IRB 6400RF 200/2.8 | ABB IRB 6400RF 200/2.5, 200/2.8 Articulated robot Product manual

Product manual

Articulated robot

IRB 6400RF

M2004

Product manual

IRB 6400RF - 200/2.5

IRB 6400RF - 200/2.8

M2004

ID: 3HAC027076-001

Revision: A

The information in this manual is subject to change without notice and should not be construed as a commitment by ABB. ABB assumes no responsibility for any errors that may appear in this manual.

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.

In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein.

This manual and parts thereof must not be reproduced or copied without ABB's written permission, and contents thereof must not be imparted to a third party nor be used for any unauthorized purpose. Contravention will be prosecuted.

Additional copies of this manual may be obtained from ABB at its then current charge.

©Copyright 2006 ABB All right reserved.

ABB AB

Robotics Products

SE-721 68 Västerås

Sweden

Table of Contents

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

1: Safety 13

1.1: Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2: General safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.2.1 Safety in the robot system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

1.3: Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.3.1 Safety risks during installation and service work on robot . . . . . . . . . . . . . . . . . . . . . . . . . . .15

1.3.2 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

1.3.3 Safety risks related to pneumatic/hydraulic systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

1.3.4 Safety risks during operational disturbances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

1.3.5 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

1.4: Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.4.1 Safety fence dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

1.4.2 Fire extinguishing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

1.4.3 Emergency release of the robot’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

1.4.4 Brake testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

1.4.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

1.4.6 Safe use of the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

1.4.7 Work inside the robot's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

1.4.8 Translate the information on safety and information labels. . . . . . . . . . . . . . . . . . . . . . . . . . .28

1.5: Safety related instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.5.1 Safety signals, general . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

1.5.2 DANGER - Moving robots are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

1.5.3 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

1.5.4 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

1.5.5 WARNING - Safety risks during work with gearbox oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

2: Installation and commissioning 37

2.1: Transporting and Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

2.1.1 Stability / Risk of Tipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

2.1.2 System CD ROM and Diskette . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

2.2: On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

2.2.1 Lifting the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

2.2.2 Assembling the Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

2.2.3 Stress Forces. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

2.2.4 Amount of Space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

2.2.5 Manually releasing the Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

2.2.6 Process Media Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

2.2.7 Restricting the Working Space. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

2.2.8 Position Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

2.2.9 Mounting Holes for Equipment on the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

2.2.10 Signal Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

2.3: Application Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

2.3.1 Media Outlet on Upper Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

2.3.2 Media Outlet with CAN/DeviceNet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

2.3.3 Signal Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

2.4: Customer Connector Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

3: Decommissioning 63

3HAC027076-001 Revision: A


3.1: General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.1.1 robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.2: Scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.2.1 General warning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.2.2 Oil and grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

3.2.3 Parts requiring special treatment when scrapping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

3.2.4 IRB 6400R Balancing cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

3.2.5 Scrapping Balancing cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

4: Maintenance 69

4.1: Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

4.2: Instructions for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

4.2.1 Checking the oil and grease levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

4.2.2 Oil change gearbox, axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

4.2.3 Inspect and lubricate the bearings, balancing units axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

4.2.4 Lubricating piston rod, balancing unit axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

4.2.5 Oil change, axes 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79



4.2.8 Lubricating gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

4.2.9 Excess grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

4.2.10 Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

4.2.11 Checking mechanical stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

4.2.12 Replacement of SMB battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

4.2.13 Cleaning of robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

5: Repair 91

5.1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

5.1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

5.1.2 Document guidance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

5.1.3 Caution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

5.2: Mounting instructions for bearings and seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

5.2.1 Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

5.2.2 Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

5.2.3 Instructions for tightening screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

5.2.4 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

5.2.5 Checking for Play in Gearboxes and Wrist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

5.3: Motor Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

5.4: Motors Axes 1–3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

5.4.1 Changing motor including pinion axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

5.4.2 Changing motor including pinion axes 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

5.5: Motors and Gears Axes 4–6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

5.5.1 Motor axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

5.5.2 Intermediate gear, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

5.5.3 Replacing final gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

5.6: Dismounting tube shaft, upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

5.6.1 Replacing seals and bearings, upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

5.6.2 Axes 5 and 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

5.6.3 Wrist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

5.6.4 Arm extender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

5.6.5 Motor axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

5.6.6 Motor axes 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

5.6.7 Checking backlash in axes 5 and 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123



5.6.8 Adjusting backlash in axis 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

5.6.9 Adjusting the intermediate gear unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126

5.6.10 Adjusting the intermediate gear unit bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

5.7: Balancing Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

5.7.1 Dismounting balancing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

5.7.2 Replacing guide ring, balancing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131

5.7.3 Replacing bearings, balancing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

5.8: Arm System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

5.8.1 Upper arm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

5.8.2 Parallel bar with bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

5.8.3 Balancing weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

5.8.4 Lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

5.8.5 Parallel arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139

5.8.6 Parallel arm - Inner bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

5.8.7 Parallel arm - Outer bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

5.8.8 Gearbox 1-3 including base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

5.8.9 Gearbox axis 1-3, seals axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

5.8.10 Gearbox axis 1-3, seals axis 2/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

5.8.11 Brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144

5.8.12 Replace serial measurement board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

5.8.13 Replace stop pin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

5.9: Cable Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

5.9.1 Robot harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

5.9.2 Customer Harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151

5.9.3 Cabling, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

5.10: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

5.10.1 Position Switch axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155

5.10.2 Signal lamp. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156

5.10.3 Fork lift device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157

6: Calibration 159

6.1: Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

6.1.1 When to calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

6.1.2 Types of calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160

6.1.3 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

6.2: Calibration scales and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

6.2.1 Calibration movement directions for all axes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164

6.2.2 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165

6.2.3 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168

7: Tools 171

7.1: Tool List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

8: Parts list / Spare part list 173

8.1: Rebuilding Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

8.2: Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

8.2.1 Position Switch Axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177

8.2.2 Signal Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178

8.2.3 Forklift Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

8.2.4 Wrist kit 6400R 200kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180

8.2.5 Process Media Conduit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181

8.2.6 Mechanical stop 15 degr. axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

8.2.7 Mechanical stop 7,5 degr. axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183



8.2.8 Mechanical stop axes 2 and 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

8.3: Spare Part List robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

8.3.1 Robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

8.3.2 Axis 1-3 Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

8.3.3 Upper Arm Complete. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

8.3.4 Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

8.3.5 Miscellaneous . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

9: Mechanical drawings 191

9.1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

9.2: Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Mechanical drawing 1:1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193











Mechanical drawing 2:6.1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204




Mechanical drawing 2:10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208










10: Circuit diagram 219

10.1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

10.2: Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Sheet 101: Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Sheet 102: Connection Point Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

Sheet 103: Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223

Sheet 104: Brake Unit / Serial Measurement Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

Sheet 105: Axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Sheet 106: Axes 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Sheet 107: Axes 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Sheet 108: Axis 4 / Signal lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

Sheet 109: Axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

Sheet 109,1: Axis 5 (Long Cable). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

Sheet 110: Axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Sheet 111: Customer Power/Signal Connection CANBUS / P-BUS / I-BUS . . . . . . . . . . . . . . . . 232

Sheet 112: Customer Power/Signal Connection Extended. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Sheet 113: Customer Power/Signal Connection or feeding Servo Gun/Fan . . . . . . . . . . . . . . . . . 234

Sheet 114: Switches Axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235



Sheet 115: Switches Axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236

Sheet 116: Switches Axis 2/3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .237




Overview

About this manual

This manual contains instructions for:

• mechanical and electrical installation of the robot

• maintenance of the robot

• mechanical and electrical repair of the robot.

Usage

This manual should be used during:

• installation, from lifting the robot to its work site and securing it to the foundation to making it ready for operation

• maintenance work

• repair work and calibration.

Who should read this manual?

This manual is intended for:

• installation personnel

• maintenance personnel

• repair personnel.

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

Safety

Installation and commissioning

Decommissioning

Maintenance

Repair

Calibration

Tools

Parts list / Spare part list

Contents

Safety information

Information about installation of the robot.

Environmental information about the robot.

Information about maintenance work, including maintenance schedules.

Information about repair work.

Information about calibration of the robot.

Tools needed to repair the robot.

Part list

References

Reference

Product specification - IRB 6400RF M2004


Document Id

3HAC026552-001

9

Revisions

Reference

Product manual - IRC5

Operating manual - IRC5 with FlexPendant

Operating manual - Levelmeter Calibration

Operating manual - Service Information System

Technical reference manual - System parameters

Application manual - Additional axes and stand alone controller

Document Id

3HAC021313-001

3HAC16590-1

3HAC022907-001

3HAC025709-001

3HAC17076-1

3HAC021395-001

Revision

-

A

Description

First edition.

Changes made in:

• Prerequisites in section O v erview

• Oil change in section Maintenance

10 3HAC027076-001 Revision: A

Product documentation, M2004

General

The robot documentation may be divided into a number of categories. This listing is based on the type of information contained within the documents, regardless of whether the products are standard or optional. This means that any given delivery of robot products will not contain

all documents listed, only the ones pertaining to the equipment delivered.

However, all documents listed may be ordered from ABB. The documents listed are valid for

M2004 robot systems.

Product manuals

All hardware, robots and controller cabinets, will be delivered with a Product manual which is divided into two parts:

Product manual, procedures

• Safety information

•

Installation and commissioning (descriptions of mechanical installation, electrical connections and loading system software)

• Maintenance (descriptions of all required preventive maintenance procedures including intervals)

•

Repair (descriptions of all recommended repair procedures including spare parts)

• Additional procedures, if any (calibration, decommissioning)

Product manual, reference information

• Reference information (article numbers for documentation referred to in Product manual, procedures, lists of tools, safety standards)

•

Part list

• mechanical drawings or exploded views

•

Circuit diagrams

The product manual published as a PDF consists of only one file where the two parts are presented together, as one Product manual.

RobotWare manuals

The following manuals describe the robot software in general and contain relevant reference information:

• RAPID Overview: An overview of the RAPID programming language.

•

RAPID reference manual : Description of all RAPID instructions.

• Technical reference manual - System parameters: Description of system parameters and configuration workflows.

3HAC027076-001 Revision: A 11

Application manuals

Specific applications (e.g. software or hardware options) are described in Application

manuals. An application manual can describe one or several applications.

An application manual generally contains information about:

• The purpose of the application (what it does and when it is useful)

•

What is included (e.g. cables, I/O boards, RAPID instructions, system parameters)

• How to use the application

•

Examples of how to use the application

Operating manuals

This group of manuals is aimed at those having first hand operational contact with the robot, i.e. production cell operators, programmers and trouble shooters. The group of manuals includes:

•

Getting started - IRC5 and RobotStudio Online

• Operating manual - IRC5 with FlexPendant

•

Operating manual - RobotStudio Online

• Trouble shooting manual for the controller and robot


1: Safety

Introduction

1: Safety

1.1: Introduction

Overview

The safety information in this manual is divided in two categories:

• general safety aspects, important to attend to before performing any service work on the robot. These are applicable for all service work and are found in section

General safety information on page 14

.

• specific safety information, pointed out in the procedure at the moment of the danger.

How to avoid and eliminate the danger is either detailed directly in the procedure, or further detailed in separate instructions, found in section

Safety related instructions on page 29

.


1: Safety

1.2.1 General safety information

1.2: General safety information

1.2.1 Safety in the robot system

Validity and responsibility

The information does not cover how to design, install and operate a complete system, nor does it cover all peripheral equipment, which can influence the safety of the total system. To protect personnel, the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed.

The users of ABB industrial robots are responsible for ensuring that the applicable safety laws and regulations in the country concerned are observed and that the safety devices necessary to protect people working with the robot system are designed and installed correctly.

Personnel working with robots must be familiar with the operation and handling of the industrial robot, described in the applicable documents, e.g. Operating manual - IRC5 with

FlexPendant (M2004) and Product manual.

Connection of external safety devices

Apart from the built-in safety functions, the robot is also supplied with an interface for the connection of external safety devices. Via this interface, an external safety function can interact with other machines and peripheral equipment. This means that control signals can act on safety signals received from the peripheral equipment as well as from the robot.

Limitation of liability

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

Related information

Type of information Detailed in document

Installation of safety devices

Changing operating modes

Restricting the working space

Product manual for the robot

Operating manual - IRC5 with

FlexPendant (RobotWare 5.0)

Product manual for the robot

Section


Start-up

Operating modes



1: Safety

1.3.1 Safety risks

1.3: Safety risks

1.3.1 Safety risks during installation and service work on robot

Overview

This section includes information of general safety risks to be considered when performing installation and service work on the robot.

General risks during installation and service

•

The instructions in the Product Manual - Installation and Commissioning must always be followed.

• Emergency stop buttons must be positioned in easily accessible places so that the robot can be stopped quickly.

•

Those in charge of operations must make sure that safety instructions are available for the installation in question.

• Those who install the robot must have the appropriate training for the robot system in question and in any safety matters associated with it.

Nation/region specific regulations

To prevent injuries and damage during the installation of the robot system, the regulations applicable in the country concerned and the instructions of ABB Robotics must be complied with.

Non-voltage related risks

• Safety zones, which have to be crossed before admittance, must be set up in front of the robot's working space. Light beams or sensitive mats are suitable devices.

•

Turntables or the like should be used to keep the operator out of the robot's working space.

• The axes are affected by the force of gravity when the brakes are released. In addition to the risk of being hit by moving robot parts, you run the risk of being crushed by the parallel arm.

•

Energy, stored in the robot for the purpose of counterbalancing certain axes, may be released if the robot, or parts thereof, are dismantled.

• When dismantling/assembling mechanical units, watch out for falling objects.

•

Be aware of stored heat energy in the controller.

• Never use the robot as a ladder, i.e. do not climb on the robot motors or other part during service work. There is a serious risk of slipping because of the high temperature of the motors or oil spills that can occur on the robot.


1: Safety

1.3.1 Safety risks during installation and service work on robot

To be observed by the supplier of the complete system

• The supplier of the complete system must ensure that all circuits used in the safety function are interlocked in accordance with the applicable standards for that function.

•

The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner, in accordance with the applicable standards for the emergency stop function.

Complete robot

Safety risk

Hot components!

Description

Removed parts may result in collapse of robot!

Caution!

Motors and gears are HOT after running the robot!

Touching the motors and gears may result in burns!

Warning!

Take any necessary measures to ensure that the robot does not collapse as parts are removed, e.g. secure the lower arm with fixtures if removing motor, axis 2.

Cabling

Safety risk

Cable packs are sensitive to mechanical damage!

Description

Caution!

The cable packs are sensitive to mechanical damage!

They must be handled with care, especially the connectors, in order to avoid damaging them!

Gearboxes and motors

Safety risk

Gears may be damaged if excessive force is used!

Description

Caution!

Whenever parting/mating motor and gearbox, the gears may be damaged if excessive force is used!


1: Safety

1.3.2 Safety risks related to tools/workpieces

1.3.2 Safety risks related to tools/workpieces

Safe handling

It must be possible to safely turn off tools, such as milling cutters, etc. Make sure that guards remain closed until the cutters stop rotating.

It should be possible to release parts by manual operation (valves).

Safe design

Grippers/end effectors must be designed so that they retain workpieces in the event of a power failure or a disturbance of the controller.

CAUTION!

Ensure that a gripper is prevented from dropping a workpiece, if such is used.


1: Safety

1.3.3 Safety risks related to pneumatic/hydraulic systems

1.3.3 Safety risks related to pneumatic/hydraulic systems

General

Special safety regulations apply to pneumatic and hydraulic systems.

Residual energy

•

Residual energy may be present in these systems. After shutdown, particular care must be taken.

• The pressure in pneumatic and hydraulic systems must be released before starting to repair them.

Safe design

•

Gravity may cause any parts or objects held by these systems to drop.

• Dump valves should be used in case of emergency.

•

Shot bolts should be used to prevent tools, etc., from falling due to gravity.


1: Safety

1.3.4 Safety risks during operational disturbances

1.3.4 Safety risks during operational disturbances

General

• The industrial robot is a flexible tool which can be used in many different industrial applications.

•

All work must be carried out professionally and in accordance with the applicable safety regulations.

• Care must be taken at all times.

Qualified personnel

•

Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts.

Extraordinary risks

If the working process is interrupted, extra care must be taken due to risks other than those associated with regular operation. Such an interruption may have to be rectified manually.


1: Safety

1.3.5 Risks associated with live electric parts

1.3.5 Risks associated with live electric parts

Voltage related risks, general

• Although troubleshooting may, on occasion, have 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.

•

The mains supply to the robot must be connected in such a way that it can be turned off outside the robot’s working space.

Voltage related risks, controller IRC5

A danger of high voltage is associated with the following parts:

•

Be aware of stored electrical energy (DC link, ultra capacitor bank) in the controller.

• Units inside the controller, e.g. I/O modules, can be supplied with power from an external source.

•

The mains supply/mains switch

• The transformers

•

The power unit

• The control power supply (230 VAC)

•

The rectifier unit (400-480 VAC and 700 VDC. Note: Capacitors!)

• The drive unit (700 VDC)

•

The drive system power supply (230 VAC)

• The service outlets (115/230 VAC)

•

The customer power supply (230 VAC)

• The power supply unit for tools, or special power supply units for the machining process.

•

The external voltage connected to the control cabinet remains live even when the robot is disconnected from the mains.

• Additional connections.

Voltage related risks, robot

A danger of high voltage is associated with the robot in:

• The power supply for the motors (up to 800 VDC).

•

The user connections for tools or other parts of the installation (max. 230 VAC, see chapter Installation and commissioning in the Product manual).

Voltage related risks, tools, material handling devices, etc

Tools, material handling devices, etc., may be live even if the robot system is in the OFF position. Power supply cables which are in motion during the working process may be damaged.


1: Safety

1.4.1 Safety actions

1.4: Safety actions

1.4.1 Safety fence dimensions

General

Install a safety cell around the robot to ensure safe robot installation and operation.

Dimensioning

Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the robot is dropped or released at maximum speed. Determine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell (see Product Specification IRB 6400RF - Section 1.5/Description,

Robot Motion).

Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot.


1: Safety

1.4.2 Fire extinguishing

1.4.2 Fire extinguishing

NOTE!

Use a CARBON DIOXIDE (CO

2

) extinguisher in the event of a fire in the robot (robot or controller)!


1: Safety

1.4.3 Emergency release of the robot’s arm

1.4.3 Emergency release of the robot’s arm

Description

In an emergency situation, any of the robot's axes may be released manually by pushing the brake release buttons on the robot.

How to release the brakes is detailed in section:

•

Manually releasing the Brakes on page 46

.

The robot arm may be moved manually on smaller robot models, but larger models may require using an overhead crane or similar.

Increased injury

Before releasing the brakes, make sure that the weight of the arms does not increase the pressure on the trapped person, further increasing any injury!


1: Safety

1.4.4 Brake testing

1.4.4 Brake testing

When to test

During operation the holding brake of each axis motor wear normally. A test may be performed to determine whether the brake can still perform its function.

How to test

The function of the holding brake of each axis motor may be checked as detailed below:

1. Run each robot axis to a position where the combined weight of the robot arm and any load is maximized (max. static load).

2. Switch the motor to the MOTORS OFF position with the Operating mode selector on the controller.

3. Check that the axis maintains its position.

If the robot does not change position as the motors are switched off, then the brake function is adequate.


1: Safety

1.4.5 Risk of disabling function "Reduced speed 250 mm/s"

1.4.5 Risk of disabling function "Reduced speed 250 mm/s"

NOTE!

Do not change "Transm gear ratio" or other kinematic parameters from the FlexPendant or a

PC. This will affect the safety function Reduced speed 250 mm/s.


1: Safety

1.4.6 Safe use of the FlexPendant

1.4.6 Safe use of the FlexPendant

NOTE!

The enabling device is a push button located on the side of the FlexPendant which, when pressed halfway in, takes the system to MOTORS ON. When the enabling device is released or pushed all the way in, the robot is taken to the MOTORS OFF state.

To ensure safe use of the FlexPendant, the following must be implemented:

•

The enabling device must never be rendered inoperative in any way.

•

During programming and testing, the enabling device must be released as soon as there is no need for the robot to move.

• The programmer must always bring the FlexPendant with him/her, when entering the robot's working space. This is to prevent anyone else taking control of the robot without the programmer knowing.


1: Safety

1.4.7 Work inside the robot's working range

1.4.7 Work inside the robot's working range

WARNING!

If work must be carried out within the robot’s work envelope, the following points must be observed:

•

The operating mode selector on the controller must be in the manual mode position to render the enabling device operative and to block operation from a computer link or remote control panel.

• The robot’s speed is limited to max. 250 mm/s when the operating mode selector is in position "manual mode with reduced speed". This should be the normal position when entering the working space. The position "manual mode with full speed (100%)" may only be used by trained personnel who are aware of the risks that this entails.

•

Pay attention to the rotating axes of the robot! Keep a distance to the axes in order not to get entangled with hair or clothing. Also be aware of any danger that may be caused by rotating tools or other devices mounted on the robot or inside the cell.

• Test the motor brake on each axis, according to section

Brake testing on page 24

.


1: Safety

1.4.8 Translate the information on safety and information labels

1.4.8 Translate the information on safety and information labels

Labels on the product

Both the robot and the controller are marked with several safety and information labels, containing important information about the product. The information is useful for all personnel handling the robot system, eg. during installation, service or operation.

Translation possibilities

The labels fitted to the product contain space for adding a fourth language underneath the three standard languages (English, German and French).

Add a local language to the label by:

• using a transparent sticker over the standard label with text added in a fourth language.

Drawings detailing the design (text, figure, dimensions) of the standard labels can be ordered from ABB. Notice that each label is identified according to the article number located in the lower corner of the label.

Example of transparent sticker

The figure below shows the location of the free space on one of the labels on the robot, where the fourth language can be added. The figure also shows a transparent sticker, containing the text in Swedish.

xx0500002517

A Free space for adding a fourth language


1: Safety

1.5.1 Safety related instructions

1.5: Safety related instructions

1.5.1 Safety signals, general

General

This section specifies all dangers that may arise from performing the work detailed in the manual. Each danger is detailed in its own section consisting of:

•

A caption specifying the danger level (DANGER, WARNING or CAUTION) and the type of danger.

• A brief description of what will happen if the operator/service personnel do not eliminate the danger.

•

An instruction of how to eliminate the danger to facilitate performing the activity at hand.

Danger levels

The table below defines the captions specifying the danger levels used throughout this manual.

Symbol

danger warning

Designation

DANGER

WARNING

ELECTRICAL

SHOCK

Signification

Warns that an accident will occur if the instructions are not followed, resulting in a serious or fatal injury and/or severe damage to the product. It applies to warnings that apply to danger with, for example, contact with high voltage electrical units, explosion or fire risk, risk of poisonous gases, risk of crushing, impact, fall from height etc.

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

The electrocution or electrical shock symbol indicates electrical hazards which could result in severe personal injury or death.

Electrical shock

CAUTION caution

Warns that an accident may occur if the instructions are not followed, that can result in injury and/or damage to the product. It also applies to warnings of risks that include burns, eye injury, skin injury, hearing damage, crushing or slipping, tripping, impact, fall from height etc. Furthermore, it applies to warnings that include function requirements when fitting and removing equipment, where there is a risk of damaging the product or causing a breakdown.


1: Safety

1.5.1 Safety signals, general

Symbol Designation Signification

ELECTROSTATIC

DISCHARGE (ESD)

The electrostatic discharge (ESD) symbol indicates electrostatic hazards which could result in severe damage to the product.

Electrostatic discharge

(ESD)

NOTE Note symbols alert you to important facts and conditions.

Note

TIP Tip symbols direct you to specific instructions, where to find additional information or how to perform a certain operation in an easier way.

Tip


1: Safety

1.5.2 DANGER - Moving robots are potentially lethal!

1.5.2 DANGER - Moving robots are potentially lethal!

Description

Any moving robot is a potentially lethal machine.

When running the robot, it may perform unexpected and sometimes irrational movements.

However, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the robot working range.

Elimination

Action

1. Before attempting to run the robot, make sure all emergency stop equipment is correctly installed and connected.

2. If possible, use the hold-to-run button whenever possible.

The hold-to-run button is used in manual mode, not in automatic mode.

3. Make sure no personnel are present within the robot working range before pressing the start button.

Note

Emergency stop equipment such as gates, tread mats, light curtains, etc.

How to use the hold-to-run control in

RobotWare 5.0 is detailed in section

How to use the hold-to-run function

in the

Operating manual - IRC5 with Flex-

Pendant.


1: Safety

1.5.3 DANGER - First test run may cause injury or damage!

1.5.3 DANGER - First test run may cause injury or damage!

Description

Since performing a service activity often requires disassembly of the robot there are several safety risks to take into consideration before the first test run.

Elimination

Follow the procedure below when performing the first test run after a service activity (repair, installation or maintenance):

Action

1. Remove all service tools and foreign objects from the robot and its working area!

2. Install all safety equipment properly!

3. Make sure all personnel are standing at a safe distance from the robot, i.e. out of its reach behind safety fences, etc.!

4. Pay special attention to the function of the part previously serviced!


1: Safety

1.5.4 WARNING - The unit is sensitive to ESD!

1.5.4 WARNING - The unit is sensitive to ESD!

Description

ESD (electro static 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. This discharge may destroy sensitive electronics.

Elimination

Action Note

1. Use a wrist strap Wrist straps must be tested frequently to ensure that they are not damaged and are operating correctly.

2. Use an ESD protective floor mat.

The mat must be grounded through a currentlimiting resistor.

3. Use a dissipative table mat.

The mat should provide a controlled discharge of static voltages and must be grounded.


1: Safety

1.5.5 WARNING - Safety risks during work with gearbox oil

1.5.5 WARNING - Safety risks during work with gearbox oil

Description

When handling the gearbox oil, there are several dangers to both personal injuries and product damages! Following safety information must be regarded before performing any work with the oil in the gearboxes!

Warnings and elimination

Warning Description Elimination / Action

Changing and draining gearbox oil may require handling hot oil of up to 90 °C!

Make sure that protective gear like goggles and gloves are always worn during this activity.

-

Hot oil!

When opening the oil plug, there may be pressure present in the gearbox, causing oil to spray from the opening!

Open oil plug carefully and keep away from the opening. Do not overfill the gearbox when filling.

-

Possible pressure build up in gearbox!

-

Do not overfill!

-

Do not mix types of oil!

Overfilling of gearbox oil can lead to internal over-pressure inside the gearbox which in turn may:

• damage seals and gaskets

• completely press out seals and gaskets

• prevent the robot from moving freely.

Mixing types of oil may cause severe damage to the gearbox!

Make sure not to overfill the gearbox when filling with oil!

After filling, check the correct oil level.

When filling gearbox oil, do not mix different types of oil unless specified in the instruction.

Always use the type of oil specified by the manufacturer!


1: Safety


Warning Description

Warm oil drains quicker than cold oil.

Elimination / Action

When changing gearbox oil, first run the robot for a time to heat up the oil.

-

Heat up the oil!

-

Specified amount depends on drained volume!

The specified amount of oil is based on the total volume of the gearbox. When changing the oil, the amount of refilled oil may differ from the specified amount, depending on how much oil has previously been drained from the gearbox.

After refilling, check the oil level.


1: Safety



Installation and commissioning

Transporting and Unpacking

2: Installation and commissioning

2.1: Transporting and Unpacking

Unpacking

CAUTION!

Before starting to unpack and install the robot, read the safety regulations and other instruc-

tions very carefully. See

Safety on page 13

.

The installation shall be made by qualified installation personnel and should conform to all national and local codes.

NOTE!

When you have unpacked the robot, check that it has not been damaged during transport or while unpacking.

NOTE!

If the signal lamp option is selected, the signal lamp is fitted under the protective cover on axis four housing to protect it during transport.

Operating conditions:

Ambient temperature

Relative humidity

+5

°C (41°F) to +50°C (122°F)

Max. 95% at constant temperature

Storage conditions:

If the equipment is not going to be installed straight away, it must be stored in a dry area at an ambient temperature between -25

°C (-13°F) and +55°C (131°F).

When air transport is used, the robot must be located in a pressure-equalized area.

The net weight of the robot is approximately:

Robot Type IRB 6400R M2004

2,5-200

2,8-200

Weight

2230 kg (4916 lb.)

2390 kg (5269 lb.)

Whenever the robot is transported, axis 2 must be bent backwards 30

° and axis 3 must be moved down to a position against the rubber stops on axis 2.


Installation and Comissioning

2.1.1 Stability / Risk of Tipping

2.1.1 Stability / Risk of Tipping

WARNING!

When the robot is not fastened to the floor and standing still, the robot is not stable in the whole working area. When the arms are moved, care must be taken so that the centre of gravity is not displaced, as this could cause the robot to tip over.

The following table shows the positions where there is a risk of tipping. For definition of position 0 and 5, refer to

Product Specification for IRB 6400RF

.

In position NEW, with axis 2 at an angle of -35

° and axis 3 at an angle of 0°, there is no risk of the robot tipping.

Working Area Pos. 0

Version

Load=0 kg

Load=max

2.5-200 Stable

2.8-200 Stable

Risk of tipping

Risk of tipping

Working Area Pos. 5 NEW Pos.

Load=0 kg

Risk of tipping

Risk of tipping

Load=max

Load=0 kg

Load=max

Stable Stable Risk of tipping

Risk of tipping

Stable Stable

All other axes should have an angle of 0

°.

For Foundry (F) version, see corresponding non F-version.

2.1.2 System CD ROM and Diskette

The system CD ROM and the robot parameter disk are delivered with the robot system.



2.2.1 On-site installation

2.2: On-site installation

2.2.1 Lifting the robot

General

If the integrated lifting ears on the front cannot be reached, the robot must be reoriented to the sync position (applicable to versions 2.8-120 and 3.0-75 only).

The best way to lift the robot is to use four lifting straps of similar length with hooks and a traverse crane, lifting tool 3HAC 3083-1 is recommended. Attach the straps to the integrated

lifting eyes on both sides of the frame (see

Figure 1

). The lifting strap dimensions must comply with the applicable standards for lifting. It is also possible to use two lifting devices

(option) for use with a fork lift truck (see

Figure 2

).

WARNING!

The following lifting instructions are valid for a “naked” robot. Whenever additional equipment is put on the robot, the centre of gravity can change and make lifting dangerous.Never walk under a suspended load.

Crane lift for:

2.5-200 and 2.8-200

Figure 1 Lifting the robot using a Traverse Crane



2.2.1 Lifting the robot

Fork lift for:

2.5-200 and 2.8-200

View from the side

400

40

467

675

800

(If adjusted to recommended transport position)

914

754

View from the rear

1280

View from above

Figure 2 Lifting the robot using a Fork Lift Truck. (Dimensions in mm.)

WARNING!

Crane lifting is not permitted using the fork lift arrangement.



2.2.2 Assembling the Robot

2.2.2 Assembling the Robot

Support points

The four support points of the robot foot must be mounted on four flat surfaces with a flatness within the specification. Use shims if necessary. The rest of the surface must be flat within ±

2 mm. Footprint diagram, see

Figure 3

. Floor mounted models can be tilted max. 5

o

.

Levelness

The levelness requirement for the surface is as follows:

0.5

Bolting down the robot

The robot is fixed with eight M24 bolts which must be tightened alternately.

Y

317.34

(4x)

243.5 (4x)

3

7

.5

°

(4

) x

15

°

(4 x)

R 400

Z

B

B

X

4x

∅

0.1

∅

50 (8x)

∅

28 (8x)

A A

B - B

Figure 3 Bolting down the robot

NOTE!

All eight bolts must be used.

A - A

+2

15

0

100 ±0.5

∅

45 H7 (4x)




Suitable bolts

Suitable bolts

Quality

Suitable washer

Tightening torque

M24x140 Socket screw

8.8

OD = 44 mm (1.7 in.)

ID = 25 mm (1 in.)

T = 4 mm (0.16 in.)

775 Nm

It is recommended that the robot is mounted with M24x140, 8.8 socket screws (3) on two base plates (1) with four locating bushings (2), that allows the same robot to be re-mounted without program adjustment (see

Figure 4

).

For base plate measures (see

Figure 5

).

For locating bushing measures (see

Figure 3

).

When bolting a mounting plate or frame to a concrete floor, follow the general instructions for expansion-shell bolts. The screw joint must be able to withstand the stress loads defined

in Chapter .

42

Figure 4 Base Plate

3

1

2


A - A

15

+2

0

R max 1,2

∅

45 H9

+0,062

0

3x45º



127

70

27

0

A

M24(x4)

A

∅

24(x6)

M16(x2)

M24(x4)

153,84

80

0

Figure 5 Base Plate Measures

Orienting the robot

To orient the robot when attaching it to the floor, three guide pins can be fitted in the appropriate holes,

∅ 8,5 mm (see

Figure 6

).

∅

8,5 (3x)

Figure 6 Orientation Holes



2.2.3 Stress Forces

2.2.3 Stress Forces

Stiffness

The stiffness of the foundation must be designed to minimize the influence on the dynamic behavior of the robot. For optimal performance the frequency of the foundation with the robot weight must be higher than 22 Hz

NOTE!

TuneServo can be used for adapting the robot tuning to a non-optimal foundation.

All Versions

Load

Force xy

Force z

Torque xy

Torque z

Endurance load

(in operation)

±14 000 N

22 000 ±8 000 N

± 34 000 Nm

±7 000 Nm

Max. load

(emergency stop)

±38 000 N

22 000 ±19 000 N

±61 000 Nm

±15 000 Nm

Force xy and torque xy are vectors that can have any direction in the xy plane.

44

Z

Figure 7 The Directions of the Stress Forces

Y

X



2.2.4 Amount of Space required

2.2.4 Amount of Space required

General

The amount of working space required to operate the robot is illustrated in

Figure 8

.

The working range for axis 1 is +/- 180°.

CAUTION!

There are no software or mechanical limits for the working space under the base of the robot.

NOTE!

All dimensions in illustration refer to the wrist centre in mm.

2.5-200 and 2.8-200

2.8

2.5

2600

2762

909

1083

1229

2469

2800

Figure 8 The Working Space required for the robot.(Note! The 3.0 series is no longer available)

305

645



2.2.5 Manually releasing the Brakes

2.2.5 Manually releasing the Brakes

General

All axes come equipped with holding brakes. When the position of a robot axis needs to be changed without connecting the controller, an external voltage supply (24 V DC) must be connected to enable disengagement of the brakes.

The voltage supply should be connected to the connector at the base of the robot (see

Figure

9

).

WARNING!

For robots with serial no. 64-15011 to 64-15015, the pins 37 (0V) and 33 (+24V) are used to supply power for releasing the brakes.

Pin 11: 24V

Pin 12: 0V

Figure 9 Connection of External Voltage to enable Disengagement of the Brakes

WARNING!

External power must be connected as shown in

Figure 9

. Incorrectly connected power can

release all brakes, causing immediate movement of all axes.

Voltage connected

When the controller or the voltage device is connected, as illustrated above, the brakes can be released one by one by means of the push-buttons on the brake release unit on the exterior of the axis 3 gear box. The push-buttons are marked with the appropriate axis name. The names of the axes and their motion patterns are illustrated in

Figure 10

.

WARNING!

Be very careful when disengaging the brakes. The axes become activated very quickly and may cause damage or injury.


1

2

3

4

5

6

Brake release

Figure 10 The Robot Axes and Motion Patterns


2.2.5 Manually releasing the Brakes

Axis 3

Axis 4

Axis 5

Axis 6

Axis 2

Axis 1



2.2.6 Process Media Conduit

2.2.6 Process Media Conduit

General

It is recommended that the process media conduit is used in combination with the following hoses and cables:

- 3x25 mm

2

ELOCAB weld cable

- 3x35 mm

2

ELOCAB weld cable

- Parker hoses type 837 BM-8WP

Restriction

This will give under specific circumstances a life span of 4 years with 3 shift operation

(2,000,000 cycles).

If the process media conduit is only used in an area between 100

° and 180°, the inactive part of the protective hose should be tied up to the upper guiding rail.

180

°

100

°

Figure 11 Restricted Working Space

Restricted working space



2.2.7 Restricting the Working Space

2.2.7 Restricting the Working Space

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, both mechanically and using software. Installation of an optional extra stop for the main axes

1, 2 and 3 is described below.

Limiting the working space using software is described in the chapter Technical reference manual- System parameters.

Axis 1

The range of rotation for axis 1 can be limited mechanically by fitting extra mechanical stops, with 7.5

° or 15° graduation.

Instructions for doing this are supplied with the kit.

WARNING!

The mechanical stop pin and the extra moveable mechanical stop arm for axis 1 must absolutely be replaced after a hard collision, if the pin or arm has been deformed.

Movable stop

Axes 2 and 3

Holes for extra stops

Figure 12 Mechanically limiting Axis 1

Fixed stop

The working range of axes 2 and 3 is limited by mechanical stops and can be reduced by adding up to six fixed mechanical stops with 15

° graduation.

The stops are fitted on the inside of the frame to each axis.

Extra stops must be fitted in a row, starting at the fixed stop.

WARNING!

When fitting extra stops, the cams for the position switch should not be mounted in position.



2.2.7 Restricting the Working Space

Holes for extra stops

Figure 13 Mechanically limiting Axes 2 and 3



2.2.8 Position Switches

2.2.8 Position Switches

General

Position switches can be installed on axis 1.

The switches can be connected to the controller. In the controller the signals are connected to screw terminals.

Maximum voltage/current for the position switches:

Voltage:

Current:

240 Volt AC

6 A

Instructions for fitting and adjusting of Cams and Stops

The cams are mounted in whole lengths and must therefore be cut to suit the application. Use a sharp knife and a rubber hammer, for example.

It is important that the entry edge on the cam is chamfered to an angle of max. 30

°. If the angle

is larger there is a risk of damaging the position switch (see

Figure 14

).

The ends of the cam, that are in the channel of the profile, must be cut at an angle of 90

° so

that the contact area for the stop is as large as possible (see

Figure 15

).

When fitting the cam, it is important that the edges on the openings at the ends of the profile are properly chamfered.

The cam stop comprises an M5 nut with an M5 x 6 stop screw. When the screw is tighten into the material at the bottom of the profile, the nut is pushed up to the top of the channel and

forms a lock for the cam (see

Figure 14

).

3

1. Cam stop

2. Adjustable cam

3. Profile

M5 nut

M5 x 6 stop screw

30°

1

2

Figure 14 Adjusting and locking the Cams for the Position Switch; the Figure shows the Position Breaker for Axis 2



2.2.8 Position Switches

Figure 15 Cutting the Cam

90

°

30

°



2.2.9 Mounting Holes for Equipment on the robot

2.2.9 Mounting Holes for Equipment on the robot

CAUTION!

Never drill a hole in the robot without first consulting maintenance staff or the design department at ABB

Illustrations

A A

D

E

Length of M10(x4)

inside upper arm

<5 mm.

M10 (4x)

50

B

D

B

E

M10 (2x) See E-E

104 for “Hole 1”

93 for “Hole 2”

See E-E

C

685 (/2.5-X)

1030 (/2.8-X)

175

112

A - A

C

F

282

B - B

M10 (2x) M10 (2x)

80

378

C - C

F

(See F-F on the next page)

93

260

M10 (4x) Depth 20

150

75

D - D

Figure 16 Holes for mounting Extra Equipment. (Dimensions in mm.)

“Hole 1”

180 150

E - E

“Hole 2”

M10 (2x)

25



2.2.9 Mounting Holes for Equipment on the robot

60

°

30 o

D=10 H7 depth 10

M10 (6x) depth 18

8

D=125

F - F

Figure 17 The mechanical Interface (Mounting Flange) ISO 9409-1-A125. (Dimensions in mm.)

8

30

°

D=10 H7 Depth 10

M10 (6x) Depth 18

8

60

°

D=125

10

°

D=10 H7 Depth 10 8

F - F

Figure 18 The mechanical Interface of the Insulated Flange ISO 9409-1-A125. (Dimensions in mm.)

Quality of Screws for fitting Extra Equipment

When fitting tools on the robot’s mounting flange (see above), use only screws with quality of 12.9. When fitting other equipment, standard screws with quality 8.8 can be used.

Loads

It is important to define the loads properly (with regard to the position of centre of gravity and inertia factor) in order to avoid jolting movements and unnecessary stops due to overloaded motors.

For more information see

Product Specification for IRB 6400RF

for load diagrams, permitted extra loads (equipment) and their positions. The loads must also be defined in the software, see

Operating manual - IRC5 with FlexPendant

.

Stop Time and Braking Distances

For information about brake performance, please contact ABB.



2.2.10 Signal Lamp

2.2.10 Signal Lamp

General

The connections for the signal lamp R2.H1 and R2.H2 are located under the cover for motor axis 4.

NOTE!

When included in the robot delivery, the signal lamp is placed under the axis 4 cover during transportation. Install the signal lamp according to steps 1-3 below before running the robot.

Installation of Signal Lamp

The following steps details how to install the signal lamp.

.

1.

2.

3.

Action

Dismount cover axis 4

Mount the signal lamp to the bracket according to

Figure 19

Mount the cover

Figure 19 Signal Lamp mounted on Bracket

Cover axis 4

Signal lamp

R2.H1

R2.H2

Figure 20 Connections of Signal Lamp



2.2.10 Signal Lamp



2.3.1 Application Interface

2.3: Application Interface

2.3.1 Media Outlet on Upper Arm

General

The harness for air supply and signals to upper arm is integrated into the robot arm system.

The inlets are located at robot base, see

Figure 22

, and outlets on the upper arm housing or

on the moveable part on the upper arm, see

Figure 21

.

Air connection R1.CAIR and R2.CAIR

G1/2" - 14

Max. 10 bar. One hose with inner diameter 13 mm.

Signal Connection on Upper Arm

Connections for R2.CP, R2.CS, R3.CANBUS and R3.IBUS/PBUS

For complete customer connector kit, see section

For Connector R2 on page 61

.

CS

CP

Field Bus

FCI 12-pin UTO

FCI 4-pin UTO

CAN/DeviceNet

Signal Connection at Base

Connections for R1.CP/CS. CP, CS signals and field bus are integrated in one connector.

For complete customer connector kit, see section


.

Signal Specification

CAN/DeviceNet

- Signal

- Power

CS signal

CP power

2

2

10

2 + earth

50V AC/DC, 250 mA, min. AWG24

50V AC/DC, 2A, AWG24

50V AC/DC, 250 mA, AWG24

250V AC, 8A, 1.0 mm

2



2.3.1 Media Outlet on Upper Arm

58

R2.CP

Figure 21 Location of Customer Connections on Upper Arm / Arm Housing

R2.CS

R3.CANBUS

R3.IBUS/PBUS

R2.CAIR

R1.MP

R1.CP/CS

(field bus)

R1.SW1

R1.WELD

R1.PROC3

R1.SMB

R1.SW2/3 R1.CAIR

R1.PROC2

R1.PROC1

Figure 22 Location of Customer Connections on Base



2.3.2 Media Outlet with CAN/DeviceNet

2.3.2 Media Outlet with CAN/DeviceNet

General

The CAN/CP/CS cable is connected to connector R1.CP/CS on the robot foot and to terminal inside the controller cabinet. The terminals are pre mounted in the cabinet if the robot is ordered with option “Media Outlet on Upper Arm” (see

Figure 23

and

Figure 24

).

For customer connections to connectors R2.CP, R2/CS and R3.CANBUS, see recommendations for connector kit in section


.

For installation without CAN/CP/CS cable connected between robot and controller, see recommendations for connector kit in section


.

Illustration

R2.CP

R2.CS

R2.CAIR

R3.CANBUS

Figure 23 Location of Customer Connections on Upper Arm / Arm Housing

R1.CP/CS

XT6

XT5

Foundry

XS6

Robot Controller (top view)

A

XS6

A - A

Figure 24 CAN Bus Connection in Cabinet

A

XT6 XT5



2.3.3 Signal Connections

2.3.3 Signal Connections

With CAN bus

Signal name Customer terminal

controller,

XT5-XT6

Customer connector on robot base, R1.CP/CS

(cable not supplied)

Customer con-

nector on upper arm/arm housing, R2.CP-

R2.CS-R3.CAN-

BUS

Power supply

CPA

CPB

PE

Signals

CSA

CSB

CSC

XT6.1

XT6.2

XT6.3

CSD

CSE

CSF

CSG

CSH

CSJ

CSK

CAN/DeviceNet

XT5.8

XT5.9

XT5.10

XT5.1

XT5.2

XT5.3

XT5.3

XT5.5

XT5.6

XT5.7

DRAIN

+24VCAN

0VCAN

CAN_H

CAN_L

XS6.3

XS6.5

XS6.1

XS6.4

XS6.2

R1.CP/CS.1 (3p D-Sub)













R1.CP/CS.1 (9pD-Sub)




R2.CP.A

R2.CP.B

R2.CP.C

R2.CS.A

R2.CS.B

R2.CS.C

R2.CS.D

R2.CS.E

R2.CS.F

R2.CS.G

R2.CS.H

R2.CS.J

R2.CS.K

R3.CAN bus.1

R3.CAN bus.2

R3.CAN bus.3

R3.CAN bus.4

R3.CAN bus.5


Installation and Commissioning

Customer Connector Kit

2.4: Customer Connector Kit

For Connector R1

R1.CP/CS

Year model:

Content:

Installation:

Type:

Special tool need:

3HAC 11989-1

IRB 6400RF M2004

Hood IP 68, Triple screw cap, D-sub adapter, D-sub 25p, D-sub 9p,

Power D-sub, Sockets (0.20–0.56 mm

2

), Power sockets (1.5 mm

2

),

Shield rings for D-sub, Label (R1.CP/CS), screws.

See 3HAC 12332-1 (Included in the kit.)

D-subs integrated in one AMP Hood IP 68.

Crimping tool, stripping pliers.

D-Sub 9p

D-Sub 25p

Adapter

D-Sub Power


R2.CP+R2.CS

Year model:

Content:

Installation:

Type:

Special tool need:

3HAC 11991-1

IRB 6400RF M2004

Multiple connector 4p, Multiple connector 12p, Adapters,

Pins (0.25–0.5 mm

2

), Pins (0.5–1.5 mm

2

), Angled shrinking hoses

12p+4p, Bottle shaped shrinking hose 12p, Label (R2.CP, R2.CS).


Burndy. Angle or bottle shaped. Pins for two wire dimensions 12p.

Crimping tool, hot air gun, stripping pliers.


R3.CANBUS

Year model:

Content:

Installation:

Type:

Special tool need:

3HAC 12030-1

IRB 6400RF M2004

Male connector.


Straight.

Crimping tool, hot air gun, stripping pliers.


Installation and Commissioning

Customer Connector Kit


Decomissioning

3.1.1 General

3: Decommissioning

3.1: General

The components of the robot are manufactured from many different materials. Some of them are listed below to facilitate scrapping, i.e. so that the components can be disposed of in a way that does not have a detrimental effect on anyone’s health or the environment.

3.1.1 robots

Material

Grey cast iron

Batteries,

NiCad or Lithium

Copper

Cast iron/nodular iron

Steel

Samarium-Cobalt

Neodymium

Plastic/rubber (PVC)

Oil, grease

Aluminium

Examples of components

Counter-weight

Serial measurement board

Part of

IRB 6400RF

All robot types

Cables, motors All robot types

Base, lower arm, upper arm, parallel bar/arm All robot types

Gears, screws, base-frame, etc.

Brakes, motors

Brakes, motors

All robot types

IRB 1400, 2400,

4400

IRB 6400, 640

Cables, connectors, drive belts, etc.

Gearboxes

Covers, sync. brackets

Castings in wrist, upper arm tubular

All robot types

All robot types

All robot types

IRB 1400, 2400

3.2: Scrapping

WARNING!

The Counter-weight for robots 6400 contains grey cast iron and must therefore always be recycled.

3.2.1 General warning

WARNING!

Before removing any parts from the robot, study the dismantling instructions for the component in question. Dismantling instructions can be found under Repairs.

3.2.2 Oil and grease

Where possible, arrange for the oil and grease to be recycled. Dispose of via an authorized person/contractor in accordance with local regulations. Do not dispose of oil and grease near lakes, ponds, ditches, down drains, or on to soil. Incineration may be carried out under controlled conditions in accordance with local regulations.

Also note that:

• Spills may form a film on water surfaces causing damage to organisms. Oxygen transfer could also be impaired.

• Spillage may penetrate the soil causing ground water contamination.


Decomissioning

3.2.3 Parts requiring special treatment when scrapping

3.2.3 Parts requiring special treatment when scrapping

Special care is needed when removing certain parts from the robot, before scrapping the part in question. The types of robot on which there are such parts are listed below together with a description of how they should be removed.


Decomissioning

3.2.4 IRB 6400R Balancing cylinder

3.2.4 IRB 6400R Balancing cylinder

The balancing cylinder contains 1–2 pre-loaded spiral springs. Before scrapping (melting down, or other form of destruction) the springs must be unloaded in a safe way, (see

Scrapping Balancing cylinders on page 66

).

There are different types of balancing cylinder with a pre-loading force between 4500–8000

N

The free length of the unloaded springs is about 300–400 mm excluding the length of the balancing cylinder.

Double Spiral spring

Single Spiral spring

Figure 25 Balancing cylinder, IRB 6400.


Decomissioning

3.2.5 Scrapping Balancing cylinders

3.2.5 Scrapping Balancing cylinders

WARNING!

It is most important that no enclosed spaces remain when the scrap is shipped to the steel plant for recycling.

General method

The normal way to scrap the balancing cylinder is to use a so-called shredder or scrapping mill. All the balancing cylinders can be treated in this way.

All-enclosed scrapping mills in which the scrap is ground to chips, e.g “Newell heavy duty

shredder plant 2205” or similar, are available at all major scrap merchants.

Alternative methods

If a scrapping mill is not available, the balancing cylinder (except 3HAA 0001-EZ) can be

opened by means of a blowpipe as shown in the sketches (see

Scrapping balancing cylinders on page 66

).

• Balancing unit for IRB 6400RF.

Cut a hole (250 x 150 mm) in the mantel surface and then cut all the uncovered spring.

Finally cut a hole (40 mm) in the piston rod, alt. A, or cut off the piston rod end, alt. B.

• Balancing unit for Shelf version.

Cut a hole (250 x 150 mm) in the outer mantel surface and cut the uncovered spring so it will be possible to cut another hole (200 x 100 mm) in the inner mantel surface. Cut the inner spring and cut off the piston rod end.

ca. 250 ca. 200

Cut off Piston rod

Figure 26 Scrapping balancing cylinders


Decomissioning


Ca Ø 40mm

Cut off Spiral spring ca. 250

Hole in the Piston rod

Cut off Spiral spring

Alternative A ca. 250

Cut off Piston rod

Figure 27 Scrapping balancing cylinders

Alternative B

Figure 28 scrapping Balancing cylinders


Decomissioning



Maintenance

Intervals

4: Maintenance

4.1: Intervals

Prescribed maintenance

Balancing unit axis 2

Bearings, inspection


Bearings, greasing


Piston rod/Guide ring

Cabling (see

Cabling Life

Time on page 70

).

Mechanical stop axis 1

Gearbox 6

Grease changing

Gearbox axis 1

Oil changing (see

Operating life of gearbox axis

1 on page 71

).

Gearboxes axes 2-5

Oil changing

Oil level axes 1-5

Accumulator for-measuring system

Exchange

Position Switch X

1

Inspection

twice a year once a year

Maintenance intervals

4 000 h or

2 years

12 000 h or

3 years

X

5 years

X

2

X

3

X

4

X

X

X

1

X

3 years

7

20 000 h or

4 years

X

5

X

6

X

X

8

1. For foundry operation.

2. If the robot operation is utilized in adverse conditions (for example: particleladen environments, such as spot welding, grinding, deflashing, etc.), perform preventive maintenance more

frequently to ensure proper reliability of the robot system. See

Lubricating piston rod, balancing unit axis 2 on page 78

.

3. Inspect all visible cabling. Change if damaged (valid for all cabling except cabling on axes 1 and 4).

4.Check the mechanical stop devices for deformation and damage. If the stop pin or the adjustable stop arm is bent, it must be replaced. See

Checking mechanical stop on page 85

.

5.For press-tending refer to grease changing and operating life for gearbox axis 6,

see

Grease change axis 6 on page 71

and

Operating life of gearbox axis 1 on page 71

.

6. Recommended interval for oil change axis 1, see

Oil exchange axis 1 on page

70

. Approx. estimate of operating life of gearbox axis 1 as a function of the cycle

time. For press-tending see

Operating life of gearbox axis 1 on page 71

.

7. see

Location of SMB battery on page 86


Maintenance

Intervals

8. Not required in an ordinary industrial environment

Cabling Life Time

Min. life time

No. of cycles robot cabling axis 1

Customer cabling axis 1 robot cabling axis 4

Customer cabling axis 4

4

·

10

6

3

·

10

6

2

·

10

6

1

·

10

6

Figure 29 Cabling life time (3-shift = 500 000 cycles per year or 5 000 h per year).

NOTE!

The rest of the robot and customer cabling = 8 years.

25mm

2

SW-cabling internal

35mm

2

SW-cabling internal

(Rotation angle)

Oil exchange axis 1

Operation

(years)

20000 h

4

3

2

1

5000 h

5 s (PT)

Figure 30 Recommended interval for Oil exchange axis 1. (3-shift)

10 s (SW)

(Cycle time)


Maintenance

Intervals

Operating life of gearbox axis 1

40 000

30 000

20 000

10 000

Life time (operation) (h)

Grease change axis 6

3 4 5 6 7 8 9

Figure 31 Approx. estimate of operating life of gearbox axis 1 as a function of the cycle time for press-tending.

Cycle time (s)

Operation (h)

25 000

20 000

15 000

10 000

5 000

50 100

Figure 32 Recommended interval for changing grease on axis 6

150

Moment of inertia Ja6

6

(kgm

2

)

Operating life of gearbox axis 6

The table below details the approx. estimate of operating life of gearbox axis 6 as a function of the moment of inertia Ja6. Ja6 according to the Product Specification, chapter 3.


Maintenance

Intervals

Life time (operation) (h)

45 000

40 000

35 000

30 000

25 000

20 000

15 000

10 000

5 000

50 100

Figure 33 Approx. estimate of operating life of gearbox axis 6.

150

Moment of inertia Ja6

6

(kgm

2

)


Maintenance

Instructions for maintenance

4.2: Instructions for maintenance

General instructions for the robot

Check regularly:

for any oil leaks. If a major oil leak is discovered, call for service personnel.

for excessive play in gears. If play develops, call for service personnel.

that the cabling between the control cabinet and robot is not damaged.

Check after a collision with external objects:

that the upper and lower arms and the wrist is not damaged. If damage is discovered, call for service personnel.

NOTE!

Cleaning, see

Cleaning of robot on page 89

.


Maintenance

4.2.1 Checking the oil and grease levels

4.2.1 Checking the oil and grease levels

Axis 6

The level in the gearbox is checked by adding new grease until grease comes out through the special draining hole, see

Lubricating gearbox, axis 6 on page 82

.

Axes 1, 2, 3, 4 and 5.

The level is checked by opening the oil plugs. See

Oil change gearbox, axis 1 on page 75

,

Oil change, axes 2 and 3 on page 79

and


.

Oil levels

Axis 1

Axis 2/3

Axis 4/5

Minimum 15 mm under the level of the filling plug, see

Oil plugs. on page

75

<11>


Oil plugs, axes 2 and

3. on page 79

<14>


Drain hole axis 4 on page 80

<B>


Maintenance

4.2.2 Oil change gearbox, axis 1

4.2.2 Oil change gearbox, axis 1

Procedure

The following procedures details how to change oil in gearbox, axis 1.

Action

1. Remove the three plugs with sealing rings, see Figure 34.

• ventilation plug (10) (breather)

• level plug (11) and filling plug

• drain nut (12).

2. Drain off the used oil through the hose.

3. Refit the drain nut (12).

4. Fill up with new oil until the oil level reaches the lower edge of the fill and level hole.

5. Refit the filling plug (11) and ventilation plug (10).

6. Tightening torque, oil plugs: 60 Nm

Oil type and volume

Volume approx

Type of oil:

Equivalents:

11.2 liters. (3.35 US gallon)

ABB 1171 2016-604

- Castrol Alpha SP 320

- Esso Spartan EP 320

- Klüber Lamora 320

- Mobil Mobilgear X320

- Shell Omala Oil 320

- Texaco Meropa 320

- Statoil Loadway EP

10

11

12

Figure 34 Oil plugs.


Maintenance

4.2.3 Inspect and lubricate the bearings, balancing units axis 2

4.2.3 Inspect and lubricate the bearings, balancing units axis 2

General

The bearings should be inspected and lubricated every 12 000 hours (4 000 hours for

Foundry).

NOTE!

Make sure the shaft between the upper and lower arms does not rotate when unscrewing the lock nut.

Required equipment

Type of grease:

Equivalents:

ABB 3HAB 3537-1

Shell Alvania WR 2

Preparations

1.

2.

Action

Move axis 2 to the sync position.

Remove the locknuts, the outer support washers, and sealing rings.

Inspect

1.

2.

3.

4.

5.

6.

7.

Action

Fit the auxiliary shafts on the upper and lower axes (upper: aux. shaft

3HAC 5276-1, lower: aux. shaft 3HAC 5275-1). The shafts should be tightened to their bottom position.

Off-load the bearings using an M10x50 screw at the cylinder top.

Put out the cylinder so that the inner rings are fully exposed. Wipe the inner rings clean and check that there are no pressure marks or other similar deformations. It is quite normal for the bearing races to have a darker color than the surrounding material.

Inspect the bearings, support washers and sealing rings.

Push in the cylinder, make sure the inner support washers and sealing rings gets in correct position.

Remove the auxiliary shafts.

Inspect the parts to ensure nothing looks abnormal, see Repairs.

Lubrication

76

1.

Action

Fit the lubricating tool 3HAC 5222-1. The tool should be tightened to the bottom position using hand power only.


Maintenance

4.2.3 Inspect and lubricate the bearings, balancing units axis 2

2.

3.

4.

5.

6.

Action

Grease through the nipple. Continue greasing until the clean grease exudes behind the inner sealing ring. Repeat procedure for the other bearings.

Remove the lubricating tool and clean the threads on the shaft ends free from grease. Clean also from old grease on the inner side.

Refitt the outer sealing rings, apply some grease on the support washers, apply

Loctite 243 on the KM nuts, not on the shafts, and tighten them to a torque of 50-

60 Nm.

Check play (min. 0.1 mm) between support washer and bearingseat at both bearings.

Remove the M12 screw.

Related information

For more information about the procedure of replacing bearings, see

Replacing bearings, balancing unit on page 132

.


Maintenance

4.2.4 Lubricating piston rod, balancing unit axis 2

4.2.4 Lubricating piston rod, balancing unit axis 2

General

Move axis 2 to a position where the balancing units are in the horizontal position.

Wear

Check the guide ring for wear. If there is a risk of metallic contact between the piston rod and the end cover, the guide ring must be replaced. For replacement, see

Replacing guide ring, balancing unit on page 131

.

The article number of the guide ring is 3HAC 3476-1.

Lubrication

The piston rods should be lubricated. Clean the piston rod and apply new grease when necessary.

Type of grease:

- Castrol Spheerol SX2 or equivalent

- Shell SRS 4000

- OK Super Grease L2.

- Statoil Uniway 2X2N


Maintenance

4.2.5 Oil change, axes 2 and 3

4.2.5 Oil change, axes 2 and 3


Volume approx:

Type of oil:

Equivalents:

Axis 2 11.5 liters. (3.35 US gallon)

Axis 3 12.0 liters. (3.50 US gallon)

ABB 1171 2016-604






- Texaco Meropa 320


Procedures

1.

2.

3.

4.

5.

6.

7.

Action

Remove the three plugs with sealing rings see Figure 35.

• Ventilation plug (13) (breather)

• Level plug (14) and filling plug

• Drain plug (15)

Drain off the used oil through the drain hole.

Clean the drain plug (15) before refitting.

Refit the drain plug with sealing ring.

Fill up with new oil until the oil level reaches the lower edge of the level hole.

Refit the filling plug (14) and ventilation plug (13).

Tightening torque, oil plugs: 60 Nm

13

14

15

Figure 35 Oil plugs, axes 2 and 3.


Maintenance




Volume approximately.:

Correct oil level for axis 4 is to the lower edge of the upper oil level plug (B).

Type of oil:

6 liters (1.75 US gallon).

ABB 1171 2016-604

Equivalents: - Castrol Alpha SP 320





- Texaco Meropa 320


Procedures

1.

2.

3.

4.

5.

6.

Action

Move the upper arm to the horizontal position.

Remove the plugs (A) and (B).

Drain off the old oil through the hole (A). See

Figure 36

.

Clean the magnetic drain plug before refitting.

Refit the drain plug (A).

Fill up with new oil until the oil level reaches the lower edge of the filling hole (B).

B

Figure 36 Drain hole axis 4

A


Maintenance



1.

2.

3.

4.

5.

Action

Move the upper arm to the horizontal position with axis 4 turned +90 o

Open the oil plug 1, and then oil plug 2 so that air can enter, see

Figure 37

Rotate axis 4 manually backwards and forwards to drain the oil, after first releasing the brake on axis 4.

Clean the magnetic drain plug before refitting.

Turn axis 4 through -90 o

before filling oil. Fill oil through hole 2 until the oil is level with the lower edge of the filler hole.

Volume approximately:

Type of oil:

Equivalents:

6.5 liters (1.717 US gallon)

NOTE!

Correct oil level for axis 5 is to the lower edge of the oil level plug.

ABB 1171 2016-604






- Texaco Meropa 320


2

1

Figure 37 Oil change axis 5.


Maintenance

4.2.8 Lubricating gearbox, axis 6

4.2.8 Lubricating gearbox, axis 6

This section details how to lubricate the gearbox, axis 6.

Important information!

When using compressed air driven tools as a filling device, do not use more than 0.1 bar pressure. Also when using a hand grease gun, caution must be taken to avoid high pressure.

This is to prevent damage to the seals.

Volume and type

The amount and type of grease is listed below.

Type

Optimol Longtime PD 0

Art no.

Volume (new gearbox) Volume

(change)

3HAA 1001-294 0,30 liter / 0.085 gallon 1 liter / 0.28 gallon

Lubricating instructions

NOTE!

It is important that the drain plug is completely removed.

All the following instructions refer to the illustration on

Filling and drain plug. on page 84

.

4.

5.

6.

Step Action

1.

2.

Remove the plug from the drain hole on flange of gearbox (1).

Remove the plug from the filling hole of motor housing (2)

3.

Place the two holes as far away from each other as possible to ensure that the grease is changed at every part inside the gearbox.

Add grease through the hole of the motor housing (2).

Continue to add grease until new grease comes from the drain hole (1).

Remove any excess grease as described in

Excess grease on page 83

.


Maintenance

4.2.9 Excess grease

4.2.9 Excess grease

The following actions should be considered before refitting the plugs.

All the following instructions refer to the illustrations

Filling and drain plug. on page 84

.

WARNING!

To prevent over-pressure and the risk of leakage, the gearbox must be drained from excess grease before the plugs are replaced

Step Action

1.

Turn the filling hole of motor housing (2) facing down.

2.

3.

Open the drain hole (1) on the flange of the motor.

Rotate axis 6 backwards and forwards a couple of times until excess grease is pressed out of the hole on motor housing (2). The amount that should come out is min. 0.1 liters and max 0.2 liters.

4.

Use compressed air through the hole on the motor housing to get the excess grease out, where the application makes it difficult to make big axis movements, or if the grease is cold.

NOTE!

It is still necessary to move the axis backwards and forwards as much as possible.


Maintenance

4.2.10 Illustrations

4.2.10 Illustrations

A

2

B

1

1

Figure 38 Filling and drain plug.

Pos.

1

2

Description

Drain plug

Filling plug

NOTE!

The positions of the filling(2) and drain (1) plugs are facing each other.

2


Maintenance

4.2.11 Checking mechanical stop

4.2.11 Checking mechanical stop

Check regularly, as follows:

Mechanical stop Check

Fixed stop

Stop pin

Adjustable stop

Article number

-that the stop is not damaged

-that the stop pin can move in both directions

-that the stop pin is not bent.

3HAC 3667-1

-that the stops are not damaged.

-If the fixed stop arm is damaged, it must be replaced.

-If the pin is bent, a collision between the swinging stop arm and the stop pin has probably occurred. A bent stop pin must always be replaced by a new one.

-If any of the adjustable stops are damaged, they must be replaced by new ones

-If any damper is deformed it must be replaced.

3HAC 4656-1 15° (Option)

3HAC 4657-1 7.5° (Option)


Maintenance

4.2.12 Replacement of SMB battery

4.2.12 Replacement of SMB battery

Location of SMB battery

The SMB battery (SMB = serial measurement board) is located on the left hand side of the frame as shown in the figure below.

A

Figure 39 Battery location

A SMB battery cover


Equipment, etc.

Battery pack

Standard toolkit

Circuit Diagram

-

Spare part no. Note

3HAC 16831-1 Battery includes protection circuits. Replace it only with given spare part no. or an ABB approved equivalent.

See

Tool List on page 171

.

See

Circuit diagram on page 219

.

Removal, battery

The procedure below details how to remove the SMB battery.


Maintenance


1.

Action

Move the robot to its calibration position.

2.

Note

This is done in order to facilitate the updating of the revolution counter.

3.

WARNING!

Turn off all electric power, hydraulic and pneumatic pressure supplies to the robot!

4.

5.

6.

esd

WARNING!

The unit is sensitive to ESD, before handling the unit please observe the safety information in

WARNING - The unit is sensitive to ESD! on page 33

.

Remove the SMB battery cover by unscrewing its attachment screws.

See


.

Pull out the battery and disconnect the battery cable.

Remove the SMB battery. Battery includes protection circuits. Replace it only with the specified spare part or with an ABB approved equivalent.

See


.

See


.

Refitting, battery

The procedure below details how to refit the SMB battery.

Action

1.


For Foundry Prime robots: Do not turn off the air pressure to motors and SMB.

2.

Note

esd

WARNING!

The unit is sensitive to ESD, before handling the unit please observe the safety information in section

WARNING - The unit is sensitive to

ESD! on page 33

.


Maintenance


Action Note

3.

Reconnect the battery cable to the SMB battery pack and fit it to the frame.

Art. no. is specified in

Required equipment on page 86

. Shown in the

figure


.

4.

5.

Secure the SMB battery cover with its attachment screws.

Update the revolution counter.

Shown in the figure


.

Detailed in section

Updating revolution counters on page 165

.

6.

DANGER!

Make sure all safety requirements are met when performing the first test run. These are further detailed in section

DANGER - First test run may cause injury or damage! on page 32 .


Maintenance

4.2.13 Cleaning of robot

4.2.13 Cleaning of robot

Instructions

The protection class is IP 67, which means that the robot is watertight, assuming that no covers or other protective parts have been removed. When cleaning the robot, the bearings, electrical connection boxes, switches, and contacts need no extra protection, but the following must be taken into consideration

Cleaning

For steam cleaning:

Cleaning with water:

Note

• water pressure at nozzle: max. 2500 kN/m

2

(25 bar)

• type of nozzle: fan jet, min. 45º spread

• flow: max. 100 liters/min.

• distance from nozzle to encapsulation: min. 0.4 m

• water temperature: max. 80º C

• avoid pointing the water jet at bearing seals, contacts, and other seals

• fan jet nozzle should be used, min. 45º spread

• max. water pressure on enclosures: 50 kN/m2

(0.5 bar)

• flow: max. 100 liters/min.

NOTE!

Higher pressures and temperatures should not be used because this will shorten the service life of paintwork, rust inhibitors, signs, and labels.


Maintenance

4.2.13 Cleaning of robot


Repairs

5.1.1 Introduction

5: Repair


5.1.1 General information

The industrial robot system IRB 6400 comprises two separate units; the control cabinet and the mechanical unit. The service of the mechanical unit is described in this document.

As regards service, the mechanical unit is divided into the following main parts:

• Electrical System

• Motor Units

• Mechanical System

The Electrical System is routed through the entire robot and consists of two major systems; power cabling and signal cabling. The power cabling feeds the robot axes' motor units. The signal cabling feeds the various controlling parameters like axis positions, motor revs, etc.

The AC type Motor Units provide the motive power for the various robot axes via gears.

Mechanical brakes, electrically released, lock the motor units when the robot is inoperative for more than 1000 hours.

The Mechanical System has 6 axes, enabling the flexible robot motions.

Axis 3

Axis4

Axis 5

Axis 6

Axis 2

Axis 1

Figure 40 The robot axes and motion patterns.

Axis No. 1 rotates the robot via a frame.

Axis No. 2, which provides the lower arm´s reciprocating movement, is supported in the frame. The Lower Arm forms together with the Parallel Arm and the Parallel Bracket, a par-


Repairs

5.1.1 General information allelogram against the Upper Arm. The Parallel Bracket is mounted in bearings in the Parallel

Arm and in the Upper Arm.

Axis No. 3 provides elevation of the robot's upper arm.

Axis No. 4, located in the Upper Arm, provides a rotary motion of the Upper Arm.

The Wrist is bolted to the Upper Arm's forward end and comprises the axes Nos. 5 and 6. The latter axes form a cross.

Axis No. 5 provides a tilting motion and Axis No. 6 a turning motion. A connection is arranged for various customer tools at the front end of the wrist in the Turn Disc. The tool (or robot) can be equipped with pneumatic control via an external air supply (option). The signals to/from the tool can be supplied via internal customer connections (option).

WARNING!

The Control Cabinet must be switched off during all service work on the robot! Before doing any work on the robot measurement system (measurement board, cabling), the accumulator power supply must always be disconnected.

When service work is finished, the calibration position should always be checked with the system disc.

The Brake Release Unit should be connected as indicated in


.

WARNING!

Special care must be taken when the brakes are operated manually. This applies particularly when the robot is started up, either for the first time or after a stoppage. The safety instructions in the Programming Manual must be complied with at all times.


Repairs

5.1.2 Document guidance

5.1.2 Document guidance

The subsequent chapters describe the type of service work that can be carried out by the Customer´s own service staff on site. Certain types of work, requiring special experience or special aids, are not dealt with in this manual. In such cases, the defective module or component should be replaced on site. The faulty item should be sent to ABB for service.

Calibration. Recalibration of the robot may have to be carried out after replacing mechanical unit parts or when the motor and feedback unit have been separated; or when a resolver error has occurred or the power supply between a measurement board and resolver has been inter-

rupted. The procedure is described in detail in

Calibration on page 159

.

WARNING!

When work is done on the robot signal cabling, this may result in the robot moving to incorrect positions. After doing such work, it is important that the robot calibration position is checked. If a calibration fault is discovered, the robot must be recalibrated.

For more information, see


.

Tools. Two types of tools are required for various service jobs involving dismantling; on the one hand, conventional tools like socket and ratchet spanners, etc.; on the other hand, special tools may be necessary, depending on what type of service is being carried out. The conventional tools are not dealt with in this manual, based on the assumption that the service personnel have sufficient technical basic competence. However, service work requiring the use of special tools is described in this manual.

Exploded views. In the Spare Parts chapter of this manual, there are a number of exploded view mechanical drawings illustrating the robot parts, intended to facilitate quick identification of both the type of service required and the composition of the various components. The parts are item numbered on the mechanical drawings. The mechanical drawings are referred to in the manual text within "arrow heads" (< >) as exploded view numbers. Where reference is made to mechanical drawings, other than those specified in the paragraph title, the mechanical drawing number is included in the item number reference, for example <5/19> or <10:2/

5>, the digit(s) before the slash referring to the mechanical drawing number.

Numbers in brackets ( ) refer to figures in the text.

The mechanical drawings also include information such as article number, designation and relevant data.

NOTE!

This manual is not to be considered as a substitute for a proper training course. This document is intended for use after the course has been completed.


Repairs

5.1.3 Caution

5.1.3 Caution

WARNING!

The mechanical unit contains several parts which are too heavy to lift manually. As these parts must be moved with precision during any maintenance and repair work, it is important to have a suitable lifting device available.

The robot should always be switched to MOTORS OFF before allowing anyone to enter its working space.


Repairs

5.2.1 Mounting instructions for bearings and seals

5.2: Mounting instructions for bearings and seals

5.2.1 Bearings

General

1.

2.

3.

Action

Let the new bearing remain in its wrapping until it is time for fitting, to avoid contamination of the bearing.

Ensure that all parts included in the bearing fitting are free from burrs, grinding waste and other contamination. Cast components must be free from foundry sand.

Bearing rings, inner rings and roller elements must under no circumstances be subjected to direct impact. Also, the roller elements must not be exposed to any stresses during the assembly work.

Tapered Bearings

Greasing Bearings

Action

1.

The bearing should be tensioned gradually until the recommended pre-tension is achieved.

2.

It is important to note that the roller elements must be rotated a specified number of turns before pre-tensioning is carried out, and also rotated during the pre-tensioning sequence.

3.

The above procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange. Also, it is important that the bearing is properly aligned, as this will directly affect the life span of the bearing.

Action

1.

The bearing must be greased after fitting. The main reason for this is the requirement for cleanliness. Good quality lubricating grease should be used, for example 3HAB

3537-1.

2.

Grooved ball bearings should be filled with grease from both sides.

3.

Tapered roller bearings and axial needle bearings shall be greased in the split condition.

4.

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 surplus grease will be thrown out from the bearing when the robot is started up.

5.

During operation, the bearing should be filled to 70–80% of the available volume.

6.

Ensure that grease is handled and stored properly, to avoid contamination.


Repairs

5.2.2 Seals

5.2.2 Seals

Rotating Seals

NOTE!

The most common cause of leakage is incorrect fitting

1.

2.

3.

4.

6.

7.

8.

9.

5.

Action.

The sealing surfaces should be protected during transport and mounting.

The seal should be kept in the original wrappings or be well protected.

Sealing surfaces must be inspected before mounting. If scratches or damage are found, that may result in future leakage, the seal must be replaced.

Seals should also be checked before mounting to ensure that:

• there is no damage to the sealing edge (feel with a fingernail)

• the seal is of the correct type (provided with cutting edge)

• there is no other damage.

Grease the seal just before fitting it, but not too early as there is a risk of dirt and foreign particles adhering to the seal. The space between the dust tongue and sealing lip should be filled to 2/3 with grease of quality 3HAB 3537-1. The rubber coated external diameter must also be greased.

The fitting of seals and gears must be carried out on clean workbenches.

Mount the seal correctly. If it is misaligned, there is a risk of leakage due to the pumping effect.

Always mount the seal with a mounting tool. Never hammer directly on the seal, as this may result in leakage.

Use a protective sleeve for the sealing lip during mounting, when sliding over threads, key ways, etc.

Flange Seals and Static Seals

1.

2.

3.

4.

5.

Action

Check the flange surfaces. They must be even and free from pores. It is easy to check flatness using a gauge on the fastened joint (without sealing compound).

Differences in surface level or the presence of burrs due to incorrect machining are not permissible. If flange surfaces are defective, the parts must not to be used, because leakage could result.

The surfaces must be properly cleaned in accordance with ABB recommendations.

Distribute the sealing compound evenly over the surface, preferably with a brush.

Tighten the screws evenly when fastening the flange joint.


O-rings

Repairs

5.2.2 Seals

1.

2.

3.

4.

5.

6.

Action

Check the o-ring grooves. The grooves must be geometrically correct and free from pores and contamination.

Check the o-ring with regard to surface defects, burrs, shape accuracy, etc.

Ensure that the correct o-ring size is used.

Tighten the screws evenly when assembling.

Defective o-rings and o-ring grooves must not be used.

Fitting defective parts will result in leakage. Grease the o-ring with lubricant 3HAB

3537-1 before mounting.


Repairs

5.2.3 Instructions for tightening screw joints

5.2.3 Instructions for tightening screw joints

General

It is of the utmost importance that all screw joints be tightened with the correct torque.

Application

The following tightening torques are to be used for all screw joints in metallic materials unless otherwise specified in the text.

These instructions do not apply to screw joints comprising soft or brittle materials.

For screws with a higher property class than 8.8, the data for 8.8 must be used unless otherwise specified.

Screws treated with Gleitmo (lubricated)

WARNING!

When handling screws treated with Gleitmo, protective gloves of nitrile rubber type should be used.

Screws treated with Gleitmo can be unscrewed and screwed in again 3-4 times before the slip coating disappears. Screws can also be treated with Molycote 1000.

When screwing in new screws that are not Gleitmo treated, these should first be lubricated with Molycote 1000 and tightened to the specified torque.

Assembly

Lubrication with molybdenum disulphide grease (Molycote 1000) should only be used when specified in the text.

Screws lubricated with Molycote 1000 and then torque tightened, should also to be lubricated between the washer and the head of the screw.

Screws with dimension M8 or larger should be tightened with a torque-wrench, if possible.

Screws with dimension M6 or smaller may be tightened to the correct torque using tools without torque indication, by personnel with adequate mechanical training and instruction.


Repairs

5.2.4 Tightening torques

5.2.4 Tightening torques

Screws with slotted or cross recessed head

Dimension

M 2.5

M 3

M 4

M 5

M 6

Screws with hexagon socket head

Tightening torque - Nm

Class 4.8 “Dry”

0.25

0.5

1.2

2.5

5.0

Dimension

Tightening torque - Nm

Class 8.8 “Dry”

Class 10.9

Molycote 1000

Gleitmo 610

M 5

M 6

M 8

M 10

M 12

M 16

6

10

24

47

82

200

28

55

95

235

Class 12.9

Molycote 1000

Gleitmo 610

35

70

120

300


Repairs

5.2.5 Checking for Play in Gearboxes and Wrist

5.2.5 Checking for Play in Gearboxes and Wrist

NOTE!

When checking for play in gearboxes the brakes must be disengaged.

When trying to move an arm manually when the brakes are engaged, some play can be felt.

The play that can be felt is between the brake disk and the motor shaft, not in the gearbox itself. This is because the rotating brake disk is connected to the motor shaft by splines. This is why the brakes must be disengaged before testing for play in the gearboxes and wrist. The brakes are disengaged by pressing the enable button on the teach pendant.

NOTE!

The play in the brake disk does not affect the robot motion or accuracy.


Repairs

Motor Units

5.3: Motor Units

General

Each robot axis is provided with a motor unit consisting of:

• A synchronous AC motor

• A brake unit

• A feedback unit.

A gear on the output shaft of the motor forms together with the gear on each axis,

The electro-magnetic brake is built into the motor unit. The brake is released by a 24 V DC

supply. For brake release see


.

The feedback unit consists of a resolver mounted on the motor shaft and is built into the motor unit in a similar way as the brake.

Power and signal connections to the motor units are via separate cables between connections points inside the robot and each motor. The cables are connected to the motor units with connectors.

• The feedback unit is fitted by the motor manufacturer and must never be separated from the motor.

• The communication angle is + 90° (COMOFF=2048).

The motors never need commutating.

• The motor, resolver and brake is to be regarded as an replacement motor unit. Faulty motor units are repaired by the motor manufacturer at the request of the ABB service organization.

• The cable routing is shown in Figure 41. Note that the signal connection and the power

connection must not be entwined.

Signal connection

Figure 41 Cable routing in the motor unit.

Power connection


Repairs

Motor Units


Repairs

5.4.1 Motors Axes 1–3

5.4: Motors Axes 1–3

5.4.1 Changing motor including pinion axis 1

Refer to mechanical drawing no. 2:5.

Removal:

WARNING!

Be careful not to tap or hit the shaft axially, nor displace the shaft axially in any way, as this could give rise to an incorrect air gap in the brake.

Action

1.

6.

7.

2.

3.

4.

5.

WARNING!


Unscrew the motor flange, 4 screws <104>.

Unscrew the 3 screws on the top of the motor.<3-5> Remove the cover.

Disconnect connectors in the motor.

Use a portable power supply 24V DC to release the brakes (pin no.11, +24V and pin no.12, 0V) so it is possible to pull out and turn the motor and minimize the risk of damaging the pinion and gear.

Attach a hoist and the lifting device (3HAC 6876-1) to the motor. The weight of the motor is 17 kg.

Pull and turn out the motor. In case of difficulty use two screws in the threaded holes (M10) on the motor flange to push out the motor from its attachment.

Refitting:

6.

7.

8.

1.

2.

3.

4.

5.

Action

Ensure that sealing surfaces are clean and not scratched.

Apply oil to the sealing surfaces to ensure that the O-ring runs smoothly

Release the brakes.

Attach a hoist and the lifting device (3HAC 6876-1) to the motor.

Turn the motor carefully so that the pinion and the gears in the gearbox fits together.

Apply Loctite 243 to the four screws and tighten with a torque of 47 Nm.

Calibrate the robot as described in


.

Refit the connectors and the cover.


Repairs

5.4.2 Changing motor including pinion axes 2 and 3

5.4.2 Changing motor including pinion axes 2 and 3

Refer to mechanical drawing 2:5.

Removal:

WARNING!

Be careful not to tap or hit the shaft axially, nor displace the shaft axially in any way, as this could give rise to an incorrect air gap in the brake.

Secure the axis with mechanical stops, 3HAC 3665-1 (part of 3HAC 4658-1), so that the balancing weight for the axis cannot fall down.

Action

1.

4.

5.

6.

7.

2.

3.

8.

9.

WARNING!


Release the brakes on that axis where the motor change should be done, to ensure that the robot axis is disengaged or in what way the axis is moving.

Then you can lock the axis into place by mounting one or more moveable stops,

3HAC 3665-1 (part of 3HAC 4658-1), to prevent the axis from falling.

Drain the gearbox oil, see

Oil change, axes 2 and 3 on page 79

and unscrew the motor flange, 4 screws <104>.

Unscrew the 3 screws on the top of the motor <3-5>. Remove the cover.

Disconnect connectors from the motor.

Use a portable power supply 24V DC to release the brakes (pin no.11, +24V and pin no.12, 0V) so it is possible to pull and turn the motor out and minimize the risk of damaging the pinion and gear.

Attach a hoist and the lifting device (3HAC 6876-1) to the motor. The weight of the motor is 17 kg.

Pull and turn out the motor, in case of difficulty use two screws in the threaded holes (M10) on the motor flange to push out the motor from its attachment.

Refitting

104

5.

6.

7.

1.

2.

3.

4.

Action


Apply oil to the sealing surfaces to ensure that the O-ring runs smoothly.


Release the brakes and turn the motor carefully so that the pinion and the gears in the gearbox fit together.


Apply Loctite 243 to the four motor screws and tighten with a torque of 47 Nm.

Remove the extra mechanical stops.


Repairs


8.

9.

Action

Fill the gearbox with oil, ABB 1171 2016-604, volume 12 liters. Regarding replacements oils, see the Maintenance Manual IRB 6400.



.


Repairs



Repairs

5.5.1 Motors and Gears Axes 4–6

5.5: Motors and Gears Axes 4–6

5.5.1 Motor axis 4

Refer to

Mechanical drawing 2:10 on page 208

.

WARNING!

Be careful not to tap or hit the end of the shaft (axially), nor displace the shaft axially in any way. This could give rise to an incorrect air gap in the brake.

Removal:

Action

1.

5.

6.

7.

8.

9.

2.

3.

4.

WARNING!


Drain the gearbox by removing oil plugs <48> and <27> as described in


.

Secure axis 4 so it cannot rotate when the motor is removed.

Use a portable power supply 24 VDC to release the brakes (pin no.11, +24V and pin no.12, 0V). Now it is possible to pull and turn the motor out and minimize the risk of damaging the pinion and gear.

Unscrew the four cable inlet cover screws.

Dismount the cover from motor 4.


Pull out the motor and turn it. In case of difficulty, use two screws in the threaded holes (M10) on the motor flange to push out the motor from its attachment.

Disconnect the electrical connectors.

Refitting:

5.

6.

7.

1.

2.

3.

4.

Action



Apply oil to the sealing surfaces to ensure that the O-ring runs smoothly.

Apply Loctite 574 in form of a string to the surface around the locating hole for motor axis 4.


Refit the motor with the motor label facing down.

Use a portable power supply 24 VDC to release the brakes (pin no.11, +24V and pin no.12, 0V). Turn the motor carefully so that the pinion and the gears in the gearbox fit together.


Repairs

5.5.1 Motor axis 4

8.

9.

10.

Action

Apply Loctite 243 to the four M8x25 motor screws and tighten with a torque of 47

Nm.

Fill the gearbox with oil as described in


.




Repairs

5.5.2 Intermediate gear, axis 4

5.5.2 Intermediate gear, axis 4

Refer to


.

Removal:

Action

1.

6.

7.

8.

2.

3.

4.

5.

WARNING!


Drain the gearbox of oil.

Secure axis 4 mechanically.

Remove the cover <28>.

Remove the motor as described in

Motor axis 4 on page 107

.

Unscrew the screws <14>.

Unscrew nuts <18> and remove the wedges <17> and remove screws <14>.

Pull out the intermediate gear unit.

Refitting:

4.

5.

6.

1.

2.

3.

Action

Refit the gear and tighten screws <14> only very slightly by hand.

Refit the motor as described in


.

Adjust the backlash by moving the intermediate wheel to obtain the minimum backlash (0.01-0.03 mm) between the final gear and the motor gear, at three points, by turning axis 4. Ensure that when axis 4 is turned, the gears do not “scrape” together.

Tighten screws <14> with a torque of 70 Nm.

Apply oil to the sliding surface and insert the 3 wedges <17> with 4 tension washers

<43> at each wedge and the nuts <18> on studs <16>. Apply Loctite <39> and tighten with a torque of 8 Nm.

NOTE!

Make sure that the wedges are mounted turned in the right direction, and fit the tension washers with their concave sides facing each other.


Repairs

5.5.2 Intermediate gear, axis 4

Action

7.

8.

9.

NOTE!

Check the backlash.

Refit cover <28> with screw <30>and washer <31> with a new seal <29> and tighten with a torque of 10 Nm.

Refit the motor. Fill oil and calibrate as described in


.


Repairs

5.5.3 Replacing final gear

5.5.3 Replacing final gear

Refer to


.

Removal:

Action

1.

2.

3.

4.

5.

6.

7.

8.

WARNING!


Dismount cabling in the upper arm as in section

Robot harness on page 147

.

Dismount adjustable intermediate gear as in section

Intermediate gear, axis 4 on page 109

.

Mount the special hydraulic tool, 6896 134-AN, to the tubular shaft end.

Remove the cover in the gear <11> and mount nipple, SKF 234 063, with NIKE quick coupling, I-AQU 8.

Mount tool, 6396 134-AT with hydraulic cylinder NIKE I-CH 612, on the gear <11> with three hexagon screws M12x70 10.9.

Connect pump 3HAB 8582-1 to the cylinder and nipple in the gear.

Pump up the pressure, with both taps on the valve open. When the gear moves sufficiently so that the pressure disappears between the gear and the shaft, close one of the taps. Continue pumping in this way until the gear has been removed.

WARNING!

Be careful with the surface at the end of the shaft.

Otherwise there may be oil leakage.

Refitting:

1.

2.

3.

Action

Heat up the gear <11> to 160 o

C using an induction heater or oven.

Mount tool 6896 134-BU on the end of the tube shaft.

4.

5.

6.

7.

NOTE!

The following steps must be carried out in sequence while the gear is still hot.

Refit gear on the tube shaft.

Mount tool, 6896 134-FK.

Mount hydraulic cylinder NIKE I-CH 612 with regulator.

Press the gear on the shaft with a force of 16 000 N, equivalent to 8.7-9.2 MPA, check the pressure gauge (part of pump 3HAB 8582-1).


Repairs

5.5.3 Replacing final gear

8.

9.

10.

11.

12.

Action

Check that the distance ring <12> is pressed in position behind the gear.

The pressure must be retained until the gear has cooled down and shrunk on to the shaft.

Refit intermediate wheel as in section


.

Refit the cabling in the upper arm as in section


.

Calibrate the robot as described in Chapter


.


Repairs

5.5.3 Dismounting tube shaft, upper arm

5.6: Dismounting tube shaft, upper arm

Refer to


.

Removal:

Action

1.

6.

7.

8.

9.

10.

11.

2.

3.

4.

5.

WARNING!


Dismount wrist as in

Wrist on page 117

.

Dismount cabling in upper arm as in section


.

Dismount the motor axis 4 as described in section


.

Dismount the adjustable intermediate gear as in section


.

Dismount final gear as in section

Replacing final gear on page 111

.

Remove the mechanical stop <23> for axis 4.

Rotate axis 4 so that the damper <22> is visible and can be removed.

Remove the stop on shaft <20>.

Press the tube shaft out with tool 3HAB 8079-1.

12.

NOTE!

The extender 3HAB 8008-1, included in 3HAB 8079-1, can also be used to get the tube through the second bearing

Knock the bearing <6> out.

Refitting:

1.

2.

3.

4.

5.

6.

Action

Cover the sliding surfaces, for the seal rings, with some tape.

Apply some grease on the diameters of the tubular shaft where the seals must pass.

“Fix” the NILOS-ring <7> in the upper arm housing with some grease.

Refit the seal <8> on tube shaft.

Refit bearing <6>. Use tool 6896 134-S + 6896 134-S + NIKE 1-CH-612. Alternatively, heat up the bearing to 120°C and Refit on the shaft. Let the bearing cool down before further assembly.

Grease the bearing.


Repairs

5.5.3 Dismounting tube shaft, upper arm

7.

8.

9.

10.

11.

12.

13.

14.

Action

Press the shaft into the housing using the tools 6896 134-FL, 3HAB 1428-1 + NIKE

1-CH-612, 3HAC 1894-1, 3HAC 1893-1.

Refit the distance ring <12> on the tube.

Refit the final gear according to section

Replacing final gear on page 111

.

Refit the motor and intermediate wheel as in


and section


.

Refit the stop <20> on the tube shaft. Lock the screws <21> with Loctite 243 and tighten with a torque of 84 Nm.

Refit the damper <22> and the mechanical stop <23> with seal and tighten screws

<25> with a torque of 22 Nm. Use Loctite 243. Apply some grease on the sliding surfaces.

Refit the cabling as in section


.

Calibrate the robot as described in chapter


.


Repairs

5.6.1 Replacing seals and bearings, upper arm

5.6.1 Replacing seals and bearings, upper arm

Refer to


.

Removal:

Action

1.

2.

3.

4.

5.

WARNING!


Dismount the tube shaft as in section

Dismounting tube shaft, upper arm on page

113

.

Knock bearing <6> off the tube shaft <5>.

Knock bearing <6> out, inside housing <3>.

Knock out the sealing <10>.

Refitting:

1.

2.

3.

4.

Action

Mount a new sealing ring <10>, apply some grease on the diameter inside the upper arm house. Use tool 6896 134-FA.

Refit seal ring <8> on to the tube shaft.

Refit bearing <6> according to section

Dismounting tube shaft, upper arm on page

113

, point 15.

5.

6.

7.

8.

NOTE!

Let the bearing cool down before mounting the shaft.

Apply grease in the bearing.

Refit the tube shaft as described in section

Dismounting tube shaft, upper arm on page 113

, step 11–17.

Install bearing <6> in the housing.Apply grease in the bearing. Use tool 6896 134-

FC + Nike 1-CH-612.

Continue with the tube shaft mounting according to section

Dismounting tube shaft, upper arm on page 113

, step 18–24.


Repairs

5.6.2 Axes 5 and 6

5.6.2 Axes 5 and 6

The wrist includes axes 5 and 6 and forms a complete exchangeable unit, comprising motor units and gears.

See spare parts list for types of wrist that can be supplied and for article numbers.

Some maintenance and repair work can be carried out by your own service personnel:

•

Oil change as described in the


and

Lubricating gearbox, axis 6 on page 82

.

• Change of motor and gear, axis 6.

• Change of motor, axis 5.

• Checking backlash, axes 5 and 6.

• Adjusting backlash in axis 5.

When a complete service of the wrist is required, including mounting/adjusting of gear axis 5, the wrist should be sent to ABB for service.


Repairs

5.6.3 Wrist

5.6.3 Wrist

Removal:

Refer to


.

Action Note/Illustration

1.

2.

3.

WARNING!


Remove the cables to motor axis 6 as described in section.

Attach a hoist to the wrist so that it cannot rotate.

Detailed in

Cabling, axis 6 on page

154

.

4.

5.

6.

Unscrew screws <6>.

Pull out the wrist from the upper arm.

• If an arm extender is mounted, the cables must be dismounted before

pulling out the wrist, see

Arm extender on page 118

.

Remove the cables to motor axis 5.

Figure 42

Detailed in


.

Detailed in

Refitting:

1.

2.

3.

4.

5.


Refit the cables to motor axis 5.

Refit the friction washers <12> between upper arm and wrist.

Lubricate screws <6> with Molycote 1000 and tighten with a torque of 120 Nm.

Refit cable harness to axis 6 as described in section

Cabling, axis 6 on page 154

.



.

Detailed in


.

Detailed in


.


Repairs

5.6.4 Arm extender

5.6.4 Arm extender

Refer to


and


.

Removal

Action

1.

2.

3.

4.

WARNING!


Dismount the wrist as described in section

Wrist on page 117

.

Connect a hoist to the extender <3>.

Unscrew screws <2:8/6> for the extender and remove it.

Refitting

1.

2.

3.

4.

Action

Lift the extender in position.

Mount friction washers <12> between upper arm and extender.

Lubricate the screws <2:8/6> with Molycote 1000 and tighten with a torque of

120 Nm.

Mount the wrist as described in section

Wrist on page 117

.


Repairs

5.6.5 Motor axis 5

5.6.5 Motor axis 5

Refer to


.

Removal

Action

1.

5.

6.

2.

3.

4.

WARNING!


Dismount the wrist as described in section

Wrist on page 117

.

Drain the oil by opening both magnetic plugs.

Remove screws <3>. Press out the motor <2> use two screws in the threaded holes (M8) on the motor flange to push out the motor from its attachment. Keep track of the shims <7> between the motor flange and wrist housing.

Measure the distance between the motor flange and the outer surface of the gear.

Use tool 6896 134-GN. Make a written note of the distance.

WARNING!


7.

8.

WARNING!

Make sure the oil injector is filled with oil.

Press out the gear from the shaft.

NOTE!

This gear is matched with the other parts of the bevel gear <5> for axis 5. If the motor is changed, the gear must be moved over to the new motor axis. If the gear is damaged, the complete bevel gear set unit must be replaced.

Please contact ABB when replacement of the bevel gear set unit is necessary.

Refitting

1.


Action

Check that there is an o-ring on the new motor, (the o-ring should be mounted from the supplier).

119

Repairs

5.6.5 Motor axis 5

2.

3.

4.

5.

Action

Remove the cover on the motor.

Clean the hole where the pinion is to be mounted and the pinion with isopropanol

(Art. No.1177 1012-208).

Apply a thin film of mineral oil (CS 320) to the pinion shaft and the pinion hole.

6.

NOTE!

The oil is applied to make the pinion run smoothly and to achieve an even friction torque when assembling the pinion.

Place the motor and pinion in the press fixture, see

Press fixture. on page 120

.

120

7.

8.

9.

10.

11.

Figure 43 Press fixture.

Press the pinion on to the new motor and check the pressing force according to the table below.

If the pressing force is outside the given range, or if the pinion “jumps” in bit by bit, it must be dismounted, checked, cleaned, and oiled before it is assembled once again.

The new motor with pinion must be measured and modified with the existing shims to the measured value on the old motor. Use tool 6896 134-GN.

Release the brake. Mount the motor. Use a new O-ring <2.3>. Apply Loctite 243 on screws <3> and tighten with a torque of 24 Nm.

Fill the gearbox with oil according to the

Oil levels on page 74

.


Repairs

5.6.6 Motor axes 6

5.6.6 Motor axes 6

Refer to


and


.

NOTE!

It is not necessary to remove the wrist from the upper arm see

Wrist on page 117

.

Removal:

Action

1.

2.

3.

4.

5.

6.

WARNING!


Dismount cabling for axis 6 as described in

Cabling, axis 6 on page 154

.

Drain the oil in axis 5. Open both magnetic plugs.

Unscrew screws <2:11/13>. Dismount shaft <2:11/12> with help of 2 screws (M8 threads in the shaft).

Loosen screw <2:11/31> and remove the cover <2:11/38>.

7.

8.

9.

10.

11.

NOTE!

If the wrist is turned so the cover is on the upper side, it is not necessary to drain all the oil in the wrist before removing the cover.

Remove the cover <2:11/16> by deforming it (a new cover must be fitted).

Loosen screws <2:11/33>.

Free the motor including gear from the shaft <2:11/34> and lift out.

Loosen screws <2:12/4>. Dismount the gear with the help of 2 screws (M8 threads in the motor flange).

Loosen screws <2:12/5>. Dismount the pinion with tool 3HAA 7601-043.

Refitting:

1.

2.

Action

Mount the pinion on a new motor. Use a pin screw, M5x120 with nut, to press the gear in place. If this is difficult, warm the pinion slightly. Tighten screw <2:12/5> with a torque of 6 Nm and apply Loctite 243.


Repairs

5.6.6 Motor axes 6

Action

3.

7.

8.

9.

10.

11.

4.

5.

6.

12.

13.

14.

NOTE!


Mount the gear on the motor, tighten with screws <2:12/4>. Use a new O-ring

<2:12/2>.

Turn the gear so that the screw hole and magnetic oil plug come in the right position.

Lubricate the screws with Molycote 1000 and tighten with a torque of 35 Nm.

Mount the motor unit in the wrist. Fix against item <2:11/34>.

Lubricate the screws <2:11/33> with Molycote 1000 and tighten with a torque of 70/

120 Nm.

Mount shaft <2:11/12> with screws <2:11/13> and Loctite 243, tightening torque 24

Nm.

Mount cover <2:11/16> (new cover) and cover <2:11/38>. Use a new gasket

<2:11/28>. Cross tighten screws <2:11/31> to 10 Nm.

Fill oil in axis 5 as described in

Oil levels on page 74

.

Fill axis 6 with grease as described in

Excess grease on page 83

.



.


Repairs

5.6.7 Checking backlash in axes 5 and 6

5.6.7 Checking backlash in axes 5 and 6

Checking total backlash axis 5

Refer to


.

1.

2.

3.

4.

Action

Mount the tool 3HAB 7449-1 on the

mounting flange, see

Figure 44

.

Search for the largest backlash.

Make sure that the brake is engaged.

Apply the dial indicator against the mounting flange on axis 6, 195 mm from the centre on axis 5, see

Figure 44

.

Note/Illustration

Tool

3HAB 7449-1

700

D=160 h7

195

40 N / 10 N

Axis 5

Wrist centre

5.

6.

7.

8.

9.

10.

Apply the spring balance (0-50 N) 700 mm from the centre on axis 5, see

Figure 44

.

Load the spring balance to 40 N, then decrease to 10 N.

Reset the dial indicator in this position.

Change the direction of pull and load to

40 N, then decrease to 10 N.

Read the value on the dial indicator.

Decrease the measured value by 0.02 mm (to compensate for the measurement force 10 N).

• If the measured backlash value is

≥

0.25 mm, an adjustment of the backlash is recommended.

Figure 44


Repairs

5.6.7 Checking backlash in axes 5 and 6

Checking backlash axis 6

Refer to


.

1.

Action

Mount the tool 6896 134-CF, see

Figure 45

.

Action

190

Axis 6

500

150 N / 30 N

Figure 45

2.

3.

4.

5.

6.

7.

8.

9.

Make sure that the brake is engaged.

Apply the dial indicator against the tool 190 mm from the centre of axis 6, see

Figure 44

.

Apply the spring balance 500 mm from the centre on axis 6, see

Figure 44

.

Load the spring balance to 150 N. then decrease to 30 N.

Reset the dial indicator in this position.

Change the pull angle and load to 150 N, then decrease to 30 N.

Read the value on the dial indicator.

Decrease the measured value by 0.04 mm

(to compensate for the measurement force

10 N). If the measured backlash value is

≤

0.06 mm, it is within the normal tolerances.

NOTE!

The backlash in the gear unit cannot be adjusted. If necessary, the gear unit must be replaced, see section

Motor axes 6 on page 121

.


Repairs

5.6.8 Adjusting backlash in axis 5

5.6.8 Adjusting backlash in axis 5

Refer to


.

1.

A.

B.

Action

Remove the cover <38>. Investigate the cause of the excessive backlash on axis 5. Then take action as described in one of the following alternatives:

The intermediate gear unit <37> is stuck, the backlash between gears

<5> and <34> is excessive. The backlash must be 0 to 0.08 mm, measured at three different points.

• Adjust the backlash as described


The intermediate gear unit <37> has become loose. Check that the gears

<5> and other parts (<18>, <20>, <21>, <22> and <43>) are not damaged or loose.

• Replace damaged parts and adjust the backlash as described in

Adjusting the intermediate gear unit on page 126

.

C.

There is backlash in the bearings of the intermediate gear unit <37>.

• Adjust the bearing as described in section

Adjusting the intermediate gear unit bearings on page 127

• Adjust to the correct backlash as described in section

Adjusting backlash in axis 5 on page 125

.


Repairs

5.6.9 Adjusting the intermediate gear unit

5.6.9 Adjusting the intermediate gear unit

Refer to


.

1.

2.

5.

6.

3.

4.

Action

Remove the wedges <21>. Check that they are not damaged.

Adjust the intermediate gear unit <37> with the centre screw <18>.

• The gear mesh backlash between the pinion <5> and the gearwheel must be 0 - 0.08 mm. Measure the backlash at three different places.

• Use the tool 6896 134-AU and a dial indicator on a magnetic foot.

Tighten the intermediate gear unit <37> using the screw <18>, to a torque of 93 Nm

± 5%.

Apply oil on and mount the wedges <21> and the 4 tension washers <43> (fit them as shown on mechanical drawing 2:11).

Tighten the wedges alternately with the nuts <22>. Torque 12 Nm ± 5%. Apply

Loctite 243 to lock the nuts.

Check the total backlash after tightening as described in section

Checking backlash in axes 5 and 6 on page 123

.


Repairs

5.6.10 Adjusting the intermediate gear unit bearings

5.6.10 Adjusting the intermediate gear unit bearings

Refer to figure below.

The roller bearing (1) must be pre-tensioned to eliminate any backlash.

1.

2.

3.

4.

5.

6.


Remove the stop screw (2) and the locknut (3).

Clean the threads in the hub (4) and the locknut (3).

Apply Loctite 290 on the threads in the hub and the locknut.

Tighten the locknut (3). Torque 85 Nm ±

5% (for a replacement bearing).

Use the tool 3HAB 1022-1 together with the torque-wrench.

Fit the stop screw (2), extra locking. Apply

Loctite 243.

4 1 2

Figure 46 Intermediate wheel unit

3

NOTE!

If the same bearing is fitted again, the torque should be 70-75 Nm.


Repairs

5.6.10 Adjusting the intermediate gear unit bearings


Repairs

5.7.1 Balancing Unit

5.7: Balancing Unit

5.7.1 Dismounting balancing unit

Refer to


(Foundry).

Dismounting:

Action

1.

2.

3.

4.

5.

6.

WARNING!


Place the lower arm in sync position.

Secure the arm system against movement, we recommend use of a movable stop axes. 2/3 (art. no. 3HAC 3665-1) included in Mech. stop ax.2/3 set (art. no. 3HAC

4658-1)

Dismount one of the protection hoods <12>on top of the cylinder and insert an M12 screw and tighten until the spring force is neutralized. The length of the cylinder is now locked.

Prepare the lift, use lifting tool 3HAC 11601-1.

7.

8.

WARNING!

Make sure that the shaft between the upper and lower arms does not rotate when unscrewing the lock nuts. Use key handle 46 mm.

Dismount <7> and <8> and lift away the cylinder.

Dismount the inner races with a puller.

Mounting:

3.

4.

1.

2.

Action

Place rings, support washers, sealing rings on the upper and lower pivot shaft,

(grease the support washer to fix them in place).

Place the inner races of the bearings on the new balancing cylinder use tool 3HAC

5281-1

Mount the auxiliary shafts on the upper and lower shafts. (Upper shaft: auxiliary shaft 3HAC 5275-1, lower shaft: auxiliary shaft 3HAC 5276-1.)

Hang up the new balancing unit on the upper auxiliary shaft, adjust the length between the bearings with the M12 screw (if the distance is to long the bearings will be damage) while pushing the balancing cylinder carefully in place by hand force on to the lower shaft, (do not use a hammer of any type, the bearings may be damaged).


Repairs

5.7.1 Dismounting balancing unit

5.

6.

Action

Dismount the auxiliary shafts, grease the bearings with tool 3HAC 5222-1.

7.

8.

9.

10.

NOTE!

It is of great importance that the bearings are thoroughly lubricated. Lubricate the bearings with ABB art. no. 3HAB 3537-1 (Shell ALVANIA WR2) or equivalent grease

Dismount the tool, and clean the threads on the shaft ends.

Mount the outer support rings, sealing rings <7>, <8> and the lock nut <5>. Use a

KM-10 socket, Loctite 243 and a torque wrench to lock the nuts to a torque of 120

Nm.

Dismount the M12x50 screw <12> on the top of the cylinder, remount the plastic plug. Check that there is a margin between support washers and cylinder ears (min.

0.1 mm).

Move axis 2 in both directions to make sure that everything working accurately.


Repairs

5.7.2 Replacing guide ring, balancing unit

5.7.2 Replacing guide ring, balancing unit

Refer to


.

NOTE!

Use reconditioning kit 3HAC 8982-1

Removal:

Action

1.

2.

3.

4.

WARNING!


Move axis 2 to a position where the balancing unit is in the horizontal position.

Remove the circlip from the end cover of balancing unit.

Remove the worn out guide ring and clean the piston rod.

Refitting:

1.

2.

3.

Action

Place the two halves around the piston rod with the smallest outer diameter facing outwards, locate the new guiding ring in the end cover.

Install the circlip.

Lubricate the piston rod, see

Lubricating piston rod, balancing unit axis 2 on page

78

.


Repairs

5.7.3 Replacing bearings, balancing unit

5.7.3 Replacing bearings, balancing unit

Refer to


.

NOTE!

Use reconditioning kit 3HAC 8983-1 (Foundry).

1.

2.

3.

4.

Action

Dismantle the balancing unit according to section

Dismounting balancing unit on page 129

.

Push out the old bearing, using tool 3HAC 8981-1.

Turn the tool upside down. Place the new bearing on the tool with the bearing number upwards (facing the tool). Push the new bearing down.

Mount the balancing unit according to section

Dismounting balancing unit on page

129

.


Repairs

5.8.1 Arm System

5.8: Arm System

5.8.1 Upper arm

Refer to:


,


,


and


Removal:

WARNING!

Secure axis 3 with mechanical stops, 3HAC 3665-1 (part of 3HAC 4658-1), so that the balancing weight for axis 3 cannot fall down.

Action

1.

2.

3.

4.

WARNING!


Dismount balancing units <2:1/5> as described in


or


.

Remove the cables and air hose inside the upper arm as in

Robot harness on page

147

.

Attach a hoist and the lifting device (3HAC 1817-1) to the upper arm. See

Figure

47

.

5.

6.

7.

8.

Figure 47 Lifting the upper arm.

Remove the parallel arm<2:1/3> see section

Parallel arm on page 139

.

Remove the KM nut <2:2/208> on each shaft.

Remove the stop screws <2:2/201> in the axis 4 housing.

Remove the protective plates <2:3/10> on the inner side of the shaft, unscrew the shafts <2:2/200>. The bearing is pressed out with the shaft.

Lift the upper arm away.

9.

WARNING!

Be careful with the threads on the shafts.


Repairs

5.8.1 Upper arm

Refitting:

8.

9.

10.

11.

12.

13.

14.

4.

5.

6.

7.

1.

2.

3.

NOTE!

Mount the left side first, complete, robot seen from behind!

Action

Move the upper arm to its mounting position.

Mount V-ring <2:2/203> and distance ring <2:2/202> on shaft <2:2/200>.

Clean the cones in the axis 4 housing and on the shaft. Lubricate the M80 thread and the cones with Molycote 1000.

Mount the shaft <2:2/200> in the axis 4 housing. Tighten with a torque of 400 Nm.

Apply Loctite 243 on stop screw <2:2/201> and tighten with 34 Nm.

Mount sealing ring <2:2/204>, turn the largest diameter inwards.

Lubricate the bearings <2:2/205> before installation on the shaft. Use lubricant

3HAB3537-1 (Shell Alvania WR2) <2:2/11>.

Install the bearing with pressing tool 3HAC 5025-1.

Fill with grease <2:2/11> outside bearing

Install the o-ring <2:2/213 + 2:2/11> on sealing ring <2:2/213> and insert in the lower arm.

Install the o-ring <2:2/212 + 2:2/11> on the shaft.

Install the sealing assembly <2:2/207>.

Mount the KM nut <2:2/208>. Apply Loctite 243 and tighten the nut to 90 Nm.

15.

16.

17.

18.

NOTE!

If the pressing tool is not used, tighten to 180 Nm, then loosen the nut again and tighten with a torque of 90 Nm.

Mount the right side according to paragraphs 10-18 (similar to the left side except the distance ring <2:2/202>

Mount the parallel bar.

Mount the cabling as described


.

Mount the balancing units as described in


.


Repairs

5.8.2 Parallel bar with bearings

5.8.2 Parallel bar with bearings

Refer to


.

Removal:

WARNING!

Secure axis 3 with mechanical stops, 3HAC 3665-1 (part of 3HAC 4658-1), so that the balancing weight for axis 3 cannot fall down, and secure the upper arm with a hoist or similar.

Action

1.

2.

3.

4.

5.

6.

WARNING!


Attach a hoist and lifting device to the parallel bar.

Dismount screw and washer <:lt>224, 223<:gt> on the lower bearing of the parallel bar.

Dismount screw and washer <:lt>224, 223<:gt> on the upper bearing of the parallel bar".

Press the shafts out with a hydraulic press and toll 3HAC 5021-1

Lift the bar away.

Refitting:

1.

2.

3.

4.

5.

6.

Action

Lift the parallel bar in position.

Place the axial washer and cover washer on each side of the bearing

Place and centre the parallel bar

Apply a thin coat of grease on the shaft

Press the shaft with a hydraulic press and tool (3HAC 5021-1)

Apply Loctite 243 and mount the screw and washer<224, 223>.

WARNING!

Do not forget to remove the 2 extra mechanical stops!


Repairs

5.8.3 Balancing weight

5.8.3 Balancing weight

Refer to


.

Removal:

Action

1.

2.

3.

4.

WARNING!


Attach a hoist with two lifting eyes to the balancing weight.

Loosen the four M16x120 screws.

Lift the weight away.

Refitting:

1.

Action

Mount in reverse order. Tighten the four M16x120 screws with a torque of 300 Nm.


Repairs

5.8.4 Lower arm

5.8.4 Lower arm

Refer to


.

Removal:

WARNING!

Be careful! Make sure that the upper arm is locked in position and cannot move.

Action

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

WARNING!


Dismount the balancing weight for axis 3. (see

Balancing weight on page 136

).

Attach a hoist to the upper arm.

Remove the locking screw and washer <223, 224> on the parallel arm and the upper arm, press the shafts out with a hydraulic press and tool no.3HAC 5021-1 and lift the parallel bar away.

Remove the harness on the upper and lower arms as described in chapter

Cable

Harness on page 147

.

Dismount the upper arm as described in

Upper arm on page 133

.

Dismount the two balancing units <4> as described in


or


.

Dismount the M16x70 screws between the parallel arm and gearbox axis 3 and between lower arm and gearbox axis 2, (the lower arm must be reorientated to make it possible to dismount all the screws) save at least two parallel placed screws on each side.

Attach a hoist to the lower arm.

11.

12.

13.

14.

15.

WARNING!

Danger! Be sure that the lower arm is properly attached to the hoist before loosening the last screws.

Dismount the last four screws.

Place a crowbar between the gearbox axis 3 and the parallel arm, and press the lower and parallel arms together.

Place a crowbar between gearbox axis 2 and the lower arm, and press to release the guiding.

Lift and remove the lower arm.

Dismount the parallel arm as in

Parallel arm on page 139

.


Repairs

5.8.4 Lower arm

Refitting:

1.

Action

Mounting in reverse order.


Repairs

5.8.5 Parallel arm

5.8.5 Parallel arm

Refer to


.

For complete sets of special tools for service on parallel arm, see chapter

Tool List on page

171

.

Removal:

Action

1.

2.

3.

4.

5.

6.

7.

WARNING!


Remove the lower arm as in

Lower arm on page 137

.

Place the arm on a workbench.

Attach a hoist to the parallel arm.

Place the Cylinder NIKE CHF 612 (1) and tools 3HAC 5526-1 (2) and 3HAC 5523-

1 (3) see

Dismounting Parallel arm and Bearings on page 140

.

Force the parallel arm to the right, seen from the rear.

Lift the parallel arm away.

Refitting:

1.

2.

3.

Action

Place the parallel arm in position.

Press the parallel arm into the lower arm with NIKE CHF 612 (1) and tools 3HAC

5526-1 (2) and 3HAC 5523-1 (3),

Mount the lower arm as described in

Lower arm on page 137

.


Repairs

5.8.5 Parallel arm

Dismount Parallel arm / Lower arm

4

3

1

Dismount inner bearing

2

1

2

3

Dismount outer bearing

2

1

5

Figure 48 Dismounting Parallel arm and Bearings


Repairs

5.8.6 Parallel arm - Inner bearing

5.8.6 Parallel arm - Inner bearing

Removal:

1.

2.

Action

Place the cylinder NIKE CHF 612 (1) and tools 3HAC 5526-1 (2), 3HAC 5523-1 (3)

and 3HAC 5522-1 (4).

Press the bearing off.

Refitting:

1.

Action

Refit in reverse order.

5.8.7 Parallel arm - Outer bearing

Removal:

1.

2.

Action

Place the cylinder NIKE CHF 612 (1) and tools 3HAC 5526-1 (2), 3HAC 5523-1 (3)

and 3HAC 5522-2 (5).

Press the bearing off.

Refitting:

1.

Action



Repairs

5.8.8 Gearbox 1-3 including base

5.8.8 Gearbox 1-3 including base

The gearbox axis 1-3 including base shall be replaced as one unit. The robot arm system unit including counter balancing weight axis 3, balancing units axis 2 and tooling are disassembled from the gearbox unit axis 1–3 and lifted by a special lifting device.

An instruction of the replacement of the gearbox unit axis 1–3 is included in the spare part.

A summary of the repair work is given below. Instruction for replacement of gearbox axis

1-3: 3HAC 12512-1

The arm system is remounted in a new complete gearbox unit axis 1-3. If a complete gearbox unit axes 1–3 cannot be used, the motor axes 1–3, must be transferred to the new gearbox before the arm system can be installed. Mechanical stops axis 1, any position switches on axes

1–3 etc. must be transferred to the new gearbox unit.

Removal

Action

1.

4.

5.

6.

7.

2.

3.

WARNING!


Remove components installed on the gear box like stop pin axis 1, vernier scales, positions switches etc.

Release all bolts except 2 x 4 safety bolts in the fittings between lower arm and parallel arm and the gearbox output shafts axis 2 and 3.

Install the lifting device (3HAC 6878-1) on the upper arm. Refer to

Figure 49

.

Release the balancing units from the shafts on the gear box.

Disconnect the controller and free the harness from the connector plate, at axis 1-

3 motors, SMB unit and brake release unit and lift it out from the axis 1 centre hole.

Remove the remaining 4 + 4 bolts and lift the arm system including the cabling away from the gear unit.

Refitting

142

5.

6.

7.

8.

1.

2.

3.

4.

Action

Lift the new gearbox in position

Transfer the motors to the new gearbox

Lift the arm system in position and install it on axis 2 side with the four safety bolts.

Install it on axis 3 side with four safety bolts.

Mount the robot cabling and connect the controller.

Install the balancing units.

Remove the lifting device from upper arm.

Install the remaining bolts on both sides and perform the torque tightening.


Repairs

5.8.9 Gearbox axis 1-3, seals axis 1

9.

Action

Install the remaining components to the new gear unit.

Figure 49 Lifting position

5.8.9 Gearbox axis 1-3, seals axis 1

Inner and outer seal on axis 1 can be replaced. Contact ABB for information about spare parts,

Instruction and special tools.

The inner seal can be replaced without dismounting the gearbox axis 1-3 from the robot arm system.

Replacement of the outer seal can be made only on a separate gearbox.

Instruction for replacement of seals axis 1 on gearbox axis 1-3: 3HAC 12513-1

5.8.10 Gearbox axis 1-3, seals axis 2/3

Seals on output shafts on axis 2/3 can be replaced. Contact ABB for information about spare parts, Instruction and special tools.

Replacement of the seals can be made only on a separate gearbox.

Instruction for replacement of seals axis 2/3 on gearbox axis 1-3: 3HAC 12513-1


Repairs

5.8.11 Brake release unit

5.8.11 Brake release unit

Refer to


.

Removal:

Action

1.

2.

3.

WARNING!


Remove the push-button unit <6> located in the frame.

Disconnect connectors R3.BU1-6(X8), R3.BU1-3(X9), R3.BU4-6(X10).

Refitting:

1.

Action



Repairs

5.8.12 Replace serial measurement board

5.8.12 Replace serial measurement board

Refer to


.

Removal:

Action

1.

2.

3.

4.

WARNING!


Remove the cover <17> located in the frame.

Disconnect connectors R2.SMB, R2.SMB 1-4, R2.SMB 3-6.

Disconnect connector R2.G (battery connector) from the SMB.

Refitting:

1.

Action



Repairs

5.8.13 Replace stop pin

5.8.13 Replace stop pin

Refer to


.

Removal:

Action

1.

2.

3.

4.

5.

WARNING!


Remove the cover on top of the housing.

Remove the M20x90 bolt <101> and the compression spring <102>.

Lift up the stop pin <8>. Check the washer item 103.

Replace with new if damaged.

Refitting:

1.

2.

3.

4.

Action

Use Loctite 415 (glue). Apply Loctite 638 (glue) on 10 mm of the threaded end.

Lubricate the rest of item 101. Tighten.

Check the function of the stop pin.

Mount the bolt <101> and the compression spring <102>.

Refit the cover on top of the housing.


Repairs

5.9.1 Cable Harness

5.9: Cable Harness

5.9.1 Robot harness

Refers to


,


,


,


and


.

It is recommended that all work on the robot harness is undertaken with axis 1 to 4 at 0º.

WARNING!

Placing more cables/hoses in the harness, without prior consent from ABB Robotics, may compromise lifetime.

Removal

We recommend that a team of at least two people undertake the job of changing a harness.

When the robot is equipped with a welding harness, this must first be removed from the base up to the harness clamp in the frame, to facilitate removal of the robot harness.

Action Action

1.

2.

3.

4.

5.

6.

7.

WARNING!


Remove the 4 screws <2:5/100> in the cover

<2:5/15> that protects the connectors on the base.

Remove the connectors R1.MP and R1.SMB from the attaching plate.

Unscrew the 3 screws on motors 1, 2, and 3 and remove the covers. Remove the connectors from the motors.

Remove the brake release units <2:5/6> and the cover of the Serial measurement board

<2:6/17> and remove the connectors.

Unscrew the 4 screws from the cable gland plate to the serial measurement board and the brake release board on the inside of the frame and pull out the cables.

Remove the cable guide <2:5/42> located between the lower and parallel arms by pressing the split part so it overlaps. Open it up and take out the cables.

robot front


Figure 50 Cable harness guide.

147

Repairs

5.9.1 Robot harness

8.

Action

Remove the hose clamp from the cover <2:5/

10> on the frame.

Action

Avoid folding!

Hose clamp

Figure 51 Cable harness clamp.

9.

10.

11.

12.

13.

14.

15.


10> on the frame.

Pull the harness up through the base from the front side of the robot.

Remove the cover <2:1/7> on the arm housing and unscrew the holders for cable guide <2:1/

251> and cable guide <2:1/252> from the tubular shaft.

Remove the 4 screws on top of motor 4 and remove the connectors. Unscrew the screws for the clamping strap fixture below motor 4

(new clamping strap fixtures are included with the harness).

Remove the cover <2:3/13> on the upper arm tube and remove the connectors to motors 5 and 6.

Remove the harness fixtures underneath the arm housing and on the front side of the upper part of the upper arm.

Pull the harness out of the tubular axle and down through the lower arm.

WARNING!

It should be remembered that connectors and wiring are sensitive parts of a harness and must be treated with care.


Refitting

Repairs

5.9.1 Robot harness

1.

Action

Point 8-7 and 5-1 in reverse. Position harness

according to

Figure 52

. The finished position of the cables on the frame should be according to

Figure 53

.


A

B

Figure 52 Location of harnesses in holder.

Welding harness

Customer harness

Robot harness

2.

3.

WARNING!

Do not twist the cables in the base.

Pull the harness up through the lower arm and pre-fit the attachment plate for the fixture in the arm housing (there is insufficient space to do this when the harness is in position).

Position of SMB gland plate

Cables to motor axis 4-6

C

4.

Figure 53 Position of cables on the frame.

The cables to motor 4 are then pulled through the arm housing and fitted before the cables to motors 5 and 6 are pulled through the arm housing. The harness is twisted ½ turn between the attachments in the under arm and upper arm so that the cables have the same length when they are subjected to bending

(This twist must be retained).

Cable fixture point

5.

Put the cables for motor 5-6 through the upper arm tube.

Figure 54 Position of cables on the frame.


Repairs

5.9.1 Robot harness

6.

Action

Perform step 9-11 in removal in reverse.

Observe the right position of the cables

(printed on cables and guide).


7.

8.

Perform step 6 in removal in reverse.

Position the screws for the hose clamps at the correct places (see

Figure 51

).

Figure 55 Right position of the cable


Repairs

5.9.2 Customer Harness

5.9.2 Customer Harness

Refers to


,


,


,


and


.

It is recommended that all work on the customer harness is undertaken with axis 1 to 4 at 0º.

WARNING!

Placing more cables/hoses in the harness, without prior consent from ABB Robotics, may compromise lifetime.

Removal

We recommend that a team of at least two people undertake the job of changing a harness.

When the robot is equipped with a welding harness, this must first be removed from the base up to the harness clamp in the frame, to facilitate removal of the customer harness (se the section about changing welding harness).

Action Action

1.

2.

3.

4.

5.

WARNING!


Remove the 4 screws <2:5/100> in the cover

<2:5/15> that protects the connectors on the base.

Remove the connectors R1.CP/CS, R1.CAIR and R1.SW2/3 if such is fitted from the attaching plate.

Remove connector R2.SW2/3 from position switches ax 2/3 if such are fitted.

Remove the cable guide <2:5/42> located between the lower and parallel arms by pressing the split part so it overlaps. Open it up and take out the cables.

robot front

Figure 56 Cable harness guide, axes 2, 3.


Repairs


6.

Action


10> on the frame.

Action

Avoid folding!

Hose clamp

Figure 57 Cable harness clamp.

7.

8.

9.

10.

11.

12.

13.

Pull the harness up through the base from the front side of the robot.

Remove the 4 screws on the connection box

(placed on arm housing or on the upper arm tube). Pull out the box, remove air connection nipple R2.CAIR and remove the backside cover (4 screws).

Remove connectors R2.CP, R2.CS and

R2.CBUS (D-SUB connector inside box).

Remove the gland plate from the backside plate.

Remove the cover <2:1/7> on the arm housing and unscrew the holders for cable guide <2:1/

251> and cable guide <2:1/252> from the tubular shaft.

Remove the harness fixtures underneath the arm housing.

Pull the harness out of the tubular axle and down through the lower arm.

WARNING!

It should be remembered that connectors and wiring are sensitive parts of a harness and must be treated with care.

Refitting

1.

Action

Perform step 6-5 and 3-1 in removal in reverse.

Position harness according to

Figure 58

. The finished position of the cables on the frame

should be according to

Figure 59

below.

Action

Connector R2.SW2/3

Note that the cable goes under the other cables

152

Figure 58 Position of the cables on the frame.


Repairs


Action Action

2.

3.

4.

WARNING!

Do not twist the cables in the base.

Pull the harness up through the lower arm and pre-fit the attachment plate for the fixture in the arm housing (there is insufficient space to do this when the harness is in position).

Pull the harness through the arm housing.

Position the various harnesses correctly in the

cover on the base (see

Position of the cables on the frame. on page 152

).

A

B

5.

6.

7.

8.

If the connection box should be fitted to the arm housing, skip this point. Pull the cables through the upper arm tube.

Perform step 9-7 in removal in reverse.



Figure 59 Location of harnesses in holder.

Welding harness

Customer harness

Robot harness

C


Repairs

5.9.3 Cabling, axis 6

5.9.3 Cabling, axis 6

Refer to


.

Removal:

Action

1.

5.

6.

7.

2.

3.

4.

WARNING!


Run axis 5 to +90° position (Tool flange facing down and parallel with floor).

Remove the covers for the cables to axis 6 on the upper arm tube and wrist.

Dismount connectors R2.MP6, R2.FB6 from the robot harness. Loosen the cable bracket and the sealing with screws <9>.

Dismount the cover at the back of the motor.

Dismount connectors R3.MP6, R3.FB6 under the cover at the rear of motor 6.

8.

NOTE!

Be careful not to damage the cables or resolver

Loosen the carrier mounted on the motor with the M4x8 screw in the bottom (not shown in mechanical drawing 2:8).

Refitting

1.

Action

Mount in reverse order. (Keep axis 5 in 90° position.)


Repairs

5.10.1 Options

5.10: Options

5.10.1 Position Switch axis 1

Refers to


.

Removal

Action

1.

2.

3.

4.

5.

6.

WARNING!


Dismount the protective plates.

Dismount the Rail bracket <5> and the 12 screws <8> from the under side of the base.

If the cams run into and overlaps on both rail sections, the cams must be dismounted before the rails.

Dismount the connector from the bracket on the left side of the robot base (seen from behind).

Dismount the two screws and remove the position switch.

Refitting

1.

Action

Mount in reverse order.


Repairs

5.10.2 Signal lamp

5.10.2 Signal lamp

Refer to


,


and


.

Removal

Action

1.

2.

3.

4.

5.

6.

WARNING!


Remove cover on axis 4 <2:1/7>.

Dismount the two screws that attach the signal lamp <2:1/117> to the bracket <2:1/

2>.

Dismount the three screws on the cover on motor axis 4 <2:10/1> and remove the cover.

Dismount the cable gland <2:20/5>.

Disconnect the connectors R2.H1 and R2.H2 <2:20/7>.

Refitting

1.

Action


Figure 60 Location of snap attachments

Refitting

1.

Action



Repairs

5.10.3 Fork lift device

5.10.3 Fork lift device

Refer to


.

Removal

Action

1.

2.

3.

WARNING!


Attach a hoist to the lifting device <100>.

Loosen the M16x60 screws <100.1> and washers <100.2>.

Refitting

1.

Action

Mount in reverse order. Tighten the M16x60 screws with a 300 Nm torque.


Repairs

5.10.3 Fork lift device


Repairs

6.1.1 Introduction

6: Calibration


General

This chapter includes general information about different calibration methods and also details procedures that do not require specific calibration equipment.

When the robot system must be recalibrated, it is done according to documentation enclosed with the calibration tools.

6.1.1 When to calibrate

The system must be calibrated if any of the below occurs.

The resolver values are changed

If resolver values are changed, the robot must be recalibrated using the calibration methods supplied from ABB. Calibrate the robot carefully with standard calibration. The different

methods are briefly described in section

Types of calibration on page 160

, and further detailed in separate Calibration manuals.

If the robot has Absolute Accuracy calibration, it is also recommended but not always needed to be calibrated for new Absolute Accuracy.

The resolver values will change when parts affecting the calibration position are replaced on the robot, e.g. motors, wrist or part of transmission.

Contents of the revolution counter memory are lost

If the contents of the revolution counter memory are lost, the counters must be updated as detailed in section


. This will occur when:

• the battery is discharged

• a resolver error occurs

• the signal between a resolver and measurement board is interrupted

• a robot axis is moved with the control system disconnected

The revolution counters must also be updated after the robot and controller are connected at the first installation.

The robot is rebuilt

If the robot has been rebuilt, e.g. after a crash or when the robot has been changed for other reachability, it needs to be recalibrated for new resolver values.

If the robot has Absolute Accuracy calibration, it needs to be calibrated for new Absolute

Accuracy.


Repairs

6.1.2 Types of calibration

6.1.2 Types of calibration

Overview

This section specifies the different types of calibration and the calibration methods that are supplied from ABB.

Types of calibration

Type of calibration

Description Calibration method

Standard calibration

Absolute Accuracy calibration

(optional)

The calibrated robot is positioned at home position, i.e. the axes positions (angles) are set to 0º.

Standard calibration data is found in the file calib.cfg, supplied with the robot at delivery.

The file identifies the correct resolver/motor position corresponding to the robot home position.

From deliveries together with RobotWare 5.0.5 and higher, the data will instead be found on the SMB (serial measurement board) in the robot, and not in a separate file.

Levelmeter calibration

(alternative method)

Based on standard calibration, and besides positioning the robot at home position, the

Absolute Accuracy calibration also compensates for:

• mechanical tolerances in the robot structure

• deflection due to load.

Absolute Accuracy calibration focuses on positioning accuracy in the Cartesian coordinate system for the robot.

Absolute Accuracy data is found in the file absacc.cfg, supplied with the robot at delivery.

The file replaces the calib.cfg file and identifies motor positions as well as absacc-compensation parameters.

From deliveries together with RobotWare 5.0.6 and higher, the data will instead be found on the SMB (serial measurement board) in the robot, and not in a separate file.

A robot calibrated with AbsAcc has a sticker next to the identification plate of the robot.

To regain 100% Absolute Accuracy performance, the robot must be recalibrated for

Absolute Accuracy!

CalibWare xx0400001197


Repairs

6.1.3 Calibration methods

6.1.3 Calibration methods

Each calibration method is detailed in a separate manual. Below is a brief description of the methods available.

Levelmeter Calibration - alternative method

Levelmeter Calibration is referred to as the alternative method for calibration of ABB robots, because of the less accurate values obtained during calibration. The method uses the same principles as Calibration Pendulum but does not have as good of mechanical tolerances to the toolkit parts as the standard method with Calibration Pendulum.

This method may, after calibration, require modifications in the robot program, and is therefore not recommended.

The calibration equipment for Levelmeter Calibration is ordered as separate parts for each robot and the operating manual for Levelmeter Calibration is enclosed with the Levelmeter

2000.

CalibWare - Absolute Accuracy calibration

In order to achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy is used as a TCP calibration. The tool CalibWare guides through the calibration process and calculates new compensation parameters. This is detailed further in the manual Instructions

for level meter calibration.

If a service operation is done to a robot with Absolute Accuracy, a new absolute accuracy calibration is required in order to establish full performance. For most cases after motor and transmission replacements that do not include taking apart the robot structure, standard calibration is sufficient. Standard calibration also supports wrist exchange.

References

Article numbers for the calibration tools are listed in section

Tools on page 171

.

The article numbers for the operating manuals for calibration are also listed in section

References on page 9

.


Repairs

6.1.3 Calibration scales and correct axis position

6.2: Calibration scales and correct axis position

Introduction

This section specifies the calibration scale positions and/or correct axis position for the

6400RF robot model.

Calibration scales/marks, IRB 6400RF

The illustration below shows the location of the calibration scales on specific plates and the calibration marks directly in the casting at axes 2 and 3.

162 xx0200000176

Pos

A

B

Axis

1

2

Art.no

3HAC4810-4

3HAA1001-73

3HAC4810-6

3HAC4810-1

3HAC4832-1

3HAC4832-2

3HAC4810-3

Description

Sync bracket

Sync plate

Sync plate

Sync bracket

Sync plate with nonie

Sync plate

Sync bracket


Repairs

6.1.3 Calibration scales and correct axis position

Pos

C

D

E

F

Axis

3

4

5

6

Art.no

3HAC4810-3

3HAC4832-1

3HAC4832-3

3HAC4810-2

3HAA1001-76

3HAA1001-79

3HAA1001-77

3HAA1001-79

3HAA1001-78

3HAA1001-174

Description

Sync bracket


Sync plate

Sync bracket

Sync plate


Sync plate


Sync plate


Calibration marks at axes 2 and 3

The calibration marks at axes 2, 3 and 6 shown in the figure above, consist of two single marks that should be positioned opposite to one another when the robot is standing in its calibration position. One of the marks is more narrow than the other and should be positioned within the limits of the wider mark.


Repairs

6.2.1 Calibration movement directions for all axes

6.2.1 Calibration movement directions for all axes

Overview

When calibrating, the axis must consistently be run towards the calibration position in the same direction, in order to avoid position errors caused by backlash in gears etc. Positive directions are shown in the figure below.

This is normally handled by the robot calibration software.

Calibration movement directions, 6 axes

Note! The figure shows an IRB 7600, but the positive direction is the same for all 6-axis robots, except the positive direction of axis 3 for IRB 6400R which is in the opposite direction!

164 xx0200000089


Repairs

6.2.2 Updating revolution counters

6.2.2 Updating revolution counters

General

This section details how to perform a rough calibration of each robot axis, i.e. updating the revolution counter value for each axis, using the pendant.

Step 1 - Manually running the robot to the calibration position

This procedure details the first step when updating the revolution counter; manually running the robot to the calibration position.

WARNING!

Axis 4 has no mechanical limitation! Cabling inside the robot may be damaged if axis 4 is oriented incorrectly when performing calibration of the robot!

Action Note

1. Select axis-by-axis motion mode.

2. Jog the robot to place the calibration marks within the tolerance zone.

Shown in section

Calibration scales and correct axis position on page 162

.

3. When all axes are positioned, store the revolution counter settings.

Detailed in section:

Step 2 - Storing the revolution counter setting with the FlexPendant on page 166

Correct calibration position of axis 4 and 6

When running the robot to calibration position, it is extremely important to make sure that axes 4 and 6 of the below mentioned robots are positioned correctly. The axes can be calibrated at the wrong turn, resulting in wrong calibrated robot.

Make sure the axes are positioned according to the correct calibration values, not only according to the calibration marks. The correct values are found on a label, located either on the lower arm or underneath the flange plate on the base.

At delivery the robot is in the correct position, do NOT rotate axis 4 or 6 at power up before the revolution counters are updated.

If one of the below mentioned axes are rotated one or more turns from its calibration position before updating the revolution counter, the correct calibration position will be lost due to uneven gear ratio. This affects the following robots:

Robot variant

IRB 140

IRB 1600

IRB6400 / 200kg

IRB6400RF / 200kg

IRB6600-175/2.55

IRB6600/6650 / others

IRB6600ID/6650ID

IRB7600

Axis 4

Yes

No

Yes

Yes

Yes

Yes

Yes

Yes

Axis 6

Yes

Yes

No

No

No

Yes

No

Yes

If the calibration marks seem to be wrong (even if the motor calibration data is correct), try


Repairs

6.2.2 Updating revolution counters to rotate the axis one turn, update the revolution counter and check the calibration marks again (try both directions, if needed).

Step 2 - Storing the revolution counter setting with the FlexPendant

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.

2. Tap the mechanical unit in question.

A screen is displayed: tap Rev. Counters.

166 en0400000771

3. Tap Update Revolution Counters....

A dialog box is displayed, warning that updating the revolution counters may change programmed robot positions:

• Tap Yes to update the revolution counters.

• Tap No to cancel updating the revolution counters.

Tapping Yes displays the axis selection window.

4. Select the axis to have its revolution counter updated by:

• Ticking in the box to the left

• Tapping Select all to update all axes.

Then tap Update.


Repairs

6.2.2 Updating revolution counters

Action

5. A dialog box is displayed, warning that the updating operation cannot be undone:

• Tap Update to proceed with updating the revolution counters.

• Tap Cancel to cancel updating the revolution counters.

Tapping Update updates the ticked revolution counters and removes the tick from the list of axes.

6.

CAUTION!

If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury!

Check the calibration position very carefully after each update.

See section

Checking the calibration position on page 168

.


Repairs

6.2.3 Checking the calibration position

6.2.3 Checking the calibration position

General

Check the calibration position before beginning any programming of the robot system. This may be done in one of two ways:

•

Using a MoveAbsJ instruction with argument zero on all axes.

• Using the Jogging window on the teach pendant.

Using a MoveAbsJ instruction on the FlexPendant, IRC5

This section describes how to create a program, which runs all the robot axes to their zero position.

Action Note

1. On ABB menu tap Program Editor.

2. Create a new program.

3. Use MoveAbsJ in the Motion&Proc menu.

4. Create the following program:

MoveAbsJ

[[0,0,0,0,0,0],[9E9,9E9,9E9,9E9,9E9,

9E9]]\NoEOffs, v1000, z50, Tool0

5. Run the program in manual mode.

6. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!

The calibration marks are shown in

section


.

How to update the revolution counters is detailed in section


.

7. Check that the positions of axes 1-2-3 are reached and that the calibration marks on axes 4-

5-6 are aligned correctly.

If they are not, update the revolution counters!

Detailed in section


.

Using the Jogging window on the FlexPendant, IRC5

This section describes how to jog the robot to all axes zero position.

Action

1. Tap Jogging in the ABB menu.

2. Tap Motion mode to choose group of axes to jog.

3. Tap axes 1-3 to jog axes 1, 2 or 3.

4. Manually run the robots axes to a position where the axis position value read on the FlexPendant, is equal to zero.

Note


Repairs


Action

5. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!

6. Check that the positions of axes 1-2-3 are reached and that the calibration marks on axes 4-5-6 are aligned correctly.

If they are not, update the revolution counters!

Note

The calibration marks are shown in section


.

How to update the counters is detailed in section


.

Detailed in section

Updating revolution counters on page

165

.


Repairs



Repairs

Tool List

7: Tools

7.1: Tool List

All sections e.g Motor Axes 1-3 refers to sections in

Repair on page 91

.

The need for special tools has been reduced to a minimum. When tools are needed for dismounting/mounting work, a description is given in the Product Manual, Chapter Repairs.

During the ordinary service training courses arranged by ABB, detailed descriptions of the tools are given together with their use

Motors Axes 1-3

.

Description

Lifting Device Axes 1–3 motor

Mechanical Stop Axes 2-3, 6-p

Motors/Gears Axes 4-6

Art. nr.

3HAC 6876-1

3HAC 4658-1

Remarks

Description Art. nr.

Lifting device, axis 4 motor

Hydraulic Pump, complete

Oil injector, gear axis 5

Nipple, gear axis 5

Nipple, gear axis 5

Pressing tool, final gear

Valve

Hydraulic cylinder

Mounting tool tube shaft

3HAC 9043-1

3HAB 8582-1

6369 901-280

6896134-AA

6896901-282

6896 134-AT/-AN

6369 901-281

6369 901-283

3HAB 1428-1

Holding tool, final gear

Pressing tool, tube shaft

Pressing tool, front bearing, tube shaft

Pressing tool, housing and rear bearing

6896 134-FK

3HAB 8079-1

6896 134-S

6896 134-FL

Pressing tool, seal inside housing 6896 134-FA

Dismounting rear bearing and housing, axis 4 6896 0011-YJ

Puller gear motor axis 6

Measurement tool, wrist


3HAA 7601-043

6896 134-CE

6896 134-CD


Measurement fixture, gear motor shaft axis 5


Tightening tool, wrist

6896 134-CF

6896 134-GN

3HAB 7449-1

3HAB 1022-1

Remarks

226 270

1018219

234063

CHF 612


Repairs

Tool List

Balancing Cylinders

Description



Description

Auxiliary shaft Bearing Race

Auxiliary shaft

Auxiliary shaft

Screw

Lifting Device

Lubricating tool

Press tool

KM 10 Socket

Arm System

Art. nr.

Art. nr.

3HAC 1893-1

3HAC 1894-1

3HAC 5281-1

3HAC 5276-1

3HAC 5275-1

M12x40

3HAC 11601-1

3HAC 5222-1

3HAC 8981-1

6369901-480

Remarks

Remarks


Lifting device Upper Arm

Lifting device Complete Arm system

3HAC 1817-1

3HAC 6878-1

KM 12 Socket 3HAC 5347-1

Mounting tool - Lower Arm/Parallel Arm 3HAC 5216-1

Dismounting tool - Lower Arm/Parallel

Arm

3HAC 5302-1

Mounting/Dismounting tool - Parallel Bar 3HAC 5021-1

Pressing tool 3HAC 5025-1

Remarks

CHF 612 included

CHF 612 included

CHF 612 included

Miscellaneous


Tool for TCP adjustment

Calibration set for Vision

3HAA 0001-UA

3HAA 0001-XR

Bracket

Lifting Tool

Calibration Equipment

3HAC 3083-1

See Chapter 9

On-Board Calibration Equipment See Chapter 10

Remarks

X=-15 mm, Z=-150 mm


Parts List/Spare Parts List

Rebuilding Parts

8: Parts list / Spare part list

8.1: Rebuilding Parts

General

The following chapters (1.1-1.5) describe the main details that differ from the basic version

IRB 6400R / 2.5-150.

Warning!

This list is valid for rebuilding to a standard. Options like Foundry or insulated tool flange are not included.

For the latest update, see the database SEROP/S Rebuilding Parts for IRB 6X00.

IRB 6400R / 2.5-200


.

3

4

2

Item

1

1

Qty

1

1

Article No.

3HAC 6933-1

3HAC 8497-2

3HAC 6668-3

3HAC 6668-4

3HAC 7020-2

Name of Item

Motor Axis 2, with pinion

Motor Axis 4, complete

Wrist Unit

Wrist Unit, insulated

Balancing Weight, 299 kg

IRB 6400R / 2.8-200


.

6

Item

1

2

8

8

1

1

1

Qty

7 1

1

1

1

Article No.

3HAC 6933-1

3HAC 8497-2

3HAC 7134-1

3HAB 7700-69

3HAA 1001-134

9ABA 142-92

3HAA 1001-297

3HAC 6668-3

3HAC 6668-4

3HAC 7021-2

3HAC 7128-1

3HAC 7962-1

3HAC 7964-1

Name of Item

Motor Axis 2, with pinion

Motor Axis 4, complete

Arm Extension

Screw, M12x50

Washer

Pin, 10x30

Friction Washer

Wrist Unit

Wrist Unit, insulated

Balancing weight 436 kg

Cover, 345

Cable Axis 5

Cable Axis 6



Rebuilding Parts

IRB 6400RF (Protection Foundry

)

Item

18

21

22

108

108

207

211

212

213

230

231

233

270

271

272

273

9

14

44

111

5

Qty

2

1

1

1

1

2

2

2

2

4

8

4

1

10

2

1

1

1

2

2

1

Foundry Art. no.

502 25 ml 12691907-1

503 25 ml 12340011-116

504 200 ml 3HAC 8286-1

515 12 9ADA 205-73

3HAC 7816-1

3HAC 7561-1

3HAC 9889-1

3HAC 8014-1

3HAC 8013-1

3HAC 7817-1

3HAA 1001-658

3HAB 3722-29

3HAC 6627-1

3HAC 7343-1

3HAC 7253-1

3HAC 7349-1

3HAC 7074-1

9ADA 629-56

3HAC 8131-1

3HAC 8103-1

3HAC 8414-1

3HAC 7258-1

3HAC 8271-1

9ADA 629-56

3HAC 4267-1

Standard

Art. no.

Name of item

Mechanical drawing

3HAC

8012-1

3HAC

8011-1

3HAA100

1-126

+2216008

5-1

Loctite 577

Loctite 574

1:3–1:5

1:3–1:5

Dinitrol 3624 1:3–1:5

Set screw, cup point 1:3–1:5

Protection cover 40p

Dustcap for receptacles, 12-p

2:1–2:3

2:1–2:3

2:1–2:3 Item 502, 503, 504,

515

Harness assembly

CP/CS a4

2:1–2:3

Harness assembly

CP/CS a3

Sealing assembly

2:1–2:3

2:1–2:3

O-Ring

O-Ring

Sealing ring

Ring

2:1–2:3

2:1–2:3

2:1–2:3

2:1–2:3 3HAC

3484-1

3HAC

3478-1

3HAC

3483-1

Support washer

Lock nut

2:1–2:3

2:1–2:3

3HAC

8009-1

3HAC

4241-1

Protection sheet

Torx pan head roll.

Screw

Protection sheet

Protection box

Harness assembly robot

Connector plate

2:1–2:3

2:1–2:3

2:1–2:3

2:1–2:3

2:5–2:6

2:5-2:6

3HAC

3774-1

Bracket

Torx pan head roll.

Screw

2:5–2:6

2:5–2:6

Upper arm, foundry 2:10



Rebuilding Parts

Item Qty

101 1

101 1

110 2

1

1

1

Foundry Art. no.

3HAC 8349-1

3HAC 8350-1

3HAC 8256-1

3HAC 8184-1

3HAC 9288-1

3HAC 9631-1

Standard

Art. no.

Name of item

Mechanical drawing

Arm extension 345 2:8–2:9 3HAC

3963-1

3HAC

3964-1

Arm extension 550 2:8–2:9

3HAC

4417-1

3HAC

7363-1

3HAC

7068-1

Foundry Logotype 2:4

Control cable power,

7 m

Control cable Can/

CP/CS

Control Profibus/CP/

CS



Rebuilding Parts



8.2.1 Options

8.2: Options

8.2.1 Position Switch Axis 1

Article No.

3HAC 10068-1

3HAC 10069-2

3HAC 10071-2

1

2

3

Name

Mechanical drawing No.

Position switch axis

1, complete/one function

2:17


1, complete/two function

2:17


1, complete/three function

2:17

1. Based on 3HAC 8478-1



Item Qty Article No.

1

4

1

1

4.101

2

4.102

16

4.103

16

5 1

1

-

1

1

5.6

5.8

5.10

1

5.11

2

1

16

5.12

1

5.14

1

5.15

1

5.16

1

3HAC 8015-1

3HAC 8016-1

3HAC 8017-1

3HAC 5414-1

3HAC 9858-7

9ADA 267-5

9ADA 205-45

3HAC 8493-1

3HAC 4766-1

9ADA 618-56

3HAC 5439-1

3HAC 8131-1

9ADA 183-81

3HAC 8103-1

3HAC 9858-1

3HAC 7074-1

Name of Item

Pos SW 1 function

Pos SW 2 functions

Pos SW 3 functions

Cam kit ax1:1

Cam

Hexagon nut

Set screw, cup point

Pos SW ax1 Mtrl. set

Connector bracket R1.SW1

Torx pan head screw

Cable bracket R1.SW1

Protection sheet

Hex socket head cap screw

Protection box

Rail complete axis 1

Protection sheet

Rem

Add-on kit/Spare part



Dimension

M5

M5x6

M6x16

M16x35



8.2.2 Signal Lamp

8.2.2 Signal Lamp

Article No.

3HAC 4804-1

Name

Part List


2:20


3

4

1

2

5

1

1

1

1

1

3HAC 2552-1

3HAC 2987-1

Name of Item

Lamp

Lamp Holder

3HAB 3772-21 O-ring

3HAC 4909-1 Bracket, signal lamp

3HAC 4772-2 Cable gland (tabular dr.)

Dimension

6 1 3HAC 4772-3 Cable gland (tabular dr.)

Pg7 (Pr12,5)

4,0-7,0

Pg9 (Pr15,2)

4,0- 6,0

7

8

9

10

11

13

904 1

2

1

2

2

5217 649-87

5217 649-70

1100 3HAC 3198-1

2 9ADA 629-56

2166 2055-3

1234 0011-116

3HAC 9650-1

Connector

Pin

Cable

Torx pan head roll. screw

Cable straps, outdoors

Flange sealing

Assembly instruction, Signal lamp

0.5-0.75 mm2

3 x AWG20

M6x16

4,8x208



8.2.3 Forklift Set

8.2.3 Forklift Set

Article No.

3HAC 10578-1

1

Name

Forklift set


Item Qty

100 2

100.1

8

100.2

8

Article No.


2:1

Name of Item

3HAC 4364-1 Fork Lift Device

3HAA 1001-186 Washer

3HAB 3409-86 Hex socket head cap screw

Rem


Dimension

M16x60/12.9



8.2.4 Wrist kit 6400R 200kg

8.2.4 Wrist kit 6400R 200kg

Item Qty

7

8

5

6

3

4

1

2

9

10

2

2

4

1

1

1

1

1

2

10

11 1

Article No.

3HAC 10383-1

Name

Wrist kit


2:25

Rem

Add-on kit

Option

Article No.

Name of Item

Dimensio n

Comments

3HAC 8628-1

3HAC 8629-1

3HAC 8630-1

3HAC 8632-1

3HAC 10384-1 Distance screw

3HAB 3772-36 O-ring

3HAC 9313-1

9ADA 183-52

Distance

Hex socket screw.

14,1x1,6

M10x35

9ADA 312-8

9ADA 312-6

2126 0023-2

Cover A

Cover B

Cover C

Plug

Plain washer

Plain washer

Hexagonal nut

10,5x20x2

6,4x12x1,

6

Pr 18,6



8.2.5 Process Media Conduit

8.2.5 Process Media Conduit

Article No.

Name


3HAC 10016-1

1

Process Media Conduit 2:24


Rem


Dimension Item Qty Article No.

15

17

18

19

9

10

11

14

7

8

5

6

3

4

1

2

20

21

22

23

24

25

1

1

2

1

8

1

1

4

1

2

8

4

1

1

1

18

1

2

4

1

5

2

3HAC 6018-1

3HAC 6018-8

3HAC 6018-9

9ADA 629-56

9ADA 312-6

3HAC 6018-13

3HAC 6018-26

3HAC 6018-3

3HAC 6018-11

6355 0004-HF

9ADA 183-35

3HAC 6018-7

9ADA 183-51

3HAB 7116-1

2166 2055-6

3HAC 4731-3

9ADA 56-26

3HAC 6018-14

3HAC 6018-28

9ADA 183-49

3HAC 4127-8

3HAC 4738-1

Name of Item

Lower process media guide

Attachment, p.media guide


Torx pan head roll. screw

Plain washer

Spacer

Upper p.guide w. support

Attachment profile


Hose Clamp 80


Attachment


Loctite 243

Cable straps, outdoors

Welding Bracket Lower Arm



Protection hose


Counters. hex head screw

Welding Cable Clamp

M6x16

6,4x12x1,6

20x12x25

M8x16

T=5

M10x30

7,6x368

M10x45

M10x20

M8x25



8.2.6 Mechanical stop 15 degr. axis 1

8.2.6 Mechanical stop 15 degr. axis 1

Article No.

3HAC 4656-1

Name

Part List


2:1 (item 101)

Rem


Item Qty

4

5

1

3

4

1

2

4

Article No.

Name of Item

3HAC 4089-2

3HAB 3409-86

Stop lug 5deg, casting



3HAC 4660-1 Assembly of mech. stop ax 1

Dimension

M16x60/12.9



8.2.7 Mechanical stop 7,5 degr. axis 1

8.2.7 Mechanical stop 7,5 degr. axis 1

Article No.

3HAC 4657-1

Name

Part List


2:1 (item 101)


3

4

1

2

5

2

2

4

4

1

3HAC 4089-2

3HAC 4090-2

Name of Item

Stop lug 5deg, casting

Stop lug 2.5deg, casting

3HAB 3409-86 Hex socket head cap screw


3HAC 4660-1 Assembly of mech. stop ax 1

Rem


Dimension

M16x60/12.9



8.2.8 Mechanical stop axes 2 and 3

8.2.8 Mechanical stop axes 2 and 3

Article No.

3HAC 4658-1

Name

Part List


Rem

2:3 (item 102,103) Add-on kit/Spare part

Dimension Item Qty Article No.

3

4

1

2

6

6

6

1

3HAC 3665-1

3HAB 3409-69

Name of Item

Stop ax.2/3



3HAC 4659-1 Assembly of mech stop 2/3

M12x50/12.9



8.3.1 Spare Part List robot

8.3: Spare Part List robot

8.3.1 Robot

Drawing number 3HAC 3972-1

Item Number

Actions and

Supplements

Painted

1

Spare P. Number

Parallel Arm +

Bearings

Balancing Unit

3HAC 4058-1

3HAC 3608-1

Balancing Weight

318 kg/299 kg

3HAC 9737-1

Balancing Weight

476 kg/436 kg

3HAC 9749-1

Painted

1

Iron, Painted

Iron, Painted

1

1

3HAC 7169-1

3HAC 9484-1

Foundry

3HAC 7020-2

3HAC 7021-2

1. All painted parts are in orange color. Other colors in stock, available with longer time of delivery.



8.3.2 Axis 1-3 Complete

8.3.2 Axis 1-3 Complete


Item Number Actions and Supplements

Spare P.

Number

Gearbox Axis 1–3 3HAC 9687-1 Painted

1

(Foundry Version)

Seal Kit Axis 1

Seal Kit Axis 2–3

Gearbox axis 1–3 with motors.

Ver.2.5-200, 2.8-

200

Lower Arm

Motor Axis 1 +

Pinion

Motor Axis 2 +

Pinion 200kg

Motor Axis 3 +

Pinion 150–

200kg

Motor axis 1 (3HAC 6930-1)



Painting and protection on request.

3HAC 4344-1 Painted

1

(3HAC 4725-1 /

3 HAC 5127-1)

3HAC 4646-1 Painted

1

(3HAC 8279-1 +

3HAC 4520-1)

3HAC 4648-1 Painted

1

, (3HAC 8280-1 +

3HAC 4520-1)

3HAC 4649-1 Painted

1

(3HAC 8280-1 +

3HAC 4520-1)

Brake release unit

Cover R1

3HAC 4615-1 Push button guard

Brake release card

3HAC 4680-1 Painted

1

3HAC 5500-1 Painted

1

Cover Mechanical Stop

Cover SMB 3HAC 4605-1 Painted

1

, with Sealing

3HAC 7149-1

3HAC 12069-1

3HAC 12069-2

3HAC 7149-4

3HAC 7150-1

3HAC 6930-1

3HAC 6935-1

3HAC 6935-1

3HAC 6499-1

3HAC 4620-1

3HAC 7126-1

3HAC 7165-1

3HAC 7166-1

1. All painted parts are in orange color. Other colors in stock, available with longer time of delivery.



8.3.3 Upper Arm Complete

8.3.3 Upper Arm Complete


Item Number Actions and Supplements

Motor Axis 4 +

Pinion 200 kg

3HAC 4070-1 Painted

1

(3HAC 3606-1+

3HAC 8418-1)

Axis 4 Housing 3HAC 3938-1 Painted

1

Cover Axis 4 3HAC 4807-1 Painted

1

Upper Arm

Arm Extender

345

3HAC3774-1 Painted

1

3HAC 8349-1 Painted

1

Arm Extender

550

3HAC 8350-1 Painted

1

Cover Axis 4

Wrist

3HAA 1001-33 Painted

1

3HAC 3975-1 Painted

1

(3HAC 5127-1),

Motor Axis 6 + Gear Unit 6 +

Motor Axis 5

Wrist 200 kg, insulated

Wrist 200 kg

Foundry

Motor Axis 5

200 kg

Motor Axis 6 +

Gearbox

3HAC 3606-1

3HAC 3974-1

Spare Part No.

3HAC 6937-1

3HAC 7015-1

3HAC 7167-1

3HAC 9160-1

Foundry

3HAC 9161-1

Foundry

3HAC 3610-1 + 3HAC 13998-

1 + 3HAC 3606-1

3HAC 14000-4

3HAC 3610-1 + 3HAC 13997-

1 + 3HAC 3606-1

3HAC 14000-6

3HAC 8606-2

Motor Axis 6 +

Gearbox 200 kg

Motor Axis 6 +

Gearbox 200 kg, insulated

Motor Axis 6

Cover 200 kg

3HAC 3610-1

Painted

1

(3HAC 3610-1 +

3HAC 13997-1)

Painted

1

(3HAC 3610-1 +

3HAC 13998-1)

Painted

3HAB 8402-1 Painted

1

1

3HAC 14003-1

3HAC 14004-1

3HAC 7157-2

3HAC 7017-1



8.3.4 Harness

8.3.4 Harness

Item Number

Harness CP/CS

Axis 3

Harness CP/CS

Axis 4

3HAC 8013-1

3HAC 8014-1

Actions and

Supplements

Foundry

Foundry

Spare P. Number

3HAC 10662-2

3HAC 10663-2



8.3.5 Miscellaneous

8.3.5 Miscellaneous

Item

Cover

Cover

Number

3HAC 4547-1

3HAC 4674-1

Actions and

Supplements

Painted

Painted

1

1

Spare P. Number

3HAC 7129-1

3HAC 7128-1

1.

All painted parts are in orange color. Other colors in stock, available with longer time of delivery.



8.3.5 Miscellaneous


9: Mechanical drawings


Overview

This chapter includes mechanical drawings with illustrations of the robot.

Foldouts

Introduction


9.2: Illustrations

Mechanical drawing 1:1

Foldouts

Illustrations


Foldouts

Illustrations




Foldouts

Illustrations


Foldouts

Illustrations




Foldouts

Illustrations


Foldouts

Illustrations




Foldouts

Illustrations


Foldouts

Illustrations




Foldouts

Illustrations


Foldouts

Illustrations




Foldouts

Illustrations


Foldouts

Illustrations

Mechanical drawing 2:6.1



Foldouts

Illustrations


Foldouts

Illustrations




Foldouts

Illustrations


Foldouts

Illustrations




Foldouts

Illustrations


Foldouts

Illustrations




Foldouts

Illustrations


Foldouts

Illustrations




Foldouts

Illustrations


Foldouts

Illustrations




Foldouts

Illustrations


Foldouts

Illustrations




Foldouts

Illustrations


Foldouts

Illustrations


10: Circuit diagram


Overview

This chapter includes the complete circuit diagram for the robot.

Circuit diagram

Introduction


Circuit diagram

Introduction


10.2: Diagrams

Sheet 101: Contents

Circuit diagram

Diagrams


Sheet 102: Connection Point Location

Circuit diagram

Diagrams


Sheet 103: Legend

Circuit diagram

Diagrams


Sheet 104: Brake Unit / Serial Measurement Board

Circuit diagram

Diagrams


Sheet 105: Axis 1

Circuit diagram

Diagrams


Sheet 106: Axes 2

Circuit diagram

Diagrams


Sheet 107: Axes 3

Circuit diagram

Diagrams


Sheet 108: Axis 4 / Signal lamp

Circuit diagram

Diagrams



Circuit diagram

Diagrams


Sheet 109,1: Axis 5 (Long Cable)

Circuit diagram

Diagrams



Circuit diagram

Diagrams


Circuit diagram

Diagrams

Sheet 111: Customer Power/Signal Connection CANBUS / P-BUS / I-BUS


Sheet 112: Customer Power/Signal Connection Extended

Circuit diagram

Diagrams


Circuit diagram

Diagrams

Sheet 113: Customer Power/Signal Connection or feeding Servo Gun/Fan


Sheet 114: Switches Axis 1

Circuit diagram

Diagrams


Sheet 115: Switches Axis 2

Circuit diagram

Diagrams


Sheet 116: Switches Axis 2/3

Circuit diagram

Diagrams


ABB AB

Robotics Products

S-721 68 VÄSTERÅS

SWEDEN

Telephone: +46 (0) 21 344000

Telefax: +46 (0) 21 132592

IRB 6400RF 200/2.8 | ABB IRB 6400RF 200/2.5, 200/2.8 Articulated robot Product manual

Product manual

Articulated robot

Product manual

1: Safety

2: Installation and commissioning

Crane lift for:

Fork lift for:

3

1

2

- 3x25 mm

ELOCAB weld cable

- 3x35 mm

ELOCAB weld cable

- Parker hoses type 837 BM-8WP

3: Decommissioning

4: Maintenance

2

1

5: Repair

Signal connection

Power connection

If the same bearing is fitted again, the torque should be 70-75 Nm.

6: Calibration

7: Tools

8: Parts list / Spare part list

9: Mechanical drawings

10: Circuit diagram

Key Features

Related manuals

Frequently Answers and Questions

How do I change the oil in the gearbox of axis 1?

What kind of safety devices are available for the IRB 6400RF robot?

What is the recommended maintenance schedule for the IRB 6400RF robot?

What are the safety risks when working with the robot's gearbox oil?

How do I calibrate the IRB 6400RF robot?

Table of contents

IRB 6400RF 200/2.8 | ABB IRB 6400RF 200/2.5, 200/2.8 Articulated robot Product manual

Product manual

Articulated robot

Product manual

1: Safety

2: Installation and commissioning

Crane lift for:

Fork lift for:

3

1

2

- 3x25 mm

ELOCAB weld cable

- 3x35 mm

ELOCAB weld cable

- Parker hoses type 837 BM-8WP

3: Decommissioning

4: Maintenance

2

1

5: Repair

Signal connection

Power connection

If the same bearing is fitted again, the torque should be 70-75 Nm.

6: Calibration

7: Tools

8: Parts list / Spare part list

9: Mechanical drawings

10: Circuit diagram

Key Features

Related manuals

ABB Robotics

IRB 120

ABB

IRB 7600

ABB

IRB 6650

ABB

IRB 660 180/3.15

Flintec

55-01-10 Weigh Module

ABB

IRB1410

ABB

IRB1410

Dodge

Metric ISN Unitized Safety Mount Spherical Roller Bearings 115 to 170 mm

ABB

IRB 4400 - LS

ABB

M2000

ABB

IRB 360/1 - 800

ABB

IRB 140T type C

Frequently Answers and Questions

How do I change the oil in the gearbox of axis 1?

What kind of safety devices are available for the IRB 6400RF robot?

What is the recommended maintenance schedule for the IRB 6400RF robot?

What are the safety risks when working with the robot's gearbox oil?

How do I calibrate the IRB 6400RF robot?

Table of contents