axis 4 or 6 at power up before the revolution counters are updated If one of the below mentioned axes are rotated one or more turns from its calibration position before updating the revolution counter the correct calibration position will be lost due to uneven gear ratio This affects the following robots If the calibra...

Page 395: ...0400000771 3 Tap Update Revolution Counters A dialog box is displayed warning that updating the revolution counters may change programmed robot positions Tap Yes to update the revolution counters Tap No to cancel updating the revolution counters Tapping Yes displays the axis selection window 4 Select the axis to have its revolution counter updated by Ticking in the box to the left Tapping Select a...

Page 396: ...0 ABB All rights reserved 6 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 the section Checking the calibration position on page 395 Action Continued ...

Page 397: ...rogram MoveAbsJ 0 0 0 0 0 0 9E9 9E9 9E9 9E9 9E9 9E9 NoEOffs v1000 z50 Tool0 5 Run the program in manual mode 6 Check that the calibration marks for the axes align correctly If they do not update the revolution counters The calibration marks are shown in the section Calibration scale and correct axis position on page 390 How to update the revolution counters is detailed in section Updating revoluti...

Page 398: ...5 Calibration information 5 6 Checking the calibration position 3HAC026876 001 Revision F 396 Copyright 2007 2010 ABB All rights reserved ...

Page 399: ...terials 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 are installed If the robot or the control unit is partially or completely disposed of the various parts must be grouped together according to their nature that is all iron together and all plastic together and disposed of acco...

Page 400: ...ulations Do not dispose of oil and grease near lakes ponds ditches down drains or onto soil Incineration must be carried out under controlled conditions in accordance with local regulations Also note that Spills may form a film on water surfaces causing damage to organisms Oxygen transfer could also be impaired Spillage may penetrate the soil causing ground water contamination Material Example app...

Page 401: ...on on field decommissioning The procedure below details the actions to perform on field when the balancing device is to be decommissioned Equipment Art no Note Standard toolkit The content is defined in the section Standard toolkit on page 409 Cutting torch For opening housing and cutting coils Other tools and procedures may be required See references to these procedures in the step by step instru...

Page 402: ...g device The device also contains some grease 2 Place the device on a workbench or similar Make sure it is clamped in position with a vice or similar 3 Open a hole in the side of the housing as shown in the figure Use a cutting torch The measurements shown below are maximum values xx0700000391 4 Cut the coils of the three springs inside the housing as specified below Outer spring cut at least five...

Page 403: ...3HAC026876 001 Revision F Copyright 2007 2010 ABB All rights reserved 7 Reference information 7 1 Introduction General This chapter includes general information complementing the more specific information in the different procedures in the manual ...

Page 404: ... Principles for design EN ISO 10218 11 Robots for industrial environments Safety requirements Part 1 Robot EN ISO 9787 Manipulating industrial robots Coordinate systems and motion nomenclatures EN ISO 9283 Manipulating industrial robots Performance criteria and related test methods EN ISO 14644 12 Classification of air cleanliness EN ISO 13732 1 Ergonomics of the thermal environment Part 1 EN IEC ...

Page 405: ...All rights reserved Other standards Standard Description ANSI RIA R15 06 Safety Requirements for Industrial Robots and Robot Systems ANSI UL 1740 option 429 1 Safety Standard for Robots and Robotic Equipment CAN CSA Z 434 03 option 429 1 Industrial Robots and Robot Systems General Safety Require ments Continued ...

Page 406: ...07 2010 ABB All rights reserved 7 3 Unit conversion Converter table Use the table below to convert units used in this manual Quantity Units Length 1 m 3 28 ft 39 37 in Weight 1 kg 2 21 lb Pressure 1 bar 100 kPa 14 5 psi Force 1 N 0 738 lbf Moment 1 Nm 0 738 lbf tn Volume 1 L 0 264 US gal ...

Page 407: ...e or injury Gleitmo treated screws Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint Screws treated with Gleitmo may be reused 3 4 times before the coating disappears After this the screw must be discarded and replaced with a new one When handling screws treated with Gleitmo protective gloves of nitrile rubber type should be used Screws lubricated in oth...

Page 408: ...d and never use pneumatic tools Use the correct tightening technique that is do not jerk Tighten the screw in a slow flowing motion Maximum allowed total deviation from the specified value is 10 The table below specifies the recommended standard tightening torque for oil lubricated screws with slotted or cross recess head screws The table below specifies the recommended standard tightening torque ...

Page 409: ...fies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass Dimension Tightening torque Nm Class 10 9 Molycote lubricated Tightening torque Nm Class 12 9 Molycote lubricated M8 28 35 M10 55 70 M12 96 120 M16 235 280 M20 550 M24 790 950 Dimension Tightening torque Nm Nominal Tightening torque Nm Min Tightening torque Nm Max 1 8 12 8 15 ...

Page 410: ...ecified All components exceeding 22 kg 50 lbs are highlighted 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 Example Below is an example of how a weight specification is presented inside a procedure table Action Note CAUTION The motor we...

Page 411: ...olkit and defined in the table below This way the tools required are the sum of the Standard toolkit and any tools listed in the instruction Contents standard toolkit Qty Tool Rem 1 Ring open end spanner 8 19 mm 1 Socket head cap 5 17 mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 10 100 Nm 1 Torque wrench 75 400 Nm 1 Ratchet head for torque wrench 1 2 2 Hexagon headed screw M10x100 1...

Page 412: ...ns in the Product manual procedures Description Qty Art no Extension 300mm for bits 1 2 1 3HAC12342 1 Guide pins M8 x 100 2 3HAC15520 1 Guide pins M8 x 150 2 3HAC15520 2 Guide pins M10 x 100 2 3HAC15521 1 Guide pins M10 x 150 2 3HAC15521 2 Lifting tool wrist unit 1 3HAC13605 1 Lifting tool motor ax 1 4 5 1 3HAC14459 1 Lifting tool motor ax 2 3 4 1 3HAC026061 001 Removal tool motor M10x 2 3HAC14972...

Page 413: ... 3HAC15994 1 Lifting device lower arm 1 3HAC027794 001 Lifting device gearbox axis 3 1 3HAC032724 001 Lifting eye 2 3HAC025333 001 Lifting eye VLBG M12 1 3HAC16131 1 Lifting eye M16 2 3HAC14457 4 Lifting tool chain 1 3HAC15556 1 Lifting tool gearbox axis 2 1 3HAC025214 001 Measuring tool 1 6896134 GN Motor press pinion 1 3HAC021883 001 Oil injector max 500 MPa 1 3HAC021590 001 Press gear axis 1 1 ...

Page 414: ...ation Pendulum method Oil exchange equipment The table below specifies the recommended equipment for oil exhange Description Art no Note Calibration Pendulum toolkit 3HAC15716 1 Complete kit that also includes operating manual Description Art no Note Oil exchange equipment 3HAC021745 001 Includes vacuum pump with regulator hose and coupling couplings and adapters pump manual with hose and coupling...

Page 415: ...ference in the design is described in Design 1 and Design 2 of IRB 6640 on page 48 The following setups for the tool are described Tool description on page 414 Removal front shaft design 1 and 2 on page 415 Removal front bearing Design 1 on page 419 Refitting front bearing and sealing Design 1 on page 421 Removal front bearing Design 2 on page 422 Refitting front bearing with sealing Design 2 on p...

Page 416: ... ABB All rights reserved Tool description xx0900000024 Item Mark Description 1 Hydraulic cylinder not included in tool 3HAC028920 001 ordered sepa rately 2 A Press tool D 103 3 D Press tool D 54 4 Threaded bar M16 5 B Adapter M16 M20 6 F Knurled nut D 80 7 C Slide hammer Distance 8 Nut M16 Continued Continues on next page ...

Page 417: ... shaft Design 1 and 2 In the figure only Design 1 is shown 9 E Press tool D 85 10 K Press tool D 100 11 G Press tool D 110 12 J Press tool D 90 13 H Press tool D 62 Item Mark Description Configuration 8 C 4 B xx0900000026 1 Assemble the adapter B into the shaft 2 Assemble the threaded bar M16 into the adapter 3 Assemble the Slide hammer Distance on to the threaded bar M16 4 Assemble the nut M16 xx...

Page 418: ... All rights reserved Alternative con figuration 4 F 1 A B xx0900000028 1 Assemble the adapter B into the shaft 2 Assemble the threaded bar M16 into the adapter 3 Assemble the Press tool D 103 on to the threaded bar M16 4 Assemble the hydraulic press 5 Assemble the knurled nut D 80 xx0900000029 Continued Continues on next page ...

Page 419: ... 417 3HAC026876 001 Revision F Copyright 2007 2010 ABB All rights reserved Refitting front shaft design 1 and 2 The following configuration is used for refitting of the front shaft Design 1 and 2 Configuration 8 C 4 xx0900000063 xx0900000091 Continued Continues on next page ...

Page 420: ...8920 001 3HAC026876 001 Revision F 418 Copyright 2007 2010 ABB All rights reserved xx0900000065 1 Assemble the threaded bar M16 4 2 Assemble the Slide hammer Distance C on to the threaded bar M16 3 Assemble the nut M16 8 xx0900000064 Continued Continues on next page ...

Page 421: ...guration is used for removal of the front bearing Design 1 Configuration D A C 8 4 xx0900000031 1 Assemble the press tool D 54 D onto the threaded bar 4 2 Assemble the threaded bar M16 with the press tool through the assembled bearing 3 Assemble the Press tool D 103 on to the threaded bar M16 4 Assemble the Slide hammer Distance 5 Assemble the nut M16 xx0900000032 Continued Continues on next page ...

Page 422: ...tive con figuration D A 1 F 4 xx0900000033 1 Assemble the press tool D 54 D onto the threaded bar 4 2 Assemble the threaded bar M16 with the press tool through the assembled bearing 3 Assemble the Press tool D 103 A on to the threaded bar M16 4 Assemble the hydraulic press 1 5 Assemble the Knurled nut D 80 F xx0900000034 Continued Continues on next page ...

Page 423: ...ign 1 The following configuration is used for refitting of the front bearing and sealing Design 1 Configuration 4 F E C 8 xx0900000036 1 Insert the threaded bar 4 through the new bearing and place it in the ear 2 Assemble the Knurled nut D 80 F 3 Assemble the Press tool D 85 E 4 Assemble the Slide hammer Distance C 5 Assemble the Nut M16 8 xx0900000037 Continued Continues on next page ...

Page 424: ...ation is used for removal of the front bearing Design 2 Configuration H A C 8 4 xx0900000038 1 Assemble the press tool D 62 H onto the threaded bar 4 2 Assemble the threaded bar M16 with the press tool through the assembled bearing 3 Assemble the Press tool D 103 A on to the threaded bar M16 4 Assemble the Slide hammer Distance C 5 Assemble the nut M16 8 xx0900000039 Continued Continues on next pa...

Page 425: ...tive con figuration H A 1 F 4 xx0900000040 1 Assemble the press tool D 62 H onto the threaded bar 4 2 Assemble the threaded bar M16 with the press tool through the assembled bearing 3 Assemble the Press tool D 103 A on to the threaded bar M16 4 Assemble the hydraulic press 1 5 Assemble the Knurled nut D 80 F xx0900000041 Continued Continues on next page ...

Page 426: ...ign 2 The following configuration is used for refitting of the front bearing with sealing Design 2 Configuration 4 F J 7 8 xx0900000042 1 Insert the threaded bar 4 through the new bearing and place it in the ear 2 Assemble the Knurled nut D 80 F 3 Assemble the Press tool D 90 J 4 Assemble the Slide hammer Distance C 5 Assemble the Nut M16 8 xx0900000043 Continued Continues on next page ...

Page 427: ...2 The following configuration is used for removal of the rear shafts Design 1 and 2 Configuration B A J C 8 4 xx0900000044 1 Assemble the adapter B into the shaft 2 Assemble the threaded bar 4 and the adapter B 3 Assemble the Press tool D 103 A on to the threaded bar M16 4 Assemble the Slide hammer Distance C 5 Assemble the nut M16 8 xx0900000045 Continued Continues on next page ...

Page 428: ...s Design 1 The following configuration is used for refitting of the rear shafts Design 1 Configuration 4 F G C 8 xx0900000047 1 Insert the threaded bar 4 through the new bearing 2 Assemble the Knurled nut D 80 F 3 Assemble the Press tool D 110 G 4 Assemble the Slide hammer Distance C 5 Assemble the Nut M16 8 xx0900000060 xx0900000048 Continued Continues on next page ...

Page 429: ...g rear shafts Design 2 The following configuration is used for refitting of the rear shafts Design 2 Configuration 4 K G C 8 xx0900000049 1 Insert the threaded bar 4 through the new bearing 2 Assemble the Press tool D 100 K 3 Assemble the Press tool D 110 G 4 Assemble the Slide hammer Distance C 5 Assemble the Nut M16 8 xx0900000061 xx0900000050 Continued ...

Page 430: ...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 This implies that the instructions delivered with the lifting equipment should be stored for later reference ...

Page 431: ...Revision F Copyright 2007 2010 ABB All rights reserved 8 Spare parts 8 1 Spare parts and exploded views Introduction Spare parts and exploded views are not included in the manual but delivered as a separate document on the documentation DVD Article number 3HAC038330 001 ...

Page 432: ...8 Spare parts 8 1 Spare parts and exploded views 3HAC026876 001 Revision F 430 Copyright 2007 2010 ABB All rights reserved ...

Page 433: ...C024480 005 IRC5 Panel Mounted Controller 3HAC026871 005 IRC5 Compact 3HAC031403 003 Product Article numbers for circuit diagrams IRB 120 3HAC031408 003 IRB 140 3HAC6816 3 IRB 260 3HAC025611 001 IRB 360 3HAC028647 009 IRB 660 3HAC025691 001 IRB 1410 3HAC2800 3 IRB 1600 3HAC021351 003 IRB 2400 3HAC6670 3 IRB 2600 3HAC029570 007 IRB 4400 4450S 3HAC9821 1 3HAC9821 1 IRB 4600 3HAC029038 003 IRB 6400RF...

Page 434: ...9 Circuit diagrams 9 1 About circuit diagrams 3HAC026876 001 Revision F 432 Copyright 2007 2010 ABB All rights reserved Continued ...

Page 435: ...nation 43 sensitive equipment 43 wrist strap connection point 43 F fire extinguishing 25 FlexPendant jogging to calibration position 395 MoveAbsJ instruction 395 updating revolution counters 393 foundation loads 59 requirements 59 G gearbox axis 3 replacement 376 gearbox axis 6 replacement 382 H hold to run 29 I inspecting oil levels axis 6 132 installation mechanical stop axis 1 98 mechanical sto...

Page 436: ...se manipulator arm 26 service 16 signal lamp 31 signals 34 signals in manual 34 symbols 34 symbols on manipulator 36 test run 41 working range 30 wrist strap 43 safety equipment mechanical stop 98 mechanical stop axis 2 100 mechanical stop axis 3 102 signal lamp 159 safety risk electric parts 23 hot parts 19 hydraulic system 21 installation 17 oil change 44 operational disturbance 22 pneumatic sys...

Page 437: ... 272 V validity and responsibility 16 W weight balancing device 302 313 base plate 73 77 complete arm system 254 256 gearbox 379 380 lower arm 281 282 motor 330 340 upper arm 274 276 wrist unit 266 267 270 271 weight robot 58 working range 60 restricting axis 1 98 restricting axis 2 100 restricting axis 3 102 wrist unit replacement 264 ...

Page 438: ...4363HAC026876 001 Revision F Copyright 2007 2010 ABB All rights reserved ...

Page 439: ......

Page 440: ...ABB Robotics S 721 68 VÄSTERÅS SWEDEN Telephone 46 0 21 344000 3HAC 026876 001 Revision F en ...

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