ABB IRB6400, Assembly Manuallines

Page 1: ...Effective Date June 1 1996 FlexibleAutomationInc 1250 Brown Road Auburn Hills Mich 48326 1 800 451 6268 FOR IRB6400 INDUSTRIAL ROBOT MECHANICAL DISASSEMBLY ASSEMBLY GUIDELINES Manual Part 7000695 001 ...

Page 2: ...idelines Safety During Maintenance Safety During Programming Safety Control Chain of Operation Risks Associated with Live Parts Limitation of Liability 3 ROBOT HANDLING Robot Lifting Crane Lifting Robots Fork Lifting Robots Crane Fork Lifting S 2 9 120 Robots Fork Lifting PE 2 9 75 Robots Releasing Axes Brakes Manually Restricting Axes Movement Mechanically 4 MAINTENANCE General Maintenance Mainte...

Page 3: ...tion Lower Parallel Arm Removal Installation Upper Arm Assembly Removal Installation 7 AXIS 4 GUIDELINES Motor Removal Installation Intermediate Gear Unit Removal Installation Final Gear Removal Installation Tube Shaft Removal Installation 8 AXIS 5 GUIDELINES Motor Removal Installation Wrist Assembly Removal Installation 9 AXIS 6 GUIDELINES Motor Gear Reduction Unit Assembly Removal Installation 1...

Page 4: ...ing Calibration Procedure Alternative Calibration Procedure Calibration Equipment 12 PARTS LISTS ILLUSTRATIONS Base B Shoulder S Lower Arm L Upper Arm U Wrist W Face F Shoulder Shelf Mounted SM Lower Arm Early Robot Models LE Base Fan BF 13 REFERENCE MECHANICAL LAYOUTS 14 REFERENCE CABLE LAYOUTS Table of Contents Cont Table of Contents Cont ...

Page 5: ...Disassembly Assembly Guidelines IRB 6400 Introduction SECTION 1 ...

Page 6: ...uidelines IRB 6400 Introduction INTRODUCTION Table of Contents Page Subject 1 1 How to Use This Manual 1 5 What You Must Know to Use the Robo t 1 6 Robot Components 1 7 Robot Identification 1 8 Symbols Used in this Manual a ...

Page 7: ...uipment You should read and unde r stand this information and periodically review it to ensure you are working safely Section 3 ROBOT HANDLING Section 3 presents data and illustrations on how to lift the robot how to man u ally release the robot axes brakes and how to mechanically restrict axis mov e ment Section 4 MAINTENANCE Section 4 contains the robot periodic maintenance schedule detailed mai...

Page 8: ... as guidelines when you disasse m ble and assemble components associated with the robot s Axis 5 These ou t lines are presented in a clear step by step format Each part involved in a procedure is identified by a number that is in a list and on an exploded illustr a tion For example motor W52 is illustrated on the W exploded illustration and listed in the illustration s accompanying parts list in S...

Page 9: ...ponents W WRIST components F FACE components SM SHELF MOUNTED SHOULDER components Note that the Shelf mounted shoulder components DO NOT have disassembly and assembly guidelines in this manual The exploded illustration and parts list are included for parts identification only LA EARLY MODEL LOWER ARM components Note that the early model lower arm components DO NOT have disassembly and as sembly gu...

Page 10: ... electrical cables reference layouts that you can refer to for added clarification of component relationship The layouts are actual copies of working drawings and have reference numbers that DO NOT refer to reference numbers in the disassembly and assembly guidelines However they can help to clarify several procedures ...

Page 11: ...wer supply must always be switched off whenever work is carried out Note that even though the power is switched off any orange colored cables may be live The reason for this is that these cables are connected to external equipment and are consequently not affected by the mains switch on the robot controller WARNING ALL PERSONNEL WORKING WITH THE ROBOT SYSTEM MUST BE COMPLETELY FAMILIAR WITH THE SA...

Page 12: ...ote that the left side of the robot is on your left side if you were standing behind and facing In short the robot s left side is the same as your left side LEFT SIDE UPPER ARM LOWER ARM PARALLEL ARM WRIST FACE SHOULDER BASE BALANCE CYLINDER BALANCE WEIGHT AXIS 4 MOTOR AXIS 3 MOTOR AXIS 2 MOTOR AXIS 1 MOTOR inside AXIS 5 MOTOR inside ROBOT S ROBOT S RIGHT SIDE AXIS 6 MOTOR ...

Page 13: ...botics Type Manufacturing no M94A Type IRB 6400 2 4 120 Nom load see instruction s Net weight IRB 6400 2 4 120 1825 KG 2 4 150 2 8 120 1950 KG 3 0 75 1950 KG S 2 9 120 2450 KG PE 2 25 75 1524 KG ABB Robotics Products AB S4 M94A program Program No3HAB XXXX X Boot Disk1 2 Serial NoIRB 6400 XXXX Property of ABB Västerås Sweden All rights reserved Reproduction modification use or disclosure to third p...

Page 14: ...pment if care is not followed NOTE This symbol calls your attention to added information worthy of your notation BULLET The bullet is used to denote an item in a list of important items It is also used to denote a step in a list of important steps to follow to perform a procedure COMPONENT WEIGHT The component weight box is used to give you a quick reference to the appro x imate weight of the comp...

Page 15: ...Disassembly Assembly Guidelines IRB 6400 Safety SECTION 2 ...

Page 16: ...f Contents Page Subject 2 1 Important 2 2 General Safety 2 3 Safety Features 2 4 Safety Guidelines 2 5 Safety During Maintenance 2 6 Safety During Programming 2 7 Safety Control Chain of Operation 2 8 Risks Associated with Live Parts 2 9 Limitation of Liability a ...

Page 17: ...vailable from the DEPARTMENT OF LABOR WASHINGTON D C Read all safety precautions before operating the robot Failure to follow safety instructions may result in personal injury and or damage to machine comp o nents The information in this manual does not discuss how to design install or ope r ate a complete system It does not cover external equipment not supplied by ABB ABB has supplied the robot w...

Page 18: ...n effect The robot should be approached with the same caution as any other industrial machine Although ABB robots are designed for the greatest possible safety no machine is completely safe and it is impossible to entirely eliminate the h u man factor This robot was designed with safety in mind It has a dedicated safety system based on a two channel circuit which is monitored continuously If an er...

Page 19: ... s safety functions to be activated both by peripheral equi p ment and by the robot itself Delayed Safeguarded Space Sto p Such as a Hold circuit A delayed stop gives a smooth stop The robot stops in the same way as a normal program stop with no deviation from programmed path After 1 2 seconds the power supplied to the motors shuts off Restricting the Working Space The movement of each of the axes...

Page 20: ...e robot when the sy s tem is in the RUN mode One person should remain outside the envelope with the sole responsibility of activating the EMERGENCY STOP button in case a dangerous situation should arise If you have to be within the work envelope of the robot Make sure that the entire work cell has been prepared for safe operation before running the robot system Correct all abnormal conditions of t...

Page 21: ...rds When working on the robot controller or while the robot is in the production mode make sure that the work envelope is clear of personnel Always disconnect main power and Lock Out the switch box before i n spection Replace all equipment service covers after performing a maintenance pr o cedure Always have an escape path planned Never slow or stop the robot with any body part or makeshift device...

Page 22: ...ole control of the programmer Only the programmer is allowed in the restricted work envelope Movement of equipment into the work envelope must be under the sole control of the programmer The robot must always be operated at slow speeds except when a higher speed is needed for program verification The programmer must always be outside the restricted work envelope of the robot before initiating the ...

Page 23: ...electrical safety chains are continuously monitored and the robot reverts to the MOTORS OFF mode when a fault is detected by the computer MO TORS OFF mode means that drive power is removed from the robot s motors and the brakes are applied The status of the switches are indicated by the LEDs on the front of the System board DSQC 256A in the Control Cabinet If any contact in the safety chain of ope...

Page 24: ...or tooling or special power supply units for the m a chining process The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains Additional connections Manipulator A danger of high voltage is associated with the manipulator in The power supply for the motors up to 340 V DC The user connections for tooling or other parts of the installation ...

Page 25: ...lated Information Described in Installation of safety device s IRB 6400 Product Manual Chapter 7 Installation and Commissioning ABB Part 3HAB 0009 55 Changing robot mode s S4 User s Guide Chapter 4 Basic Operations ABB Part 3HAB 5805 1 Limiting the working space S4 User s Guide Chapter 12 System Parameters ABB Part 3HAB 5805 1 IRB 6400 Product Manual Chapter 7 Installation and Commissioning ABB Pa...

Page 26: ...Disassembly Assembly Guidelines IRB 6400 Robot Handling SECTION 3 ...

Page 27: ...HANDLING Table of Contents Page Subject 3 1 Robot Lifting 3 2 Crane Lifting Robots 3 3 Fork Lifting Robots 3 4 Crane Fork Lifting S 2 9 120 Robot s 3 4 Fork Lifting PE 2 25 75 Robots 3 5 Releasing Axes Brakes Manually 3 6 Restricting Axes Movement Mechanicall y a ...

Page 28: ...Figure 1 The lifting straps dimensions must comply with the applicable standards for lif t ing It is also possible to mount two lifting devices option for use of a fork lift see Figure 3 WARNING NEVER WALK UNDER A SUSPENDED LOAD Figure 1 Lifting the manipulator using a traverse crane LIft position Version A 2 4 120 2 4 150 2 8 120 3 0 75 700 700 1350 1350 Crane lift for 2 4 120 2 4 150 2 8 120 and...

Page 29: ...ot Handling Page 3 2 Figure 2 Lifting the manipulator with the arm system in the calibration position Lifting wires must go between the upper arm and motor of axis 4 Crane lift in calibation position for models 2 4 120 2 4 150 2 8 120 and 3 0 7 5 ...

Page 30: ... the manipulator using a fork lift WARNING CRANE LIFT IS NOT ALLOWED WITH FORK LIFT ARRANGEMENT Fork lift for models 2 4 120 2 4 150 2 8 120 and 3 0 7 5 400 1120 1050 valid for 2 4 150 2 8 120 3 0 75 A 400 910 Lift position Version A 2 4 120 2 4 150 2 8 120 3 0 75 700 700 1350 1350 ...

Page 31: ...WARNING FORK LIFT BRACKET MUST BE REMOVED BE FORE ROBOT IS OPERATED Figure 4 Lifting the manipulator using a crane or a fork lift Figure 5 Lifting the manipulator using a fork lift Crane lift for S 2 9 120 Fork lift for S 2 9 120 400 910 700 Fork lift for PE 2 25 75 ...

Page 32: ...ction of external voltage to enable releasing of the brakes When the controller or the voltage device is connected illustrated above the brakes can be released separately by means of the push buttons on the brake release unit on the exterior of the axis 3 gear box The push buttons are marked with the appropriate axis name The names of the axes and their m o tion patterns are illustrated in Figure ...

Page 33: ...tion for axis 1 can be limited mechanically by fitting extra m e chanical stop arms 3HAB 4224 001 Instructions for doing this are supplied with the kit CAUTION THE MECHANICAL STOP PIN AND THE EXTRA MOV ABLE MECHANICAL STOP ARM FOR AXIS 1 BE REPLACED AF TER ANY HARD COLLISION TYPE STOP IF THE PIN OR ARM HAS BEEN BENT OR DAMAGED IN ANY WAY Axes 2 and 3 The working range of axes 2 and 3 is limited by...

Page 34: ...Disassembly Assembly Guidelines IRB 6400 Maintenance SECTION 4 ...

Page 35: ...is 6 Gearbox F17 4 12 Checking Axis 1 Mechanical Stop 4 13 Changing Measuring System Battery 4 14 Changing Axis 1 Cooling Filter 4 15 Changing Control Air Conditioner Filter 4 16 Changing Control Memory Battery Backup 4 17 Adjustments 4 17 Adjusting Axis 4 Gear Play 4 17 Adjusting Play Between Intermediate Gear U74 Final Gear U41 4 17 Adjusting Play Between Axis 4 Motor Pinion U42 Intermediate Gea...

Page 36: ...uired Use a vacuum cleaner or wipe it with a cloth Compressed air and harsh solvents that can damage the sealing joints bearings lacquer or cabling must not be used The control system is completely enclosed which means that the electro n ics are protected in a normal working environment In very dusty enviro n ments nevertheless the interior of the cabinet should be inspected at regular intervals U...

Page 37: ...K ONCE A YEAR 6000 HRS OR 3 YEARS X X X X X X X X Gearbox 1 2 3 6 GREASE CHANGING 3 yrs X X X 3 yrs 1 2 3 4 5 6 5 X X X X X PRESCRIBED MAINTENANCE 1 Recommended interval for large movements on axis 1 over 45 Typical for materals handling 2 Inspect all visible cabling Change if damaged 3 Check the mechanical stop devices for deformation and damage If the stop pin or the adjustable stop arm is bent ...

Page 38: ...sonnel that the cabling between the control cabinet and robot is not damaged Cleaning Clean the robot exterior with a cloth when necessary Do not use aggre s sive solvents which may damage paint or cabling Checking Oil and Grease Levels Axes 1 2 3 and 6 The level in the gearboxes is checked by adding new grease until grease comes out through the special draining holes See pages 4 5 4 6 4 11 Axes 4...

Page 39: ...two plug holes Grease through the two nipples 1 Turn the axis 1 90o while greasing is in progress Continue greasing until new grease exudes from the rubber seal 2 Remove excess grease with a cloth Type of grease ABB art no 1171 4013 301 quality 7 1401 301 ESSO Beacon EP 2 Shell Alvanina EP Grease SKF Grease LGEP 2 BP Energrease LS EP 2 Tools See Tool List page 4 25 A A A A 1 2 A A ...

Page 40: ...e drain tube See Vo l ume below Axis 1 should be slowly moved backwards and forwards while greasing Move the axes backwards and forwards a couple of times before the plugs are replaced so that excess grease is pressed out This is to prevent over pressure in the gearbox with risks for leakage Volume 1 3 litres 0 36 US gallon About 3 0 litres 0 82 US gallon should be used when changing the grease Ty...

Page 41: ...ds several times while greasing Continue greasing until new grease exudes from the drain hole 2 See Volume below Move the axes backwards and forwards a couple of times before the plugs are replaced so that excess grease is pressed out This is to prevent over pressure in the gearbox with risks for leakage Volume 1 3 litres 0 36 US gallon About 2 0 litres 0 82 US gallon should be used when changing ...

Page 42: ...it the drain plug A Fill up with new oil until the oil level reaches the lower edge of the filling hole B For S 2 9 120 robots only Move the upper arm to the maximum upper position before draining the oil Move the upper arm to the vertical position before filling oil Fill up with new oil until the level is 30 35 mm below the upper side of the cover Volume approx 6 litres 1 75 US gallon Correct oil...

Page 43: ... IRB 6400 Page 4 8 Maintenance Type of oil ABB 1171 2016 604 Equivalents BP Energol GR XP 320 Castrol Alpha SP 320 Esso Spartan EP 320 Klüber Lamora 320 Mobil Mobilgear 632 Optimol Optigear 5180 Shell Omala Oil 320 Texaco Meropa 320 ...

Page 44: ...ake on Axis 4 Clean the magnetic drain plug 1 before refitting Turn Axis 4 90o before filling oil Fill the oil through hole 1 until the oil is level with the lower edge of the filler hole For S 2 9 120 Robots Move the upper arm to the max upper position before draining the oil Move the upper arm to the vertical position before filling oil Fill up with new oil until the oil is level with the edge o...

Page 45: ... IRB 6400 Page 4 10 Maintenance Type of oil ABB 1171 2016 604 Equivalents BP Energol GR XP 320 Castrol Alpha SP 320 Esso Spartan EP 320 Klüber Lamora 320 Mobil Mobilgear 632 Optimol Optigear 5180 Shell Omala Oil 320 Texaco Meropa 320 ...

Page 46: ...f the turning gear or radiell nipple of turning gear 3 Rotate axis 6 while greasing Continue to grease until new grease exudes from the drain hole 1 See Volume below Move Axis 6 backwards and forwards a couple of times before the plugs are replaced so that excess grease is pressed out This is to prevent over pressure in the gearbox with risks for leakage Volume 0 25 litres 0 07 US gallon About 0 4...

Page 47: ...ns that the stop pin is not bent Adjustable stop arms that the arms are not bent If any of the adjustable stop arms is bent it shall be replaced by a new one WARNING IF THE STOP PIN IS BENT A COLLISION BE TWEEN THE SWINGING STOP ARM AND THE STOP PIN HAS PROBABLY OCCURRED A BENT STOP PIN SHALL ALWAYS BE REPLACED BY A NEW ONE Article number Stop pin 3HAB 4082 1 Adjustable stop arm 3HAB 4533 3 Option...

Page 48: ...hrown away it must always be handled as hazar d ous waste Set the robot to the MOTORS OFF operating mode This means that it will not have to be coarse calibrated after the change Unplug the battery connector R2 G from the serial measuring board and cut the tie wraps that keep the battery unit in place Install a new battery with two new tie wraps and connect the plug to the serial measuring board N...

Page 49: ...es IRB 6400 Page 4 14 Maintenance Changing Axis 1 Cooling Filte r Loosen the filter holder at the intake and remove filter Insert the new filter and replace the filter holder The article number of the filter is 3HAA 1001 612 FILTER ...

Page 50: ...00 Page 4 15 Maintenance Changing Control Air Conditioner Filte r Remove the grating on the left side of the refrigerating machine Remove the old filter and insert a new one Replace the grating The article number of the filter is 7820 004 3 ...

Page 51: ...lls could overheat Do not burn or dispose of batteries in nor mal trash collection batteries should be collected for disposal in a proper and safe way for disposing of lithium batteries Store the parameters and the program on a diskette in order not to lose important information from the memory Turn the main electrical disconnect switch OFF Unplug the battery connectors from the backplane Remove t...

Page 52: ... rotating Adjusting Play Between Intermediate Gear U74 and Final Gear U41 1 Attach magnetic base of dial indicator to machined surface where the axis 4 motor mount to the upper casting 2 Set dial indicator to read on large diameter intermediate gear U74 tooth slot 3 Shift hub U72 around until play is between 0 0004 0 001 in 4 Tighten three screws U67 to a torque of 52ft lbs 5 Tighten hex nuts U76 ...

Page 53: ... Gallons Checking Axis 5 Gear Play The following conditions are to exist before play is checked Oil drained from gear case W8 Gear case cover W68 and gasket W67 removed Axis 5 motor W52 brake engaged holding axis 5 from turning Checking play Mount fixing plate tool ABB 6896 134 CE in three cover screw holes Mount a magnetic dial indicator to the fixing plate tool Measure play against front part of...

Page 54: ...magnetic base mounted Adjusting play between intermediate gear and pinion gear Shift the intermediate gear hub W38 to obtain a play 0 00 0 08 mm between the intermediate gear W41 and the pinion W76 Measure the play at three different places Tighten the intermediate gear hub W38 with the center screw W48 and torque to 70 ft lb Install wedges W64 Install spring washers W65 Concave surfaces face each...

Page 55: ...new bearings are being installed tighten the locknut W43 to a torque of 64 ft lb 5 Use tool ABB 3HAB 1022 1 together with the torque wrench If the old bearings are being re installed tighten the locknut W43 to a torque of 52 56 ft lb Use tool ABB 3HAB 1022 1 together with the torque wrench REFERENCE DRAWINGS Exploded View 3HAA 0001 GX pg 13 18 Assemblies W pg 12 5 3HAA 0001 GX pg 13 21 REQUIRED TO...

Page 56: ...4 CF Measure play with a dial indicator 190 mm from center of axis 6 Maximum play allowed is 0 06 mm Play cannot be adjusted Complete gear reduction unit must be replaced if play exceeds the allowed amount REFERENCE DRAWINGS Exploded View 3HAA 0001 APJ pg 13 15 Assemblies U pg 12 4 3HAA 0001 AP pg 13 14 3HAA 0001 CS pg 13 17 REQUIRED TOOLS Dial Indicator ABB 6896 134 CF F pg 12 6 3HAB 4172 1 pg 13...

Page 57: ...AXIS 1 FOR PRESS TENDING HEAVY DUTY OPERATIO N Option 51 PT adaptation for IRB 6400 2 8 120 Hreavy duty axis 1 option 5X installed 12 000 7 000 9 000 10 000 11 000 6 000 8 000 4 5 5 5 6 6 5 Cycle time s 4 5 Operation h Cycle time s Life time operation h 40 000 30 000 20 000 10 000 3 4 5 6 7 8 9 ...

Page 58: ...nes IRB 6400 Page 4 23 Maintenance Moment of inertia Ja6 kgm2 50 100 120 40 000 30 000 20 000 10 000 Life time operation h 12 000 11 000 10 000 9 000 8 000 7 000 6 000 5 000 4 000 Operation h Moment of inertia Ja6 kgm2 50 100 120 ...

Page 59: ...ressure gaugeI VRF 31 Holding tool tube shaft end6896 134 BU Holding tool final gear6896 134 FK Pressing tool tube shaft6896 0011 YJ Pressing tool housing and rear bearing6896 134 FL Hydraulic cylinderNIKE CLF 50 10 HoseNIKE LS 150 HoseNIKE SL 51 2 units Pressure gaugeNIKE AMT 150 Lifting device for bearing axis 16896 134 XD Lifting device gear coupling disc6896 134 FW FX Hydraulic cylinderNIKE I ...

Page 60: ...r KM socket4 KM 6 Tubular KM socket ext for S 2 9 1203HAA 7601 038 Guide pins 2M12x200 Guide pins 2M12x300 Tightening tool3HAB 1022 1 Calibration Tool for TCP Check Tool for TCP adjustment3HAA 1001 UA X 15 mm Z 150mm Calibration set for Vision3HAA 0001 XR Tools for Grease Replacement Axis 1 3 Axis 1 Socket3HAB 156 1 Nipple3HAA 7601 090 HoseD 18 12 mm L 1000 mm Hose ClipD 15 20 mm SocketSquare 1 2 ...

Page 61: ...Disassembly Assembly Guidelines IRB 6400 Axis 1 SECTION 5 Disassembly Assembly ...

Page 62: ...ts Page Subject Mechanical Procedures 5 1 Motor S16 Removal 5 3 Motor S16 Installation 5 5 Gear Reduction Unit S59 Removal 5 8 Gear Reduction Unit S59 Installatio n 5 11 Bearing B47 Removal 5 14 Bearing B47 Installation 5 17 Illustration Base Parts 5 18 Illustration Shoulder Parts a ...

Page 63: ... MP1 B18 FROM MOTOR S16 6 REMOVE MOTOR S16 FROM ROBOT a Remove 4 screws S13 and 4 washers S15 b Use two M8 x 40 screws in threaded holes in motor mounting flange to loosen motor mounting Permatex S17 was used to install motor and mounting joint will be hard to break free c Carefully lift motor S16 straight up and out of robot CAUTION DO NOT TAP OR HIT MOTOR SHAFT d Cover cavity to prevent objects ...

Page 64: ...e screw S19 Use a strap wrench to hold pinion from rotating while removing screw b If pinion S18 is tight on motor S16 shaft screw an M10x150 screw into threaded hole and pull pinion from motor shaft with the help of a small 3 jaw gear puller Use the key slot hole in the side of the pinion to engage one jaw of the puller c Pinion S18 is matched to gear reduction unit S59 so keep it for re assembly...

Page 65: ...lide a washer over the M10x150 Rod thread on an M10 hex nut and wind the nut down the stud pressing on the pinion S18 CAUTION DO NOT TAP OR HIT MOTOR SHAFT d Remove the threaded rod washer and nut e Apply Loctite 242 S20 to screw S19 and insert in end of motor S16 shaft Torque to 52 ft lb Use strap wrench to hold pinion from turning 3 APPLY PERMATEX 3 S17 TO MOTOR S16 MOUNTING SURFACE 4 CAREFULY S...

Page 66: ...delines 6 CONNECT MOTOR CABLES S22 a Connect signal cable R3 FB1 S22 b Connect power cable R2 MP1 B18 7 INSTALL HOLDER S25 WITH SCREW S24 USE TIE WRAP S23 TO SECURE CABLES TO HOLDER 8 INSTALL COVER S43 WITH SCREWS S42 9 CALIBRATE AXIS 1 as outlined in Section 11 ...

Page 67: ...lug connector R2 SMB X2 at serial measuring board on measure card unit S10 d Disconnect air hose in the base casting near the axis 1 motor 5 SLIDE CABLE GUIDE RAIL B16 OUT OF WAY a Remove screw B13 and washer B15 on right side that is hold ing cable guide rail B16 b Just loosen screw B13 on left side Leave it engaged to hold plate B23 in place c Slide cable guide rail B16 away from cable to provid...

Page 68: ...EQUIPMENT as shown in the figure Take up all slack in lifting cables but do not actually lift NOTE It is important to adjust cable lengths so lift action is straight up and down to keep bearing S46 alignment square to its bore CAUTION ROBOT MUST BE LIFTED STRAIGHT UP IN A BAL ANCED CONDITION BE SURE SLING LENGTHS ARE COR RECT FOR LIFTING STRAIGHT UP 9 DISCONNECT GEAR REDUCTION UNIT S59 FROM BASE H...

Page 69: ...efully lift robot straight up pulling bearing S46 out of its bore in base housing B24 b Set robot on safe supports that allow access to remove gear reduction unit S59 from underneath c DO NOT remove lifting equipment Use it to add to the safety of supporting the robot 13 REMOVE GEAR REDUCTION UNIT S59 a Remove screws S61 and washers S60 b Remove gear reduction unit S59 c Remove friction ring S57 O...

Page 70: ...t this time f Remove threaded guide pins g Insert remaining two screws S61 with washers S60 h Progressively tighten all screws S61 Torque to 90 ft lb 4 SET ROBOT ONTO BASE B24 a Lightly grease O Ring S63 with lubricating grease S74 Set O Ring in place in base housing B24 b Position friction ring S62 and set in place in base housing B24 c Insert two M12x200 threaded rods into threaded holes in base...

Page 71: ... Insert screws S44 and washers S45 Progressively tighten and torque to 90 ft lb c Tighten screws S50 Torgue to 224 ft lb d Tighten screws S53 Torque to 90 ft lb SEE MOTOR INSTALLATION PAGE 5 3 7 RE MOUNT SYNC PLATE BRACKET AT LEFT SIDE TOP OF BASE HOUSING B24 8 REMOVE LIFTING EQUIPMENT 9 CONNECT LOWER CABLE B18 CONNECTORS a Connect the following connectors R2 CS R2 CP R2 MP5 6 R2 MP4 R2 MP3 R2 MP2...

Page 72: ...left side screw S14 apply Loctite 242 S12 and re insert Tighten screw 12 CONNECT AIR HOSE PLUG IN CONNECTOR R2 SMB a Plug in connector R2 SMB X2 at serial measuring board on measure card unit S10 b Install air hose as required c Position serial measurement board in mounted position and secure with screws S12 13 INSTALL COVER B9 a Mount air hose connection to cover B9 b Mount cover B9 to base housi...

Page 73: ... S21 c Disconnect air hose if installed d Unplug connector R2 SMB X2 at serial measuring board on measure card unit S10 5 SLIDE CABLE GUIDE RAIL B16 OUT OF WAY a Remove screw B13 and washer B15 on right side that is hold ing cable guide rail B16 b Just loosen screw B13 on left side Leave screw to hold plate B23 in place c Slide cable guide rail B16 away from cable to provide working room and clear...

Page 74: ...NT as shown below Take up all slack in lifting cables but do not actually lift yet It is important to adjust cable lengths that result in the lift action being straight up and straight down to keep bearing S46 squared to its bore in base housing B24 CAUTION ROBOT MUST BE LIFTED STRAIGHT UP IN A BAL ANCED CONDITION BE SURE SLING LENGTHS ARE COR RECT FOR LIFTING 9 DISCONNECT GEAR REDUCTION UNIT S59 ...

Page 75: ... out of its bore in base housing B24 If necessary adjust lifting cable lengths to ensure robot is lifted up with bearing square to its bore in base b Set robot on safe supports that allow access to remove bearing S46 from underneath c DO NOT remove lifting equipment Use it to add to the safety of supporti6g the robot 13 REMOVE BEARING S46 FROM FRAME HOUSING S21 a Prepare to catch bearing S46 when ...

Page 76: ...t O Ring in place in base housing B24 b Insert friction ring S62 and set in place in base housing B24 c Insert two guide rods M16x300 into base of robot to hold friction ringsin position d Carefully lower robot until bearing S46 is just about to enter its seat in base housing B24 e Align bearing screw holesusing two screws S44 f Continue to lower robot until bearing S46 is fully seated 4 MOUNT BEA...

Page 77: ...ighten screws S53 Torque to 90 ft lb 6 RE MOUNT SYNC PLATE BRACKET AT LEFT SIDE TOP OF BASE HOUSING B24 7 REMOVE LIFTING EQUIPMENT 8 CONNECT LOWER CABLE B18 CONNECTORS a Connect the following connectors R2 CS R2 CP R2 MP5 6 R2 MP4 R2 MP3 R2 MP2 and R2 FAN if fan installed b Connect the following connectors to brake release unit S64 R3 BU4 6 X10 R3 BU1 6 X8 R3 BU1 3 X9 c Mount brake release unit S6...

Page 78: ... S12 and re insert Tighten screw 11 CONNECT AIR HOSE PLUG IN CONNECTOR R2 SMB a Plug in connector R2 SMB X2 at serial measuring board on measure card unit S10 b Install air hose as required c Position measure card unit in mounting position and secure with screws S12 12 INSTALL COVER B9 a Mount air hose connection to cover B9 b Mount cover B9 to base housing B24 and secure with screws B8 13 GREASE ...

Page 79: ...14 Loctite 242 1269 0014 410 15 2 Washer 6 4x12x1 6 2151 2062 153 16 1 Cable Guide Rail 3HAA 1001 691 17 4 Screw M6x8 2121 2416 368 18 1 Lower Cable Assembly without cust connect 3HAB 4248 1 with cust connection S 2 9 120 3HAB 4249 1 1 Earth sign 2940 0412 1 1 Screw M6x20 2121 2411 370 1 Washer 6 4x12x1 6 2151 2062 153 19 2 Washer 8 4x16x1 6 2151 2062 165 20 2 Screw M8x40 8 8 2121 2519 459 21 Loct...

Page 80: ...062 177 48 15 Screw M12x70 12 9 3HAB 3409 73 49 1 Plug KR 1 2 2522 2021 113 50 3 Screw M16x140 12 9 3HAB 3409 95 51 Loctite 577 1269 1907 1 52 3 Washer Spring 3HAA 1001 181 53 3 Screw M12x140 12 9 3HAB 3409 200 54 Loctite 577 1269 1907 1 55 3 Washer Support 3HAA 1001 200 ITEM QTY DESCRIPTION ABB PART NO 56 Ref Installation Aid Tool 3HAB 1067 6 57 1 Friction Ring 3HAA 1001 614 58 1 O Ring 245 0x3 0...

Page 81: ...Disassembly Assembly Guidelines IRB 6400 Axes 2 3 SECTION 6 Disassembly Assembly ...

Page 82: ...6 8 Balance Cylinder L63 L85 Remova l 6 9 Balance Cylinder L63 L85 Installatio n 6 10 Parallel Bar L42 Removal 6 11 Parallel Bar L42 Installation 6 12 Bearings L40 L56 Removal 6 13 Bearings L40 L56 Removal 6 14 Lower Parallel Arm L17 L58 Remova l 6 16 Lower Parallel Arm L17 L58 Installatio n 6 17 Upper Arm Assembly Removal 6 19 Upper Arm Assembly Installation 6 21 Illustration Shoulder Parts 6 22 ...

Page 83: ...HANICALLY LOCKED FROM MOVING 3 TURN ELECTRICAL DISCONNECT SWITCH OFF AND LOCK IT IN THE OFF POSITION WARNING BE SURE ELECTRICAL DISCONNECT SWITCH IS OFF AND LOCKED IN OFF POSITION 4 DISCONNECT CABLES S66 FROM AXIS MOTOR S71 a Axis 3 connectors are R3 MP3 R3 FB3 b Axis 2 connectors are R3 MP2 R3 FB2 REFERENCE DRAWINGS Exploded View S pg 6 23 12 2 Assemblies 3HAA 0001 EP pg 13 10 Hand Tools Small 3 ...

Page 84: ...tion unit is going to be installed mount the new pinion that comes with it on the motor shaft a Remove screw S68 Use a strap wrench to hold pinion from rotating while removing screw b If pinion S68 is tight on motor S71 shaft screw an M10x150 screw into threaded hole and pull pinion from motor shaft with the help of a small puller Use the key slot hole in the side of the pin ion to engage one jaw ...

Page 85: ...S70 onto the shaft by winding the nut down the rod DO NOT TAP OR HIT THE MOTOR SHAFT IN ANY WAY CAUTION DO NOT TAP OR HIT MOTOR SHAFT d Remove the threaded rod nut and washer e Apply Loctite 242 S69 to screw S68 and insert in end of motor S71 shaft Torque to 35 ft lb Use strap wrench to keep pinion from turning 2 CLEAN MOUNTING SURFACES 3 MOUNT MOTOR S71 TO PLATE S37 a Lightly grease S74 O Ring S3...

Page 86: ...6 4 Axes 2 3 Guidelines 4 CONNECT CABLES S66 TO AXIS MOTOR S71 a Axis 3 connectors are R3 MP3 R3 FB3 b Axis 2 connectors are R3 MP2 R3 FB2 5 REMOVE LOWER ARM LOCKING SCREWS AND OR PARALLEL ARM SUPPORT BAR 6 CALIBRATE AXIS as outlined in Section 11 ...

Page 87: ...ximately 10 and 2 o clock b Thread two M12 x 200 threaded rods into the threaded holes of the two removed screws S31 These rods will serve as guide pins to aid in disassembly NOTE If the optional gear reduction unit removal tool ABB 6896 0011 YL is used guide pins are not required 5 REMOVE GEAR REDUCTIONS UNIT S35 a Remove screws S27 and washers S26 b Remove screws S29 and washers S28 c Remove gea...

Page 88: ...ace d Slip gear reduction unit onto guide pins and into mounted position in frame housing S21 e Use lifting tool 6896 0011 YL to lift RV into position f Lubricate three screws S29 and washers S28 with Molycote 1000 and insert through center of gear reduction unit into M12 threaded holes Start threads but do not tighten g Lubricate three screws 27 and washers S26 with Molycote 1000 and insert throu...

Page 89: ... washers S30 with Molycote 1000 grease d Insert screws S31 with washers S30 into motor mounting plate removing the two guide pins for last two screws Torque to 90 ft lb NOTE Pinion is matched to the gear reduction unit If a new motor is going to be installed mount the old pinion on the new motor shaft If a new gear reduction unit is going to be installed mount the new pinion that comes with it on ...

Page 90: ...0 screw until it mechanically stops Cylinder springs will now be locked and cylinder center distance held so cylinder can be easily remounted 4 ATTACH HOIST TO BALANCING CYLINDER L63 L85 5 REMOVE NUTS L66 L90 Nuts are Loctited 6 REMOVE BALANCING CYLINDER Carefully pry top off approx i mately half way Then pry bottom all the way off Make sure cylinder weight is supported by hoist then pry top compl...

Page 91: ...haft approximately half way b Mount lower end of balancing cylinder Alternate pushing ends onto shafts so as not to bind 3 TYPE A B CYLINDERS ONLY INSERT CIRCLIP L65 TYPE C CYLINDER ONLY a Apply lubricating grease to both sides of sliding ring L88 b Insert sliding ring L88 in place Orient as shown in figure c Insert washer L89 Orient as shown in figure 4 INSTALL NUT L66 L90 a Apply Loctite 242 L67...

Page 92: ...PS L71 a Mark clamps so they can be reassembled in the same place b Remove screws L69 and washers L70 c Remove clamps L71 5 REMOVE CLAMPS U58 a Mark clamps so they can be reassembled in the same place b Remove screws U56 and washers U57 c Remove clamps L58 6 TAP PARALLEL BAR TO LOOSEN IT FROM MOUNTING AND LIFT L42 AWAY THE HOIST IS NOW HOLDING THE UPPER ARM IN POSITION E E REFERENCE DRAWINGS Explo...

Page 93: ...move parallel bar L42 pg 6 10 2 Remove retaining ring L52 3 Press using a hand press the shaft L46 out towards snap ring slot 4 Remove seal ring L50 L43 5 Remove nut L49 locking ring L48 6 Press using a hand press the spherical bearing off of the adapter sleeve REFERENCE DRAWINGS Exploded View L pg 6 24 12 4 Assembly 3HAA 0001 ES pg 13 12 Hand Tools REQUIRED TOOLS E E Hand Press ...

Page 94: ...rod L46 2 Press spherical bearing L47 onto adapter sleeve L45 3 Place lock washer L48 and lock nut L49 on adapter sleeve tighten until no more play exists 4 Press shaft and bearing assembly into parallel arm until bearing seats 5 Place seals L43 and L50 over the ends of bearing assembly 6 Install snap ring L52 REFERENCE DRAWINGS Exploded View L pg 6 24 12 4 Assembly 3HAA 0001 ES pg 13 12 Hand Tool...

Page 95: ...amps are balanced and neither clamp end bottoms out against housing U61 3 INSTALL CLAMPS L71 a Lubricate screws L69 and washers L70 with Molycote 1000 grease b Install clamps L71 with screws L69 and washers L70 Torque 224 ft lb Tighten so clamps are balanced and neither clamp end bottoms out against parallel arm L58 4 REMOVE ALL HOISTS AND EXTRA MECHANICAL STOPS 5 CALIBRATE AXIS 3 as outlined in S...

Page 96: ...d starting page 6 14 2 REMOVE BEARING L40 a Remove spacer L41 b Remove bearing L40 parallel arm L58 using a bearing puller 3 REMOVE BEARING L56 a Remove bearing L56 from parallel arm L58 using a bearing puller b Remove spacer L57 REFERENCE DRAWINGS Exploded View L pg 6 24 12 3 Assembly 3HAB 4162 2 pg 13 11 Hand Tools REQUIRED TOOLS Bearing Puller ...

Page 97: ...ng L40 onto parallel arm L58 shaft c Install spacer L41 2 INSTALL BEARING L56 a Heat bearing L56 to 250 F 120 C b Install spacer L57 c Install bearing L56 on parallel arm L58 shaft 3 IF READY INSTALL LOWER ARM PARALLEL ARM as outlined starting on page 6 18 REFERENCE DRAWINGS Exploded View L pg 6 24 12 3 Assembly 3HAB 4162 2 pg 13 11 Hand Tools REQUIRED TOOLS Heating Oven ...

Page 98: ...ashers L75 c Lift weight L68 away and set in a safe place 5 ATTACH HOIST TO LOWER ARM FRAME L17 AS SHOWN IN FI G URE AT LEFT 6 REMOVE AXIS 2 3 GEAR REDUCTION UNITS as outlined on page 6 5 7 REMOVE LOWER ARM L17 AND PARALLEL ARM L58 a Remove locking screws from step 2 b Carefully lift lower arm L17 and parallel arm L58 assembly from frame housing S21 REFERENCE DRAWINGS Exploded View S pg 6 23 12 2 ...

Page 99: ...Open arms out b Use wood to block arms at joint to lay level on working surface as necessary c Force the parallel arm to the side to disengage the lower arm Bearings may be tight Use the threaded holes and a combination of threaded studs washers and nuts to help in forcing the arms apart d Pull lower arm L17 away from parallel arm L58 LOWER ARM PARALLEL ARM WEIGH APPROX 300 LB ...

Page 100: ...assembly during installation 3 INSTALL AXIS 2 3 GEAR REDUCTION UNIT S35 as outlined on page 6 6 4 INSTALL UPPER ARM as outlined on page 7 1 7 5 COMPLETE INSTALLATION OF PARALLEL BAR L42 as outlined on page 6 13 6 SECURE AXIS 2 WITH LOCKING SCREW INTO LOWER ARM L17 SECURE AXIS 3 WITH EXTRA MECHANICAL STOPS 7 INSTALL COUNTERBALANCE WEIGHT L68 a Lift weight L68 into position for mounting b Insert scr...

Page 101: ... AS SHOWN IN FIGURE BELOW 5 DETACH PARALLEL BAR L42 AT TOP a Mark clamps U58 so they can be reassembled in same location b Remove screws U56 and washers U57 c Remove clamps U58 d Let parallel bar L42 swing back and rest on counterbalance weight L68 6 REMOVE NUTS L8 AND L24 An extended socket wrench is required for nuts used on S 2 9 120 robots E E REFERENCE DRAWINGS Exploded View L pg 6 24 12 3 As...

Page 102: ... L18 WITHOUT FIRST REMOVING SET SCREWS U64 b Carefully unscrew shafts L16 and L18 from lower arm frame L17 Protect threads from damage NOTE Both shaft assemblies Ll16 L18 have nilos rings L11 or L22 spacers L10 or L23 bearing L12 or L21 sealing ring L13 or L20 and V ring L15 or L19 CAUTION SHAFT L16 HAS AN ADDITIONAL SPACER L14 THIS ADDED SPACER IS IMPORTANT DURING REASSEMBLY 8 LIFT UPPER ARM ASSE...

Page 103: ...COMPONENTS ONTO SHAFT L16 a Install V Ring L15 on shaft square side to shaft shoulder b Install spacer L14 onto shaft c Insert sealing ring L13 in lower arm frame L17 bore larger diameter of ring turned inward d Insert outer race of bearing L12 into lower arm frame L17 bore up against V Ring L15 e Pack inner race of bearing L12 with grease L87 and install on shaft L16 position into bearing outer r...

Page 104: ...e Insert NILOS ring L22 against bearing L21 f Install spacer L23 against bearing L22 6 INSTALL NUT L24 a Apply Loctite 242 L25 to nut L24 and thread onto shaft L18 b Tighten nut L24 Torque to 67 ft lb 7 ATTACH PARALLEL BAR L42 AT TOP a Lubricate screws U56 and washers U57 with Molycote 1000 b Install clamps U58 with screws U56 and washers U57 Torque 224 ft lb Tighten so clamps are balanced and nei...

Page 105: ...2062 177 48 15 Screw M12x70 12 9 3HAB 3409 73 49 1 Plug KR 1 2 2522 2021 113 50 3 Screw M16x140 12 9 3HAB 3409 95 51 Loctite 577 1269 1907 1 52 3 Washer Spring 3HAA 1001 181 53 3 Screw M12x140 12 9 3HAB 3409 200 54 Loctite 577 1269 1907 1 55 3 Washer Support 3HAA 1001 200 ITEM QTY DESCRIPTION ABB PART NO 56 Ref Installation Aid Tool 3HAB 1067 6 57 1 Friction Ring 3HAA 1001 614 58 1 O Ring 245 0x3 ...

Page 106: ...dapter Sleeve 2213 1905 21 46 2 Shaft 3HAA 1001 88 47 2 Spherical Bearing 3HAA 1001 189 48 2 Lock Washer Incl in Item 45 49 2 Lock Nut Incl in Item 45 50 2 Ring 3HAA 1001 86 51 Grease 1171 4012 201 52 2 Retaining Ring Snap 2154 2527 160 53 2 Screw M8x25 2121 2519 453 54 2 Washer 8 4x16x1 5 2151 2062 165 55 2 Damper 3HAA 1001 81 56 1 Spherical Roller Bearing 3HAB 4169 1 57 1 Spacer Sleeve 3HAB 4387...

Page 107: ...Disassembly Assembly Guidelines IRB 6400 Axis 4 SECTION 7 Disassembly Assembly ...

Page 108: ...ct 7 1 Motor U83 Removal 7 4 Motor U83 Installation 7 7 Intermediate Gear Unit U75 Remova l 7 10 Intermediate Gear Unit U75 Installatio n 7 12 Final Gear U41 Removal 7 15 Final Gear U41 Installation 7 17 Tube Shaft U19 Removal 7 18 Tube Shaft U19 Installation 7 20 Illustration Upper Arm Parts a ...

Page 109: ...LECTRICAL DISCONNECT SWITCH IS OFF AND LOCKED IN OFF POSITION 4 DRAIN OIL FROM HOUSING U61 a Remove plug U59 and washer U60 b Remove plug U38 and washer U39 c Drain oil d Clean and re insert plug U59 with washer U60 and plug U38 with washer U39 In rush situations you may skip to step 12 and skip backlash adjus t ments until a later time REFERENCE DRAWINGS Exploded Views S pg 7 20 12 2 Assemblies H...

Page 110: ...LL COVERS HOLDING CABLES TO COVER S6 Car e fully feed cables up and out through the three holes in cover S6 7 REMOVE CABLE TUBE HOLDER U53 a Remove screws U49 and washers U50 b Remove cover U51 c Remove screws U52 d Remove cable tube holder U53 8 DETACH UPPER CABLE U14 CLAMPS a Detach upper cable U14 clamp at inside front of lower arm L17 Leave clamp clamped to cable to maintain location b Detach ...

Page 111: ... REMOVE MOTOR U83 a Remove screws U85 with washers U84 b Carefully pull motor U83 off housing U61 c Remove O Ring U81 13 REMOVE PINION U82 FROM MOTOR U83 SHAFT CAUTION DO NOT HIT OR TAP MOTOR SHAFT a Mount SKF Oil Injector 226 270 and SKF Nipples 725 870 234 063 into the center of pinion U82 b Press pinion off motor shaft C COVER WEIGHS APPROX 20 LB MOTOR WEIGHS APPROX 35 LB MOTOR PINION NIPPLE IN...

Page 112: ...R TAP MOTOR SHAFT a Remove plug at rear of motor and place support tool ABB 6896 134 EA under motor shaft to avoid axial loading of bearings b Use tool ABB 6896 134 AC to press pinion U82 onto motor U83 c Re install plug at rear of motor E E REFERENCE DRAWINGS Exploded Views Assemblies Hand Tools ABB 6896 134 EA ABB 6896 134 AC REQUIRED TOOLS 3HAB 4163 2 pg 13 23 3HAA 0001 AAS pg 14 A 3HAB 4252 2 ...

Page 113: ...htly grease lip of seal U40 which is already installed in cover U54 c Set cover U54 and gasket U55 in place on housing U61 Use new gasket U55 if necessary d Insert screws U36 with washers U37 and tighten to secure cover to housing Cover must be oil tight 5 INSTALL TUBE BRACKET U53 a Set tube bracket U53 in place supporting cable U14 tube b Insert screws U52 and tighten 6 INSERT BOTTOM HALF OF UPPE...

Page 114: ...MSB3 6 X5 to serial measurement board on measure card unit S10 b Mount measuring card unit S10 in place c Insert screws S12 and tighten 10 CONNECT CABLE U14 CONNECTORS IN FRAME HOUSING S21 a Connect connectors R2 MP4 R2 MP5 6 R2 CP R2 CS inside frame housing S21 b Set cover S43 in place and secure with screws S42 11 FILL HOUSING U61 WITH OIL as outlined in Section 4 12 CALIBRATE AXIS 4 as outlined...

Page 115: ...NNECT SWITCH IS OFF AND LOCKED IN OFF POSITION 4 DRAIN OIL FROM HOUSING U61 a Remove plug U59 and washer U60 b Remove plug U38 and washer U39 c Drain oil d Clean and re insert plug U59 with washer U60 and plug U38 with washer U39 5 DISCONNECT CABLE U14 CONNECTORS IN FRAME HOUSING S21 a Remove screws S43 and cover S42 b Disconnect connectors R2 MP4 R2 MP5 6 R2 CP R2 CS REFERENCE DRAWINGS Exploded V...

Page 116: ...screws U52 d Remove cable tube holder U53 10 DETACH UPPER CABLE U14 CLAMPS a Detach upper cable U14 clamps at lower arm L17 Leave clamp clamped to cable to maintain location b Detach upper cable U14 clamp at housing U61 Leave clamp clamped to cable to maintain location 11 DISCONNECT CABLES AT MOTOR U83 a Disconnect connector R3 MP4 b Disconnect connector R3 FB4 12 FEED LOWER PART OF CABLE U14 UP A...

Page 117: ...Page 7 9 Axis 4 Guidelines 15 REMOVE INTERMEDIATE GEAR UNIT U75 a Remove nuts U76 b Remove washers U77 c Remove wedges U78 d Remove screws U67 with washers U68 e Remove intermediate gear unit assembly U75 INTERMEDIATE GEAR WEIGHS APPROX 15 LB ...

Page 118: ...U55 if necessary c Insert screws U36 with washers U37 and tighten to secure cover to housing Cover must be oil tight 5 INSTALL TUBE BRACKET U53 a Set tube bracket U53 in place supporting cable U14 tube b Insert screws U52 and tighten 6 INSERT BOTTOM HALF OF UPPER CABLE U14 a Feed lower part of upper cable U14 under housing U61 and down through lower arm L17 b Adjust cable clamps to mount under hou...

Page 119: ...easure card unit S10 b Mount measuring card unit S10 in place c Insert screws S12 and tighten 10 CONNECT CABLE U14 CONNECTORS IN FRAME HOUSING S21 a Connect connectors R2 MP4 R2 MP5 6 R2 CP R2 CS inside frame housing S21 b Set cover S43 in place and secure with screws S42 11 FILL HOUSING WITH OIL as outlined in Section 4 12 CALIBRATE AXIS 4 as outlined in Section 11 ...

Page 120: ...EMOVE COVER U54 AND GASKET U55 a Remove screws U36 with washers U37 b Remove cover U54 including seal ring U40 and cork gasket U55 6 DRAIN OIL FROM HOUSING U61 a Remove plug U59 and washer U60 b Remove plug U38 and washer U39 c Drain oil d Clean and re insert plug U59 with washer U60 and plug U38 with washer U39 7 LOOSEN AXIS 4 MOTOR U83 MOUNTING a Loosen screws U85 b Loosen motor in mounting REFE...

Page 121: ...of tube shaft U19 b Remove plastic cover in tube U19 and screw in nipple SKF 234 063 with quick coupling NIK E I AQU 8 Removing cover will destroy it so you will need a new cover c Mount tool ABB 6396 134 AT with hydraulic cylinder NIKE 1 CH 612 on final gear U41 with three hex screws M12x70 10 9 d Connect either pump NIKE I PP6 or hand pump NIKE I HP 416 through two way valve NIKE I VAD 2 to cyli...

Page 122: ...valve tap that directs pressure to the final gear c Remove nipple SKF 234 063 with coupling NIKE I AQU 8 Insert new cover CAUTION BE PREPARED TO CATCH GEAR WHEN IT COMES OFF TUBE SHAFT d Continue to pump in pressure to the hydraulic cylinder until final gear has been pulled from tube shaft Be prepared to catch gear as it comes off tube shaft e If cylinder stroke runs out use a spacer as required f...

Page 123: ...ONED IN PLACE BEHIND FINAL GEAR U41 4 FOLLOWING STEPS MUST BE COMPLETED WHILE FINAL GEAR IS STILL HOT a Mount final gear U41 onto tube shaft U19 and quickly place against spacer b Mount tool ABB 6896 134 FK over stud and against gear c Mount hydraulic cylinder NIKE I CH 612 with regulator valve NIKE I VRF31 over stud and screw on nut E E REFERENCE DRAWINGS Exploded View U pg 7 22 12 4 Assemblies 3...

Page 124: ... Check that tube turns before continuing 5 SET INTERMEDIATE GEAR ASSEMBLY U75 UNIT IN PLACE a Set intermediate gear unit U75 in place with intermediate gear U74 in mesh with final gear U41 b Insert screws U67 with washers U68 Lightly tighten 6 ADJUST PLAY BETWEEN INTERMEDIATE GEAR U76 AND FINAL GEAR U41 as outlined in Section 4 7 ADJUST PLAY BETWEEN MOTOR PINION U83 AND INTERMEC I ATE GEAR U76 as ...

Page 125: ...on page 7 12 5 REMOVE MECHANICAL STOP U25 a Remove screws U22 with washers U24 b Remove axis 4 stop U25 gasket U27 and rubber cushion U26 Axis 4 may have to be turned to gain access to cushion c Rotate axis 4 until stop U13 is visible Remove screws U11 and stop U13 6 REMOVE TUBE SHAFT U19 a Press tube shaft U19 out with tool ABB 6896 0011 YJ and tool NIKE 1 CH 612 Protect the surface at end of tub...

Page 126: ...o shaft Orient as shown on page 13 3 8 b Grease bearing U46 with grease U47 c Install bearing U46 to shaft Use tool ABB 6896 134 S and NIKE I CH 612 Orient as shown on page 13 3 7 d Grease seal U45 and set in place against bearing U46 4 INSTALL COMPONENTS IN HOUSING U61 a Lightly grease seal ring U44 and insert into its bore in housing U61 Use tool ABB 6896 134 FA Orient as shown on page 13 3 10 b...

Page 127: ...tube shaft and up against bearing U43 6 MOUNT MECHANICAL STOP U25 a Rotate Axis 4 until stop mounting holes are visible b Apply Loctite 242 U12 to screws U11 c Mount stop U13 with screws U11 d Rotate Axis 4 and insert rubber stopper U26 e Attach Axis 4 stop 7 MOUNT FINAL GEAR U41 as outlined on page 7 15 8 INSTALL UPPER CABLE U14 as outlined in Section 10 9 INSTALL WRIST ASSEMBLY U10 as outlinedin...

Page 128: ...0 54 Loctite 577 1269 1907 1 55 3 Washer Support 3HAA 1001 200 ITEM QTY DESCRIPTION ABB PART NO 56 Ref Installation Aid Tool 3HAB 1067 6 57 1 Friction Ring 3HAA 1001 614 58 1 O Ring 245 0x3 0 2152 0431 15 59 1 Gear Reduction Unit 3HAB 4079 1 60 8 Washer Plain 13x24x2 5 2551 2062 177 61 8 Screw M12x90 12 9 3HAB 3409 75 62 1 Friction Ring 3HAA 1001 613 63 1 O Ring 234 54x3 53 2152 0431 17 64 1 Brake...

Page 129: ...dapter Sleeve 2213 1905 21 46 2 Shaft 3HAA 1001 88 47 2 Spherical Bearing 3HAA 1001 189 48 2 Lock Washer Incl in Item 45 49 2 Lock Nut Incl in Item 45 50 2 Ring 3HAA 1001 86 51 Grease 1171 4012 201 52 2 Retaining Ring Snap 2154 2527 160 53 2 Screw M8x25 2121 2519 453 54 2 Washer 8 4x16x1 5 2151 2062 165 55 2 Damper 3HAA 1001 81 56 1 Spherical Roller Bearing 3HAB 4169 1 57 1 Spacer Sleeve 3HAB 4387...

Page 130: ...AA 1001 103 43 1 Bearing 2213 0253 5 44 1 Seal Ring 2216 0261 18 45 1 Seal 2216 0086 4 46 1 Bearing 2213 0253 5 47 Grease 1171 4013 301 48 1 Seal 3HAB 4217 1 49 3 Screw 2121 2411 368 50 3 Washer 2151 2062 153 51 1 Cover 3HAA 1001 176 52 2 Screw 2121 2411 368 ITEM QTY DESCRIPTION ABB PART NO 53 1 Cable Holder 3HAA 1001 201 54 1 Cover 3HAA 1001 33 55 1 Gasket 3HAA 1001 97 56 4 Screw 2121 2518 634 57...

Page 131: ...Disassembly Assembly Guidelines IRB 6400 Axis 5 SECTION 8 Disassembly Assembly ...

Page 132: ...00 Axis 5 Guidelines AXIS 5 Table of Contents Page Subject 8 1 Motor W52 Removal 8 3 Motor W52 Installation 8 5 Wrist Assembly U10 Removal 8 7 Wrist Assembly U10 Installation 8 9 Illustration Upper Arm Parts 8 10 Illustration Wrist Parts a ...

Page 133: ...ll motor out Use M8x65 screws in extractor holes to aid in pul l ing motor if necessary c Keep track of shims W55 so the same shims can be re installed in the same orientaion d Remove O Ring W53 4 REMOVE PINION W54 a Measure distance between motor flange and outer surface of pin ion Use tool ABB 6896 134 GN Make a written record of mea surement b Press pinion off motor shaft Use tools nipple ABB 6...

Page 134: ...matched set with bevel gear W27 assembly If motor is changed this pinion must be installed on the new motor s shaft If pinion is damaged complete bevel gear assembly W26 with new pinion must be replaced Contact ABB service to replace complete bevel gear assembly MOTOR PINION NIPPLE INJECTOR ...

Page 135: ... or all Siemens motors If replacing motor do not mix manufacturers WARNING BE SURE ELECTRICAL DISCONNECT SWITCH IS OFF AND LOCKED IN OFF POSITION 1 PRESS PINION W54 ONTO MOTOR SHAFT Use tools ABB 6896 134 EA ABB 6896 134 AD NOTE Remove plug at rear of motor and place support ABB 6896 134 EA under motor shaft to avoid axial loading of the bearings in the motor REFERENCE DRAWINGS Exploded View Assem...

Page 136: ...must be added or removed to compensate for the difference 3 MOUNT MOTOR W52 a Use a new O Ring W53 Lightly grease O Ring and set in place b Set shims W55 in place c Position motor in place ready to insert screws W49 d Apply Loctite 242 W50 to screws W49 Insert screws with washers W51 and torque 18 ft lb 4 FILL GEARBOX WITH OIL as outlined in Section 4 5 CALIBRATE AXIS 5 as outlined in Section 11 M...

Page 137: ...BB for proper service 1 Oil change per instructions in Section4 2 Change of motor and gear for Axis 6 3 Change of motor for Axis 5 4 Checking play in Axes 5 6 5 Adjusting play in Axis 5 1 TURN MAIN ELECTRICAL DISCONNECT SWITCH OFF AND LOCK IT IN THE OFF POSITION WARNING BE SURE ELECTRICAL DISCONNECT SWITCH IS OFF AND LOCKED IN OFF POSITION 2 REMOVE TOOLING 3 POSITION WRIST TO GAIN EASIEST ACCESS P...

Page 138: ...AND BREAK THE CONNECTORS a Pull wrist assembly U10 out from tube shaft U19 just far enough to disconnect connectors at the back of axis 5 motor W52 b Disconnect connectors R4 MP5 R4 FB5 at back of axis 5 motor W52 c Lift wrist assembly U10 away and set on a safe working surface Protect connectors when setting assembly down 8 IF WRIST ASSEMBLY IS GOING TO BE SHIPPED FOR SERVICE drain oil from wrist...

Page 139: ...ft wrist assembly U10 and position in front of tube shaft U19 where Axis 5 motor connectors can be connected c Connect motor connectors R4 MP5 R4 FB5 CAUTION BE CAREFUL THAT WRIST DOESN T SWING ABOUT AND BREAK THE CONNECTORS d Move wrist assembly U10 into tube shaft U19 ready for mounting Make sure motor cables are aren t binding inside tube shaft e Lubricate screws U20 and washers U21 with Molyco...

Page 140: ...Disassembly Assembly Guidelines IRB 6400 Page 8 8 Axis 5 Guidelines 4 FILL WRIST HOUSING WITH OIL as outlined in Section 4 5 CALIBRATE AXES 5 6 as outlined in Section 11 ...

Page 141: ...ew 2121 2411 368 ITEM QTY DESCRIPTION ABB PART NO 53 1 Cable Holder 3HAA 1001 201 54 1 Cover 3HAA 1001 33 55 1 Gasket 3HAA 1001 97 56 4 Screw 2121 2518 634 57 4 Washer 2151 2062 185 58 2 Clamp 3HAA 1001 13 59 1 Magnetic Plug 2522 0122 1 60 1 Washer 2152 0441 1 61 1 Housing 3HAA 0001 AA 62 2 Support Ring 3HAA 1001 124 63 2 Set Screw M10 2122 2719 401 64 1 Sync Plate Axis 3 3HAA 1001 75 65 2 Washer ...

Page 142: ... 15 2 Screw M4x8 2121 2411 287 16 1 Magnetic Plug 2522 122 1 17 1 Washer 13 5x18x1 5 2152 0441 1 18 Cover 3HAA 2166 11 19 1 Lock Nut 2126 2851 108 20 Loctite 290 1269 0014 409 21 1 Bearing 3HAA 1001 162 22 1 Bearing Housing 3HAA 1001 41 23 1 Shim Set 3HAA 0001 AF 24 1 O Ring 2152 2011 529 25 1 Bearing 3HAA 1001 168 26 1 Gear Axis 5 3HAA 0001 AO 27 1 Gear Axis 5 Assem 3HAA 0001 AG 28 1 Seal 3HAB 44...

Page 143: ...Disassembly Assembly Guidelines IRB 6400 Axis 6 SECTION 9 Disassembly Assembly ...

Page 144: ...es IRB 6400 Axis 6 Guidelines AXIS 6 Table of Contents Page Subject 9 1 Motor Reduction Unit Removal 9 3 Motor Reduction Unit Installation 9 5 Illustration Face Parts 9 6 Illustration Upper Arm Parts 9 7 Illustration Wrist Parts a ...

Page 145: ... U5 b Remove screws U6 and access cover U7 c Remove cover on back of motor d Disconnect plugs R4 MP6 R4 PTC6 R4 FB6 e Remove screws on cable cover on left side of Axis 6 motor f Remove screws U17 from cable g Carefully route cables through casting and allow to hang free 3 DRAIN OIL FROM WRIST ASSEMBLY U10 as outlined in Section 4 4 REMOVE COVER W68 a Remove screws W70 with washers W69 b Remove cov...

Page 146: ...work bench for fu r ther work 8 REMOVE GEAR REDUCTION UNIT F17 a Remove screws F23 with washers F22 b Remove gear reduction unit F17 from drive unit F10 with the help of two screws in the M8 holes in motor flange c Remove O Ring F14 9 REMOVE PINION F15 FROM MOTOR SHAFT CAUTION DO NOT TAP OR HIT MOTOR SHAFT a Remove screw F16 b Remove pinion with tool ABB 3HAA 7601 043 Use tool ABB 3HAA 7601 047 fo...

Page 147: ...and insert Torque 16 ft lb 2 MOUNT GEAR REDUCTION UNIT F17 a Lightly grease O Ring F14 and set in place b Set gear reduction unit F17 into mounting position on motor drive F10 Rotate so screw hole and magnetic oil plug come in the right position c Insert screws F23 with washers F22 Torque 26 ft lb 3 MOUNT FLANGE f20 a Lightly grease O Ring F18 and set in place b Light grease O Rings F19 and set in...

Page 148: ... pilot diameter on gear W34 b Insert screws W36 Torque to 52 ft lb c Insert cover lit W37 Use a new cover if old one was damaged in removal 6 INSTALL BEARING W6 a Install bearing W6 and spacer W7 onto bearing retainer W5 Set in place in wrist housing W8 with bearing retainer pilot diam eter inserted into motor F10 mounting bore b Apply Loctite 242 to screws W3 c Insert screws W3 and torque to 18 f...

Page 149: ...Elmo 3HAB 4172 1 Drive Unit Siements EHAA 0001 ABU 11 1 Washer 13 5x18x1 5 2152 0441 1 12 1 Magnetic Plug R 1 4 2522 0122 1 13 1 Sync Plate 3HAA 1001 174 14 1 O Ring 151 99x3 53 2152 0431 12 15 1 Input Pinion Gear 3HAA 1001 522 16 1 Screw 2121 2519 341 17 1 Reduction Gear 3HAA 0001 HJ ITEM QTY DESCRIPTION ABB PART NO 18 1 O Ring 2151 0431 21 19 1 O Ring 2152 0431 20 20 1 Flange 3HAA 1001 222 21 6 ...

Page 150: ...ew 2121 2411 368 ITEM QTY DESCRIPTION ABB PART NO 53 1 Cable Holder 3HAA 1001 201 54 1 Cover 3HAA 1001 33 55 1 Gasket 3HAA 1001 97 56 4 Screw 2121 2518 634 57 4 Washer 2151 2062 185 58 2 Clamp 3HAA 1001 13 59 1 Magnetic Plug 2522 0122 1 60 1 Washer 2152 0441 1 61 1 Housing 3HAA 0001 AA 62 2 Support Ring 3HAA 1001 124 63 2 Set Screw M10 2122 2719 401 64 1 Sync Plate Axis 3 3HAA 1001 75 65 2 Washer ...

Page 151: ... 15 2 Screw M4x8 2121 2411 287 16 1 Magnetic Plug 2522 122 1 17 1 Washer 13 5x18x1 5 2152 0441 1 18 Cover 3HAA 2166 11 19 1 Lock Nut 2126 2851 108 20 Loctite 290 1269 0014 409 21 1 Bearing 3HAA 1001 162 22 1 Bearing Housing 3HAA 1001 41 23 1 Shim Set 3HAA 0001 AF 24 1 O Ring 2152 2011 529 25 1 Bearing 3HAA 1001 168 26 1 Gear Axis 5 3HAA 0001 AO 27 1 Gear Axis 5 Assem 3HAA 0001 AG 28 1 Seal 3HAB 44...

Page 152: ...Disassembly Assembly Guidelines IRB 6400 Cables Guidelines SECTION 10 ...

Page 153: ...es Table of Contents Page Subject 10 1 Lower Cable B18 Removal 10 3 Lower Cable B18 Installation 10 5 Upper Cable U14 Removal 10 7 Upper Cable U14 Installation 10 9 Axis 6 Motor F10 Cable Removal 10 10 Axis 6 Motor F10 Cable Installation a CABLES GUIDELINES ...

Page 154: ...F POSITION 3 REMOVE SCREWS S42 AND COVER S43 4 REMOVE SCREWS B8 AND COVER B9 5 DISCONNECT LOWER CABLE B18 MOUNTING PLATE FROM BASE HOUSING B24 a Remove screws B1 b Remove cable protector B2 c Pull lower cable B18 mounting plate out from base housing B24 as far as it will go 6 DISCONNECT EARTH WIRE FROM CONTACT PLATE IN BASE HOUSING B24 REFERENCE DRAWINGS Exploded Views B pg 10 11 12 1 Assemblies H...

Page 155: ...ISCONNECT CABLE GUIDE RAIL B16 FROM BASE HOUSING B24 a Loosen screws B13 Do not remove yet b Move cable guide rail B16 out of the way c Remove the right side screw B13 and washer B15 so it won t snag on the cable or your hands Leave the left side screw B13 to hold frictionless plate B23 in position 9 DISCONNECT LOWER CABLE B18 a Remove screws B20 and washers B19 holding lower cable B18 to support ...

Page 156: ...crew B13 and fasten cable guide rail B16 to base housing B24 Use washer B15 with screw B13 c Remove left side screw B13 apply Loctite B14 and reinsert with washer B15 Tighten to secure guide rail B16 4 CHECK THAT LOWER CABLE IS FREE TO MOVE AS ROBOT ROTATES LOOSEN B10 AND B13 TO ADJUST CABLE AND RAIL AS NECESSARY RETIGHTEN SCREWS AFTER ADJUSTMENTS 5 CONNECT LOWER CABLE B18 CONNECTORS a Connect R3 ...

Page 157: ... HOU S ING B24 a Position lower cable B18 mounting plate over access hole at left rear of base housing B24 b Insert screws B1 thorough cable protector B2 and lower cable B18 mounting plate Tighten screws 8 INSTALL COVER B9 WITH SCREWS B8 9 INSTALL COVER S43 WITH SCREWS S42 10 CALIBRATE AXES as outlined in Section 11 ...

Page 158: ... CP R2 CS 5 DISCONNECT CONNECTOR ON SIGNAL MEASURE BOARD a Remove screws S12 b Pull measuring card unit S10 out c Disconnect R2 SMB3 6 X5 from signal measuring board 6 UNCOUPLE CUSTOMER AIR HOSE by accessing clamp through measuring card unit S10 opening 7 LOOSEN SMALL COVERS HOLDING CABLES TO COVER S6 CAREFULLY FEED CABLES UP AND OUT OF FRAME HOUSING S21 THROUGH THE THREE HOLES IN COVER S6 8 REMOV...

Page 159: ... to loosen right angle channel so cable connectors can be pulled through later 12 DISCONNECT MOTOR F10 CONNECTORS a Disconnect motor connectors R4 MP6 R4 FB6 and R4 PTC6 at rear of motor F10 b Pull cable and connectors through right angle channel c Remove screws U16 and U17 to free cable mounting 13 DISCONNECT ANY AIR CONNECTION CUSTOMER CONNECTORS R3 CP R3 CS ON RIGHT SIDE OF TUBE SHAFT U19 USUAL...

Page 160: ...ith screws U17 and U18 b Push cable and connectors through right angle channel c Connect connectors R4 MP6 R4 FB6 R4 PTC6 at rear of motor F10 4 MOUNT CABLE ANGLE BRACKET FOR JUNCTION BOX WITH SCREWS U15 5 CONNECT AIR CONNECTION CUSTOMER CONNECTORS R3 CP R3 CS ON RIGHT SIDE OF TUBE SHAFT U19 IF SO EQUIPPED 6 INSTALL CABLE ACCESS COVERS a Mount right angle channel over cable pit on motor F10 Use se...

Page 161: ...ble U14 clamp inside lower arm housing L17 10 CONNECT CABLES AT MOTOR U83 a Connect connector R3 FB4 at rear of motor U83 b Connect connector R3 MP4 at rear of motor U83 11 CONNECT CUSTOMER AIR HOSE by accessing clamp through measuring card unit S10 opening 12 CONNECT CONNECTOR R2 SMB3 6 X5 ON SIGNAL MEASURING BOARD a Connect connector R2 SMB3 6 X5 to sigmal measuring board in the measuring card u...

Page 162: ...NNECTORS CAN MORE EASILY BE PULLED THROUGH WHEN DISCONNECTED 7 REMOVE SCREWS U16 AND U17 TO DISCONNECT CABLE CA R RIER FROM WRIST ASSEMBLY U10 8 REMOVE AXIS 6 CABLING a Remove cover from cable junction box inside opening on left side of tube U19 and disconnect connectors R3 MP6 and R3 FB6 It may be necessary to loosen junction box mounting screws U15 to be able to move junction box around a little...

Page 163: ...crews U15 if loosened when cable was removed 2 CONNECT CABLE CARRIER TO WRIST ASSEMBLY U10 WITH SCREWS U16 AND U17 3 INSTALL ANGLE CHANNEL OVER CABLE PIT ON MOTOR F10 USE SEALANT F28 BE SURE JOINT IS LIQUID TIGHT 4 INSTALL COVER F9 WITH SCREWS F7 AND WASHERS F8 USE SEALANT F28 BE SURE JOINT IS LIQUID TIGHT 5 INSTALL COVER U7 AND GASKET U9 WITH SCREWS U6 USE SEALANT U8 BE SURE JOINT IS LIQUID TIGHT...

Page 164: ...1 1 Screw M6x20 2121 2411 370 1 Washer 6 4x12x1 6 2151 2062 153 19 2 Washer 8 4x16x1 6 2151 2062 165 20 2 Screw M8x40 8 8 2121 2519 459 21 Loctite 242 1269 0014 410 22 3 WARNING Label 3HAA 0001 SL 23 1 Frictionless Plate 3HAA 1001 695 24 1 Base Housing 3HAA 1001 653 25 1 Grease Tube Assembly 3HAA 1001 716 26 Loctite 577 1269 1907 1 27 2 Screw M6x16 2121 2411 368 28 Loctite 577 1268 1907 1 Base Syn...

Page 165: ...0 54 Loctite 577 1269 1907 1 55 3 Washer Support 3HAA 1001 200 ITEM QTY DESCRIPTION ABB PART NO 56 Ref Installation Aid Tool 3HAB 1067 6 57 1 Friction Ring 3HAA 1001 614 58 1 O Ring 245 0x3 0 2152 0431 15 59 1 Gear Reduction Unit 3HAB 4079 1 60 8 Washer Plain 13x24x2 5 2551 2062 177 61 8 Screw M12x90 12 9 3HAB 3409 75 62 1 Friction Ring 3HAA 1001 613 63 1 O Ring 234 54x3 53 2152 0431 17 64 1 Brake...

Page 166: ...A 1001 103 43 1 Bearing 2213 0253 5 44 1 Seal Ring 2216 0261 18 45 1 Seal 2216 0086 4 46 1 Bearing 2213 0253 5 47 Grease 1171 4013 301 48 1 Seal 3HAB 4217 1 49 3 Screw 2121 2411 368 50 3 Washer 2151 2062 153 51 1 Cover 3HAA 1001 176 52 2 Screw 2121 2411 368 ITEM QTY DESCRIPTION ABB PART NO 53 1 Cable Holder 3HAA 1001 201 54 1 Cover 3HAA 1001 33 55 1 Gasket 3HAA 1001 97 56 4 Screw 2121 2518 634 57 ...

Page 167: ...411 287 16 1 Magnetic Plug 2522 122 1 17 1 Washer 13 5x18x1 5 2152 0441 1 18 Cover 3HAA 2166 11 19 1 Lock Nut 2126 2851 108 20 Loctite 290 1269 0014 409 21 1 Bearing 3HAA 1001 162 22 1 Bearing Housing 3HAA 1001 41 23 1 Shim Set 3HAA 0001 AF 24 1 O Ring 2152 2011 529 25 1 Bearing 3HAA 1001 168 26 1 Gear Axis 5 3HAA 0001 AO 27 1 Gear Axis 5 Assem 3HAA 0001 AG 28 1 Seal 3HAB 4409 1 29 1 Retaining Rin...

Page 168: ... 1 Motor Siemens 3HAA 0001 XK Drove Unit Elmo 3HAB 4172 1 Drive Unit Siements EHAA 0001 ABU 11 1 Washer 13 5x18x1 5 2152 0441 1 12 1 Magnetic Plug R 1 4 2522 0122 1 13 1 Sync Plate 3HAA 1001 174 14 1 O Ring 151 99x3 53 2152 0431 12 15 1 Input Pinion Gear 3HAA 1001 522 16 1 Screw 2121 2519 341 17 1 Reduction Gear 3HAA 0001 HJ ITEM QTY DESCRIPTION ABB PART NO 18 1 O Ring 2151 0431 21 19 1 O Ring 215...

Page 169: ...Disassembly Assembly Guidelines IRB 6400 Robot Calibration SECTION 11 ...

Page 170: ...e of Contents Table of Contents Calibration Procedures 11 3 Overview 11 3 Rough Resolver Calibration Procedure 11 4 Manually Entering Calibration Values 11 10 Precision Resolver Calibration Procedure 11 14 Calibrating Axis 1 11 15 Calibrating Axis 2 6 11 16 Counter Updating Procedure 11 23 ...

Page 171: ...Disassembly Assembly Guidelines IRB6400 Page 11 2 RobotCalibration NOTES ...

Page 172: ...this battery may not be charged The control must be connected to the robot and with the main disconnect turned on it takes 18 hours to fully charge this battery and it should maintain a charge for approximately 1000 hours If this battery loses its chargeanerror 20032Revcounternotupdated willbe given after a power outage When the robots are assembled they are accurately calibrated using digital lev...

Page 173: ...esolvers in most cases After performing this procedure program touch up may be required NOTE If your application can not tolerate this roughcalibrationthenyoumaywanttouse theprecisionresolvercalibrationprocedure inthischapter 1 Movetheaxis byusingthejoystick tobecalibrated to the calibration position The more accurate this is done the better the calibration will work The calibration position is sh...

Page 174: ...should appear The calibration status will appear on the screen 7 8 9 4 5 6 1 2 3 0 1 2 stop M ov eJ M ov e J ro ut i ne Wa i t D I M ov eL M ov eL M ov eL M ov eL M ov e L U ndo 2 C ut 3 C opy 4 P ast e 5 G ot o Top 6 G ot o B ot t om 7 Mark 8 C hang e S el ect ed 9 S how V al ue 0 ModP os Search Fi l e Pr og ra m E di t V i ew I PL __ SY S I PL __ U SR MO V E24 00 mai n C o m mo n 1 Move J 2 Move...

Page 175: ...ne or more axis revolution counter is not updated Notcalibrated Indicatesthatoneormoreaxisdo not have calibration values stored 3 Press CALIB CALIBRATE The window below will appear 4 The X indicates chosen axes Press theALL function button to select all axis to be calibrated or move the cursor to the desired axis or axes and press INCL to include the axes to be calibrated 3 Calibrated Calibrate IR...

Page 176: ... window below will appear 3 Calibrated Calibrate Cancel OK The Calibrationforall marked axes will be changed It cannot be undone OK to continue 6 After receiving the warning if you wish to continue press OK again The following screen should appear File Edit View Calib 1 1 Service Calibration Unit Status IRB Synchronized ...

Page 177: ...TOR You should see the screen below File Edit 1 6 Topics Types System Parameters Manipulator Motor Name Type irb_1 irb_2 irb_3 irb_4 irb_5 irb_6 3HAB 4039 1 3HAB 4040 1 3HAB 4040 1 3HAB 4041 1 3HAB 4041 1 3HAB 4042 1 8 Thenselecttheaxisdesired Seethescreenbelow File Edit 1 6 System Parameters Manipulator Motor Motor Info Name Use Motor Type Commutator Offset Calibration Offset Com Offset Valid Cal...

Page 178: ...ue is in radians CAL OFFSET VALID Confirmation that the calibration values are valid This should be YES COM OFFSET VALID Confirmation that the commutation values are valid This should be YES 10 The value to put on the paper is the CAL OFFSET value 11 TheCALOFFSETvaluemustalsobestoredonthe floppy disk This is done while you are still looking at the resolver values by pressing FILE SAVE AS The resol...

Page 179: ...ot Computer or Memory Boards There are two ways to enter the calibration values into the control they are 1 By disk 2 Manually entering calibration values To enter the calibration values by disk 1 Press MISC SYSTEM PARAMETERS TOPIC MANIPULATOR The following screen should be seen File Edit 1 6 Topics Types System Parameters Manipulator Motor Name Type irb_1 irb_2 irb_3 irb_4 irb_5 irb_6 3HAB 4039 1...

Page 180: ...esolver values saved on it This should be Boot Disk 4 or another disk Press FILE LOAD SAVED PARAMETERS Select the file with the resolver values in it This should be a file named MOC CFG Press OK Cancel OK 1 6 Save Parameter As Name Moc Massmemory Unit flp1 syspar EIO MMC MOC Go up one level Parameters Parameters Parameters PROC Parameters ...

Page 181: ...ct resolver values from the paper next to the Axis 1 motor or wherever you have them recorded 2 Press MISC SYSTEM PARAMETERS TOPICS MANIPULATOR TYPES MOTOR You will see the screen below File Edit 1 6 Topics Types System Parameters Manipulator Motor Name Type irb_1 irb_2 irb_3 irb_4 irb_5 irb_6 3HAB 4039 1 3HAB 4040 1 3HAB 4040 1 3HAB 4041 1 3HAB 4041 1 3HAB 4042 1 ...

Page 182: ...OK 4 The information shown is NAME The name given to the axis example motor_1 CAL OFFSET The value of the resolver when it is at the calibration position This value is in radians COM OFFSET The commutation value for the motor On the IRB 6400 this value is always 1 570800 This value is in radians CAL OFFSET VALID Confirmation that the calibration values are valid This should be YES COM OFFSET VALID...

Page 183: ...rt routines To perform this procedureitisrequiredtousethecalibrationequipment 3HAA 0001 MZ Also needed to accomplish this procedure will be digital leveling equipment This equipmentdoesnotcomewiththerobot Thisequipment can be purchased through ABB Theonlytimethattheresolversshouldbecalibrated using this method is when the resolver has been mechanicallydisassembledfromthemechanical unit Suchasifamo...

Page 184: ...and insert the corresponding measuring rod 6896 0011 YN in one of the three holes in the base 5 Use the Manual Brake Release Switch for Axis 1 and manually push the robot until the measuring rod is positioned within the flat surface on the calibration fixture s elbow WARNING BE ESPECIALLY CAREFUL OPERATING THE ROBOT WHILE IN THE ROBOT WORKING AREA OR PERSONAL INJURY MAY OCCUR 6 Align the pin and t...

Page 185: ...rence plane 9 Mount elbow fixture 6896 0011 LP on the lower arm calibration plane 10 Mount sensor fixture 6808 0011 GM on the wrist calibration plane turned upwards 11 Mount intermediate plate 6896 134 GZ on the turn disc Mount elbow fixture 6808 0011 GU on the intermediate plate Note that the elbow fixture position is adjusted with a guide pin 12 Mount inclination instrument 6807 081 D One sensor...

Page 186: ... zero The gauge should read 0 12 increments 0 3 mm m The reason the calibration position is always adjusted in the directions shown in Figure 3 is that frictionandgravityforcesworktogetheragainstthe direction of movement This simplifies adjustment 14 Turn the reference sensor and move the other sensor Continue the calibration procedure for the other axes 15 When all axes have been adjusted the res...

Page 187: ... ov eL M ov eL M ov eL M ov e L U ndo 2 C ut 3 C opy 4 P ast e 5 G ot o Top 6 G ot o B ot t om 7 Mark 8 C hang e S el ect ed 9 S how V al ue 0 ModP os Search Fi l e Pr og ra m E di t V i ew I PL __ SY S I PL __ U SR MO V E24 00 mai n C o m mo n 1 Move J 2 Move L 3 4 P rocC al l 5 R ET U R N 6 I F 7 S et 8 R eset 9 Wai t D I I PLh i de T es t Select SERVICE VIEW CALIBRATION The figure below should ...

Page 188: ...Counter Indicates that one or more axis revolution counter is not updated Notcalibrated Indicatesthatoneormoreaxisdo not have calibration values stored 17 Press CALIB CALIBRATE The window below will appear 3 Calibrated Calibrate IRB 3 6 Status To calibrate include axes and press OK Axis X 1 Not Calibrated 4 Calibrated 5 Calibrated 6 Calibrated Incl All Cancel OK X 2 Not Calibrated 18 The X indicat...

Page 189: ...The window below will appear 3 Calibrated Calibrate Cancel OK The Calibration forall marked axes will be changed It cannot be undone OK to continue 20 After receiving the warning if you wish to continue press OK again The following screen will appear File Edit View Calib 1 1 Service Calibration Unit Status IRB Synchronized ...

Page 190: ...S MOTOR You will see the screen below File Edit 1 6 Topics Types System Parameters Manipulator Motor Name Type irb_1 irb_2 irb_3 irb_4 irb_5 irb_6 3HAB 4039 1 3HAB 4040 1 3HAB 4040 1 3HAB 4041 1 3HAB 4041 1 3HAB 4042 1 22 Thenselecttheaxisdesired Seethescreenbelow File Edit 1 6 System Parameters Manipulator Motor Motor Info Name Use Motor Type Commutator Offset Calibration Offset Com Offset Valid ...

Page 191: ...alue is in radians CAL OFFSET VALID Confirmation that the calibration values are valid This should be YES COM OFFSET VALID Confirmation that the commutation values are valid This should be YES 24 The value to put on the paper is theCAL OFFSET value 25 The CAL OFFSET value must also be stored on floppy disk This is done while you are still looking at the resolver values by pressing FILE SAVE AS The...

Page 192: ...ill be given after a power outage Other reasons for having to update counters are When a resolver error has occurred When the signal between the resolver and SMB has been interrupted When one of the manipulator axis has been moved without the controller being connected YoushouldNOThavetoupdatethecounterupon powering off and back on again If you do there is aprobleminthesystem 1 Movetherobottotheca...

Page 193: ...mbly Guidelines IRB6400 Page 11 24 RobotCalibration CounterUpdatingProcedure Cont The figure below shows all six axis in the calibration position NOTE if counter values are lost the robot will not move in linear motion ...

Page 194: ...ALIBRATION The following screen should be displayed File Edit View Calib 1 1 Service Calibration Unit Status IRB Not Rev updated 3 Press CALIB REV COUNTER UPDATE The following screen will be displayed 3 Calibrated Calibrate IRB 3 6 Status To calibrate include axes and press OK Axis X 1 Not Calibrated 4 Calibrated 5 Calibrated 6 Calibrated Incl All Cancel OK X 2 Not Calibrated ...

Page 195: ... after completing this procedure to load and run the calibration program on the Boot Disk 4 Explanations on how to do this is in the software loading chapter If the calibration marks do not line up after running the calibration program repeat procedure for axis that are off If mispositioning persists the resolver system must be repaired If a problem occurs for Axis 6 the cause may be that Axis 6 h...

Page 196: ...Page 11 27 RobotCalibration Disassembly Assembly Guidelines IRB6400 NOTES ...

Page 197: ...Disassembly Assembly Guidelines IRB6400 Page 11 28 RobotCalibration NOTES ...

Page 198: ...Disassembly Assembly Guidelines IRB 6400 Parts Lists Illustrations SECTION 12 ...

Page 199: ...uding Axes 1 2 3 Drives 12 3 LOWER ARM L including Parallel Arm Balancing System 12 4 UPPER ARM U including Axis 4 Drive 12 5 WRIST W including Axis 5 Drive 12 6 FACE F including Axis 6 Drive 12 7 SHOULDER SHELF MOUNTED SM including Axis 1 2 3 Drives 12 8 LOWER ARM LE for serial numbers IRB 6400 0001 0048 12 9 BASE FAN BF a PARTS LISTS ILLUSTRATIONS ...

Page 200: ... 1 1 Screw M6x20 2121 2411 370 1 Washer 6 4x12x1 6 2151 2062 153 19 2 Washer 8 4x16x1 6 2151 2062 165 20 2 Screw M8x40 8 8 2121 2519 459 21 Loctite 242 1269 0014 410 22 3 WARNING Label 3HAA 0001 SL 23 1 Frictionless Plate 3HAA 1001 695 24 1 Base Housing 3HAA 1001 653 25 1 Grease Tube Assembly 3HAA 1001 716 26 Loctite 577 1269 1907 1 27 2 Screw M6x16 2121 2411 368 28 Loctite 577 1268 1907 1 Base Sy...

Page 201: ...0 54 Loctite 577 1269 1907 1 55 3 Washer Support 3HAA 1001 200 ITEM QTY DESCRIPTION ABB PART NO 56 Ref Installation Aid Tool 3HAB 1067 6 57 1 Friction Ring 3HAA 1001 614 58 1 O Ring 245 0x3 0 2152 0431 15 59 1 Gear Reduction Unit 3HAB 4079 1 60 8 Washer Plain 13x24x2 5 2551 2062 177 61 8 Screw M12x90 12 9 3HAB 3409 75 62 1 Friction Ring 3HAA 1001 613 63 1 O Ring 234 54x3 53 2152 0431 17 64 1 Brake...

Page 202: ...dapter Sleeve 2213 1905 21 46 2 Shaft 3HAA 1001 88 47 2 Spherical Bearing 3HAA 1001 189 48 2 Lock Washer Incl in Item 45 49 2 Lock Nut Incl in Item 45 50 2 Ring 3HAA 1001 86 51 Grease 1171 4012 201 52 2 Retaining Ring Snap 2154 2527 160 53 2 Screw M8x25 2121 2519 453 54 2 Washer 8 4x16x1 5 2151 2062 165 55 2 Damper 3HAA 1001 81 56 1 Spherical Roller Bearing 3HAB 4169 1 57 1 Spacer Sleeve 3HAB 4387...

Page 203: ...AA 1001 103 43 1 Bearing 2213 0253 5 44 1 Seal Ring 2216 0261 18 45 1 Seal 2216 0086 4 46 1 Bearing 2213 0253 5 47 Grease 1171 4013 301 48 1 Seal 3HAB 4217 1 49 3 Screw 2121 2411 368 50 3 Washer 2151 2062 153 51 1 Cover 3HAA 1001 176 52 2 Screw 2121 2411 368 ITEM QTY DESCRIPTION ABB PART NO 53 1 Cable Holder 3HAA 1001 201 54 1 Cover 3HAA 1001 33 55 1 Gasket 3HAA 1001 97 56 4 Screw 2121 2518 634 57...

Page 204: ...411 287 16 1 Magnetic Plug 2522 122 1 17 1 Washer 13 5x18x1 5 2152 0441 1 18 Cover 3HAA 2166 11 19 1 Lock Nut 2126 2851 108 20 Loctite 290 1269 0014 409 21 1 Bearing 3HAA 1001 162 22 1 Bearing Housing 3HAA 1001 41 23 1 Shim Set 3HAA 0001 AF 24 1 O Ring 2152 2011 529 25 1 Bearing 3HAA 1001 168 26 1 Gear Axis 5 3HAA 0001 AO 27 1 Gear Axis 5 Assem 3HAA 0001 AG 28 1 Seal 3HAB 4409 1 29 1 Retaining Rin...

Page 205: ... 1 Motor Siemens 3HAA 0001 XK Drove Unit Elmo 3HAB 4172 1 Drive Unit Siements EHAA 0001 ABU 11 1 Washer 13 5x18x1 5 2152 0441 1 12 1 Magnetic Plug R 1 4 2522 0122 1 13 1 Sync Plate 3HAA 1001 174 14 1 O Ring 151 99x3 53 2152 0431 12 15 1 Input Pinion Gear 3HAA 1001 522 16 1 Screw 2121 2519 341 17 1 Reduction Gear 3HAA 0001 HJ ITEM QTY DESCRIPTION ABB PART NO 18 1 O Ring 2151 0431 21 19 1 O Ring 215...

Page 206: ...r 13 5x18x1 5 2151 0441 1 36 4 Magnetic Plug 1 4 2522 122 1 37 4 Screw M6x16 2121 2411 368 38 1 Cable Axis 2 3HAB 4252 2 1 Cable Axis 3 3HAA 0001 YY 39 2 Screw M10x100 12 9 Steel 3HAB 3409 62 40 2 Pinion Incl in Item 35 41 1 Motor Axis 3 3HAB 4040 1 1 Motor Axis 2 3HAB 4039 1 42 4 Washer Plain 10 5x22 2 2151 2062 173 43 4 Screw M10x25 8 8 2121 2419 493 44 4 Screw M6x110 8 8 2121 2519 364 45 1 Sign...

Page 207: ...0 2 Screw M6x12 2121 2416 366 31 1 Bracket 3HAA 1001 346 32 2 Screw M8x25 2121 2519 453 33 2 Washer 8 4x16x1 5 2151 2062 165 34 2 Damper 3HAA 1001 123 35 1 Friction Ring 3HAA 1001 613 36 1 O Ring 215 49x3 53 2152 0431 18 37 1 Sealing Ring 3HAA 1001 83 38 1 Ball Bearing 61856 2213 253 10 39 1 X Ring JF4 84 3HAA 1001 193 40 1 Middle Ring 3HAA 1001 633 41 1 Damper 3HAA 1001 622 42 2 Washer 6 4x12x1 6...

Page 208: ...001 607 4 1 Holder 3HAA 1001 606 5 1 Gasket 3HAA 1001 608 6 1 Filter 3HAA 1001 612 7 1 Cable Gland 3HAA 1001 243 1 Cable Gland Nut 2126 0023 2 8 1 Gasket 3HAA 1001 608 9 1 Flange 3HAA 1001 605 10 3 Nut 2126 2011 116 11 1 Screw M6x40 2121 2416 378 12 1 Cover 3HAA 1001 604 13 1 Holder 3HAA 1001 603 14 1 Cover 3HAA 0001 VH 15 Sealing Paste 3HAB 3172 1 Cooling Axis 1 3HAA 0001 AAB BF Disassembly Assem...

Page 209: ...Disassembly Assembly Guidelines IRB 6400 Reference SECTION 13 Mechanical Layouts ...

Page 210: ... 2 9 120 13 9 DRIVE COMPONENTS Axes 2 3 S 2 9 120 13 10 LOWER PARALLEL ARM Early S N 13 11 LOWER PARALLEL ARM Axes 2 3 13 12 PARALLEL BAR Axis 3 13 13 UPPER ARM COMPLETE Axes 4 5 6 13 14 INTERMEDIATE GEAR UNIT Axis4 13 15 INTERMEDIATE GEAR UNIT Axis4 13 16 FINAL GEAR BEARINGS Axis4 13 17 DRIVE MOTOR Axis 4 13 18 WRIST COMPLETE Axes 4 5 6 13 19 GEAR UNIT Axis 5 13 20 INTERMEDIATE GEAR UNIT Axis5 13...

Page 211: ...Disassembly Assembly Guidelines IRB 6400 Reference SECTION 14 Cable Layouts ...

Page 212: ...ON ON ROBOT 14 B POWER SIGNAL Customer Cable 14 C CABLE Axis 5 Drive Motor 14 D CABLE Axis 6 Drive Motor 14 E CABLE Axis 3 Drive Motor 14 F CABLE Axis 1 Fan 14 G CABLE Lower Assembly Complete 14 H SIGNAL CABLE Axis 1 Drive Motor 14 I CABLE Axis 2 Drive Motor 14 J CABLE Upper Assembly Complete a REFERENCE CABLE LAYOUTS ...