ABB IRB 6640 Product Manual
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ABB IRB 6640 Product Manual

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Table of Contents

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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

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Summary of Contents for ABB 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 3 Product manual IRB 6640 - 180/2.55 IRB 6640 - 235/2.55 IRB 6640 - 205/2.75 IRB 6640 - 185/2.8 IRB 6640 - 130/3.2 IRB 6640ID - 200/2.55 IRB 6640ID - 170/2.75 M2004 Document ID: 3HAC026876-001 Revision: F...
  • Page 4 Except as may be expressly stated anywhere in this manual, nothing herein shall be construed as any kind of guarantee or warranty by ABB for losses, damages to persons or property, fitness for a specific purpose or the like.

  • Page 5: Table Of Contents

    2.2 Design 1 and Design 2 of IRB 6640....... . .
  • Page 6 Table of Contents 2.6.10 Loads ..............96 2.7 Restricting the working range .
  • Page 7 4.6.5 Replacement of motor, axis 5 IRB 6640 ....... . .
  • Page 8 Table of Contents 6 Decommissioning 6.1 Introduction ..............397 6.2 Environmental information .

  • Page 9: Overview Of This Manual

    Prerequisites A maintenance/repair/installation craftsman working with an ABB Robot must: • be trained by ABB and have the required knowledge of mechanical and electrical installation/repair/maintenance work. Organization of chapters The manual is organized in the following chapters: Chapter...
  • Page 10 The following documents are referenced in some descriptions regarding robots with the option Foundry Prime. Reference Document ID Replacement gearbox axis 1 on IRB 6640 - Option Foundry 3HAC037959-001 Prime Replacement gearbox axis 2 on IRB 6640 - Option Foundry...
  • Page 11 Overview of this manual Continued Reference Document ID Replacement of motor, axis 4 - Option Foundry Prime 3HAC037959-011 Replacement of motor, axis 5 - Option Foundry Prime 3HAC037959-012 Replacement of motor, axis 6 - Option Foundry Prime 3HAC037959-013 Replacement of SMB unit - Option Foundry Prime 3HAC037959-014 Revisions Revision...
  • Page 12 Sealing compound updated in Exchange of parts on Clean room robots on page 201. • Lifting tools not applicable to IRB 6640, removed from the manual. • Weight updated for version IRB 6640ID-200/2.55 in section Pre-instal- lation procedure on page •...

  • Page 13: Product Documentation, M2004

    The manipulator documentation is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional. All documents listed can be ordered from ABB on a DVD. The documents listed are valid for M2004 manipulator systems. Product manuals...
  • Page 14 Product documentation, M2004 Continued Operating manuals The operating manuals describe hands-on handling of the products. The 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: •...

  • Page 15: How To Read The Product Manual

    How to read the product manual How to read the product manual Reading the procedures The procedures contain references to figures, tools, material, etc. The references are read as described below. References to figures The procedures often include references to components or attachment points located on the manipulator/controller.
  • Page 16 How to read the product manual 3HAC026876-001 Revision: F...

  • Page 17: Safety

    1 Safety 1.1. Introduction to safety information 1 Safety 1.1. Introduction to safety information Overview The safety information in this manual is divided in two categories: • General safety aspects, important to attend to before performing any service work on the robot.

  • Page 18: General Safety Information

    Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty by ABB that the industrial manipulator will not cause injury or damage even if all safety instructions are complied with. Related information...

  • Page 19: Safety Risks

    Nation/region specific regulations To prevent injuries and damage during the installation of the manipulator, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with. Non-voltage related risks •...
  • Page 20 1 Safety 1.2.2.1. Safety risks during installation and service work on manipulators Continued Complete manipulator Safety risk Description Hot components! CAUTION! Motors and gears are HOT after running the manipulator! Touching motors and gears may result in burns! With a higher environment temperature, more surfaces on the manipulator will get HOT and may also result in burns.

  • Page 21: Caution - Hot Parts May Cause Burns

    1 Safety 1.2.2.2. CAUTION - Hot parts may cause burns! 1.2.2.2. CAUTION - Hot parts may cause burns! Description During normal operation, many manipulator parts become hot, especially the drive motors and gears. Sometimes areas around these parts also become hot. Touching these may cause burns of various severity.

  • Page 22: Safety Risks Related To Tools/Workpieces

    1 Safety 1.2.2.3. Safety risks related to tools/workpieces 1.2.2.3. Safety risks related to tools/workpieces Safe handling It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating. It should be possible to release parts by manual operation (valves).

  • Page 23: Safety Risks Related To Pneumatic/Hydraulic Systems

    1 Safety 1.2.2.4. Safety risks related to pneumatic/hydraulic systems 1.2.2.4. Safety risks related to pneumatic/hydraulic systems General Special safety regulations apply to pneumatic and hydraulic systems. Residual energy • Residual energy can be present in these systems. After shutdown, particular care must be taken.

  • Page 24: Safety Risks During Operational Disturbances

    1 Safety 1.2.2.5. Safety risks during operational disturbances 1.2.2.5. Safety risks during operational disturbances General • The industrial manipulator is a flexible tool that can be used in many different industrial applications. • All work must be carried out professionally and in accordance with the applicable safety regulations.

  • Page 25: Risks Associated With Live Electric Parts

    1 Safety 1.2.2.6. Risks associated with live electric parts 1.2.2.6. Risks associated with live electric parts Voltage related risks, general • Although troubleshooting may, on occasion, need to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.

  • Page 26: Safety Actions

    1 Safety 1.2.3.1. Safety fence dimensions 1.2.3. Safety actions 1.2.3.1. Safety fence dimensions General Install a safety cell around the manipulator to ensure safe manipulator installation and operation. Dimensioning Dimension the 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.

  • Page 27: Fire Extinguishing

    1 Safety 1.2.3.2. Fire extinguishing 1.2.3.2. Fire extinguishing NOTE! Use a CARBON DIOXIDE (CO ) extinguisher in the event of a fire in the manipulator system (manipulator or controller)! 3HAC026876-001 Revision: F...

  • Page 28: Emergency Release Of The Manipulator's Arm

    1 Safety 1.2.3.3. Emergency release of the manipulator’s arm 1.2.3.3. Emergency release of the manipulator’s arm Description In an emergency situation, any of the manipulator's axes may be released manually by pushing the brake release buttons on the manipulator. How to release the brakes is detailed in the section: •...

  • Page 29: Brake Testing

    1 Safety 1.2.3.4. Brake testing 1.2.3.4. Brake testing When to test During operation the holding brake of each axis motor is normally worn down. A test can be performed to determine whether the brake can still perform its function. How to test The function of the holding brake of each axis motor may be checked as detailed below: 1.

  • Page 30: Risk Of Disabling Function "Reduced Speed 250 Mm/S

    1 Safety 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" 1.2.3.5. Risk of disabling function "Reduced speed 250 mm/s" NOTE! Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s". 3HAC026876-001 Revision: F...

  • Page 31: Safe Use Of The Flexpendant

    1 Safety 1.2.3.6. Safe use of the FlexPendant 1.2.3.6. Safe use of the FlexPendant NOTE! The enabling device is a push-button located on the side of the FlexPendant which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the manipulator is taken to the MOTORS OFF state.

  • Page 32: Work Inside The Manipulator's Working Range

    1 Safety 1.2.3.7. Work inside the manipulator's working range 1.2.3.7. Work inside the manipulator's working range WARNING! If work must be carried out within the manipulator’s work envelope, the following points must be observed: • The operating mode selector on the controller must be in the manual mode position to render the enabling device operational and to block operation from a computer link or remote control panel.

  • Page 33: Signal Lamp (Optional)

    1 Safety 1.2.3.8. Signal lamp (optional) 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: Safety Stops

    1 Safety 1.2.4.1. What is an emergency stop? 1.2.4. Safety stops 1.2.4.1. What is an emergency stop? Definition of emergency stop An emergency stop is a state that overrides any other manipulator control, disconnects drive power from the manipulator motors, stops all moving parts and disconnects power from any potentially dangerous functions controlled by the manipulator system.
  • Page 35 1 Safety 1.2.4.1. What is an emergency stop? Continued Emergency stop devices In a manipulator system there are several emergency 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).

  • Page 36: Safety Related Instructions

    1 Safety 1.3.1. Safety signals in the manual 1.3 Safety related instructions 1.3.1. Safety signals in the manual Introduction to safety signals This section specifies all dangers that can arise when doing the work described in this manual. Each danger consists of: •...
  • Page 37 1 Safety 1.3.1. Safety signals in the manual Continued Symbol Designation Significance ELECTROSTATIC Warns for electrostatic hazards which could result in DISCHARGE (ESD) severe damage to the product. Electrostatic discharge (ESD) NOTE Describes important facts and conditions. Note Describes where to find additional information or how to do an operation in an easier way.

  • Page 38: Safety Symbols On The Manipulator Labels

    1 Safety 1.3.2. Safety symbols on the manipulator labels 1.3.2. Safety symbols on the manipulator labels Introduction to labels This section describes safety symbols used on labels (stickers) on the manipulator. Symbol are used in combinations on the labels, describing each specific warning. The descriptions in this section are generic, the labels can contain additional information such as values.
  • Page 39 1 Safety 1.3.2. Safety symbols on the manipulator labels Continued Symbol Description Product manual Read the product manual for details. xx0900000813 Before dismantling see product manual xx0900000816 Do not dismantle Dismantling this part can cause injury. xx0900000815 Extended rotation This axis has extended rotation (working area) compared to standard.
  • Page 40 1 Safety 1.3.2. Safety symbols on the manipulator labels Continued Symbol Description Heat Risk of heat that can cause burns. xx0900000818 Moving robot The robot can move unexpectedly. xx0900000819 Brake release buttons xx0900000820 Lifting bolt xx0900000821 Lifting of robot xx0900000822 Can be used in combination with prohibition if oil is not allowed.
  • Page 41 1 Safety 1.3.2. Safety symbols on the manipulator labels Continued Symbol Description Mechanical stop xx0900000824 Stored energy Warns that this part contains stored energy. Used in combination with Do not dismantle symbol. xx0900000825 Pressure Warns that this part is pressurized. Usually contains additional text with the pressure level.

  • Page 42: Danger - Moving Manipulators Are Potentially Lethal

    1 Safety 1.3.3. DANGER - Moving manipulators are potentially lethal! 1.3.3. DANGER - Moving manipulators are potentially lethal! Description Any moving manipulator is a potentially lethal machine. When running, the manipulator may perform unexpected and sometimes irrational movements. Moreover, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the working range of the manipulator.

  • Page 43: Danger - First Test Run May Cause Injury Or Damage

    1 Safety 1.3.4. DANGER - First test run may cause injury or damage! 1.3.4. DANGER - First test run may cause injury or damage! Description Since performing a service activity often requires disassembly of the robot there are several safety risks to take into consideration before the first test run. Elimination Follow the procedure below when performing the first test run after a service activity, such as repair, installation, or maintenance.

  • Page 44: Warning - The Brake Release Buttons May Be Jammed After Service Work

    1 Safety 1.3.5. WARNING - The brake release buttons may be jammed after service work 1.3.5. WARNING - The brake release buttons may be jammed after service work Description The brake release unit has push-buttons for the brake release of each axis motor. When service work is performed inside the SMB recess that includes removal and refitting of the brake release unit, the brake release buttons may be jammed after refitting.

  • Page 45: Warning - The Unit Is Sensitive To Esd

    1 Safety 1.3.6. WARNING - The unit is sensitive to ESD! 1.3.6. WARNING - The unit is sensitive to ESD! Description ESD (electrostatic discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges.

  • Page 46: Warning - Safety Risks During Work With Gearbox Lubricants (Oil Or Grease)

    1 Safety 1.3.7. WARNING - Safety risks during work with gearbox lubricants (oil or grease) 1.3.7. WARNING - Safety risks during work with gearbox lubricants (oil or grease) Description When handling the gearbox lubricants, there is a risk of both personal injury and product damage occurring! The following safety information must be regarded before performing any work with lubricants in the gearboxes! Warnings and elimination...
  • Page 47 1 Safety 1.3.7. WARNING - Safety risks during work with gearbox lubricants (oil or grease) Continued Warning Description Elimination/Action The specified amount of oil or After refilling, check the lubricant grease is based on the total level. volume of the gearbox. When changing the lubricant, the amount refilled may differ from the specified amount,...
  • Page 48 1 Safety 1.3.7. WARNING - Safety risks during work with gearbox lubricants (oil or grease) 3HAC026876-001 Revision: F...

  • Page 49: Installation And Commissioning

    2 Installation and commissioning 2.1. Introduction 2 Installation and commissioning 2.1. Introduction General This chapter contains information for installing the robot at the working site. More detailed technical data can be found in the Product specification for the robot, such as: •...

  • Page 50: Design 1 And Design 2 Of Irb 6640

    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.

  • Page 51: Robot Transportation Precautions

    Transportation in any other way than method 1 or 2 can seriously damage the robot.If the robot is incorrectly transported and the instructions are not followed, the robot is not covered by the warranty and ABB will not accept any compensation claim. Method 1 Transportation according to method 1 is strongly recommended by ABB.
  • Page 52 2 Installation and commissioning 2.3. Robot transportation precautions Continued Method 2 Transportation according to method 2 is approved by ABB, if use of method 1 is not possible. Always follow these instructions when transporting an ABB robot according to method 2: •...
  • Page 53 2 Installation and commissioning 2.3. Robot transportation precautions Continued IRB6620/Foundry Plus xx0800000036 Transport Support Hexagon socket head cap screw M10x50 Threaded bar M10x280 Nut M10 Continues on next page 3HAC026876-001 Revision: F...
  • Page 54 2 Installation and commissioning 2.3. Robot transportation precautions Continued Transport position with a transport support All transportation of the robot with tool must follow these instructions. IRB 7600/IRB 66XX xx0800000040 Continues on next page 3HAC026876-001 Revision: F...
  • Page 55 2 Installation and commissioning 2.3. Robot transportation precautions Continued IRB 6620/Foundy Plus xx0800000041 Continues on next page 3HAC026876-001 Revision: F...
  • Page 56 2 Installation and commissioning 2.3. Robot transportation precautions Continued Recommended transport support Always use the recommended transport support when transporting a robot with tool. IRB 7600/IRB 66XX xx0800000039 Continues on next page 3HAC026876-001 Revision: F...
  • Page 57 2 Installation and commissioning 2.3. Robot transportation precautions Continued IRB 6620 xx0800000038 3HAC026876-001 Revision: F...

  • Page 58: Securing The Robot

    2 Installation and commissioning 2.4. Securing the robot 2.4. Securing the robot General This section describes how to secure the robot using the transport support. DANGER! Releasing the brakes is a hazardous action that may cause injury and damage property. It must be done with great care and only when absolutely necessary.
  • Page 59 2 Installation and commissioning 2.4. Securing the robot Continued Action Note 2. Jog the robot into a position as near above as possible to the recommended transport position for the specific robot, as specified in section Transport position CAUTION! with a transport support on page Do not try to jog the robot to the exact position (max distance 1mm).

  • Page 60: Unpacking

    The table below shows the weights of the different models: Robot model Weight IRB 6640 -180/2.55 1300 kg * IRB 6640 - 235/2.55 1310 kg * IRB 6640 - 205/2.75 1320 kg * IRB 6640 - 185/2.8 1320 kg * IRB 6640 - 130/3.2...
  • Page 61 0.5 mm Max. tilt 5° The limit for the maximum load on the robot is reduced if the robot is tilted. Contact ABB for further information about acceptable loads. Min. resonance frequency 22 Hz Storage conditions, robot The table below shows the allowed storage conditions for the robot:...

  • Page 62: Working Range And Type Of Motion

    The following figures show the working ranges of the robot models. The extreme positions of the robot arm are specified at the wrist center (dimensions in mm). IRB 6640 - 180/2.55, 235/2.55, 205/2.75, 185/2.8, 130/3.2 & IRB 6640ID - 200/2.55, 170/2.75 The illustration below shows the unrestricted working range. Measurements for the different robot variants, are shown as A to F, in the illustration below.
  • Page 63 Continued Turning radius The turning radius, shown as A in the figure below, is specified for the different robot models below the figure. xx0600003399 IRB 6640 - 2.55 2550 mm IRB 6640 - 2.75 2755 mm IRB 6640 - 2.8 2800 mm IRB 6640 - 3.2...
  • Page 64 NOTE! There are limitations of the range of movement with a DressPack/SpotPack application fitted to the robot! See product manual SpotPack/DressPack IRB 6640 chapter Installation section DressPack cable package. Art. no. can be found in section Overview of this manual on page...

  • Page 65: Risk Of Tipping/Stability

    2 Installation and commissioning 2.5.3. Risk of tipping/stability 2.5.3. Risk of tipping/stability Risk of tipping When the robot is not fastened to the foundation and standing still, the robot is not stable in the whole working area. Moving the arms will displace the center of gravity, which may cause the robot to tip over.

  • Page 66: On-Site Installation

    2 Installation and commissioning 2.6.1. Lifting the robot with fork lift 2.6 On-site installation 2.6.1. Lifting the robot with fork lift General The robot may be moved using a fork lift, provided that available special aids are used. This section describes how to attach the fork lift equipment to the robot. Fork lift device set The fork lift device set is fitted to the robot as shown in the figure below.
  • Page 67 2 Installation and commissioning 2.6.1. Lifting the robot with fork lift Continued Lifting the robot with fork lift The procedure below details how to secure the fork lift set in order to lift the robot and move it using fork lift ONLY! The illustration below shows the position of the robot when lifting it with a fork lift.
  • Page 68 2 Installation and commissioning 2.6.1. Lifting the robot with fork lift Continued Action Note 3. Fit the four fork lift pockets on the Make sure the original screws are always used (or base of the robot with its replacements of equivalent quality: M20x60, quality attachment screws.
  • Page 69 2 Installation and commissioning 2.6.1. Lifting the robot with fork lift Continued Action Note 5. Double check that all four fork lift pockets are properly secured before lifting. xx0600002930 • A: Fork lift pocket • B: Attachment screw M20x60 quality 8.8 (2 pcs x 4).

  • Page 70: Lifting Robot With Roundslings

    Attachment points The figure below shows how to attach the roundslings to the robot. xx0600003455 IRB 6640 standard. Lifting instruction 3HAC027647-001 Roundsling robot, 2.5 m (4 pcs) Capacity: 2.000 kg. 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! Lifting eye M20 (4 pcs).
  • Page 71 2.6.2. Lifting robot with roundslings Continued xx0800000059 IRB 6640, Cleanroom variant Roundsling robot, 2.5 m (4 pcs). NOTE! It is important to apply the roundsling the way the figure shows. If not, the cable harness will be damaged. Roundsling upper arm, 2 m. NOTE! Make a loop around the upper arm and wrap the roundsling twice around the upper arm! Do not stretch! Lifting eye M20 (4 pcs).
  • Page 72 2 Installation and commissioning 2.6.2. Lifting robot with roundslings Continued Lifting with roundslings Action Note 1. Attach the roundslings to the robot according to the figure Attachment points on page NOTE! For Cleanroom robots it is important to apply the roundslings: •...

  • Page 73: Manually Releasing The Brakes

    2 Installation and commissioning 2.6.3. Manually releasing the brakes 2.6.3. Manually releasing the brakes General This section details how to release the holding brakes of each axis motor. Location of brake release unit The internal brake release unit is located at the frame, as shown in the figure below. xx0600003402 Internal brake release unit with push buttons.
  • Page 74 2 Installation and commissioning 2.6.3. Manually releasing the brakes Continued Supplying power to connector R1.MP If the robot is not connected to the controller, power must be supplied to connector R1.MP on the robot in order to enable the brake release buttons. Action Note DANGER!

  • Page 75: Lifting The Base Plate

    2 Installation and commissioning 2.6.4. Lifting the base plate 2.6.4. Lifting the base plate Required equipment Equipment Art. no. Note Lifting eye, M16 3HAC14457-4 3 pcs Lifting slings 3 pcs Length: approx. 2 m Hole configuration xx0200000096 Attachment holes for lifting eyes (x3) Lifting, base plate Action Note...

  • Page 76: Securing The Base Plate

    2 Installation and commissioning 2.6.5. Securing the base plate 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 3HAC026876-001 Revision: F...
  • Page 77 2 Installation and commissioning 2.6.5. Securing the base plate Continued xx0400000715 Four holes for alternative clamping, 4x Ø18 Continues on next page 3HAC026876-001 Revision: F...
  • Page 78 • 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.
  • Page 79 2 Installation and commissioning 2.6.5. Securing the base plate Continued Recommendations, quality The table specifies any recommendations made by ABB: Variable Recommendation Recommended foundation quality 1 Steel fibre reinforced concrete foundation, 30 kg/m3, class K30, t=250 mm Recommended foundation quality 2 Sturdy concrete foundation, double reinforced by ø10...

  • Page 80: Orienting And Securing The Robot

    2 Installation and commissioning 2.6.6. Orienting and securing the robot 2.6.6. Orienting and securing the robot General This section details how to orient and secure the robot to the base plate in order to run the robot safely. The requirements made on the foundations are shown in the following tables and figures.
  • Page 81 2 Installation and commissioning 2.6.6. Orienting and securing the robot Continued Securing the robot The procedure below details how to secure the robot to the base plate after fitting the plate to the foundation. Action Note 1. Lift the robot. Detailed in section Lifting robot with roundslings.
  • Page 82 2 Installation and commissioning 2.6.6. Orienting and securing the robot Continued Hole configuration, base The illustration below shows the hole configuration used when securing the robot. xx0600003403 Cross section, guide sleeve hole The illustration below shows the cross section of the guide sleeve holes. xx0600003404 3HAC026876-001 Revision: F...

  • Page 83: Fitting Equipment On Robot

    2 Installation and commissioning 2.6.7. Fitting equipment on robot 2.6.7. Fitting equipment on robot General The robot features mounting holes for additional equipment. Access to any of the following mounting holes may be obstructed by any additional cabling, equipment, etc., fitted by the robot user. Make sure the required mounting holes are accessible when planning the robot cell.
  • Page 84 2 Installation and commissioning 2.6.7. Fitting equipment on robot Continued Robot variant IRB 6640 - 2.55 2240 mm 520 mm 1075 mm IRB 6640 - 2.75 2445 mm 725 mm 1280 mm IRB 6640 - 2.8 2240 mm 520 mm 1075 mm IRB 6640 - 3.2...
  • Page 85 The illustrations below 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 Robot variant IRB 6640 - 2.55 1142 mm 200 mm IRB 6640 - 2.75 1142 mm 200 mm IRB 6640 - 2.8...
  • Page 86 2 Installation and commissioning 2.6.7. Fitting equipment on robot Continued Illustration, fitting of extra equipment on frame The illustration below shows the mounting holes available for fitting extra equipment on the frame. xx0600003416 Continues on next page 3HAC026876-001 Revision: F...
  • Page 87 2 Installation and commissioning 2.6.7. Fitting equipment on robot Continued Illustration, fitting on turning disk The illustration below shows the mounting holes available for fitting equipment on the turning disk. There are two different versions of the turning disk, as shown in the illustrations below. xx0200000397 Turning disk type 1 Continues on next page...
  • Page 88 2 Installation and commissioning 2.6.7. Fitting equipment on robot Continued xx0200000197 Turning disk type 2 Continues on next page 3HAC026876-001 Revision: F...
  • Page 89 2 Installation and commissioning 2.6.7. Fitting equipment on robot Continued xx0500001580 Turning disk unit for robot versionIRB 6640ID. Fastener quality When fitting tools on the turning disk (see the figures above), only use screws with quality 12.9. When fitting other equipment standard screws with quality 8.8 may be used. 3HAC026876-001 Revision: F...

  • Page 90: Installation Of Cooling Fan For Motors, Axes 1 And 2 (Option)

    2 Installation and commissioning 2.6.8. Installation of cooling fan for motors, axes 1 and 2 (option) 2.6.8. Installation of cooling fan for motors, axes 1 and 2 (option) General A cooling fan can be installed on the motors of axes 1and 2. However, cooling fans for axes 1 and 2 can not be combined! The cabling for the fans is available as: •...
  • Page 91 2 Installation and commissioning 2.6.8. Installation of cooling fan for motors, axes 1 and 2 (option) Continued Cooling fan The details of the cooling fan are shown in the figure below. xx0500002158 Fanbox Attachment screws, fanbox plates (9 pcs) Groove in the connector Tightening screws, fanbox (3 pcs) xx0900000137 Fanbox...
  • Page 92 2 Installation and commissioning 2.6.8. Installation of cooling fan for motors, axes 1 and 2 (option) Continued Required equipment Equipment Art. no. Note Cooling fan 3HAC15374-1 Cabling, cooling fans, axes 3HAC023599-001 Choose this cabling if equipping the 1 or 2. robot with cooling fans on axis 1 or 2 .
  • Page 93 2 Installation and commissioning 2.6.8. Installation of cooling fan for motors, axes 1 and 2 (option) Continued Plate for customer connections, at base xx0500002301 Plate for customer connections Attachment screws, 3 pcs, M6x16 quality 8.8-A2F Installation, fan The procedure below details how to install the cooling fan on motors, axes 1 or 2 . Action Note DANGER!
  • Page 94 2 Installation and commissioning 2.6.8. Installation of cooling fan for motors, axes 1 and 2 (option) Continued Action Note 4. Fit the parts of the fanbox to the motor and reassemble with the nine attachment screws. 5. Lift the box (axis 1) so that it does not rest directly on the robot and secure the box with the three tightening screws, using locking liquid.
  • Page 95 2 Installation and commissioning 2.6.8. Installation of cooling fan for motors, axes 1 and 2 (option) Continued Action Note 5. Fit the plate for customer connections, if not Shown in the figure Plate for already fitted, to the connection plate of the robot customer connections, at base on base.
  • Page 96 2 Installation and commissioning 2.6.8. Installation of cooling fan for motors, axes 1 and 2 (option) Continued Adjustments in RobotWare Action Note 1. Modify the settings in RobotWare to RobotWare 5.0: change the settings in the include the cooling fans. Modifying options dialogue, by using the Modify Controller System Wizard in the System Builder of RobotStudio.

  • Page 97: Installation Of Foundry Plus Cable Guard (Option No. 908-1)

    2 Installation and commissioning 2.6.9. Installation of Foundry Plus Cable guard (option no. 908-1) 2.6.9. Installation 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.

  • Page 98: Loads

    2 Installation and commissioning 2.6.10. Loads 2.6.10. Loads General Any loads mounted on the robot must be defined correctly and carefully (with regard to the position of center of gravity and mass moments of inertia) in order to avoid jolting movements and overloading motors, gears and structure.

  • Page 99: Restricting The Working Range

    2 Installation and commissioning 2.7.1. Introduction 2.7 Restricting the working range 2.7.1. Introduction General When installing the robot, make sure that it can move freely within its entire working space. If there is a risk that it may collide with other objects, its working space should be limited. The working range of the following axis may be restricted: •...

  • Page 100: Mechanically Restricting The Working Range Of Axis 1

    2 Installation and commissioning 2.7.2. Mechanically restricting the working range of axis 1 2.7.2. Mechanically restricting the working range of axis 1 General The working range of axis 1 is limited by fixed mechanical stops and adjusting the system parameter configuration. The working range can be reduced by adding additional mechanical stops giving 7.5 or 15 graduation, between 22.5°...
  • Page 101 2 Installation and commissioning 2.7.2. Mechanically restricting the working range of axis 1 Continued Equipment, etc. Art. no. Note Standard toolkit The content is defined in the section Standard toolkit on page 409. Technical reference manual - System Art. no. is specified in section parameters References.

  • Page 102: Mechanically Restricting The Working Range Of Axis 2

    2 Installation and commissioning 2.7.3. Mechanically restricting the working range of axis 2 2.7.3. Mechanically restricting the working range of axis 2 General The working range of axis 2 is limited by fixed mechanical stops and can be reduced by adding up to six additional mechanical stops with 15 graduation in respective direction.
  • Page 103 2 Installation and commissioning 2.7.3. Mechanically restricting the working range of axis 2 Continued Installation, mechanical stops axis 2 The procedure below details how to fit the mechanical stops for axis 2 to the robot. An assembly drawing is also enclosed with the product. Action Note DANGER!

  • Page 104: Mechanically Restricting The Working Range Of Axis 3

    2 Installation and commissioning 2.7.4. Mechanically restricting the working range of axis 3 2.7.4. Mechanically restricting the working range of axis 3 General The working range of axis 3 is limited by fixed mechanical stops and can be reduced by adding additional mechanical stops with 20 graduation in respective direction.
  • Page 105 2 Installation and commissioning 2.7.4. Mechanically restricting the working range of axis 3 Continued xx0600002973 Mechanical stop pin, axis 3 Attachment screw and washer Required equipment 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.
  • Page 106 2 Installation and commissioning 2.7.4. Mechanically restricting the working range of axis 3 Continued Installation, mechanical stops axis 3 The procedure below details how to fit the mechanical stops for axis 3 to the robot. An assembly drawing is also enclosed with the product. Action Note DANGER!

  • Page 107: Electrical Connections

    2 Installation and commissioning 2.8.1. Robot cabling and connection points 2.8 Electrical connections 2.8.1. Robot cabling and connection points Introduction Connect the robot and controller to each other after securing them to the foundation. The lists below specify which cables to use for each respective application. Main cable categories All cables between the robot and controller are divided into the following categories: Cable category...
  • Page 108 2 Installation and commissioning 2.8.1. Robot cabling and connection points Continued Robot cable, power 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 Robot cable, signals Cable...

  • Page 109: Making Robot Ready For Operation (Foundry Prime)

    Humidity 100% Washing detergent with pH <9.0 Washing detergent must contain rust inhibitor and be approved by ABB Cleaning bath temperature <60°C, used in a typical waterjet cleaning application at suitable speed. Air specification for pressurizing of robot The air must be dry and clean, such as instrument air. The table below details the air specifications.
  • Page 110 2 Installation and commissioning 2.9.1. Additional installation procedure Continued WARNING! If the air pressure exceeds the specified, it could result in a brake failure in the motors and cause the robot arms to fall down, leading to personal injury or physical damage. NOTE! To secure the supply of air pressure, it is recommended to use a pressure sensor.
  • Page 111 2 Installation and commissioning 2.9.1. Additional installation procedure Continued Protection points at the wrist joints The illustration below shows points that are particularly sensitive to water spray. xx0600002792 Axis 5, bearing support side Axis 5, bearing gear side Axis 6, mounting flange - gear house 3HAC026876-001 Revision: F...

  • Page 112: Commissioning (Foundry Prime)

    2 Installation and commissioning 2.9.2. Commissioning (Foundry Prime) 2.9.2. Commissioning (Foundry Prime) General The following should be taken in consideration when running a robot in a water jet application cell: CAUTION! Never switch off the overpressure in motors and serial measurement compartment during cooling down of robot after it has been switched off.

  • Page 113: Making Robotready For Operation, (Cleanroom)

    2 Installation and commissioning 2.10.1. Additional installation procedure, Clean room 2.10 Making robotready for operation, (Cleanroom) 2.10.1. Additional installation procedure, Clean room General Clean room robots are specially designed to work in a clean room environment. Clean room robots are designed in order to prevent from particle emission from the robot. For example is maintenance work possible to perform without cracking the paint.
  • Page 114 2 Installation and commissioning 2.10.1. Additional installation procedure, Clean room 3HAC026876-001 Revision: F...

  • Page 115: Maintenance

    3 Maintenance 3.1. Introduction 3 Maintenance 3.1. Introduction Structure of this chapter This chapter details all maintenance activities recommended for the manipulator. It is based on the maintenance schedule located at the beginning of the chapter. The schedule contains information about required maintenance activities including intervals and refers to procedures for the activities.

  • Page 116: Maintenance Schedule And Expected Component Life

    3 Maintenance 3.2.1. Specification of maintenance intervals 3.2 Maintenance schedule and expected component life 3.2.1. Specification of maintenance intervals Introduction The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the manipulator: •...

  • Page 117: Maintenance Schedule

    3 Maintenance 3.2.2. Maintenance schedule 3.2.2. Maintenance schedule General The robot must be maintained regularly to ensure proper function. The maintenance activities and intervals are specified in the table below. Non-predictable situations also give rise to inspections of the robot. Any damages must be attended to immediately! The inspection intervals do not specify the life of each component.
  • Page 118 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Equipment Interval Detailed in section activity Changing Axis 1 gearbox oil: First change when Do not mix with other oils! reads: Kyodo Yushi TMO • Oil change, gearbox 6,000 hours axis 1 on page 165 Second change when reads: 24,000 hours...
  • Page 119 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Equipment Interval Detailed in section activity Lubrication Balancing device Every: • Lubrication of bearing spherical roller 12,000 hours bearing, balancing device on page 186 • DTC = Duty Time Counter. Shows the operational time of the robot. •...
  • Page 120 3 Maintenance 3.2.2. Maintenance schedule Continued Activities and intervals, Foundry Prime The table below specifies the required maintenance activities and intervals for Foundry Prime. Maintenance Equipment Interval Detailed in section activity Inspection Cable harness Every: Inspection, cable harness on page 142 •...
  • Page 121 3 Maintenance 3.2.2. Maintenance schedule Continued Maintenance Equipment Interval Detailed in section activity Lubrication Balancing device, Every: bearing • 6 months Rust preventing Wrist bearing Every: Rust preventive measures, support • 6 months bearing in wrist (Foundry Prime) on page 191 Rust preventive Axis 4 sealing Every: Rust preventive...

  • Page 122: Expected Component Life

    Contact the local ABB Robotics Service team for more information. The given life for the balancing device is based on a test cycle of 4,000,000 cycles that starts from the initial position and goes to maximum extension, and back.
  • Page 123 3 Maintenance 3.2.3. Expected component life Continued Expected component life - Foundry Prime The demanding nature of using Foundry Prime robots in a washing application, can shorten the life of the robot’s components compared to that of standard robots in a typical robotic application.

  • Page 124: Inspection Activities

    3 Maintenance 3.3.1. Inspection, oil level gearbox axis 1 3.3 Inspection activities 3.3.1. Inspection, oil level gearbox axis 1 Location of gearbox The axis 1 gearbox is located between the frame and base. The oil plugs are shown in the figure below.
  • Page 125 3 Maintenance 3.3.1. Inspection, oil level gearbox axis 1 Continued Inspection, oil level gearbox, axis 1 The procedure below details how to inspect the oil level in gearbox axis 1. Action Note WARNING! Handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section WARNING - Safety risks during work with gearbox lubricants (oil or...

  • Page 126: Inspection, Oil Level Gearbox Axis 2

    3 Maintenance 3.3.2. Inspection, oil level gearbox axis 2 3.3.2. Inspection, oil level gearbox axis 2 Location of gearbox The axis 2 gearbox is located in the lower arm rotational center, underneath the motor attachment. xx0600003451 Oil plug, inspection Oil plug, filling Oil plug, draining Required equipment Equipment, etc.,...
  • Page 127 3 Maintenance 3.3.2. Inspection, oil level gearbox axis 2 Continued Inspection, oil level gearbox 2 The procedure below details how to inspect the oil level in gearbox axis 2. Action Note 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...

  • Page 128: Inspection, Oil Level Gearbox Axis 3

    3 Maintenance 3.3.3. Inspection, oil level gearbox axis 3 3.3.3. Inspection, oil level gearbox axis 3 Location of gearbox The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. xx0200000230 Gearbox axis 3 Oil plug, filling Oil plug, draining Required equipment...
  • Page 129 3 Maintenance 3.3.3. Inspection, oil level gearbox axis 3 Continued Inspection, oil level gearbox 3 The procedure below details how to inspect the oil level in the gearbox axis 3. Action Note WARNING! Handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section WARNING - Safety risks during work with gearbox lubricants (oil or...

  • Page 130: Inspection, Oil Level Gearbox Axis 4

    3 Maintenance 3.3.4. Inspection, oil level gearbox axis 4 3.3.4. Inspection, oil level gearbox axis 4 Location of gearbox The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure below. xx0200000231 Oil plug, filling Oil plug, draining Required equipment...
  • Page 131 3 Maintenance 3.3.4. Inspection, oil level gearbox axis 4 Continued Inspection, oil level gearbox 4 The procedure below details how to inspect the oil level in gearbox axis 4. Action Note 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...

  • Page 132: Inspection, Oil Level, Gearbox Axis 5

    3 Maintenance 3.3.5. Inspection, oil level, gearbox axis 5 3.3.5. Inspection, oil level, gearbox axis 5 Location of gearbox The axis 5 gearbox is located in the wrist unit as shown in the figure below. xx0200000232 Oil plug, filling Oil plug, draining xx0500002013 The figure above shows the wrist unit of IRB 6640ID Wrist unit, axis 5...
  • Page 133 3 Maintenance 3.3.5. Inspection, oil level, gearbox axis 5 Continued Required equipment 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 These procedures include references be required.

  • Page 134: Inspection, Oil Level Gearbox Axis 6

    3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 3.3.6. Inspection, oil level gearbox axis 6 Location of gearbox The axis 6 gearbox is located in the wrist unit as shown in the figure below. xx0600002964 Gearbox axis 6 Oil plug, filling Oil plug, draining xx0400001092 Gearbox, axis 6...
  • Page 135 3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 Continued xx0500002017 The figure above shows the wrist unit of IRB 6640ID Gearbox, axis 6 Oil plugs, draining Oil plug, filling Type of wrist To inspect oil level for wrist type 1, see Inspection, oil level gearbox 6, wrist type 1 on page 134.
  • Page 136 3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 Continued Inspection, oil level gearbox 6, wrist type 1 Use this procedure to inspect the oil level in gearbox axis 6, for wrist type 1. Action Note WARNING! Handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section WARNING - Safety risks...
  • Page 137 3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 Continued Inspection, oil level gearbox 6, wrist type 2 Use this procedure to inspect the oil level in gearbox axis 6, for wrist type 2. Action Note WARNING! Handling gearbox oil involves several safety risks.
  • Page 138 3 Maintenance 3.3.6. Inspection, oil level gearbox axis 6 Continued Analysis of water content in oil, gearbox axis 6 (Foundry Prime) When changing oil, check for water content in oil. Then..1. More than 2% water in oil: Replacement of gearbox axis 6 is required every two years •...

  • Page 139: Inspection, Balancing Device

    3 Maintenance 3.3.7. Inspection, balancing device 3.3.7. Inspection, balancing device General Several points are to be checked on the balancing device during the inspection. This section details how to perform the inspection regarding: • dissonance • damage • leakage • contamination / lack of free space.
  • Page 140 3 Maintenance 3.3.7. Inspection, balancing device Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Design 1: 3HAC029054-001 For maintenance of balancing device. Maintenance parts, shaft Includes: • bearings, o-rings and seals (Front bearing). Design 2: 3HAC033411-001 For maintenance of balancing device.
  • Page 141 Art. no. for the kit and the documentation are specified in section Required equipment on page 138. • balancing device (a ...replace the balancing device or consult ABB Robotics. tapping sound, How to replace the device is detailed in section caused by the Replacement of balancing device. This section also...
  • Page 142 3 Maintenance 3.3.7. Inspection, balancing device Continued Check for leakage - Design 1 The front ear of the balancing device is lubricated with grease. After filling, excessive grease may normally be forced out between the shaft and the sealing ring in the sealing spacer. This is normal behaviour and must not be confused with incorrect leaks from the ear.
  • Page 143 3 Maintenance 3.3.7. Inspection, balancing device Continued Check for leakage - Design 2 The front ear of the balancing device is lubricated with grease. Leaks at o-rings, sealings etc. are not acceptable and must be attended to immediately to avoid damage to the bearing.

  • Page 144: Inspection, Cable Harness

    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 Lower arm SMB/BU unit Connectors at base Continues on next page...
  • Page 145 3 Maintenance 3.3.8. Inspection, cable harness Continued xx0800000044 IRB 6640 Cleanroom variant. Connectors at base Velcro straps Cable harness Side bracket balancing cylinder Gripping clamp (4 pcs) Required equipment Equipment, etc. Art. no. Note Standard toolkit The content is defined in the section Standard toolkit on page 409.
  • Page 146 3 Maintenance 3.3.8. Inspection, cable harness Continued Inspection, cable harness 1-4 The procedure below details how to inspect the cable harness of axes 1-4. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 147 IRB 6640 standard Cable harness axes 5-6 Cable attachment, rear of upper arm Cable attachment, upper arm tube xx0800000045 IRB 6640 Cleanroom variant. Gripping clamp Cable guide Cover Connectors at connection plate ax 3 Continues on next page 3HAC026876-001 Revision: F...
  • Page 148 3 Maintenance 3.3.8. Inspection, cable harness Continued Inspection, cable harness, axes 5-6 The procedure below details how to inspect the cable harness of axes 5-6. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.

  • Page 149: Inspection Of Air Hoses (Foundry Prime)

    3 Maintenance 3.3.9. Inspection of air hoses (Foundry Prime) 3.3.9. Inspection of air hoses (Foundry Prime) General The air hoses on Foundry Prime robots must be inspected for leakage every six months. Required equipment Equipment, etc. Art. no. Leak detection spray Pressure gauge Cut off valve Procedure...

  • Page 150: Inspection Of Surface Treatment (Foundry Prime)

    3 Maintenance 3.3.10. Inspection of surface treatment (Foundry Prime) 3.3.10. Inspection of surface treatment (Foundry Prime) Introduction to inspection of surface treatment Damage to painted surfaces must be repaired as soon as possible to avoid corrosion. All painted surfaces on the robot must be inspected. Required equipment Equipment, etc.

  • Page 151: Inspection, Information Labels

    3 Maintenance 3.3.11. Inspection, information labels 3.3.11. Inspection, information labels Location of labels The figures below show the location of the information labels to be inspected. xx0600003457 Warning label concerning high temperature (4 pcs) Warning sign, symbol of flash (located on motor cover) (5 pcs) Instruction label Warning label, tools are not allowed around the balancing device during operation Warning label concerning shutting off power...
  • Page 152 3 Maintenance 3.3.11. Inspection, information labels Continued xx0600003456 Instructional label concerning lifting the robot Warning label concerning risk of tipping Foundry logotype Warning label concerning stored energy Abs-Acc information sign Label calibration Serial no. from rating label UL-label Required equipment Equipment Art.
  • Page 153 3 Maintenance 3.3.11. Inspection, information labels Continued Inspection, labels Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 2.

  • Page 154: Inspection, Mechanical Stop Pin, Axis 1

    3 Maintenance 3.3.12. Inspection, mechanical stop pin, axis 1 3.3.12. Inspection, mechanical stop pin, axis 1 Location of mechanical stop pin The mechanical stop axis 1 is located at the base as shown in the figure below. xx0600003436 Mechanical stop pin, axis 1 Fixed mechanical stop Required equipment Equipment, etc.
  • Page 155 3 Maintenance 3.3.12. Inspection, mechanical stop pin, axis 1 Continued Inspection, mechanical stop pin The procedure below details how to inspect the mechanical stop pin axis 1. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.

  • Page 156: Inspection, Additional Mechanical Stops

    3 Maintenance 3.3.13. Inspection, additional mechanical stops 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 Additional stop, axis 1 Attachment screws and washers (2 pcs) Fixed stop Mechanical stop pin, axis 1 Continues on next page...
  • Page 157 3 Maintenance 3.3.13. Inspection, additional mechanical stops Continued xx0600003438 Additional stops, axis 3 Fixed stop, axis 3 Additional stops, axis 2 Fixed stop, axis 2 Required equipment Equipment etc. Art. no. Note Mechanical stop set, axis 1 3HAC025204-003 Includes: • Stop +15°/-7.5°...
  • Page 158 3 Maintenance 3.3.13. Inspection, additional mechanical stops Continued Inspection, mechanical stops The procedure below details how to inspect the additional mechanical stops on axes 1,2 and 3. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.

  • Page 159: Inspection, Damper Axes 2-5

    3 Maintenance 3.3.14. Inspection, damper axes 2-5 3.3.14. Inspection, damper axes 2-5 Location of dampers The figure below shows the location of all the dampers to be inspected. xx0600003440 Damper, axis 2 (2 pcs) Damper, axis 3 (2 pcs) Damper, axis 4 (1 pc) Damper, axis 5 (2 pcs) (IRB 6640ID: 4 pcs) Required equipment A damper must be replaced if damaged!
  • Page 160 3 Maintenance 3.3.14. Inspection, damper axes 2-5 Continued Inspection, dampers The procedure below details how to inspect the dampers, axes 2-5. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.

  • Page 161: Inspection, Signal Lamp (Option)

    3 Maintenance 3.3.15. Inspection, signal lamp (option) 3.3.15. Inspection, signal lamp (option) Location of signal lamp The signal lamp is located as shown in the figure below. Note that the position can differ depending on how the customer harness for axis 4-6 is mounted. See assembly drawing on the current harness for alternative positioning.
  • Page 162 3 Maintenance 3.3.15. Inspection, signal lamp (option) Continued Inspection, signal lamp The procedure below details how to inspect the function of the signal lamp. Action Note 1. Check that the signal lamp is lit when the motors are put in operation ("MOTORS ON"). DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

  • Page 163: Replacement / Changing Activities

    3 Maintenance 3.4.1. Type of oil in gearboxes 3.4 Replacement / Changing activities 3.4.1. Type of oil in gearboxes Location of gearboxes The figure shows the location of the gearboxes on the robot. xx0600003442 Gearbox, axis 1 Gearbox, axis 2 Gearbox, axis 3 Gearbox, axis 4 Gearbox, axis 5...
  • Page 164 2,500 ml Axis 4 Mobilgear 600 XP320 11712016-604 8,100 ml Axis 5 Mobilgear 600 XP320 11712016-604 IRB 6640: 6,700 ml IRB 6640ID: 5,000 ml Axis 6IRB 6640 Kyodo Yushi TMO 150 3HAC032140-001 450 ml Axis 6, IRB 6640ID Mobilgear 600 XP320...
  • Page 165 Labels at robot base Label located at robot base show the types of oil in all gearboxes. xx0600003448 IRB 6640 Label at robot base, (example of label on robot base) Mixed types of oil may cause severe damage! When refilling or replacing oil in a gearbox it is important to first check which type of oil is recommended for use in the gearbox.
  • Page 166 3 Maintenance 3.4.1. Type of oil in gearboxes Continued Rinsing the gearbox Depending on which types of oil are mixed and which type of oil shall be filled in the gearbox after rinsing, use the appropriate procedure. The same applies if the type of oil shall be changed in the gearbox. NOTE! The explanation given for Kyodo Yushi TMO 150 also applies to Shell Tivela S 150.

  • Page 167: Oil Change, Gearbox Axis 1

    3 Maintenance 3.4.2. Oil change, gearbox axis 1 3.4.2. Oil change, gearbox axis 1 Location of oil plugs The axis 1 gearbox is located between the frame and base. The oil plugs for filling and inspection are shown in the figure below. xx0600003449 Oil plug, filling Oil plug, inspection...
  • Page 168 3 Maintenance 3.4.2. Oil change, gearbox axis 1 Continued Draining oil, axis 1 The procedure below details how to drain the oil in gearbox axis 1. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no.
  • Page 169 3 Maintenance 3.4.2. Oil change, gearbox axis 1 Continued Filling oil, axis 1 The procedure below details how to fill the oil in gearbox axis 1. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.

  • Page 170: Oil Change, Gearbox Axis 2

    3 Maintenance 3.4.3. Oil change, gearbox axis 2 3.4.3. Oil change, gearbox axis 2 Location of oil plugs The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment. xx0600003451 Oil plug, inspection Oil plug, filling Oil plug, draining Required equipment Equipment, etc.
  • Page 171 3 Maintenance 3.4.3. Oil change, gearbox axis 2 Continued Draining, oil The procedure below details how to drain the oil in gearbox axis 2. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 168.
  • Page 172 3 Maintenance 3.4.3. Oil change, gearbox axis 2 Continued Filling, oil The procedure below details how to fill oil into the gearbox, axis 2. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 168.

  • Page 173: Oil Change, Gearbox, Axis 3

    3 Maintenance 3.4.4. Oil change, gearbox, axis 3 3.4.4. Oil change, gearbox, axis 3 Location of gearbox The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. xx0200000230 Gearbox axis 3 Oil plug, filling Oil plug, draining Required equipment Equipment, etc.
  • Page 174 3 Maintenance 3.4.4. Oil change, gearbox, axis 3 Continued Draining, oil The procedure below details how to drain oil from the gearbox, axis 3. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 171.
  • Page 175 3 Maintenance 3.4.4. Oil change, gearbox, axis 3 Continued Filling, oil The procedure below details how to fill oil into the gearbox, axis 3. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 171.

  • Page 176: Oil Change, Gearbox, Axis 4

    3 Maintenance 3.4.5. Oil change, gearbox, axis 4 3.4.5. Oil change, gearbox, axis 4 Location of gearbox The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure below. xx0200000231 Oil plug, filling Oil plug, draining Required equipment Equipment, etc.
  • Page 177 3 Maintenance 3.4.5. Oil change, gearbox, axis 4 Continued Draining, oil The procedure below details how to drain the oil in the gearbox, axis 4. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 174.
  • Page 178 3 Maintenance 3.4.5. Oil change, gearbox, axis 4 Continued Filling, oil The procedure below details how to fill the oil in the gearbox, axis 4. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no. for the kit is specified in Required equipment on page 174.

  • Page 179: Oil Change, Gearbox, Axis 5

    3 Maintenance 3.4.6. Oil change, gearbox, axis 5 3.4.6. Oil change, gearbox, axis 5 Location of gearbox The axis 5 gearbox is located in the wrist unit as shown in the figure below. xx0200000232 Oil plug, filling Oil plug, draining xx0500002013 Wrist unit of IRB 6640ID Oil plug, filling...
  • Page 180 3.4.6. Oil change, gearbox, axis 5 Continued Required equipment Equipment, etc. Art. no. Amount Note Lubricating oil 11712016-604 IRB 6640: Mobilgear 600 XP 320 6,700 ml IRB 6640ID: 5,000 ml Oil exchange equipment 3HAC021745-001 The content is defined in the section Special tools on page 410.
  • Page 181 3 Maintenance 3.4.6. Oil change, gearbox, axis 5 Continued Filling, oil, axis 5 The procedure below details how to change the oil in gearbox, axis 5. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no.

  • Page 182: Oil Change, Gearbox Axis 6

    3 Maintenance 3.4.7. Oil change, gearbox axis 6 3.4.7. Oil change, gearbox axis 6 Location of gearbox The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. xx0400001092 Gearbox, axis 6 Oil plug, filling Oil plug, draining xx0500002017...
  • Page 183 Required equipment Equipment, etc. Art. no. Amount Note Lubricating oilIRB 6640ID 11712016-604 6,000 ml Mobilgear 600 XP320 Lubricating oil IRB 6640 3HAC032140-001 450 ml Kyodo Yushi TMO 150 Note! Do not mix with other oil types. Oil exchange equipment 3HAC021745-001...
  • Page 184 3 Maintenance 3.4.7. Oil change, gearbox axis 6 Continued Filling, oil, axis 6 The procedure below details how to fill oil into the gearbox, axis 6. When using the oil exchange equipment, follow the instructions enclosed with the kit. Art. no.

  • Page 185: Replacement Of Smb Battery

    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 ABB approved equivalent. Standard toolkit The content is defined in the section Standard toolkit on page 409.
  • Page 186 6. Remove the SMB battery. Shown in the figure Location of SMB battery on page 183. Battery includes protection circuits. Replace it only with the specified spare part or with an ABB approved equivalent. Continues on next page 3HAC026876-001 Revision: F...
  • Page 187 3 Maintenance 3.4.8. Replacement of SMB battery Continued Refitting, battery The procedure below details how to refit the SMB battery. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.

  • Page 188: Lubrication Activities

    3 Maintenance 3.5.1. Lubrication of spherical roller bearing, balancing device 3.5 Lubrication activities 3.5.1. Lubrication of spherical roller bearing, balancing device Location of bearing (Design 1) The spherical roller bearing is located at the front ear of the balancing device, as shown in the figure below.
  • Page 189 3 Maintenance 3.5.1. Lubrication of spherical roller bearing, balancing device Continued Location of bearing (Design 2) xx0900000110 Required equipment Equipment, etc. Art. no. Note Grease 3HAA1001-294 Optimol PDO, 20 ml Lubrication nipple M6. Normally not fitted to the link ear at delivery. Grease pump Lubrication, balancing device bearing The procedure below details how to lubricate the spherical roller bearing.

  • Page 190: Rust Preventive Measures, Sealing Axis 4 (Foundry Prime)

    3 Maintenance 3.5.2. Rust preventive measures, sealing axis 4 (Foundry Prime) 3.5.2. Rust preventive measures, sealing axis 4 (Foundry Prime) Overview The sealing axis 4 is located as shown in the illustration. xx0500002869 Cover Cable guide Required equipment Equipment Art. no. Note Brush Rust preventive...
  • Page 191 3 Maintenance 3.5.2. Rust preventive measures, sealing axis 4 (Foundry Prime) Continued Procedure The procedure describes how to apply rust preventive on sealing axis 1. Action Note 1. Put the robot in a suitable position. DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots:...
  • Page 192 3 Maintenance 3.5.2. Rust preventive measures, sealing axis 4 (Foundry Prime) Continued Action Note 6. Apply rust preventive on the radial sealing and the rear part of the tube with a brush. xx0600002868 Parts: • A: Radial sealing and rear part of tube •...

  • Page 193: Rust Preventive Measures, Support Bearing In Wrist (Foundry Prime)

    3 Maintenance 3.5.3. Rust preventive measures, support bearing in wrist (Foundry Prime) 3.5.3. Rust preventive measures, support bearing in wrist (Foundry Prime) Location of bearing The support bearing in the wrist is located as shown in the illustration. xx0500002863 Bearing Cable bracket Cover Required equipment...
  • Page 194 3 Maintenance 3.5.3. Rust preventive measures, support bearing in wrist (Foundry Prime) Continued Greasing bearings The procedure describes how to apply rust preventive on the support bearing. Action Note 1. Put the robot and the upper arm in a suitable position.

  • Page 195: Cleaning Activities

    Yes. With light Yes. With cleaning Yes. With light cloth. cleaning detergent. cleaning detergent approved cleaning detergent or by ABB, spirit or detergent, spirit. isopropyl alcohol. spirit or isopropyl alcohol. Rinse with Yes. It is highly Yes. It is highly Yes.
  • Page 196 3 Maintenance 3.6.1. Cleaning, robot Continued Cleaning with water and steam Cleaning methods that can be used for ABB robots with protection Standard, Foundry Plus, Wash, Foundry Prime. Equipment, etc. Note Vacuum cleaner Cloth with mild detergent Water cleaner •...

  • Page 197: Repair

    4 Repair 4.1. Introduction 4 Repair 4.1. Introduction Structure of this chapter This chapter details all repair activities recommended for the robot and any external units of the robot. It is made up of separate procedures, each detailing a specific repair activity. Each procedure contains all the information required to perform the activity, for example spare parts numbers, required special tools and materials.

  • Page 198: General Procedures

    4 Repair 4.2.1. Performing a leak-down test 4.2 General procedures 4.2.1. Performing a leak-down test General After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test. Required equipment Equipment, etc.

  • Page 199: Mounting Instructions For Bearings

    4 Repair 4.2.2. Mounting instructions for bearings 4.2.2. Mounting instructions for bearings General This section details how to mount and grease different types of bearings on the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB3537-1 Used to grease the bearings, if not specified otherwise.
  • Page 200 4 Repair 4.2.2. Mounting instructions for bearings Continued Greasing of bearings The bearings must be greased after assembly in accordance to the instructions below: • The bearings must not be completely filled with grease. However, if space is available beside the bearing fitting, the bearing may be totally filled with grease when mounted, as excessive grease will be pressed out from the bearing when the robot is started.

  • Page 201: Mounting Instructions For Seals

    4 Repair 4.2.3. Mounting instructions for seals 4.2.3. Mounting instructions for seals General This section details how to mount different types of seals onto the robot. Equipment Equipment, etc. Art. no. Note Grease 3HAB3537-1 Used to lubricate the seals. Rotating seals The procedure below details how to fit rotating seals.
  • Page 202 If the flange surfaces are 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.

  • Page 203: Exchange Of Parts On Clean Room Robots

    4 Repair 4.2.4. Exchange of parts on Clean room robots 4.2.4. Exchange of parts on Clean room robots General When exchanging parts on a Clean room robot, it is important to make sure that after the exchange, no particles will be emitted from the joint between the structure and the new part and that the easy cleaned surface is retained.
  • Page 204 4 Repair 4.2.4. Exchange of parts on Clean room robots Continued Assemble 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...

  • Page 205: Complete Robot

    This section details how to replace the cable harness that runs undivided from axis 1 to axis 6. Replacement or cable harness for Foundry 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.
  • Page 206 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Guide plate ax 2 Cable guide Connector R1.MP Connector R1.SMB Cable protector (placed inside the lower arm) Position for SMB and brake release units Cable harness (cut away view) Velcro strap (inside lower arm on metal clamp) Cable gland (armhouse) xx0700000107 Required equipment...
  • Page 207 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Cable brackets of the upper arm xx0500002293 Cable bracket, wrist unit Cable bracket, upper arm tube Cable attachment, rear Removal, cable harness - upper arm The procedure below details how to remove the cable harness from the upper arm of the robot. Action Note 1.
  • Page 208 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note NOTE! Axis 5 must be oriented in the correct position (+90º) to allow the motor 6 cover to open! 5. Remove the cover of motor, axis 6 and disconnect all connectors beneath.
  • Page 209 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Removal, cable harness - lower arm, frame and base The procedure below details how to remove the cable harness from the lower arm, frame and base. Action Note 1. Remove the rear cover plate from the robot by Shown in the figure Location of cable removing its attachment screws.
  • Page 210 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 9. Remove the cable gland by removing the four attachment screws from inside the SMB recess. xx0700000109 • A: Cable gland • B: Attachment screws, inside SMB recess 10.
  • Page 211 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Refitting, cable harness - lower arm, frame and base The procedure below details how to refit the lower end of the cable harness to the robot. How to refit the upper end is detailed in section Refitting, cable harness - upper arm on page 211.
  • Page 212 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 7. 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 8.
  • Page 213 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 12. Refit the cable gland securing the cables to the arm house. NOTE! The cable harness is delivered in a pretwisted state. Make sure not to affect this by twisting the cable harness further in any direction.
  • Page 214 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 5. Refit the velcro strap at the guide plate axis 2. Shown in the figure Location of cable harness on page 203. 6. Gently insert the cable harness from the rear into the upper arm.
  • Page 215 4 Repair 4.3.1. Replacement of cable harness, axes 1-6 Continued Action Note 12. Refit the cover, upper arm tube and the cover, wrist unit. Make sure the cabling is placed correctly when refitting the covers, and does not get jammed. xx0200000214 Parts: •...

  • Page 216: Replacement Of Cabling, Axis 5 Motor

    4 Repair 4.3.2. Replacement of cabling, axis 5 motor 4.3.2. Replacement of cabling, axis 5 motor Location of cabling The separate cables for the axis 5 motor are located inside the upper arm tube, as shown in the figure below. xx0500002294 Motor axis 5 with connectors R4.FB5 and R4.MP5 Connectors R3.FB5 and R3.MP5...
  • Page 217 4 Repair 4.3.2. Replacement of cabling, axis 5 motor Continued Action Note 2. Remove the complete wrist unit. Detailed in section: • 6640:Removal, wrist unit on page 265. • IRB 6640ID: Removal, wrist unit on page 270. 3. Remove the cover of motor, axis 5. 4.

  • Page 218: Fitting Cable Package Attachments (Cleanroom)

    4 Repair 4.3.3. Fitting cable package attachments (Cleanroom) 4.3.3. Fitting cable package attachments (Cleanroom) Overview This section details how to fit the cable attachments for the cable harness (Cleanroom). How to replace the cable harness itself is detailed in section Replacement of cable harness, Cleanroom on page 224.
  • Page 219 4 Repair 4.3.3. Fitting cable package attachments (Cleanroom) Continued Fitting of cable package attachments - lower end The procedure below details how to install the attachments at the lower end of the cable harness (Cleanroom). Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 220 4 Repair 4.3.3. Fitting cable package attachments (Cleanroom) Continued Action Note 3. Fit the gripping clamp to the shelf with its attachment Locking liquid is specified in screws. Required equipment on page 216. Lock screws with locking liquid. xx0800000008 Parts: •...
  • Page 221 4 Repair 4.3.3. Fitting cable package attachments (Cleanroom) Continued Action Note 5. Fit the gripping clamp to the lower bracket, Locking liquid is specified in balancing cylinder with its attachment screws. Required equipment on page 216. Lock screws with locking liquid. The screws are supplied with the kit.
  • Page 222 4 Repair 4.3.3. Fitting cable package attachments (Cleanroom) Continued Action Note NOTE! The lower bracket is fitted slightly different depending on robot variant. See figure to the right! xx0800000014 • A: SW 2.55 • B: SW 2.75 8. Fit the two brackets for cable clamp on the lower Locking liquid is specified in arm with its attachment screws.
  • Page 223 4 Repair 4.3.3. Fitting cable package attachments (Cleanroom) Continued Action Note 9. Fit the gripping clamp to the bracket for cable clamp Locking liquid is specified in with its attachment screws , M8x16 quality 8.8-A2F Required equipment on page 216. (2 pcs) and washer 2 holes (2 pcs).
  • Page 224 4 Repair 4.3.3. Fitting cable package attachments (Cleanroom) Continued Action Note 3. Fit the gripping clamp to the bracket for cable clamp Locking liquid is specified in with: Required equipment on page 216. • attachment screws (2 pcs) • washer 2 holes •...
  • Page 225 4 Repair 4.3.3. Fitting cable package attachments (Cleanroom) Continued Action Note 5. Fit the connection plate axis 3 with its attachment Locking liquid is specified in screws. Required equipment on page 216. Lock screws with locking liquid. The screws are supplied with the kit. xx0800000026 Parts: •...

  • Page 226: Replacement Of Cable Harness, Cleanroom

    4 Repair 4.3.4. Replacement of cable harness, Cleanroom 4.3.4. Replacement of cable harness, Cleanroom General This section details how to replace the cable harness, Cleanroom. Fitting of cable attachments is detailed in section Fitting cable package attachments (Cleanroom) on page 216.
  • Page 227 4 Repair 4.3.4. Replacement of cable harness, Cleanroom Continued Motor axis 1 Connectors at base Required equipment Equipment Spare part no. Note Cable harness, Cleanroom See Spare parts chapter. Gasket 3HAC033489-001 Motor, axis 6 Standard toolkit The content is defined in the section Standard toolkit on page 409.
  • Page 228 4 Repair 4.3.4. Replacement of cable harness, Cleanroom Continued Action Note 7. Remove the cover on the shelf by removing its attachment screws. xx0800000049 Parts: • A: Cover • B: Shelf • C: Attachment screws M6x16 quality 8.8-A2F (4 pcs) 8.
  • Page 229 4 Repair 4.3.4. Replacement of cable harness, Cleanroom Continued Action Note 9. Open the gripping clamp and remove the cable harness from the shelf. xx0800000050 Parts: • A: Gripping clamp 10. Pull the cable harness and connectors carefully up through the cable guide in the center of the frame. xx0800000046 Parts: •...
  • Page 230 4 Repair 4.3.4. Replacement of cable harness, Cleanroom Continued Action Note 12. Disconnect connectors: • R2.SMB, R1.SMB1-3, R1.SMB4-4 to the SMB unit • X8, X9, X10 to the brake release unit xx0700000104 13. Remove the cable gland by removing its attachment screws from inside the SMB recess.
  • Page 231 4 Repair 4.3.4. Replacement of cable harness, Cleanroom Continued Action Note 14. Open the gripping clamp on the lower bracket and remove the cable harness. xx0800000053 Parts: • A: Gripping clamp 15. Remove the velcro straps on the side bracket, balancing device.
  • Page 232 4 Repair 4.3.4. Replacement of cable harness, Cleanroom Continued Removal cable harness - upper end The procedure below details how to remove the upper end of the cable harness, Cleanroom. Action Note 1. Remove the cover at the back of the upper arm tube Shown in the figure Location of by removing its attachment screws.
  • Page 233 4 Repair 4.3.4. Replacement of cable harness, Cleanroom Continued Refitting cable harness - lower end The procedure below details how to refit the lower end of the cable harness, Cleanroom. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 234 4 Repair 4.3.4. Replacement of cable harness, Cleanroom Continued Action Note 7. Fit the bracket on the cable package to the shelf with its attachment screws. xx0800000047 Parts: • A: Cable bracket (part of cable harness) • B: Shelf • C: Attachment screws M6x16 quality 8.8-A2F (2 pcs)
  • Page 235 4 Repair 4.3.4. Replacement of cable harness, Cleanroom Continued Action Note 10. Refit the cover on the shelf with its attachment screws. xx0800000049 Parts: • A: Cover • B: Shelf • C: Attachment screws M6x16 quality 8.8-A2F (4 pcs) 11. Secure the cable gland with its attachment screws from inside the SMB recess.
  • Page 236 4 Repair 4.3.4. Replacement of cable harness, Cleanroom Continued Action Note 12. Reconnect connectors: • R2.SMB, R1.SMB1-3, R1.SMB4-6 to the SMB unit • X8, X9, X10 to the brake release unit • R1.G battery cable (if it has been recon- nected) xx0700000104 13.
  • Page 237 4 Repair 4.3.4. Replacement of cable harness, Cleanroom Continued Action Note 17. Secure the cable harness to the gripping clamps on the lower arm. xx0800000051 Parts: • A: Gripping clamps 18. Continue refitting of the upper end of the cable harness.
  • Page 238 4 Repair 4.3.4. Replacement of cable harness, Cleanroom Continued Action Note 4. Reconnect all connectors on the connection plate axis 3. xx0800000055 Parts: • A: Connectors (at connection plate axis 3) 5. Reconnect all connectors at motor axis 3 and motor Shown in the figure Location of axis 4.

  • Page 239: Replacement Of Cable Harness, Axes 1-4 Irb 6640Id

    4 Repair 4.3.5. Replacement of cable harness, axes 1-4 IRB 6640ID 4.3.5. Replacement of cable harness, axes 1-4 IRB 6640ID Location of cable harness The cable harness for axes 1-4 is run throughout the base, frame and lower arm as shown in the figure below.
  • Page 240 4 Repair 4.3.5. Replacement of cable harness, axes 1-4 IRB 6640ID Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Cable harness axes 1-4 See Spare parts chapter. IRB 6640ID - 200/2.55 Cable harness axes 1-4 See Spare parts chapter.
  • Page 241 4 Repair 4.3.5. Replacement of cable harness, axes 1-4 IRB 6640ID Continued Action Note 5. Disconnect connectors R1.MP and R1.SMB. Attachment points are shown in the figure Location of cable harness on page 237. 6. Pull the cable and connectors up through the cable guide in the center of the frame.
  • Page 242 4 Repair 4.3.5. Replacement of cable harness, axes 1-4 IRB 6640ID Continued Action Note 10. Remove: • the cable gland by removing the four attachment screws from inside the SMB recess. xx0700000109 • A: Cable gland • B: Attachment screws (inside SMB recess) 11.
  • Page 243 4 Repair 4.3.5. Replacement of cable harness, axes 1-4 IRB 6640ID Continued Action Note 14. Disconnect connector R2.M5/6 at the cable division Shown in the figure Location of point. cable harness on page 237! 15. Disconnect all connectors at motor 3 and motor 4. Specified and shown in the figure Location of cable harness on page...
  • Page 244 4 Repair 4.3.5. Replacement of cable harness, axes 1-4 IRB 6640ID Continued Action Note 8. Secure the cable gland with four attachment screws from inside the SMB recess. xx0700000109 • A: Cable gland • B: Attachment screws, inside SMB recess 9.
  • Page 245 4 Repair 4.3.5. Replacement of cable harness, axes 1-4 IRB 6640ID Continued Action Note WARNING! Before continuing any service work, please observe the safety information in section WARNING - The brake release buttons may be jammed after service work on page 12.
  • Page 246 4 Repair 4.3.5. Replacement of cable harness, axes 1-4 IRB 6640ID Continued Action Note 20. If the connection between the SMB battery and Detailed in the Calibration chapter - the SMB unit has been broken, the revolution section Updating revolution counters must now be updated! counters on page 392.

  • Page 247: Replacement Of Cable Harness, Axes 5-6 - Irb 6640Id

    4 Repair 4.3.6. Replacement of cable harness, axes 5-6 - IRB 6640ID 4.3.6. Replacement of cable harness, axes 5-6 - IRB 6640ID Location of cable harness, axes 5-6 The cable harness of axes 5-6 is run inside the upper arm, as shown in the figure below. xx0500001896 Cover, upper arm tube Hood, upper arm housing...
  • Page 248 4 Repair 4.3.6. Replacement of cable harness, axes 5-6 - IRB 6640ID Continued Required equipment Equipment Spare part no. Art. no. Note Cable harness axes 5-6 See Spare parts chapter. Cable grease 3HAC 14807-1 Optitemp RB 1 Standard toolkit The content is defined in the section Standard toolkit on page...
  • Page 249 4 Repair 4.3.6. Replacement of cable harness, axes 5-6 - IRB 6640ID Continued Action Note 7. Remove the cable bracket from the upper arm housing by removing the three attachment screws (B). Leave the cabling fitted to the bracket. xx0500001905 8.
  • Page 250 4 Repair 4.3.6. Replacement of cable harness, axes 5-6 - IRB 6640ID Continued Cable layout, wrist unit The figure below shows how to run and attach the cabling inside the wrist unit. xx0500002014 Location inside the wrist unit where to strap the cabling, next to the axis 5 motor. Refitting, cable harness axes 5-6 The procedure below details how to refit the cable harness to the upper arm.
  • Page 251 4 Repair 4.3.6. Replacement of cable harness, axes 5-6 - IRB 6640ID Continued Action Note 5. Place the cabling inside the wrist unit according Shown in the figure Location of cable to the cable layout shown in the figure Cable harness, axes 5-6 on page 245.

  • Page 252: Replacement Of Complete Arm System

    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.
  • Page 253 4 Repair 4.3.7. Replacement of complete arm system Continued Required equipment Equipment, etc. Art. no. Note Holder for bits 3HAC029090-001 Bits SW10 included Guide pins M12x200 3HAC13056-3 Used to guide the complete arm system when refitting. Always use the guide pins in pairs! In order to make the refitting easier, it is recommended to use guide pins of different lengths.
  • Page 254 4 Repair 4.3.7. Replacement of complete arm system Continued Action Note 3. Fit the lifting device and adjust it Art. no. is specified in Required equipment on page as detailed in the enclosed 251. instructions. Make sure the lift is done completely level! How to Also fit a hoisting block to the adjust the lift is described in the enclosed instruction to roundsling put around the lower...
  • Page 255 4 Repair 4.3.7. Replacement of complete arm system Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 6.
  • Page 256 4 Repair 4.3.7. Replacement of complete arm system Continued Action Note 1 1. CAUTION! The complete arm system weighs 1250 kg! All lifting equipment used must be sized accordingly! 12. Lift the arm system carefully and Make sure all hooks and attachments stay in the secure it in a safe area.
  • Page 257 4 Repair 4.3.7. Replacement of complete arm system Continued Refitting, arm system The procedure describes how to lift and refit the complete arm system. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 258 4 Repair 4.3.7. Replacement of complete arm system Continued Action Note 3. Fit the lifting device as detailed in the figure Art. no. is specified in Required to the right. equipment on page 251. Also fit a hoisting block to the roundsling put Make sure the lift is done completely around the lower arm.
  • Page 259 4 Repair 4.3.7. Replacement of complete arm system Continued Action Note 6. Fit the two guide pins to the holes in gearbox Dimension is specified in Required axis 1, as shown in the figure to the right. equipment on page 251.
  • Page 260 4 Repair 4.3.7. Replacement of complete arm system Continued Action Note 9. Refit 14 of the 16 attachment screws before the arm system is completely lowered. NOTE! Use a torque wrench with a holder for bits recommended in Required equipment on page 251.
  • Page 261 4 Repair 4.3.7. Replacement of complete arm system Continued Action Note 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 3HAC026876-001 Revision: F...

  • Page 262: Upper And Lower Arm

    The turning disk is located in the front of the wrist housing as shown in the figure below. A more detailed view of the component and its position may be found in chapter Upper arm including wrist unit, motors ax. 3- 6 (IRB 6640 and IRB 6640ID) xx0300000473 Turning disk (type 1)
  • Page 263 4 Repair 4.4.1. Replacement of turning disk Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Turning disk, diam. 200 See Spare parts O-rings are not included! chapter. Turning disk, dia. 200 See Spare parts O-rings are not included. chapter.
  • Page 264 4 Repair 4.4.1. Replacement of turning disk Continued Refitting, turning disk The procedure below details how to refit the turning disk. Action Note 1. Lubricate the turning disk o-ring with grease. Art. no. is specified in Required equipment on page 261.
  • Page 265 4 Repair 4.4.1. Replacement of turning disk Continued Action Note 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 3HAC026876-001 Revision: F...

  • Page 266: Replacement Of Complete Wrist Unit

    4.4.2. Replacement of complete wrist unit Wrist unit for robot models IRB 6640ID This section is valid for robot models IRB 6640. How to replace the wrist of the models IRB 6640ID is detailed in section Replacement of complete wrist unit, IRB 6640ID on page 269.
  • Page 267 4 Repair 4.4.2. Replacement of complete wrist unit Continued Required equipment Equipment etc. Spare part no. Art. no. Note Wrist See Spare parts chapter. Guide pins M12 x 200 3HAC13056-3 Always use guide pins in pairs! Lifting tool, wrist unit 3HAC13605-1 Standard toolkit The content is defined in...
  • Page 268 4 Repair 4.4.2. Replacement of complete wrist unit Continued Action Note 7. Loosen the cable bracket, wrist unit on top of Shown in the figure Location of wrist the wrist by undoing the three attachment unit on page 264. screws. Two of the attachment screws are visibly located at the rear of the bracket and the third located at the bottom of the cable bracket, in...
  • Page 269 4 Repair 4.4.2. Replacement of complete wrist unit Continued Action Note 3. Fit the lifting tool to the wrist unit. Art. no. is specified Location of wrist unit on page 264. CAUTION! The complete wrist unit weighs 130 kg! All lifting equipment used must be sized accord- ingly! 5.
  • Page 270 4 Repair 4.4.2. Replacement of complete wrist unit Continued Action Note 12. Fasten the cable bracket at top of the wrist Shown in the figure Location of wrist unit with three attachment screws. Two of unit on page 264. them are visible at the rear attachment point and the third is located on the bottom of the cable bracket, in the center.

  • Page 271: Replacement Of Complete Wrist Unit, Irb 6640Id

    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) xx0500001567 Wrist unit...
  • Page 272 4 Repair 4.4.3. Replacement of complete wrist unit, IRB 6640ID Continued Removal, wrist unit The procedure below details how to remove the complete wrist unit from the robot. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 273 4 Repair 4.4.3. Replacement of complete wrist unit, IRB 6640ID Continued Action Note CAUTION! The complete wrist unit weighs 187 kg! All lifting equipment used must be sized accordingly! 4. Attach the lifting slings to the wrist unit and lift it to the upper arm tube.

  • Page 274: Replacement Of Upper Arm

    4 Repair 4.4.4. Replacement of upper arm 4.4.4. Replacement of upper arm Location of upper arm The upper arm is located on top of the robot as shown in the following figure. The complete upper arm includes the wrist unit but this section also describes how to remove the upper arm when there is no wrist unit mounted.
  • Page 275 4 Repair 4.4.4. Replacement of upper arm Continued Required equipment Equipment Art. no. Note Sealing, axis 2/3 3HAC17212-1 Always use a new sealing when refitting the upper arm! Washer, axis 3 (3 pcs) 3HAC12703-1 To be replaced if damaged. Guide pins, sealing axis 2/3 80 mm 3HAC14628-1 For guiding "Sealing, axis 2/3".
  • Page 276 4 Repair 4.4.4. Replacement of upper arm Continued Action Note 6. Upper arm including wrist unit: Art. no. is specified in Required equipment on page 273. Fit one of the pieces included in lifting device, upper arm to the front attachment for lifting device on the Attachment point is shown in the upper arm.
  • Page 277 4 Repair 4.4.4. Replacement of upper arm Continued Action Note 15. Carefully remove the attachment screws and Shown in the figure Location of washers, upper arm. upper arm on page 272. 16. Lift the upper arm and place it on a secure surface. Make sure the lift is done completely level! In case of necessary adjustments, use the shortening loops on the lifting tool (chain), but make sure to place the...
  • Page 278 4 Repair 4.4.4. Replacement of upper arm Continued Action Note 3. Upper arm including wrist unit: Art. no. is specified in Required equipment on page 273. Fit the lifting eye, VLBG M12 to the attachment hole, lifting eye on the wrist unit. Shown in the figure Location of upper arm on page...
  • Page 279 4 Repair 4.4.4. Replacement of upper arm Continued Action Note 10. Fit in the gearbox attachment holes with the Art. no. is specified in Required attachment holes on the lower arm with the equipment on page 273. guide pins. It may be necessary to turn the gear by rotating the motor pinion with a rotation tool, motor beneath the motor cover.
  • Page 280 4 Repair 4.4.4. Replacement of upper arm Continued Action Note 21. Recalibrate the robot. Calibration is detailed in a separate calibration manual enclosed with the calibration tools. General calibration information is included in the section Calibration infor- mation. DANGER! Make sure all safety requirements are met when performing the first test run.

  • Page 281: Replacement Of Complete Lower Arm

    4 Repair 4.4.5. Replacement of complete lower arm 4.4.5. Replacement of complete lower arm Location of lower arm The lower arm is located as shown in the figure below. A more detailed view of the component and its position may be found in chapter Exploded views in the...
  • Page 282 4 Repair 4.4.5. Replacement of complete lower arm Continued Removal, lower arm The procedure below details how to remove the complete lower arm. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 283 4 Repair 4.4.5. Replacement of complete lower arm Continued Action Note 9. Move the lower arm backwards to the lowest The figure shows IRB 6600 but the position possible. position of the lower arm shall be the same. xx0300000015 NOTE! For Cleanroom robots apply a protection where the lifting equipment and roundslings will rub against the paint of the robot.
  • Page 284 4 Repair 4.4.5. Replacement of complete lower arm Continued Refitting, lower arm The procedure below details how to refit the lower arm. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 285 4 Repair 4.4.5. Replacement of complete lower arm Continued Action Note 7. In case the hole pattern of the lower arm and Connect power supply to connector the gearbox axis 2 does not match, use power R2.MP2 supply to release the motor axis 2 brakes and •...
  • Page 286 4 Repair 4.4.5. Replacement of complete lower arm Continued Action Note 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 3HAC026876-001 Revision: F...

  • Page 287: Frame And Base

    Replacement of SMB unit for Foundry Prime For replacement of SMB unit on robots with option Foundry Prime, see Replacement of SMB unit - Option 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.
  • Page 288 4 Repair 4.5.1. Replacement of SMB unit Continued Removal, SMB unit The procedure below details how to remove the SMB unit. Action Note 1. Move the robot to the calibration position. DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 289 4 Repair 4.5.1. Replacement of SMB unit Continued Refitting, SMB unit The procedure below details how to refit the SMB unit. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.

  • Page 290: Replacement Of Brake Release Unit

    4 Repair 4.5.2. Replacement of brake release unit 4.5.2. Replacement of brake release unit Location of brake release unit The brake release unit is located together with the SMB unit on the left hand side of the frame, right next to the gearbox, axis 2, as shown in figure below. xx0700000123 Brake release unit Push button guard...
  • Page 291 4 Repair 4.5.2. Replacement of brake release unit Continued Removal, brake release unit The procedure below details how to remove the brake release unit. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 292 4 Repair 4.5.2. Replacement of brake release unit Continued Refitting, brake release unit The procedure below details how to refit the brake release unit. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 293 4 Repair 4.5.2. Replacement of brake release unit Continued Action Note WARNING! Before continuing any service work, please observe the safety information in section WARNING - The brake release buttons may be jammed after service work on page 7. Refit the push button guard to the SMB cover. Shown in the figure Location of brake release unit on page 288.

  • Page 294: Replacement Of Spherical Roller Bearing, Balancing Device

    4.5.3. Replacement of spherical roller bearing, balancing device Overview 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.
  • Page 295 4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device Continued Shaft Retaining ring, bore VK-cover VK-cover Retaining ring, bore Cradle bearing kit Hex socket head cap screw M16x70 Sealing washer Location of bearing, Design 2 xx0900000066 Shaft Washer Hex socket head cap screw M16x70 VK-cover Washer Radial sealing with dust lip 50x68x8...
  • Page 296 4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device Continued O-ring End cover Radial sealing (not used in clean room applications) Cradle bearing kit Retaining ring, bore Washer Hex socket head cap screw M16x70 VK-cover Required equipment Equipment Spare part no. Art.
  • Page 297 4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device Continued Removal, spherical roller bearing Use this procedure to remove the spherical roller bearing from the balancing device front ear. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors...
  • Page 298 4 Repair 4.5.3. Replacement of spherical roller bearing, balancing device Continued Action Note 4. Refit the new bearing and sealings. Described in section Refitting front bearing and sealing Design 1 on page or in Refitting front bearing with sealing Design 2 on page 424.

  • Page 299: Replacement Of Balancing Device (Design 1)

    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.
  • Page 300 4 Repair 4.5.4. Replacement of balancing device (design 1) Continued Required equipment Spare part Equipment Art. no. Note Balancing device See Spare parts Maintenance parts, See Spare shaft parts Maintenance parts, See Spare cradle parts Locking screw M16x60 quality 12.9 Gleitmo For securing the lower arm.
  • Page 301 4 Repair 4.5.4. Replacement of balancing device (design 1) Continued Removal balancing device, (design 1) The procedure below details how to remove the balancing device. Action Note 1. Remove all equipment, if any, on or close to the balancing device. 2.
  • Page 302 4 Repair 4.5.4. Replacement of balancing device (design 1) Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 7.
  • Page 303 4 Repair 4.5.4. Replacement of balancing device (design 1) Continued Action Note 13. Remove the retaining ring, bore (A) securing the shaft. xx0900000079 14. Remove both the cradle bearings and the balancing device shafts, using the dismounting and mounting tool 3HAC028920-00.
  • Page 304 4 Repair 4.5.4. Replacement of balancing device (design 1) Continued Refitting The procedure below details how to refit the balancing device. Action Note 1. Fit the shackle Where to attach the shackle is shown in the figure. 3HAC020540-001 to the balancing device.
  • Page 305 4 Repair 4.5.4. Replacement of balancing device (design 1) Continued Action Note 6. On the side where the retaining ring, bore is mounted. Refit the 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...
  • Page 306 4 Repair 4.5.4. Replacement of balancing device (design 1) Continued Action Note 10. Use Loctite on the threads on the balancing device. CAUTION! Do not use Loctite on the threads of the Hex socket head cap screw M16x70. xx0900000088 11. Perform the following procedure of refitting the shafts on both sides of the cradle before refitting of...
  • Page 307 4 Repair 4.5.4. Replacement of balancing device (design 1) Continued Action Note 15. Lock the cradle bearings using the retaining ring, bore (A). xx0900000089 16. Mount new VK- covers on both sides. 17. Raise the balancing device to a position where the shafts may be refitted.

  • Page 308: Replacement Of Balancing Device (Design 2)

    For replacement of balancing device on robots with option Foundry Prime, see Replacement of balancing device (design 2) - Option Foundry Prime, 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.
  • Page 309 4 Repair 4.5.5. Replacement of balancing device (design 2) Continued Equipment Spare part no. Art. no. Note Rust preventive 3HAC026621-001 Mercasol 3106 Lifting tool (chain) 3HAC15556-1 Shackle 3HAC020997-001 Press tool, balancing 3HAC020902-001 For unloading and restoring device the balancing device, (Method 1) Distance tool 3HAC030662-001 For unloading and restoring...
  • Page 310 4 Repair 4.5.5. Replacement of balancing device (design 2) Continued Action Note 4. Secure the upper arm using a lifting sling or using the locking screw (A) in the frame. xx0800000249 5. Method 1: Described in section Unloading the balancing device using hydraulic press tool.
  • Page 311 4 Repair 4.5.5. Replacement of balancing device (design 2) Continued Action Note 10. Remove the front shaft Described in section Dismounting and mounting tool using the tool 3HAC028920-001 on page 413. 3HAC028920-001. xx0900000080 • A) Protection plug (only Clean Room) •...
  • Page 312 4 Repair 4.5.5. Replacement of balancing device (design 2) Continued Action Note 14. Remove the retaining 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.
  • Page 313 4 Repair 4.5.5. Replacement of balancing device (design 2) Continued Refitting balancing device, Design 2 Action Note 1. Grease the cradle. 2. Refit one of the two retaining rings. 3. Use the tool Described in section Dismounting and mounting tool 3HAC028920-001 to refit 3HAC028920-001 on page 413.
  • Page 314 4 Repair 4.5.5. Replacement of balancing device (design 2) Continued Action Note 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.
  • Page 315 4 Repair 4.5.5. Replacement of balancing device (design 2) Continued Action Note 8. Fit the lifting tool to the balancing device. xx0900000094 CAUTION! The balancing device weighs 210 kg! All lifting equipment used must be sized accordingly! 9. Use Loctite on the threads on the balancing device.
  • Page 316 4 Repair 4.5.5. Replacement of balancing device (design 2) Continued Action Note 12. 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. 13. On the other side, use the Tightening torque 300Nm.
  • Page 317 4 Repair 4.5.5. Replacement of balancing device (design 2) Continued Action Note 16. Refit the front shaft using Described in section Dismounting and mounting tool the tool 3HAC028920- 3HAC028920-001 on page 413. 001. NOTE! Grease the shaft for easier assemble. xx0900000080 •...
  • Page 318 4 Repair 4.5.5. Replacement of balancing device (design 2) Continued Action Note 20. Fill the spherical roller bearing with 20 ml, Optimol PDO. xx0900000102 3HAC026876-001 Revision: F...

  • Page 319: Unloading The Balancing Device Using Distance Tool

    4 Repair 4.5.6. Unloading the balancing device using distance tool 4.5.6. Unloading the balancing device using distance tool Overview This section 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.
  • Page 320 4 Repair 4.5.6. Unloading the balancing device using distance tool Continued 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.
  • Page 321 4 Repair 4.5.6. Unloading the balancing device using distance tool Continued Action Note/Illustration 4. Jog the robot lower arm backward until the pressure from the balancing device release. xx0800000481 CAUTION! Secure the upper arm before removing the shaft. 3HAC026876-001 Revision: F...

  • Page 322: Restoring The Balancing Device Using Distance Tool

    4 Repair 4.5.7. Restoring the balancing device using distance tool 4.5.7. Restoring the balancing device using distance tool 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 3HAC030662-001 from a dismounted balancing device. Required equipment Spare part Equipment...
  • Page 323 4 Repair 4.5.7. Restoring the balancing device using distance tool Continued Action Note/Illustration 4. Mount the cover on the Apply Sikaflex 521FC on the end cover gasket. back of the cylinder using the four screws. xx0900000104 5. Use Loctite 577 on the Tightening torque 47Nm four screws.

  • Page 324: Unloading The Balancing Device Using Hydraulic Press Tool

    4 Repair 4.5.8. Unloading the balancing device using hydraulic press tool. 4.5.8. Unloading the balancing device using hydraulic press tool. Prerequisite This section details how to unload the balancing device using the hydraulic press tool. The lower arm must be secured before unloading the balancing device! How to secure the lower arm is detailed in the current repair activity, for example removal of the balancing device.
  • Page 325 4 Repair 4.5.8. Unloading the balancing device using hydraulic press tool. Continued Required equipment Equipment, etc. Art. no. Note Press tool, balancing device 3HAC020902-001 Includes • press device 3HAC15767-2 • press device 3HAC18100-1 Choose the correct device, depending on model of balancing device. Hydraulic cylinder 3HAC11731-1 To be used with the press tool.
  • Page 326 4 Repair 4.5.8. Unloading the balancing device using hydraulic press tool. Continued Action Note 2. Fit the correct press device and moving pin to Shown in the figure Press tool and the press tool. Secure with the bolt, press hydraulic cylinder on page 322.

  • Page 327: Restoring The Balancing Device Using A Hydraulic Press Tool

    4 Repair 4.5.9. Restoring the balancing device using a hydraulic press tool. 4.5.9. Restoring the balancing device using a hydraulic press tool. Overview This section details how to restore the balancing device and how to remove the press tool from the device. DANGER! There is a high tensioned spring inside the balancing device, incorrect handling may cause injuries and damage property.
  • Page 328 4 Repair 4.5.9. Restoring the balancing device using a hydraulic press tool. Continued Required equipment Equipment, etc. Art. no. Note Hydraulic cylinder 3HAC11731-1 To be used with press tool. Hydraulic pump, 80 MPa 3HAC13086-1 To be used with hydraulic cylinder. Locking liquid Loctite 577 Used to secure the attachment screws of the...
  • Page 329 4 Repair 4.5.9. Restoring the balancing device using a hydraulic press tool. Continued Action Note DANGER! The rear cover of the balancing device is a safety device for the piston rod during operation! Make sure the cover is properly secured before commissioning of the robot! 3HAC026876-001 Revision: F...

  • Page 330: Motors

    Replacement of motor axis 1 for Foundry Prime For replacement of motor axis 1 on robots with option Foundry Prime, 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.
  • Page 331 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Equipment, etc. Spare part no. Art. no. Note Extension 300mm for 3HAC12342-1 bits 1/2" 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...
  • Page 332 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 6. In order to release the brakes, connect the 24 VDC Connect to connector R2.MP1 power supply. • +: pin 2 • -: pin 5 7. Remove the motor by unscrewing its four Shown in the figure Location of attachment screws and plain washers.
  • Page 333 4 Repair 4.6.1. Replacement of motor, axis 1 Continued Action Note 9. Disconnect the brake release voltage. 10. Reconnect all connectors beneath the motor cover. 11. Refit the cable gland cover at the cable exit with its Make sure the cover is tightly two attachment screws.

  • Page 334: Replacement Of Motor Axis 2

    Replacement of motor axis 2 for Foundry Prime For replacement of motor axis 2 on robots with option Foundry Prime, see Replacement of motor axis 2 - Option Foundry Prime, 3HAC037959-009 (available on ABB Library). Location of motor The motor, axis 2, is located on the left-hand side of the robot as shown in the figure below.
  • Page 335 4 Repair 4.6.2. Replacement of motor axis 2 Continued Equipment, etc. Spare part no. Art. no. Note Extension bar, 300 3HAC12342-1 mm for bits 1/2" Power supply 24 VDC, 1.5 A For releasing the brakes. Rotation tool 3HAC17105-1 Used to rotate the motor pinion when mating it to the gear when brakes are released with 24VDC...
  • Page 336 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note 6. Remove the cable gland cover at Shown in the figure Location of motor on page the cable exit by unscrewing its two 332. attachment screws. Make sure the gasket is not damaged! 7.
  • Page 337 4 Repair 4.6.2. Replacement of motor axis 2 Continued Refitting, motor The procedure below details how to refit the motor axis 2. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 338 4 Repair 4.6.2. Replacement of motor axis 2 Continued Action Note 10. Secure the motor with four attachment screws M10 x 40, tightening torque: 50 Nm. and plain washers. Reused screws may be used, providing they are lubricated as detailed in the section Screw joints on page 405 before...

  • Page 339: Replacement Of Motor, Axis 3

    Replacement of motor axis 3 for Foundry Prime For replacement of motor axis 3 on robots with option Foundry Prime, see Replacement of motor, axis 3 - Option Foundry Prime, 3HAC037959-010 (available on ABB Library). Location of motor The motor axis 3 is located on the left hand side of the robot as shown in the figure below.
  • Page 340 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Equipment, etc. Spare part no. Art. no. Note Removal tool, 3HAC14973-1 Always use the removal tools motor M12x in pairs! Lifting tool, motor 3HAC026061-001 ax 2, 3, 4 Bolts M16x60 3HAB3409-86 (for mechanical stop axis 3) Washers (for...
  • Page 341 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Removal, motor The procedure below details how to remove motor, axis 3. Action Note 1. Unload the upper arm of the robot by either: • Use a fork lift to rest the upper arm onto.
  • Page 342 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note CAUTION! The motor weighs 27 kg! All lifting equipment used must be sized accordingly! 13. Lift the motor to get the pinion away from the gear. 14. Remove the motor by gently lifting it Make sure the motor pinion is not damaged! straight out and disconnect the brake release voltage.
  • Page 343 4 Repair 4.6.3. Replacement of motor, axis 3 Continued Action Note 9. Use the rotation tool in order to rotate the motor Art no. is specified in Required pinion when mating it to the gear! equipment on page 337. Fit the motor, making sure the motor pinion is Make sure the motor pinion does not properly mated to the gear of gearbox, axis 3.

  • Page 344: Replacement Of Motor, Axis 4

    Replacement of motor axis 4 for Foundry Prime For replacement of motor axis 4 on robots with option Foundry Prime, see Replacement of motor, axis 4 - Option Foundry Prime, 3HAC037959-011 (available on ABB Library). Location of motor The motor axis 4 is located on the left-hand side of the upper arm as shown in the figure below.
  • Page 345 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Equipment, etc. Spare part no. Art. no. Note Extension 300mm 3HAC12342-1 for bits 1/2" Rotation tool 3HAC17105-1 Used to rotate the motor pinion when mating it to the gear when brakes are released with 24 VDC power supply.
  • Page 346 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note 5. Disconnect all connectors beneath the motor cover. 6. In order to release the brake, connect the 24 Connect to connector R2.MP4 VDC power supply. • +: pin 2 •...
  • Page 347 4 Repair 4.6.4. Replacement of motor, axis 4 Continued Action Note 6. Use the rotation tool in order to rotate the Art. no. is specified in Required motor pinion when mating it to the gear! equipment on page 342. Fit the motor, making sure the motor pinion Make sure the motor pinion does not get is properly mated to the gear, axis 4.

  • Page 348: Replacement Of Motor, Axis 5 Irb 6640

    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 Motor, axis 5 Upper arm tube...
  • Page 349 4 Repair 4.6.5. Replacement of motor, axis 5 IRB 6640 Continued Equipment, etc. Spare part no. Art. no. Note O-ring 21522012-430 Must be replaced when reassembling motor! Loctite 574 Option Foundry Prime Grease 3HAC3537-1 For lubricating the o-ring. Isopropanol 11771012-208 For cleaning motor pinion and motor pinion hole.
  • Page 350 4 Repair 4.6.5. Replacement of motor, axis 5 IRB 6640 Continued Action Note 3. Remove the wrist unit. Detailed in the section Removal, wrist unit on page 265. 4. Place the wrist unit safely on a workbench, in a fixture or similar.
  • Page 351 4 Repair 4.6.5. Replacement of motor, axis 5 IRB 6640 Continued Refitting, motor, axis 5 The procedure below details how to refit motor, axis 5. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!
  • Page 352 4 Repair 4.6.5. Replacement of motor, axis 5 IRB 6640 Continued Action Note 10. Fit the motor, with guidance from the pins, Make sure the motor pinion does not making sure the motor pinion is properly mated get damaged! to the gear of axis 5.

  • Page 353: Replacement Of Motor, Axis 5, Irb 6640Id

    4 Repair 4.6.6. Replacement of motor, axis 5, IRB 6640ID 4.6.6. Replacement of motor, axis 5, IRB 6640ID Location of motor, axis 5 The motor of axis 5 is located on the bottom side of the wrist, when axis 4 is placed in calibration position.
  • Page 354 4 Repair 4.6.6. Replacement of motor, axis 5, IRB 6640ID Continued Removal tools, motor attachment screws The figure below shows the required dimensions of the tools, in order to access the attachment screws of the motor. xx0500002271 Allen key, No 6 Socket, max Ø16 mm Torque wrench Removal, motor axis 5...
  • Page 355 4 Repair 4.6.6. Replacement of motor, axis 5, IRB 6640ID Continued Refitting, motor axis 5 The procedure below details how to refit the motor, axis 5. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.

  • Page 356: Replacement Of Motor, Axis 6, Irb 6640

    The motor axis 6 is located in the center of the wrist unit as shown in the figure below. A more detailed view of the component and its position may be found in chapter Upper arm including wrist unit, motors ax. 3- 6 (IRB 6640 and IRB 6640ID) xx0700000126 Gearbox, axis 6...
  • Page 357 4 Repair 4.6.7. Replacement of motor, axis 6, IRB 6640 Continued Equipment, etc. Spare part no. Art. no. Note Power supply 24 VDC, 1.5 A For releasing the brakes. Grease 3HAB3537-1 For lubricating the o-ring. Standard toolkit The content is defined in the...
  • Page 358 4 Repair 4.6.7. Replacement of motor, axis 6, IRB 6640 Continued Action Note 6. Remove the motor by unscrewing its four attachment screws and plain washers. xx0600003038 • A: Tilthouse • B: Motor, axis 6 • C: Attachment screws (4 pcs) 7.
  • Page 359 4 Repair 4.6.7. Replacement of motor, axis 6, IRB 6640 Continued Action Note 4. Fit the motor, with guidance from the pins, Make sure the pinion on the motor making sure the motor pinion is properly mated shaft is not damaged! to the gear of gearbox, axis 6.

  • Page 360: Replacement Of Motor, Axis 6, Irb 6640Id

    Replacement motor axis 6 for Foundry Prime For replacement of motor axis 6 on robots with option Foundry Prime, see Replacement of motor, axis 6 - Option Foundry Prime, 3HAC037959-013 (available on ABB Library). Location of motor, axis 6 The motor of axis 6 is located on top of the wrist, when axis 4 is placed in calibration position.
  • Page 361 4 Repair 4.6.8. Replacement of motor, axis 6, IRB 6640ID Continued Equipment Spare part no. Art. no. Note Other tools and These procedures include procedures may be references to the tools required. See required. references to these procedures in the step- by-step instructions below.
  • Page 362 4 Repair 4.6.8. Replacement of motor, axis 6, IRB 6640ID Continued Refitting, motor axis 6 The procedure below details how to refit the motor, axis 6. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.

  • Page 363: Gearboxes

    Replacement gearbox axis 1 for Foundry Prime For replacement 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 Gearbox, axis 1 RV 320C-191.35...
  • Page 364 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Gearbox, axis 1 See Spare parts Includes: • gearbox • o-ring O-ring 3HAB3772-93 Replace only when damaged. 380.6x3.53 O-ring (3 pcs) 3HAB3772-97 23x3.6 Support, base and 3HAC15535-1...
  • Page 365 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Removal The procedure below details how to remove the gearbox axis 1. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 366 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 12. Unscrew the 12 attachment screws and washers securing the gearbox to the base. xx0600003069 • A: Gearbox, axis 1 • B: Attachment screw, M16x60 CAUTION! The gearbox weighs 108 kg! All lifting equipment used must be sized accordingly! 14.
  • Page 367 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Refitting The procedure below details how to remove the gearbox axis 1. Action Note 1. If the base not already is resting on the Mounting of the support base and gear, support base and gear, axis 1, this should be axis 1 is detailed in section Removal on done first.
  • Page 368 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 9. Refit the gearbox to the base with its Shown in the figure Location of gearbox attachment screws and washers. axis 1 on page 361. M16x60 quality 12.9 (12 pcs) Tightening torque: 300 Nm.
  • Page 369 4 Repair 4.7.1. Replacement gearbox axis 1 Continued Action Note 15. Refit the lower end of thecable harness. Detailed in section Replacement of cable harness, axes 1-6 on page 203. NOTE! For Cleanroom robots the procedure is detailed in section Replacement of cable harness, Cleanroom on page 224.

  • Page 370: Replacement Gearbox Axis 2

    Replacement gearbox axis 2 for Foundry Prime For replacement of gearbox axis 2 on robots with option Foundry Prime, see Replacement gearbox axis 2 on IRB 6640 - Option Foundry Prime, 3HAC037959-002 (available on ABB Library). Location of gearbox axis 2 The gearbox axis 2 is located in the lower arm rotational center.
  • Page 371 4 Repair 4.7.2. Replacement gearbox axis 2 Continued Equipment, etc Spare part no. Art. no. Note Other tools and These procedures procedures may be include references to required. See references the tools required. to these procedures in the step-by-step instruc- tions below.
  • Page 372 4 Repair 4.7.2. Replacement gearbox axis 2 Continued Action Note 5. Fit the lifting tool on the upper and lower arms as shown in the figure to the right. Secure the robot in an overhead crane. xx0700000350 Parts: • A: Lifting eye (on armhouse) •...
  • Page 373 4 Repair 4.7.2. Replacement gearbox axis 2 Continued Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB. 9. Remove the lower end of the Detailed in the section Replacement of cable cable harness.
  • Page 374 4 Repair 4.7.2. Replacement gearbox axis 2 Continued Action Note 17. Fit the lifting tool for lifting the Art. no. is specified in Required equipment on page gearbox in the uppermost hole 368. and secure it with a roundsling. xx0900000114 The figure shows IRB6640.
  • Page 375 4 Repair 4.7.2. Replacement gearbox axis 2 Continued Refitting The procedure below details how to refit gearbox axis 2. Action Note 1. Make sure the o-ring is fitted to the gearbox. Lightly lubricate it with grease. xx0600003128 • A : O-ring 3HAB3772-91 CAUTION! The gearbox weighs 98 kg! All lifting equipment used must be...
  • Page 376 4 Repair 4.7.2. Replacement gearbox axis 2 Continued Action Note 4. Fit two guide pins in two of the attachment holes, parallel to each other. 5. Lift the gearbox on to the guide pins and push it in mounting position. 6.
  • Page 377 4 Repair 4.7.2. Replacement gearbox axis 2 Continued Action Note 10. Refit the lower arm to the M16x50 (20 pcs) gearbox axis 2 with its Tightening torque: 300 Nm. attachment screws. 11. Refit motor axis 2. Detailed in the section Replacement of motor axis 2 on page 332.

  • Page 378: Replacement Of Gearbox, Axis 3

    4.7.3. Replacement of gearbox, axis 3 Replacement gearbox axis 3 for Foundry Prime For replacement of gearbox axis 3 on robots with option Foundry Prime, see Replacement 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.
  • Page 379 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Gearbox See Spare parts Includes chapter. • gearbox • o-ring. Does not include the sealing, axis 2/3! O-ring 3HAB3772-68 1 pc on the gearbox. Replace if damaged.
  • Page 380 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Removal, gearbox axis 3 The procedure below details how to remove gearbox, axis 3. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 381 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note 9. If required, use screws in the holes Art. no. is specified in Required equipment on page (A) shown in the figure to the right 377. to press the gearbox free. xx0200000201 •...
  • Page 382 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Refitting, gearbox axis 3 The procedure below details how to refit gearbox, axis 3. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 383 4 Repair 4.7.3. Replacement of gearbox, axis 3 Continued Action Note 8. Fit the gearbox onto the guide Make sure the o-rings are seated properly and the pins and slide it into position. gearbox correctly oriented! 9. Remove the lifting tool. 10.

  • Page 384: Replacement Of Gearbox, Axis 6

    4.7.4. Replacement of gearbox, axis 6 Replacement gearbox axis 6 for Foundry Prime For replacement of gearbox 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.
  • Page 385 4 Repair 4.7.4. Replacement of gearbox, axis 6 Continued Required equipment Equipment, etc. Spare part no. Art. no. Note Gearbox See Spare parts Includes o-ring 3HAB3772-58 Gearbox, wrist type 1 Gearbox, wrist type 2 See Spare parts Includes o-ring 3HAB3772-57 Washers 3HAA1001-172 Not included in gearbox!
  • Page 386 4 Repair 4.7.4. Replacement of gearbox, axis 6 Continued Removal, gearbox The procedure below details how to remove gearbox, axis 6. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 387 4 Repair 4.7.4. Replacement of gearbox, axis 6 Continued Refitting, gearbox The procedure below details how to refit gearbox, axis 6. Action Note DANGER! Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot! For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.
  • Page 388 4 Repair 4.7.4. Replacement of gearbox, axis 6 Continued Action Note 7. Perform a leak-down test. Detailed in the section Performing a leak- down test on page 196. 8. Refill the gearbox with oil. Detailed in the section Oil change, gearbox axis 6 on page 180.

  • Page 389: Calibration Information

    The resolver values are changed If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration. The different methods are briefly described in the section Calibration methods on page 388, and further detailed in separate calibration manuals.

  • Page 390: Calibration Methods

    5 Calibration information 5.2. Calibration methods 5.2. Calibration methods Overview This section specifies the different types of calibration and the calibration methods that are supplied by ABB. Types of calibration Type of Description Calibration method calibration Standard The calibrated robot is positioned at home...
  • Page 391 Calibration Pendulum - standard method Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB 6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the standard type of calibration. It is the recommended method in order to achieve proper performance.

  • Page 392: Calibration Scale And Correct Axis Position

    Introduction This section specifies the calibration scale positions and/or correct axis position for all robot models. Calibration scales/marks, IRB 6640 and IRB 6640ID The figure below shows the positions of the calibration marks on the robot. xx0700000340 Calibration mark axis 1...

  • Page 393: Calibration Movement Directions For All Axes

    5 Calibration information 5.4. Calibration movement directions for all axes 5.4. Calibration movement directions for all axes Overview When calibrating, the axis must consistently be run towards the calibration position in the same direction in order to avoid position errors caused by backlash in gears and so on. Positive directions are shown in the graphic below.

  • Page 394: Updating Revolution Counters

    Robot variant Axis 4 Axis 6 IRB 6640 -180/2.55 IRB 6640 - 235/2.55, 205/ 2.75, 185/2.8, 130/3.2 IRB 6640ID - 170/2.75, 200/ 2.55 If the calibration marks seem to be wrong (even if the motor calibration data is correct), try to rotate the axis one turn, update the revolution counter and check the calibration marks again (try both directions, if needed).
  • Page 395 This procedure details the second step when updating the revolution counter; storing the revolution counter setting with the FlexPendant (RobotWare 5.0). Action 1. On the ABB menu, tap Calibration. All mechanical units connected to the system are shown along with their calibration status.
  • Page 396 5 Calibration information 5.5. Updating revolution counters Continued Action CAUTION! If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury! Check the calibration position very carefully after each update. See the section Checking the calibration position on page 395.

  • Page 397: Checking The Calibration Position

    Use this procedure to create a program that runs all the robot axes to their zero position. Action Note 1. On ABB menu tap Program Editor. 2. Create a new program. 3. Use MoveAbsJ in the Motion&Proc menu. 4. Create the following program:...
  • Page 398 5 Calibration information 5.6. Checking the calibration position 3HAC026876-001 Revision: F...

  • Page 399: Decommissioning

    6 Decommissioning 6.1. Introduction 6 Decommissioning 6.1. Introduction Introduction This section contains information to consider when taking a product, robot or controller, out of operation. It deals with how to handle potentially dangerous components and potentially hazardous materials. 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.

  • Page 400: Environmental Information

    6 Decommissioning 6.2. Environmental information 6.2. Environmental information Hazardous material The table specifies some of the materials in the robot and their respective use throughout the product. Dispose of the components properly to prevent health or environmental hazards. Material Example application Batteries, NiCad or Lithium Serial measurement board Copper...

  • Page 401: Decommissioning Of Balancing Device

    6 Decommissioning 6.3. Decommissioning of balancing device 6.3. Decommissioning of balancing device General There is much energy stored in the balancing device. Therefore a special procedure is required to dismantle it. The coil springs inside the balancing device exert a potentially lethal force unless dismantled properly.
  • Page 402 6 Decommissioning 6.3. Decommissioning of balancing device Continued Decommissioning at decommissioning company, balancing device The instruction below details how to decommission the balancing device. Contact ABB Robotics for further consultation. Action Note DANGER! There is stored energy built up by high...

  • Page 403: Reference Information

    7 Reference information 7.1. Introduction 7 Reference information 7.1. Introduction General This chapter includes general information, complementing the more specific information in the different procedures in the manual. 3HAC026876-001 Revision: F...

  • Page 404: Applicable Safety Standards

    7 Reference information 7.2. Applicable safety standards 7.2. Applicable safety standards Standards, EN ISO The manipulator system is designed in accordance with the requirements of: Standard Description EN ISO 12100 -1 Safety of machinery - Basic concepts, general principles for design - Part 1: Basic terminology, methodology EN ISO 12100 -2 Safety of machinery - Basic concepts, general principles for...
  • Page 405 7 Reference information 7.2. Applicable safety standards Continued Other standards Standard Description ANSI/RIA R15.06 Safety Requirements for Industrial Robots and Robot Systems ANSI/UL 1740 Safety Standard for Robots and Robotic Equipment (option 429-1) CAN/CSA Z 434-03 Industrial Robots and Robot Systems - General Safety Require- ments (option 429-1) 3HAC026876-001 Revision: F...

  • Page 406: Unit Conversion

    7 Reference information 7.3. Unit conversion 7.3. Unit conversion Converter table Use the table below to convert units used in this manual. Quantity Units Length 3.28 ft 39.37 in Weight 1 kg 2.21 lb Pressure 1 bar 100 kPa 14.5 psi Force 0.738 lbf Moment...

  • Page 407: Screw Joints

    UNBRAKO screws UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.
  • Page 408 7 Reference information 7.4. Screw joints Continued Tightening torque Before tightening any screw, note the following: • Determine whether a standard tightening torque or special torque is to be applied. The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure descriptions.
  • Page 409 7 Reference information 7.4. Screw joints Continued The table below specifies the recommended standard tightening torque for Molycote- lubricated screws with Allen head screws. Tightening torque (Nm) Tightening torque (Nm) Dimension Class 10.9, Molycote-lubricated Class 12.9, Molycote-lubricated The table below specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass.

  • Page 410: Weight Specifications

    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.

  • Page 411: Standard Toolkit

    7 Reference information 7.6. Standard toolkit 7.6. Standard toolkit General All service (repairs, maintenance and installation) procedures contain lists of tools required to perform the specified activity. All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the Standard toolkit and defined in the table below.

  • Page 412: Special Tools

    7 Reference information 7.7. Special tools 7.7. Special tools General All service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in the section Standard toolkit on page 409, and of special tools, listed directly in the instructions and also gathered in this section.
  • Page 413 7 Reference information 7.7. Special tools Continued Description Art. no. Guide pins M12 x 150 3HAC13056-2 Guide pins M12 x 200 3HAC13056-3 Guide pins M12 x 250 3HAC13056-4 Guide pins M16 x 250 3HAC13120-4 Guide pins M16 x 300 3HAC13120-5 Guide pins, sealing ax 2/3, 100mm 3HAC14628-2 Guide pins, sealing ax 2/3, 80mm...
  • Page 414 7 Reference information 7.7. Special tools Continued Calibration equipment, Calibration Pendulum The table below specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method. Description Art. no. Note Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating manual.

  • Page 415: Dismounting And Mounting Tool 3Hac028920-001

    General This section details how to configure the tool 3HAC028920-001 for dismounting and mounting the balancing device on the IRB 6640 Design 1 and Design 2. The difference in the design is described in Design 1 and Design 2 of IRB 6640 on page The following setups for the tool are described: •...
  • Page 416 7 Reference information 7.8. Dismounting and mounting tool 3HAC028920-001 Continued Tool description xx0900000024 Item Mark Description Hydraulic cylinder not included in tool 3HAC028920-001 (ordered sepa- rately). Press tool D=103 Press tool D=54 Threaded bar, M16 Adapter M16/M20 Knurled nut D=80 Slide hammer / Distance Nut M16 Continues on next page...
  • Page 417 7 Reference information 7.8. Dismounting and mounting tool 3HAC028920-001 Continued Item Mark Description Press tool D=85 Press tool D=100 Press tool D=110 Press tool D=90 Press tool D=62 Removal front shaft design 1 and 2 The following configuration is used for removal of the front shaft Design 1 and 2. In the figure only Design 1 is shown.
  • Page 418 7 Reference information 7.8. Dismounting and mounting tool 3HAC028920-001 Continued Alternative con- figuration: • • • • • 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.
  • Page 419 7 Reference information 7.8. Dismounting and mounting tool 3HAC028920-001 Continued Refitting front shaft design 1 and 2 The following configuration is used for refitting of the front shaft Design 1 and 2. Configuration: • • • xx0900000063 xx0900000091 Continues on next page 3HAC026876-001 Revision: F...
  • Page 420 7 Reference information 7.8. Dismounting and mounting tool 3HAC028920-001 Continued 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 Continues on next page 3HAC026876-001 Revision: F...
  • Page 421 7 Reference information 7.8. Dismounting and mounting tool 3HAC028920-001 Continued Removal front bearing Design 1 The following configuration is used for removal of the front bearing Design 1. Configuration: • • • • • xx0900000031 1) Assemble the press tool D=54 (D) onto the threaded bar (4).
  • Page 422 7 Reference information 7.8. Dismounting and mounting tool 3HAC028920-001 Continued Alternative con- figuration • • • • • 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.
  • Page 423 7 Reference information 7.8. Dismounting and mounting tool 3HAC028920-001 Continued Refitting front bearing and sealing Design 1 The following configuration is used for refitting of the front bearing and sealing Design 1 Configuration: • • • • • xx0900000036 1) Insert the threaded bar (4) through the new bearing and...
  • Page 424 7 Reference information 7.8. Dismounting and mounting tool 3HAC028920-001 Continued Removal front bearing Design 2 The following configuration is used for removal of the front bearing Design 2. Configuration: • • • • • xx0900000038 1) Assemble the press tool D=62 (H) onto the threaded bar (4).
  • Page 425 7 Reference information 7.8. Dismounting and mounting tool 3HAC028920-001 Continued Alternative con- figuration: • • • • • 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.
  • Page 426 7 Reference information 7.8. Dismounting and mounting tool 3HAC028920-001 Continued Refitting front bearing with sealing Design 2 The following configuration is used for refitting of the front bearing with sealing Design 2. Configuration: • • • • • xx0900000042 1) Insert the threaded bar (4) through the new bearing and...
  • Page 427 7 Reference information 7.8. Dismounting and mounting tool 3HAC028920-001 Continued Removal rear shafts Design 1 and 2 The following configuration is used for removal of the rear shafts Design 1 and 2. Configuration: • • • • • • xx0900000044 1) Assemble the adapter (B) into the shaft.
  • Page 428 7 Reference information 7.8. Dismounting and mounting tool 3HAC028920-001 Continued Refitting rear shafts Design 1 The following configuration is used for refitting of the rear shafts Design 1. Configuration: • • • • • xx0900000047 1) Insert the threaded bar (4) through the new bearing.
  • Page 429 7 Reference information 7.8. Dismounting and mounting tool 3HAC028920-001 Continued Refitting rear shafts Design 2 The following configuration is used for refitting of the rear shafts Design 2. Configuration: • • • • • xx0900000049 1) Insert the threaded bar (4) through the new bearing.

  • Page 430: Lifting Equipment And Lifting Instructions

    7 Reference information 7.9. Lifting equipment and lifting instructions 7.9. Lifting equipment and lifting instructions General Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure. The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment.

  • Page 431: Spare Parts

    8 Spare parts 8.1. Spare parts and exploded views 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. 3HAC026876-001 Revision: F...
  • Page 432 8 Spare parts 8.1. Spare parts and exploded views 3HAC026876-001 Revision: F...

  • Page 433: Circuit Diagrams

    IRB 6400RF 3HAC8935-1 IRB 6600 type A 3HAC025744-001 IRB 6600 type B 3HAC025744-001 IRB 6620 3HAC025090-001 IRB 6620LX 3HAC025090-001 IRB 6640 3HAC025744-001 IRB 6650S 3HAC025744-001 IRB 6660 3HAC029940-001 (DressPack) 3HAC025744-001 IRB 7600 3HAC025744-001 Continues on next page 3HAC026876-001 Revision: F...
  • Page 434 9 Circuit diagrams 9.1. About circuit diagrams Continued 3HAC026876-001 Revision: F...

  • Page 435: Index

    Index Absolute Accuracy, calibration 389 gearbox axis 3, replacement 376 gearbox axis 6, replacement 382 balancing device bearing, replacement 292 brake release unit, replacement 288 hold-to-run 29 brakes testing function 27 inspecting oil levels axis 6 132 cable harness axes 1-4, replacement 237 installation cable harness axes 1-6, replacement 203 mechanical stop axis 1 98...
  • Page 436 Index replacement safety equipment bearing, balancing device 292 mechanical stop 98 brake release unit 288 mechanical stop axis 2 100 cable harness axes 1-4 237 mechanical stop axis 3 102 cable harness axes 1-6 203 signal lamp 159 cabling axis 5 214 safety risk complete arm system 250 electric parts 23...
  • Page 437 Index updating revolution counters 392 upper arm, replacement 272 validity and responsibility 16 weight balancing device 302 base plate 73 complete arm system 254 gearbox 379 lower arm 281 motor 330 upper arm 274 wrist unit 266 weight, robot 58 working range 60 restricting axis 1 98 restricting axis 2 100...
  • Page 438 4363HAC026876-001 Revision: F...
  • Page 440 ABB Robotics S-721 68 VÄSTERÅS SWEDEN Telephone: +46 (0) 21 344000...

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