ABB IRB 6640 Product Manual

Product manual

Articulated robot

IRB 6640 - 180/2.55

IRB 6640 - 235/2.55

IRB 6640 - 205/2.75

IRB 6640 - 185/2.8

IRB 6640 - 130/3.2

IRB 6640ID - 200/2.55

IRB 6640ID - 170/2.75

M2004

Product manual

IRB 6640 - 180/2.55

IRB 6640 - 235/2.55

IRB 6640 - 205/2.75

IRB 6640 - 185/2.8

IRB 6640 - 130/3.2

IRB 6640ID - 200/2.55

IRB 6640ID - 170/2.75

M2004

Document ID: 3HAC026876-001

Revision: F

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 2007-2010 ABB All rights reserved.

ABB AB

Robotics Products

SE-721 68 Västerås

Sweden

Table of Contents

Overview of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1 Safety 15

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

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

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

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

1.2.2.1 Safety risks during installation and service work on manipulators. . . . . . . . . . . . . . . . . . 17

1.2.2.2 CAUTION - Hot parts may cause burns! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

1.2.2.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.2.2.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

1.2.2.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

1.2.2.6 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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

1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1.2.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

1.2.3.3 Emergency release of the manipulator’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

1.2.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 28

1.2.3.6 Safe use of the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

1.2.3.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

1.2.3.8 Signal lamp (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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

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

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

1.3.1 Safety signals in the manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

1.3.2 Safety symbols on the manipulator labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1.3.3 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

1.3.4 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

1.3.5 WARNING - The brake release buttons may be jammed after service work . . . . . . . . . . . . . . . . 42

1.3.6 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

1.3.7 WARNING - Safety risks during work with gearbox lubricants (oil or grease) . . . . . . . . . . . . . . 44

2 Installation and commissioning 47

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

2.2 Design 1 and Design 2 of IRB 6640. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

2.3 Robot transportation precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

2.4 Securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

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

2.5.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

2.5.2 Working range and type of motion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

2.5.3 Risk of tipping/stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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

2.6.1 Lifting the robot with fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

2.6.2 Lifting robot with roundslings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

2.6.3 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

2.6.4 Lifting the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

2.6.5 Securing the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

2.6.6 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

2.6.7 Fitting equipment on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

2.6.8 Installation of cooling fan for motors, axes 1 and 2 (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

2.6.9 Installation of Foundry Plus Cable guard (option no. 908-1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

3HAC026876-001 Revision: F 3


2.6.10 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

2.7 Restricting the working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

2.7.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

2.7.3 Mechanically restricting the working range of axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

2.7.4 Mechanically restricting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

2.8 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

2.8.1 Robot cabling and connection points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

2.9 Making robot ready for operation (Foundry Prime). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

2.9.1 Additional installation procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

2.9.2 Commissioning (Foundry Prime). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

2.10 Making robotready for operation, (Cleanroom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

2.10.1 Additional installation procedure, Clean room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

3 Maintenance 113

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

3.2 Maintenance schedule and expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

3.3.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122




3.3.5 Inspection, oil level, gearbox axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130


3.3.7 Inspection, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

3.3.8 Inspection, cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

3.3.9 Inspection of air hoses (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

3.3.10 Inspection of surface treatment (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

3.3.11 Inspection, information labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

3.3.12 Inspection, mechanical stop pin, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

3.3.13 Inspection, additional mechanical stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

3.3.14 Inspection, damper axes 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

3.3.15 Inspection, signal lamp (option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

3.4 Replacement / Changing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

3.4.1 Type of oil in gearboxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

3.4.2 Oil change, gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

3.4.3 Oil change, gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

3.4.4 Oil change, gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171



3.4.7 Oil change, gearbox axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

3.4.8 Replacement of SMB battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

3.5 Lubrication activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

3.5.1 Lubrication of spherical roller bearing, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

3.5.2 Rust preventive measures, sealing axis 4 (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

3.5.3 Rust preventive measures, support bearing in wrist (Foundry Prime). . . . . . . . . . . . . . . . . . . . . 191

3.6 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

3.6.1 Cleaning, robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

4 3HAC026876-001 Revision: F


4 Repair 195

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

4.2.4 Exchange of parts on Clean room robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

4.3 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

4.3.1 Replacement of cable harness, axes 1-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

4.3.2 Replacement of cabling, axis 5 motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

4.3.3 Fitting cable package attachments (Cleanroom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

4.3.4 Replacement of cable harness, Cleanroom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

4.3.5 Replacement of cable harness, axes 1-4 IRB 6640ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

4.3.6 Replacement of cable harness, axes 5-6 - IRB 6640ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245

4.3.7 Replacement of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250

4.4 Upper and lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

4.4.1 Replacement of turning disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260

4.4.2 Replacement of complete wrist unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264

4.4.3 Replacement of complete wrist unit, IRB 6640ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

4.4.4 Replacement of upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

4.4.5 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279

4.5 Frame and base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

4.5.1 Replacement of SMB unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

4.5.2 Replacement of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288

4.5.3 Replacement of spherical roller bearing, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

4.5.4 Replacement of balancing device (design 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 297

4.5.5 Replacement of balancing device (design 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

4.5.6 Unloading the balancing device using distance tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

4.5.7 Restoring the balancing device using distance tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320

4.5.8 Unloading the balancing device using hydraulic press tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

4.5.9 Restoring the balancing device using a hydraulic press tool.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

4.6.1 Replacement of motor, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

4.6.2 Replacement of motor axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332



4.6.5 Replacement of motor, axis 5 IRB 6640 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

4.6.6 Replacement of motor, axis 5, IRB 6640ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351

4.6.7 Replacement of motor, axis 6, IRB 6640 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354

4.6.8 Replacement of motor, axis 6, IRB 6640ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

4.7.1 Replacement gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

4.7.2 Replacement gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368

4.7.3 Replacement of gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376

4.7.4 Replacement of gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382

5 Calibration information 387

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387

5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388

5.3 Calibration scale and correct axis position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

5.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391

5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392

5.6 Checking the calibration position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395



6 Decommissioning 397

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397

6.2 Environmental information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398

6.3 Decommissioning of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399

7 Reference information 401

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401

7.2 Applicable safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402

7.3 Unit conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

7.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405

7.5 Weight specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408

7.6 Standard toolkit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409

7.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410

7.8 Dismounting and mounting tool 3HAC028920-001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413

7.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428

8 Spare parts 429

8.1 Spare parts and exploded views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429

9 Circuit diagrams 431

9.1 About circuit diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431

Index 433


Overview of this manual

Overview of this manual

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

Contents

Safety information that must be read through before performing any installation or service work on the robot. Contains general safety aspects as well as more specific information on how to avoid personal injuries and damage to the product.

Required information about lifting and installation of the robot.

Installation and commissioning

Maintenance

Repair

Calibration information

Decommissioning

Step-by-step procedures that describe how to perform maintenance of the robot. Based on a maintenance schedule that may be used to plan periodical maintenance.

Step-by-step procedures that describe how to perform repair activities of the robot. Based on available spare parts.

Procedures that do not require specific calibration equipment.

General information about calibration.

Environmental information about the robot and its components.

3HAC026876-001 Revision: F

Continues on next page

7


Continued

Chapter

Reference information

Spare part / part list

Exploded views

Circuit diagram

Contents

Useful information when performing installation, maintenance or repair work. Includes lists of necessary tools, additional documents, safety standards etc.

Complete spare part list and complete list of robot components, shown in exploded views.

Detailed illustrations of the robot with reference numbers to the part list.

Reference to the circuit diagram for the robot..

References

Reference Document ID

Product specification - IRB 6640

Circuit diagram IRB 6640

Product manual - DressPack/SpotPack IRB 6640

Product manual - IRC5

Operating manual - IRC5 with FlexPendant

Operating manual - Calibration Pendulum

Operating manual - Service Information System

3HAC028284-001

3HAC025744-001

3HAC028638-001

3HAC021313-001

3HAC16590-1

3HAC16578-1

3HAC025709-001

Application manual - Additional axes and stand alone controller 3HAC021395-001

Technical reference manual - System parameters 3HAC17076-1

Application manual - Electronic Position Switches

Application manual - CalibWare Field 5.0

3HAC027709-001

3HAC030421-001

Other references

8

The following documents are referenced in some descriptions regarding robots with the option Foundry Prime.

Reference Document ID

Replacement gearbox axis 1 on IRB 6640 - Option Foundry

Prime


Prime


Prime


Prime

3HAC037959-001

3HAC037959-002

3HAC037959-003

3HAC037959-004

Replacement of cable harness, axis 1-6 - Option Foundry

Prime

3HAC037959-005

Replacement of balancing device (design 1) - Option Foundry

Prime

3HAC037959-006

Replacement of balancing device (design 2) - Option Foundry

Prime

3HAC037959-007

Replacement of motor, axis 1 - Option Foundry Prime 3HAC037959-008

Replacement of motor, axis 2 - Option Foundry Prime


3HAC037959-009

3HAC037959-010




Continued

Reference




Replacement of SMB unit - Option Foundry Prime

Document ID

3HAC037959-011

3HAC037959-012

3HAC037959-013

3HAC037959-014

Revisions

Revision Description

-

A

B

C

D

E

First edition

Product name Sikaflex 252FC is changed to Sikaflex 521FC. New article number is 3HAC026759-001.

Cleanroom variant added throughout the manual.

Changes made in:

• Prerequisites in section Overview

• Oil change in section Maintenance

Content updated in section:

• 2.9 Making robot ready for operation, Cleanroom / 2.9.1 Additional installation procedure

Changes made in:

• Section Maintenance, Repair and Spare part list regarding new lower arm and new balancing device called (design 2).

Changes made in:

• New Spare part list

• Section Repair regarding balancing device

• New section regarding tool 3HAC028920-001

• Section Maintenance schedule in chapter Maintenance: Intervals for inspection activities and oilchanges has been revised.

• Section Maintenance schedule in chapter Maintenance: Overhaul of robot is new.

• Section Maintenance schedule in chapter Maintenance: The information about Service Information System (SIS) has been updated.

• Section Maintenance schedule in chapter Maintenance: Interval for replacement of battery pack changed.

• Section Expected component life in chapter Maintenance: The lifetime of certain parts have been revised.

• Section Cleaning of robot updated

• Section What is an emergency stop? added to chapter Safety.

This revision includes the following additions:

• New WARNING! added in Safety chapter section Work inside the

robot´s working range.

• New WARNING! added in Safety chapter section WARNING! - Safety

risks during work with gearbox oil.

• The text in the introductions to chapters Installation, Maintenance and

Repair has been updated concerning the robot being connected to earth when power connected.

• Section Expected component life in chapter Maintenance: The lifetime of certain parts has been updated.

• Section Type of oil in chapter Maintenance has been updated.

• Section Foundry Plus,Cable guard added to chapter Installation.



9


Continued

Revision Description

F This revision includes the following additions:

• Instructions about Foundry Prime has been updated throughout the manual. The updates in the Repair chapter is presented as separate documents on the documentation DVD and ABB Library. Article numbers can be found in the beginning of the sections in question.

•

Sealing compound updated in Exchange of parts on Clean room robots on page 201

.

• Lifting tools not applicable to IRB 6640, removed from the manual.

•

Weight updated for version IRB 6640ID-200/2.55 in section Pre-installation procedure on page 58

.

• Working area updated for variants IRB 6640-2.55 and 6640ID-2.55 in

section Working range and type of motion on page 60

.

• Lifting equipment and tools for the robot throughout the manual, updated.

• Section Fitting cable package attachments (Cleanroom) moved from

Installation chapter to Repair chapter.

• Wrist type 1 added throughout the manual where it has been missing.

Updates in section

Maintenance schedule on page 115

:

• Interval updated for inspection of balancing device (Foundry Prime).

• Interval updated for lubrication of balancing device bearing (Foundry

Prime).

• Rust preveting activity for axis 1 sealing (Foundry Prime) removed.

• Inspection of surface treatment added (Foundry Prime).

Updates in the chapter Safety:

• Updated safety signal graphics for the levels Danger and Warning, see

Safety signals in the manual on page 34

.

•

New safety labels on the manipulators, see Safety symbols on the manipulator labels on page 36 .

• Revised terminology: robot replaced with manipulator.


Product documentation, M2004

Product documentation, M2004

Categories for manipulator documentation

The manipulator documentation is divided into a number of categories. This listing is based on the type of information in the documents, regardless of whether the products are standard or optional.

All documents listed can be ordered from ABB on a DVD. The documents listed are valid for

M2004 manipulator systems.

Product manuals

All hardware, manipulators and controllers will be delivered with a Product manual that contains:

• Safety information.

• Installation and commissioning (descriptions of mechanical installation, electrical connections).

• 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).

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

• Parts list.

• Foldouts or exploded views.

• Circuit diagrams (or references to circuit diagrams).

Technical reference manuals

The technical reference manuals describe the manipulator software in general and contain relevant reference information.

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

• RAPID Instructions, Functions and Data types: Description and syntax for all

RAPID instructions, functions, and data types.

• RAPID Kernel: A formal description of the RAPID programming language.

• System parameters: Description of system parameters and configuration workflows.

Application manuals

Specific applications (for example 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 (for example cables, I/O boards, RAPID instructions, system parameters, CD with PC software).

• How to use the application.

• Examples of how to use the application.



11

Product documentation, M2004

Continued

Operating manuals

The operating manuals describe hands-on handling of the products. The manuals are aimed at those having first-hand operational contact with the product, that is production cell operators, programmers, and trouble shooters.

The group of manuals includes:

• Emergency safety information

• General safety information

• Getting started, IRC5 and RobotStudio

• IRC5 with FlexPendant

• RobotStudio

• Introduction to RAPID

• Trouble shooting, for the controller and manipulator.


How to read the product manual

How to read the product manual

Reading the procedures

The procedures contain references to figures, tools, material, etc. The references are read as described below.

References to figures

The procedures often include references to components or attachment points located on the manipulator/controller. The components or attachment points are marked with italic text in the procedures and completed with a reference to the figure where the current component or attachment point is shown.

The denomination in the procedure for the component or attachment point corresponds to the denomination in the referenced figure.

The table below shows an example of a reference to a figure from a step in a procedure.

Action

8.

Remove the rear attachment screws, gearbox.

Note/Illustration

Shown in the figure Location of gearbox on page xx .

References to required equipment

The procedures often include references to equipment (spare parts, tools, etc.) required for the different actions in the procedure. The equipment is marked with italic text in the procedures and completed with a reference to the section where the equipment is listed with further information, that is article number and dimensions.

The designation in the procedure for the component or attachment point corresponds to the designation in the referenced list.

The table below shows an example of a reference to a list of required equipment from a step in a procedure.

Action

3.

Fit a new sealing, axis 2 to the gearbox.


Art. no. is specified in Required equipment on page xx .

Safety information

The manual includes a separate safety chapter that must be read through before proceeding with any service or installation procedures. All procedures also include specific safety information when dangerous steps are to be performed.

Read more in the chapter Safety on page 15

.


How to read the product manual


1 Safety

1.1. Introduction to safety information

1 Safety

1.1. Introduction to safety information

Overview

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

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

General safety information on page 16 .

• Specific safety information, pointed out in the procedures. How to avoid and eliminate the danger is either described directly in the procedure, or in specific instructions in the section

Safety related instructions on page 34 .


1 Safety

1.2.1. Safety in the manipulator system

1.2 General safety information

1.2.1. Safety in the manipulator 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 that 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 manipulator is installed.

The users of ABB industrial manipulators 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 manipulator system are designed and installed correctly. Personnel working with manipulators must be familiar with the operation and handling of the industrial manipulator as described in the applicable documents, for example:

• Operating manual - IRC5 with FlexPendant

• Product manual

Connection of external safety devices

Apart from the built-in safety functions, the manipulator is also supplied with an interface for the connection of external safety devices. Via this interface, an external safety function can interact 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 manipulator.

Limitation of liability

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

Related information

Type of information Detailed in document

Installation of safety devices

Changing operating modes

Restricting the working space

Section

Product manual for the manipulator

Operating manual - IRC5 with

FlexPendant

Product manual for the manipulator


Operating modes



1 Safety

1.2.2.1. Safety risks during installation and service work on manipulators

1.2.2. Safety risks

1.2.2.1. Safety risks during installation and service work on manipulators

Overview

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

General risks during installation and service

• The instructions in the Product manual in the chapter Installation and commissioning must always be followed.

• Emergency stop buttons must be positioned in easily accessible places so that the manipulator 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 manipulator must have the appropriate training for the equipment in question and in any safety matters associated with it.

Nation/region specific regulations

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

Non-voltage related risks

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

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

• The axes are affected by the force of gravity when the brakes are released. In addition to the risk of being hit by moving manipulator parts, there is a risk of being crushed by the parallel arm (if there is one).

• Energy stored in the manipulator for the purpose of counterbalancing certain axes may be released if the manipulator, 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 manipulator as a ladder, that is, do not climb on the manipulator motors or other parts 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 manipulator.

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.



1 Safety

1.2.2.1. Safety risks during installation and service work on manipulators

Continued

Complete manipulator

Safety risk

Hot components!

Description

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!

Balancing device

Removed parts may result in collapse of manipulator!

CAUTION!

Motors and gears are HOT after running the manipulator!

Touching motors and gears may result in burns!

With a higher environment temperature, more surfaces on the manipulator will get HOT and may also result in burns.

WARNING!

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

2.

Safety risk

Dangerous balancing device!

Description

WARNING!

Do not under any circumstances, deal with the balancing device in any other way than that detailed in the product documentation! For example, attempting to open the balancing device is potentially lethal!


1 Safety

1.2.2.2. CAUTION - Hot parts may cause burns!

1.2.2.2. CAUTION - Hot parts may cause burns!

Description

During normal operation, many manipulator parts become hot, especially the drive motors and gears. Sometimes areas around these parts also become hot. Touching these may cause burns of various severity.

Because of a higher environment temperature, more surfaces on the manipulator get hot and may result in burns.

Elimination

The instructions below detail how to avoid the dangers specified above:

Action

1. Always use your hand, at some distance, to feel if heat is radiating from the potentially hot component before actually touching it.

2. Wait until the potentially hot component has cooled if it is to be removed or handled in any other way.

Info


1 Safety

1.2.2.3. Safety risks related to tools/workpieces

1.2.2.3. Safety risks related to tools/workpieces

Safe handling

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

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

Safe design

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

CAUTION!

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


1 Safety

1.2.2.4. Safety risks related to pneumatic/hydraulic systems

1.2.2.4. Safety risks related to pneumatic/hydraulic systems

General

Special safety regulations apply to pneumatic and hydraulic systems.

Residual energy

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

• 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

1.2.2.5. Safety risks during operational disturbances

1.2.2.5. Safety risks during operational disturbances

General

• The industrial manipulator is a flexible tool that can be used in many different industrial applications.

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

• 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

1.2.2.6. Risks associated with live electric parts

1.2.2.6. Risks associated with live electric parts

Voltage related risks, general

• Although troubleshooting may, on occasion, need to be carried out while the power supply is turned on, the robot must be turned off (by setting the mains switch to OFF) when repairing faults, disconnecting electric leads and disconnecting or connecting units.

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

Voltage related risks, IRC5 controller

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

• Be aware of stored electrical energy (DC link, Ultracapacitor bank unit) in the controller.

• Units such as 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 additional tools, or special power supply units for the machining process.

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

• Additional connections.

Voltage related risks, manipulator

A danger of high voltage is associated with the manipulator 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 the 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

1.2.3.1. Safety fence dimensions

1.2.3. Safety actions

1.2.3.1. Safety fence dimensions

General

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

Dimensioning

Dimension the fence or enclosure to enable it to withstand the force created if the load being handled by the manipulator is dropped or released at maximum speed. Determine the maximum speed from the maximum velocities of the manipulator axes and from the position at which the manipulator is working in the work cell (see the section Robot motion in the

Product specification).

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


1 Safety

1.2.3.2. Fire extinguishing

1.2.3.2. Fire extinguishing

NOTE!

Use a CARBON DIOXIDE (CO

2

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


1 Safety

1.2.3.3. Emergency release of the manipulator’s arm

1.2.3.3. Emergency release of the manipulator’s arm

Description

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

How to release the brakes is detailed in the section:

•

Manually releasing the brakes on page 71 .

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

Increased injury

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


1 Safety

1.2.3.4. Brake testing

1.2.3.4. Brake testing

When to test

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

How to test

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

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

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

3. Check that the axis maintains its position.

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


1 Safety

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

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

NOTE!

Do not change Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC. This will affect the safety function "Reduced speed 250 mm/s".


1 Safety

1.2.3.6. Safe use of the FlexPendant

1.2.3.6. Safe use of the FlexPendant

NOTE!

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

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

• The enabling device must never be rendered inoperational in any way.

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

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

Enabling device

The enabling device is a manually operated, constant pressure push-button which, when continuously activated in one position only, allows potentially hazardous functions but does not initiate them. In any other position, hazardous functions are stopped safely.

The enabling device is of a specific type where you must press the push-button only half-way to activate it. In the fully in and fully out positions, manipulator operation is impossible.

Hold-to-run function

The hold-to-run function allows movement when a button connected to the function is actuated manually and immediately stops any movement when released. The hold-to-run function can only be used in manual mode.

How to operate the hold-to-run function is described in Operating manual - IRC5 with

FlexPendant.


1 Safety

1.2.3.7. Work inside the manipulator's working range

1.2.3.7. Work inside the manipulator's working range

WARNING!

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

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

• The manipulator’s speed is limited to max. 250 mm/s when the operating mode selector is in the 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 manipulator! Keep a distance to the axes in order not to get entangled with hair or clothing. Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell.

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

Brake testing on page 27

.

WARNING!

NEVER, under any circumstances, stay beneath any of the manipulator’s axes! There is always a risk that the manipulator will move unexpectedly when manipulator axes are moved using the enabling device or during other work inside the manipulator’s working range.


1 Safety

1.2.3.8. Signal lamp (optional)

1.2.3.8. Signal lamp (optional)

Description

A signal lamp with a yellow fixed light can be mounted on the manipulator, as a safety device.

Function

The lamp is active in MOTORS ON mode.

Further information

Further information about the MOTORS ON/MOTORS OFF mode may be found in the product manual for the controller.


1 Safety

1.2.4.1. What is an emergency stop?

1.2.4. Safety stops

1.2.4.1. What is an emergency stop?

Definition of emergency stop

An emergency stop is a state that overrides any other manipulator control, disconnects drive power from the manipulator motors, stops all moving parts and disconnects power from any potentially dangerous functions controlled by the manipulator system.

An emergency stop state means that all power is disconnected from the manipulator except for the manual brake release circuits. You must perform a recovery procedure, i.e, resetting the emergency stop button and pressing the Motors On button, in order to return to normal operation.

The manipulator system can be configured so that the emergency stop results in either:

• An uncontrolled stop, immediately stopping the manipulator actions by disconnecting power from the motors.

• A controlled stop, stopping the manipulator actions with power available to the motors so that the manipulator path can be maintained. When completed, power is disconnected.

The default setting is uncontrolled stop. However, controlled stops are preferred since they minimize extra, unnecessary wear on the manipulator and the actions needed to return the manipulator system back to production. Please consult your plant or cell documentation to see how your manipulator system is configured.

NOTE!

The emergency stop function may only be used for the purpose and under the conditions for which it is intended.

NOTE!

The emergency stop function is intended for immediately stopping equipment in the event of an emergency.

NOTE!

Emergency stop should not be used for normal program stops as this causes extra, unnecessary wear on the manipulator. For how to perform normal program stops, see the section Stopping programs inOperating manual - IRC5 with FlexPendant.

Classification of stops

The safety standards that regulate automation and manipulator equipment define categories in which each type of stop applies:

If the stop is...

... then it is classified as...

uncontrolled controlled category 0 (zero) category 1

32



1 Safety

1.2.4.1. What is an emergency stop?

Continued

Emergency stop devices

In a manipulator system there are several emergency stop devices that can be operated in order to achieve an emergency stop. There are emergency stop buttons available on the

FlexPendant and on the controller cabinet (on the Control Module on a Dual Cabinet

Controller). There can also be other types of emergency stops on your manipulator. Consult your plant or cell documentation to see how your manipulator system is configured.


1 Safety

1.3.1. Safety signals in the manual

1.3 Safety related instructions

1.3.1. Safety signals in the manual

Introduction to safety signals

This section specifies all dangers that can arise when doing the work described in this manual.

Each danger consists of:

• 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 on how to eliminate the danger to simplify doing the work.

Danger levels

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

Symbol danger warning

Designation

DANGER

WARNING

ELECTRICAL

SHOCK

Significance

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.

Warns for 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.

34



Symbol

1 Safety

1.3.1. Safety signals in the manual

Continued

Designation Significance

ELECTROSTATIC

DISCHARGE (ESD)

Warns for electrostatic hazards which could result in severe damage to the product.

Electrostatic discharge

(ESD)

NOTE Describes important facts and conditions.

Note

TIP Describes where to find additional information or how to do an operation in an easier way.

Tip


1 Safety

1.3.2. Safety symbols on the manipulator labels

1.3.2. Safety symbols on the manipulator labels

Introduction to labels

This section describes safety symbols used on labels (stickers) on the manipulator.

Symbol are used in combinations on the labels, describing each specific warning. The descriptions in this section are generic, the labels can contain additional information such as values.

Types of labels

Both the manipulator 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 manipulator system, for example during installation, service, or operation.

The safety labels are language independent, they only use graphics. See Symbols on safety labels on page 36 .

The information labels can contain information in text (English, German, and French).

Symbols on safety labels

Symbol Description

Warning!

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

xx0900000812 xx0900000811

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.

Prohibition

Used in combinations with other symbols. xx0900000839

36



Symbol xx0900000813

1 Safety


Continued

Description

Product manual

Read the product manual for details.

Before dismantling see product manual xx0900000816

Do not dismantle

Dismantling this part can cause injury.

xx0900000815 xx0900000814 xx0900000808 xx0900000810

Extended rotation

This axis has extended rotation (working area) compared to standard.

Brake release

Pressing this button will release the brakes. This means that the manipulator arm can fall down.

Tip risk when loosening bolts

The manipulator can tip over if the bolts are not securely fastened.

Crush

Risk for crush injuries.

xx0900000817



37

1 Safety


Continued

Symbol Description

Heat

Risk of heat that can cause burns.

xx0900000818

Moving robot

The robot can move unexpectedly. xx0900000819

Brake release buttons xx0900000820

Lifting bolt

38 xx0900000821

Lifting of robot xx0900000822 xx0900000823

Oil

Can be used in combination with prohibition if oil is not allowed.



Symbol

1 Safety


Continued

Description

Mechanical stop xx0900000824 xx0900000825

Stored energy

Warns that this part contains stored energy.

Used in combination with Do not dismantle symbol.

Pressure

Warns that this part is pressurized. Usually contains additional text with the pressure level.

xx0900000826

Shut off with handle

Use the power switch on the controller.

xx0900000827


1 Safety

1.3.3. DANGER - Moving manipulators are potentially lethal!

1.3.3. DANGER - Moving manipulators are potentially lethal!

Description

Any moving manipulator is a potentially lethal machine.

When running, the manipulator may perform unexpected and sometimes irrational movements. Moreover, all movements are performed with great force and may seriously injure any personnel and/or damage any piece of equipment located within the working range of the manipulator.

Elimination

Action Note

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

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

2. Usually the hold-to-run function is active only in manual full speed mode. To increase safety it is also possible to activate hold-to-run for manual reduced speed with a system parameter.

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

How to use the hold-to-run function is described in section How to use the hold-

to-run function in the Operating manual -

IRC5 with FlexPendant.

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


1 Safety

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

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

Description

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

Elimination

Follow the procedure below when performing the first test run after a service activity, such as repair, installation, or maintenance.

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, that is out of its reach behind safety fences, etc!

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

Collision risks

CAUTION!

When programming the movements of the manipulator always check potential collision risks before the first test run!


1 Safety

1.3.5. WARNING - The brake release buttons may be jammed after service work

1.3.5. WARNING - The brake release buttons may be jammed after service work

Description

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

DANGER!

If the power is turned on while a brake release button is jammed in depressed position, the affected motor brake is released! This may cause serious personal injuries and damage to the manipulator.

Elimination

To eliminate the danger after service work has been performed inside the SMB recess, follow the procedure below.

Action

1. Make sure the power is turned off.

2. Remove the push-button guard, if necessary.

3. Check the push-buttons of the brake release unit by pressing them down, one by one.

Make sure none of the buttons are jammed in the tube.

4. If a button gets jammed in the depressed position, the alignment of the brake release unit must be adjusted so that the buttons can move freely in their tubes!


1 Safety

1.3.6. WARNING - The unit is sensitive to ESD!

1.3.6. WARNING - The unit is sensitive to ESD!

Description

ESD (electrostatic discharge) is the transfer of electrical static charge between two bodies at different potentials, either through direct contact or through an induced electrical field. When handling parts or their containers, personnel not grounded may potentially transfer high static charges. 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.

Location of wrist strap button

The location of the wrist strap button is shown in the following illustration.

IRC5

The wrist strap button is located in the top right corner.

xx0500002171

A Wrist strap button


1 Safety

1.3.7. WARNING - Safety risks during work with gearbox lubricants (oil or grease)

1.3.7. WARNING - Safety risks during work with gearbox lubricants (oil or grease)

Description

When handling the gearbox lubricants, there is a risk of both personal injury and product damage occurring! The following safety information must be regarded before performing any work with lubricants in the gearboxes!

Warnings and elimination

Warning Description Elimination/Action

Changing and draining gearbox oil or grease may require handling hot lubricant heated up to 90 °C!

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

-

Hot oil or grease!

When working with gearbox lubricant there is a risk of an allergic reaction!

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

.

Allergic reaction

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

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

-

Possible pressure build-up in gearbox!

-

Do not overfill!

-

Do not mix types of oil!

Overfilling of gearbox lubricant can lead to internal overpressure inside the gearbox which in turn may:

• damage seals and gaskets

• completely press out seals and gaskets

• prevent the robot from moving freely.

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

After filling, check the correct level.

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

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

Always use the type of oil specified by the manufacturer!

Warm oil drains quicker than cold oil.

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

-

Heat up the oil!

44



1 Safety


Continued

Warning

-

Specified amount depends on drained volume!

Description Elimination/Action

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

After refilling, check the lubricant level.


1 Safety



2 Installation and commissioning

2.1. Introduction


2.1. Introduction

General

This chapter contains information for installing the robot at the working site.

More detailed technical data can be found in the Product specification for the robot, such as:

• load diagram

• permitted extra loads (equipment)

• location of extra loads (equipment).


Before any installation work is commenced, it is extremely important that all safety information is observed!

There are general safety aspects that must be read through, as well as more specific safety information that describes the danger and safety risks when performing the procedures. Read the chapter

Safety on page 15 before performing any installation work.

NOTE!

If the robot is connected to power, always make sure that the robot is connected to earth before starting any installation work!

For more information see:

• Product manual - IRC5

• Product manual - IRC5 Compact

• Product manual - Panel Mounted Controller



2.2. Design 1 and Design 2 of IRB 6640

2.2. Design 1 and Design 2 of IRB 6640

Differences in design

There are some differences in the two designs of the robot IRB 6640, design 1 has:

• one ear on the lower arm as shown in the figure for design 1.

Design 2 has:

• two ears on the lower arm as shown in the figure for design 2

Design 1

Design 2 xx0800000401

48 xx0800000402



2.3. Robot transportation precautions

2.3. Robot transportation precautions

General

This section details ABB approved transportation precautions for ABB robots.

CAUTION!

All transportation in or outside the plant, must be carried out according to description in method 1.If transportation according to method 1 is not possible, use method 2.

Transportation in any other way than method 1 or 2 can seriously damage the robot.If the robot is incorrectly transported and the instructions are not followed, the robot is not covered by the warranty and ABB will not accept any compensation claim.

Method 1

Transportation according to method 1 is strongly recommended by ABB.

xx0800000030

Always follow these instructions when transporting an ABB robot according to method 1:

• Always remove the tool before transportation of the robot.

• Always place the robot in the ABB recommended transport position, detailed in section

Risk of tipping/stability on page 63 .

• Always read and follow the instructions in section

Pre-installation procedure on page

58



49



Continued

Method 2

Transportation according to method 2 is approved by ABB, if use of method 1 is not possible.

Always follow these instructions when transporting an ABB robot according to method 2:

• Always read and follow the instructions in section

Securing the robot on page 56

• Always place the robot in the ABB recommended transport position for robot with

tool, detailed in sub section Transport position with a transport support on page 52 .

• Always use the recommended transport support detailed in sub section

Recommended transport support on page 54 .

IRB7600/IRB66XX

50 xx0800000037

A

B

C

D

Transport Support

Hexagon socket head cap screw M16x140

Threaded bar M10x200

Nut M10



IRB6620/Foundry Plus



Continued xx0800000036

C

D

A

B

Transport Support

Hexagon socket head cap screw M10x50

Threaded bar M10x280

Nut M10



51



Continued

Transport position with a transport support

All transportation of the robot with tool must follow these instructions.

IRB 7600/IRB 66XX

52 xx0800000040



IRB 6620/Foundy Plus






53



Continued

Recommended transport support

Always use the recommended transport support when transporting a robot with tool.

IRB 7600/IRB 66XX

54 xx0800000039



IRB 6620






2.4. Securing the robot

2.4. Securing the robot

General

This section describes how to secure the robot using the transport support.

DANGER!

Releasing the brakes is a hazardous action that may cause injury and damage property. It must be done with great care and only when absolutely necessary.

Securing the robot

56 xx0800000062

Action Note

1. Mount the transport support’s lower end to the robot using the recommended screw joint, (A) in figure.

Do not tighten the screw.

See attachment point for the specific robot in

the section Transport position with a transport support on page 52

.




2.4. Securing the robot

Continued

Action Note

2. Jog the robot into a position as near above as possible to the recommended transport position for the specific robot, as specified in section

Transport position with a transport support on page 52

.

CAUTION!

Do not try to jog the robot to the exact position (max distance 1mm).

3. Use the brake release for axis 3 to reach the final resting position on the transport

support, see the section Manually releasing the brakes on page 71 .

See attachment point for the specific robot in the section

Transport position with a transport support on page 52

4. Tighten all the attachment screws, (A) and (B), in the figure with the brake release for axis 3 still activated starting with the lower attachment screw.

CAUTION!

Do not attempt to tighten any attachment screws without first releasing the brakes.

This can seriously damage the robot.

5. Use the brake release for axis 5 and 6 to reach the final resting position for the tool, see the section

Manually releasing the brakes on page 71



2.5.1. Pre-installation procedure

2.5 Unpacking

2.5.1. Pre-installation procedure

General

This section is intended for use when unpacking and installing the robot for the first time. It also contains information useful during later re-installation of the robot.

Checking the pre-requisites for installation

The checklist below details what must be observed before proceeding with the actual installation of the robot:

Action

1. Make sure only qualified installation personnel conforming to all national and local codes are allowed to perform the installation.

2. Visually inspect the robot to make sure it is not damaged.

3. Make sure the lifting device used is suitable to handle the weight of the robot as

specified in Weight, robot on page 58

.

4. If the robot is not installed directly, it must be stored as described in Storage conditions, robot on page 59 .

5. Make sure the expected operating environment of the robot conforms to the specifications as described in

Operating conditions, robot on page 59 .

6. Before taking the robot to its installation site, make sure the site conforms to

Loads on foundation, robot on page 59

,

Requirements, foundation on page 59 and Protection classes, robot on page 59

.

7. Before moving the robot, please observe Risk of tipping/stability on page 63 regarding

risk of tipping!

8. When these prerequisites are met, the robot may be taken to its installation site as described in section: On-site installation .

Weight, robot

The table below shows the weights of the different models:

Robot model

IRB 6640 -180/2.55

IRB 6640 - 235/2.55

IRB 6640 - 205/2.75

IRB 6640 - 185/2.8

IRB 6640 - 130/3.2

IRB 6640ID - 200/2.55

IRB 6640ID - 170/2.75

* Weight of robot excluding DressPack.

Weight

1300 kg *

1310 kg *

1320 kg *

1320 kg *

1340 kg *

1400 kg *

1405 kg *

58




2.5.1. Pre-installation procedure

Continued

Loads on foundation, robot

The table below shows the various forces and torques working on the foundation during different kinds of operation, in relation to the base coordinate system.

Note! These forces and torques are extreme values that are rarely encountered during operation. The values also never reach their maximum at the same time!

Force

Force xy

Force z

Torque xy

Torque z

Endurance load (operation)

± 8.5 kN

15.0 ± 9.0 kN

± 20.1 kNm

± 5.1 kNm

Max. load (emergency stop)

± 20.4 kN

15.0 ± 20.0 kN

± 45.2 kNm

± 10.6 kNm

Requirements, foundation

The table below shows the requirements for the foundation where the weight of the installed robot is included:

Requirement Value Note

Min. levelity

Max. tilt

0.5 mm

5° The limit for the maximum load on the robot is reduced if the robot is tilted.

Contact ABB for further information about acceptable loads.

Min. resonance frequency 22 Hz

Storage conditions, robot

The table below shows the allowed storage conditions for the robot:

Parameter

Min. ambient temperature

Max. ambient temperature

Max. ambient temperature (less than 24 hrs)

Max. ambient humidity

Value

-25° C

+55° C

+70° C

Max. 95% at constant temperature

Operating conditions, robot

The table below shows the allowed operating conditions for the robot:

Parameter

Min. ambient temperature

Max. ambient temperature

Max. ambient humidity

Value

+5° C

+50° C

Max. 95% at constant temperature

Protection classes, robot

The table below shows the protection class of the robot:

Equipment Protection class

Robot

Cooling fans (option)

IP 67

IP 54



2.5.2. Working range and type of motion

2.5.2. Working range and type of motion

Working range

The following figures show the working ranges of the robot models. The extreme positions of the robot arm are specified at the wrist center (dimensions in mm).

IRB 6640 - 180/2.55, 235/2.55, 205/2.75, 185/2.8, 130/3.2 & IRB 6640ID - 200/2.55, 170/2.75

The illustration below shows the unrestricted working range. Measurements for the different robot variants, are shown as A to F, in the illustration below.

60 xx0600003396

Robot model A B C D E F

IRB 6640-2.55

IRB 6640-2.75

IRB 6640-2.8

IRB 6640-3.2

3015 mm

3219 mm

286 mm

268 mm

2550 mm

2755 mm

903 mm

961 mm

IRB 6640ID-2.55 3015 mm 286 mm 2550 mm 903 mm

IRB 6640ID-2.75 3219 mm 268 mm 2755 mm 961 mm

1119 mm 1814 mm

1252 mm 1999 mm

3261 mm 533 mm 2800 mm 1004 mm 1324 mm 2061 mm

3665 mm 713 mm 3200 mm 1067 mm 1604 mm 2445 mm

1549 mm

1682 mm

1814 mm

1999 mm





Continued

Turning radius

The turning radius, shown as A in the figure below, is specified for the different robot models below the figure.

xx0600003399

IRB 6640 - 2.55

IRB 6640 - 2.75

IRB 6640 - 2.8

IRB 6640 - 3.2

IRB 6640ID - 2.55

IRB 6640ID - 2.75

2550 mm

2755 mm

2800 mm

3200 mm

2550 mm

2755 mm

Type of motion

2

3

4

Axis Type of motion

1 Rotation motion

5

Arm motion

Arm motion

Wrist motion

Bend motion

Range of movement Note

+170° to -170° Movement range can be set to:

+220º to -220º (option 561-1)

+85º to -65º

+70º to -180º

+300º to -300º IRB 6640ID: the range of movement is the combined value for axis 4 and 6 together.

IRB 6640:

+120º to -120º

IRB 6640ID:

+100º to -100º



61



Continued

Axis

6

Type of motion

Turn motion

Range of movement Note

IRB 6640:

+360º to -360º (default),

± 96 revolutions

IRB 6640ID:

+300º to -300º

±300º max

1)

1)

The minimum combination of axes 4 and 6.

NOTE!

There are limitations of the range of movement with a DressPack/SpotPack application fitted to the robot! See product manual SpotPack/DressPack IRB 6640 chapter Installation section

DressPack cable package. Art. no. can be found in section

Overview of this manual on page

7

.



2.5.3. Risk of tipping/stability

2.5.3. Risk of tipping/stability

Risk of tipping

When the robot is not fastened to the foundation and standing still, the robot is not stable in the whole working area. Moving the arms will displace the center of gravity, which may cause the robot to tip over.

Do not change the robot position before securing it to the foundation!

Stabililty

The figure below shows the robot in its shipping position, which also is its most stable position. xx0600003400

WARNING!

The robot is likely to be mechanically unstable if not secured to the foundation!



2.6.1. Lifting the robot with fork lift

2.6 On-site installation

2.6.1. Lifting the robot with fork lift

General

The robot may be moved using a fork lift, provided that available special aids are used.

This section describes how to attach the fork lift equipment to the robot.

Fork lift device set

The fork lift device set is fitted to the robot as shown in the figure below.

Required equipment xx0600002910

A

B

Fork lift pocket

Attachment screw M20x60 quality 8.8 (2 pcs x 4)

Equipment

Fork lift device set

Standard toolkit

Art. no.

-

3HAC025040-003

Note

The content is defined in the section

Standard toolkit on page 409

.

64





Continued

Lifting the robot with fork lift

The procedure below details how to secure the fork lift set in order to lift the robot and move it using fork lift ONLY!

The illustration below shows the position of the robot when lifting it with a fork lift.

xx0600003401

Action Note

1. Move the robot to the position as shown in the figure above!

Release the brakes if required as detailed in the section


.

2.

NOTE!

No load is permitted on the robot!

DANGER!

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

For Foundry Prime robots:

Do not turn off the air pressure to motors and SMB.



65



Continued

Action Note

3. Fit the four fork lift pockets on the base of the robot with its attachment screws.

Make sure the original screws are always used (or replacements of equivalent quality: M20x60, quality

8.8)!

Attachment points on the robot are shown in the figure below.

66

4.

NOTE!

For Cleanroom robots, protective

plates are applied between the

fork lifting pocket and the robot

base, in order to prevent from particle emission when lifting.

xx0600002927

• A: Attachment holes for fork lift xx0800000042

Parts:

• A: Fork lifting pocket

• B: Protective plate

• C: Robot base



Action

5. Double check that all four fork lift pockets are properly secured before lifting.

Note




• A: Fork lift pocket

• B: Attachment screw M20x60 quality 8.8 (2 pcs x 4). Tightening torque : 300 Nm

6. Insert the fork lift forks into the pockets.

7.

CAUTION!

The robot weighs up to 1450 kg depending on variant! (See lifting instruction for details)

All lifting equipment used must be sized accordingly!

NOTE!

When the robot is equipped with forklift pockets an extra weight of 90 kg must be added!

8. Carefully lift the robot and move it to its installation site.

9.

NOTE!

Move the robot with low speed!

WARNING!

Personnel must not, under any circumstances, be present under the suspended load!



2.6.2. Lifting robot with roundslings

2.6.2. Lifting robot with roundslings

General

The robot may be lifted with roundslings according to the illustration below. The illustration is identical with the label attached to the robot’s lower arm.

Attachment points

The figure below shows how to attach the roundslings to the robot.

68 xx0600003455

IRB 6640 standard.

C

D

-

A

B

Lifting instruction 3HAC027647-001

Roundsling robot, 2.5 m (4 pcs) Capacity: 2.000 kg.

Roundsling upper arm, 2 m. Note! Make a loop around the upper arm and wrap the roundsling twice around the upper arm! Do not stretch!

Lifting eye M20 (4 pcs). Note! Fit lifting eyes in the rear holes.

Holes for lifting eyes in the robotbase. (Rear holes)






IRB 6640, Cleanroom variant

A

B

C

D

Roundsling robot, 2.5 m (4 pcs). NOTE! It is important to apply the roundsling the way the figure shows. If not, the cable harness will be damaged.

Roundsling upper arm, 2 m. NOTE! Make a loop around the upper arm and wrap the roundsling twice around the upper arm! Do not stretch!

Lifting eye M20 (4 pcs). NOTE! Fit lifting eyes in the rear holes!

Positions for cellular plastic. NOTE! Do not lift without! See procedure below for more specific information where to apply the cellular plastic.

Sling specification

Sling type

Roundsling, robot

Roundsling, upper arm

Qty

4 pcs

1 pc

Lifting capacity

2 000 kg

2 000 kg

Length / Note

2.5 m

Note! Do not stretch!

2 m

Secures against rotation.



69



Continued

Lifting with roundslings

Action

1. Attach the roundslings to the robot according to

the figure Attachment points on page 68 .

Note

NOTE!

For Cleanroom robots it is important to apply the roundslings:

• between robot harness and lower arm

• behind the side bracket, balancing cylinder.

2.

3.

NOTE!

For Cleanroom robots apply a protection where the lifting equipment and roundslings will rub against the paint of the robot.

In order to prevent from particle emission while lifting, put for example a 20 mm thick cellular

plastic sheet around the places on the robot where the lifting equipment may rub against the paint.

Put the 20 mm cellular plastic sheet as extra protection in the following places:

• Around the upper arm

• Lower arm

• Balancing device

• Around motor axis 2 (Not shown in figure) xx0800000060

Protective cellular plastic sheets at:

• A: Upper arm

• B: Lower arm

• C: Balancing device

4.

CAUTION!

The robot weighs up to 1450 kg depending on variant! (See lifting instruction for details)


NOTE!

If the robot is equipped with fork lift

pockets an extra weight of 90 kg must be added to the robot weight!

WARNING!

Personnel must not, under any circumstances, be present under the suspended load!



2.6.3. Manually releasing the brakes

2.6.3. Manually releasing the brakes

General

This section details how to release the holding brakes of each axis motor.

Location of brake release unit

The internal brake release unit is located at the frame, as shown in the figure below.

xx0600003402

A Internal brake release unit with push buttons.

Releasing the brakes

The procedure below details how to release the holding brakes when the robot is equipped with an internal brake release unit.

Action

1. The internal brake release unit is located on the frame beside motor axis 1.

The internal brake release unit is equipped with six buttons for controlling the axes brakes. The buttons are numbered according to the numbers of the axes.

If the robot is not connected to the controller, power must be supplied to the connector R1.MP according to the

section Supplying power to connector R1.MP on page 72

.

2.

Note

DANGER!

When releasing the holding brakes, the robot axes may move very quickly and sometimes in unexpected ways!

Make sure no personnel is near or beneath the robot arm!

3. Release the holding brake on a particular robot axis by pressing the corresponding button on the internal brake release unit.

The brake will function again as soon as the button is released.



71


2.6.3. Manually releasing the brakes

Continued

Supplying power to connector R1.MP

If the robot is not connected to the controller, power must be supplied to connector R1.MP on the robot in order to enable the brake release buttons.

Note

1.

Action

DANGER!

Incorrect connections, such as supplying power to the wrong pin, may cause all brakes to be released simultaneously!

2. Supply 0V on pin 12 and 24V on pin 11.

xx0600002937



2.6.4. Lifting the base plate

2.6.4. Lifting the base plate

Required equipment

Equipment

Lifting eye, M16

Lifting slings

Hole configuration

Art. no.

3HAC14457-4

Note

3 pcs

3 pcs

Length: approx. 2 m

Lifting, base plate xx0200000096

A Attachment holes for lifting eyes (x3)

1.

Action Note

CAUTION!

The base plate weighs 353 kg! All lifting equipment used must be sized accordingly!

2. Fit the lifting eyes in the specified holes.

3. Fit the lifting slings to the eyes and to the lifting device.

Shown in the figure Hole configuration on page 73 .



2.6.5. Securing the base plate

2.6.5. Securing the base plate

General

This section details how to secure the base plate.

Base plate, dimensions

74 xx0100000105






A Four holes for alternative clamping, 4x Ø18



75



Continued

Base plate, grooves and holes

The illustration below shows the orienting grooves and guide sleeve holes in the base plate.

xx0300000045

A

B

C

Guide sleeve holes (2 pcs)

Orienting grooves (3 pcs)

Levelling bolts, attachment holes (4 pcs)


Equipment Art. no. Note

Base plate

Standard toolkit

Other tools and procedures may be required. See references to these procedures in the step-bystep instructions below.

3HAC12937-9 Includes

• guide sleeves, 3HAC12937-3

• levelling screws, 9ADA120-79

• attachment screws and washers for securing the robot to the base plate.

A drawing of the base plate itself may be ordered from ABB Robotics!

- The content is defined in the section


.

These procedures include references to the tools required.

76





Continued

Recommendations, quality

The table specifies any recommendations made by ABB:

Variable Recommendation

Recommended foundation quality 1 Steel fibre reinforced concrete foundation, 30 kg/m3, class K30, t=250 mm

Recommended foundation quality 2 Sturdy concrete foundation, double reinforced by ø10 mm steel bars, distance 140 mm, class K25, t=250

Recommended bolt quality and dimension

Hilti HDA-P, M20 x 250/50 (maximum thickness of base plate = 50 mm)

Hilti HDA-P, M20 x 250/100 (maximum thickness of base plate = 100 mm)

Base plate

This section details how to secure the base plate to the foundation.

Note Action

1. Make sure the foundation is level.

2.

CAUTION!

The base plate weighs 353 kg! All lifting equipment used must be sized accordingly!

3. Orient the base plate in relation to the robot work location using the three grooves in the base plate.

Shown in the figure

Base plate, grooves and holes on page 76 .

4. Lift the base plate to its mounting position. Detailed in section

Lifting the base plate on page 73 .

5. Use the base plate as a template and drill 16 attachment holes as required by the selected bolt dimension.

If possible, observe the recommendations specified in section

Recommendations, quality on page 77 . ABB does not

assume any responsibility for other foundation qualities, due to great variations in the foundation properties.

6. Fit the base plate and use the levelling bolts to level the base plate.

Shown in the figure

Base plate, grooves and holes on page 76 .

7. If required, fit strips of sheet metal underneath the base plate to fill any gaps.

8. Secure the base plate to the foundation with screws and sleeves.

9. Recheck the four robot contact surfaces on the base plate to make sure they are level and flat.

If they are not, pieces of sheet metal or similar may be used to bring the base plate to a level position.

Maximum allowed deviation: 0.5 mm



2.6.6. Orienting and securing the robot

2.6.6. Orienting and securing the robot

General

This section details how to orient and secure the robot to the base plate in order to run the robot safely. The requirements made on the foundations are shown in the following tables and figures.

Illustration, robot fitted to base plate

The illustration below shows the robot base fitted to the base plate.

xx0600002933

C

D

A

B

Robot attachment bolts and washers, 8 pcs (M24 x 100)

Orienting grooves in the robot base and in the base plate

Levelling screws. Note! Remove before the robot base is fitted!

Base plate attachment screws

Attachment screws

The table below specifies the type of securing screws and washers to be used for securing the robot to the base plate/foundation.

Suitable screws, lightly lubricated: M24 x 100

Quality: Quality 8.8

Suitable washer:

Tightening torque:

Thickness: 4 mm

Outer diameter: 44 mm

Inner diameter: 25 mm

725 Nm

78





Continued

Securing the robot

The procedure below details how to secure the robot to the base plate after fitting the plate to the foundation.

Action

1. Lift the robot.

2. Move the robot to the vicinity of its installation location.

3. Fit two guide sleeves to the guide sleeve holes in the base plate.

Note

Detailed in section Lifting robot with roundslings .

4. Guide the robot gently using two M24 screws while lowering it into its mounting position.

5. Fit the bolts and washers in the base attachment holes.

NOTE!

One of the guide sleeve holes is elongated!

Make sure the robot base is correctly fitted onto the guide sleeves!

Specified in Attachment screws on page 78 .

Shown in the figure Illustration, robot fitted to base plate on page 78

.

6. Tighten the bolts in a criss-cross pattern to ensure that the base is not distorted.

NOTE!

Lightly lubricate the screws before assembly!



79



Continued

Hole configuration, base

The illustration below shows the hole configuration used when securing the robot.

xx0600003403

Cross section, guide sleeve hole

The illustration below shows the cross section of the guide sleeve holes.

80 xx0600003404



2.6.7. Fitting equipment on robot

2.6.7. Fitting equipment on robot

General

The robot features mounting holes for additional equipment.

Access to any of the following mounting holes may be obstructed by any additional cabling, equipment, etc., fitted by the robot user. Make sure the required mounting holes are accessible when planning the robot cell.

NOTE!

For Cleanroom robots there may not be any additional equipment fitted to the robot except in the following places:

• turning disk

• armhouse

• frame.

Additional cables from base to upper arm, may not be fitted to Cleanroom robots!

Illustration, fitting of extra equipment on lower arm

The illustrations below shows the mounting holes available for fitting extra equipment on the lower arm.

Make sure not to damage the robot cabling on the inside of the lower arm when fitting extra equipment. Always use appropriate attachment screws!

Note! Extra equipment may not be mounted on the lower arm of IRB 6640ID!

Note! Extra equipment may not be fitted on the lower arm of Cleanroom robots!

xx0600003405



81



Continued

Robot variant

IRB 6640 - 2.55

IRB 6640 - 2.75

IRB 6640 - 2.8

IRB 6640 - 3.2

IRB 6640ID - 2.55

IRB 6640ID - 2.75

A

2240 mm

2445 mm

2240 mm

2445 mm

2240 mm

2445 mm

B

520 mm

725 mm

520 mm

725 mm

520 mm

725 mm

C

1075 mm

1280 mm

1075 mm

1280 mm

1075 mm

1280 mm

82 xx0600003406

Robot variant

IRB 6640 - 2.55

IRB 6640 - 2.75

IRB 6640 - 2.8

IRB 6640 - 3.2

IRB 6640ID - 2.55

IRB 6640ID - 2.75

A

400 mm

500 mm

400 mm

500 mm

400 mm

500 mm

B

13 mm

13 mm

13 mm

13 mm

13 mm

13 mm

C

40 mm

30 mm

40 mm

30 mm

40 mm

30 mm





Continued

Illustration, fitting of extra equipment on upper arm

The illustrations below shows the mounting holes available for fitting extra equipment on the upper arm.

Note! Extra equipment may not be fitted on the upper arm of IRB 6640ID and Cleanroom robots!

xx0600003414

Robot variant

IRB 6640 - 2.55

IRB 6640 - 2.75

IRB 6640 - 2.8

IRB 6640 - 3.2

IRB 6640ID

IRB 6640ID

A

1142 mm

1142 mm

1392 mm

1592 mm

1142 mm

1142 mm

B

200 mm

200 mm

200 mm

200 mm

290 mm

290 mm xx1000000158



83



Continued

Illustration, fitting of extra equipment on frame

The illustration below shows the mounting holes available for fitting extra equipment on the frame.

xx0600003416

84





Continued

Illustration, fitting on turning disk

The illustration below shows the mounting holes available for fitting equipment on the turning disk.

There are two different versions of the turning disk, as shown in the illustrations below.

xx0200000397

Turning disk type 1



85



Continued

86 xx0200000197

Turning disk type 2






Turning disk unit for robot versionIRB 6640ID.

Fastener quality

When fitting tools on the turning disk (see the figures above), only use screws with quality

12.9. When fitting other equipment standard screws with quality 8.8 may be used.



2.6.8. Installation of cooling fan for motors, axes 1 and 2 (option)

2.6.8. Installation of cooling fan for motors, axes 1 and 2 (option)

General

A cooling fan can be installed on the motors of axes 1and 2. However, cooling fans for axes

1 and 2 can not be combined!

The cabling for the fans is available as:

• separate cabling for axis 1 or 2, including only connections for the cooling fans on

axes 1 or 2. Installation of this cabling is detailed in section Installation, separate fan cabling axis 1 or 2 on page 92 .

Location of cooling fans

The fans are installed on the motors, axes 1-2, as shown in the figure below.

xx0700000116

A

B

C

Cooling fan, axis 1

Cooling fan, axis 2

Rear cover plate

88



Cooling fan



Continued

The details of the cooling fan are shown in the figure below.

xx0500002158

C

D

A

B

Fanbox

Attachment screws, fanbox plates (9 pcs)

Groove in the connector

Tightening screws, fanbox (3 pcs) xx0900000137

A

B

C

D

Fanbox

Groove in the connector

Back plate

Part of the fanbox that can be removed, if needed.



89



Continued


Equipment Art. no.

Note

Cooling fan

Cabling, cooling fans, axes

1 or 2.

3HAC15374-1

3HAC023599-001 Choose this cabling if equipping the robot with cooling fans on axis 1 or 2 .

Plate for customer connections

Additional cabling to and inside the controller

Material set fan axes 1 and

2

-

3HAC025778-001 An additional connection plate must be fitted to the robot base, if not already installed. The plate is shown in the figure

Plate for customer connections, at base on page 91

.

3HAC023999-001

3HAC025488-001

The set includes:

• fan axes 1 & 2 cable harness

• plate, customer

• attachment screws and nuts.

Cable harness inside controller

Locking liquid -

Standard toolkit

Circuit diagram -

-

3HAC025744-001

Loctite 243. Used for the three tightening screws.


Standard toolkit on page 409 .

See the chapter Circuit diagram .



90





Continued

Plate for customer connections, at base xx0500002301

A

B

Plate for customer connections

Attachment screws, 3 pcs, M6x16 quality 8.8-A2F

Installation, fan

The procedure below details how to install the cooling fan on motors, axes 1 or 2 .

Note

1.

Action

DANGER!




2. Prepare the fanbox for installation:

• disassemble the two parts of the box by removing the nine attachment screws

• loosen the three tightening screws, to avoid damaging the surfaces of the motor when fitting the fanbox

• turn the connector to the correct position; axis 1: groove pointing inwards, as shown in the figure

Cooling fan on page 89 . Position for axis 2 is shown in

the same figure.

Shown in the figure

Cooling fan on page 89 .

3. Temporarily lift the motor cabling out of the way of the current motor to make room for the fanbox.



91



Continued

Action

4. Fit the parts of the fanbox to the motor and reassemble with the nine attachment screws.

5. Lift the box (axis 1) so that it does not rest directly on the robot and secure the box with the three tightening screws, using locking liquid. Tighten them properly so that the box is firmly attached to the motor.

6. Install the cabling and make adjustments in RobotWare, as described in the following procedures.

Note

Separate cabling for axis 1 or 2

The figure below shows the cabling used only for the fan on axis 1 or 2.

xx0500002173

A

B

C

Cable bracket

Connector R1.SW2/3, connected to the robot base

Connector R3.FAN2, connected to the fan of axis 1or 2

Installation, separate fan cabling axis 1 or 2

The procedure below details how to install the separate cabling for the cooling fan of axis 1 or 2.

Action

1. Move the robot to its calibration position.

Note

Shown in section Calibration scale and correct axis position on page

390

.

2.

DANGER!




3. Remove the rear cover plate from the robot base. Shown in the figure

Location of cooling fans on page 88

.

4. Remove the cable bracket (A) Shown in the figure

Separate cabling for axis 1 or 2 on page 92

92





Continued

Action Note

5. Fit the plate for customer connections, if not already fitted, to the connection plate of the robot base.

Shown in the figure Plate for customer connections, at base on page 91

.

Art. no. is specified in

Required equipment on page 90 .

6. Run the cabling up through the base and frame, beneath the balancing device.

7. Secure the cable bracket to the bracket of the robot cabling inside the frame.

Run the cable underneath the robot cabling and out through the side of the frame, at motor, axis 1

. The correct cable run is shown in the figure to the right!

NOTE!

There is a risk of the balancing device damaging the cable if it is not protected by the robot cabling!

8. Connect the connector R3.FAN2 to the fan of axis

1or 2.

xx0500002174

A. Cable bracket. Also shown

in the figure Separate cabling for axis 1 or 2 on page 92 .

NOTE!

Fans on both axis 1 and 2 can not be used at the same time!

9. Connect the connector R1.SW2/3 to the base of the robot. Make sure that the cabling, run through the frame and base, is not twisted and runs freely from the robot cabling.

10. Refit the rear cover plate to the robot base.

11. Install additional cabling to and inside the controller.

Also make adjustments in RobotWare, as described in the following procedure.

Cable is specified in section

Fan cables, robot base to control cabinet (option) on page 106

.



93



Continued

Adjustments in RobotWare

Action

1. Modify the settings in RobotWare to include the cooling fans.

Note

RobotWare 5.0: change the settings in the

Modifying options dialogue, by using the

Modify Controller System Wizard in the

System Builder of RobotStudio. Read more about modifying the system in Operating

manual - RobotStudio.



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

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

Introduction

How to install the Foundry Plus Cable guard is described in the instruction delivered with the cable guard.

Separate instructions for IRB 140, 1600, 6620, 6640, 6650S, 6660 and 7600 are available in

English, German, French, Spanish and Italian and can be found on the DVD delivered with the Cable guard, article number 3HAC035933-001.



2.6.10. Loads

2.6.10. Loads

General

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

CAUTION!

Incorrectly defined loads may result in operational stops or major damage to the robot.

References

Load diagrams, permitted extra loads (equipment) and their positions are specified in the

Product Specification . The loads must also be defined in the software as detailed in Operating

manual IRC5 with FlexPendant.

Stop time and braking distances

Robot motor brake performance depends on any loads attached. For information about brake performance, see Product Specification for the robot.



2.7.1. Introduction

2.7 Restricting the working range

2.7.1. Introduction

General

When installing the robot, make sure that it can move freely within its entire working space.

If there is a risk that it may collide with other objects, its working space should be limited.

The working range of the following axis may be restricted:

• Axis 1, hardware (mechanical stop) and software.

• Axis 2, hardware (mechanical stop) and software

• Axis 3, hardware (mechanical stop) and software

This section describes how to install hardware that restricts the working range.

Note! Adjustments must also be made in the robot configuration software (system parameters). References to relevant manuals are included in the installation procedures.



2.7.2. Mechanically restricting the working range of axis 1

2.7.2. Mechanically restricting the working range of axis 1

General

The working range of axis 1 is limited by fixed mechanical stops and adjusting the system parameter configuration. The working range can be reduced by adding additional mechanical stops giving 7.5 or 15 graduation, between 22.5° and 135° in both directions.

Mechanical stops, axis 1

The illustration below shows the mounting position of the stop pin and one of the additional mechanical stops available for axis 1.

xx0600002938

A

B

C

D

Movable mechanical stop

Attachment screw plus washer, M12 x 40 quality 12.9 (2 pcs)

Fixed mechanical stop

Mechanical stop pin axis 1


98

Equipment, etc.

Movable mechanical stop set, axis 1

(+15°/-7.5°)

Art. no.

Note

3HAC025204-003 Includes:

• two stops (+15°/ -7.5°),

3HAC025366-001

• two stops (+7.5°/ -15°),

3HAC025367-001

• attachment screws and washers

• document for movable mech.stop,

3HAC025204-002





Continued

Equipment, etc.

Standard toolkit

Technical reference manual - System parameters

-

-

Art. no.

Note



Art. no. is specified in section

References .

Installation, mechanical stops axis 1

The procedure below details how to fit the mechanical stops of axis 1 to the robot. An assembly drawing is also enclosed with the product.

Note

1.

Action

DANGER!



Do not turn off the air pressure to motors and

SMB.

2. Fit the additional mechanical stop to the frame according to the figure

Mechanical stops, axis 1 on page 98

.

3.

Tightening torque: 120 Nm.

NOTE!

To use the option 561-1 Extended working

range axis 1 the software working range limitations must be redefined in the system parameters, topic Motion. The Arm parameters Upper Joint Boundand Lower

Joint Bound must be changed to 3.84 respectively -3.84. The values are in radians, that is 3.84 radians = 220 deg.

The system parameters that must be changed (Upper joint bound and Lower

joint bound) are described in Technical

reference manual - System parameters.

4.

WARNING!

If the mechanical stop pin is deformed after a hard collision, it must be replaced!

Deformed movable stops and/or additional

stops as well as deformed attachment

screws must also be replaced after a hard collision.





General

The working range of axis 2 is limited by fixed mechanical stops and can be reduced by adding up to six additional mechanical stops with 15 graduation in respective direction.


The illustration below shows the mounting position of the mechanical stops on axis 2.

xx1000000163

The figure shows IRB 7600 but the principle is the same.

A

B

C

Additional stops, axis 2

Fixed stop, axis 2

Attachment screw + washer M16x50 quality 12.9


Equipment, etc.

Art. no.

Note

Mechanical stop set, axis 2 3HAC020885-001 Includes six stops, attachment screws, washers and assembly drawings.

Standard toolkit The content is defined in the section


Technical reference manual

- System parameters


References on page 8 .

100





Continued


The procedure below details how to fit the mechanical stops for axis 2 to the robot. An assembly drawing is also enclosed with the product.

Note

1.

Action

DANGER!




SMB.

2. Fit and tighten the additional stops in a row, starting from the fixed stop.


Shown in the figure

Mechanical stops, axis 2 on page 100 .

3. The software working range limitations must be redefined to correspond to the changes in the mechanical limitations of the working range.




4.

WARNING!









General

The working range of axis 3 is limited by fixed mechanical stops and can be reduced by adding additional mechanical stops with 20 graduation in respective direction.


The illustration below shows the mounting position of the mechanical stops on axis 3.

102 xx0300000048

The figure shows IRB 7600 but the principle is the same.

A

B

C

Additional mechanical stops


Attachment screw M16x60 quality 12.9






A

B

Mechanical stop pin, axis 3

Attachment screw and washer


Equipment, etc.

Mechanical stop set, axis 3

Art. no.

3HAC13128-1

Standard toolkit

Technical reference manual -

System parameters

-

-

Note

Includes:

• six stops, one with 80° restriction, 3HAC12708-3 (use when limitation angle >=80), and five with 20°, 3HAC12708-1.

• attachment screws.



.


References on page 8

.



103



Continued


The procedure below details how to fit the mechanical stops for axis 3 to the robot. An assembly drawing is also enclosed with the product.

Note

1.

Action

DANGER!




SMB.

2. Fit and tighten the additional stops in a row, starting from the fixed stop.


Shown in the figure Mechanical stops, axis 3 on page 102

3.

NOTE!

The software working range limitations

(system parameters) must be redefined to correspond to the changes in the mechanical limitations of the working range.




4.

WARNING!







2.8.1. Robot cabling and connection points

2.8 Electrical connections

2.8.1. Robot cabling and connection points

Introduction

Connect the robot and controller to each other after securing them to the foundation. The lists below specify which cables to use for each respective application.

Main cable categories

All cables between the robot and controller are divided into the following categories:

Cable category Description

Robot cables

Fan cables (option)

Handles power supply to and control of the robot's motors as well as feedback from the serial measurement board.

Specified in the table

Robot cables on page 105 .

Handles supply to and feedback from any cooling fan on the robot.

Specified in the table

Fan cables, robot base to control cabinet (option) on page 106

.

Customer cables (option) Handles communication with equipment fitted on the robot by the customer, including databus communication, low voltage signals and high voltage power supply + protective ground.

See the product manual for the controller

1)

.

External axes cables (option) Handles power supply to and control of the external axes' motors as well as feedback from the servo system.

See the Application manual - Additional axes and stand alone controller (M2004)

1)

.

1) Art. no. is specified in section

References on page 8

.

The cable categories are divided into sub-categories, specified below:

Robot cables

These cables are included in the standard delivery. They are completely pre-manufactured and ready to plug in.

Cable sub-category Description

Robot cable, power

Robot cable, signals

Connection point, cabinet

Connection point, robot

R1.MP Transfers drive power from the drive units in the control cabinet to the robot motors.

XS1

Transfers resolver data from and power supply to the serial measurement board.

XS2 R1.SMB



105


2.8.1. Robot cabling and connection points

Continued

Robot cable, power

Cable

Robot cable, power: 7 m




Robot cable, signals

Cable

Robot cable signal, shielded: 7 m




Art. no.

3HAC11818-1

3HAC11818-2

3HAC11818-3

3HAC11818-4

Art. no.

3HAC7998-1

3HAC7998-2

3HAC7998-3

3HAC7998-4

Fan cables, robot base to control cabinet (option)

These cables are not included in the standard delivery, but are included in the delivery if the fan option is ordered. Fans can also be ordered without cables. The cables are completely premanufactured and ready to plug in.

Cabling to be installed on the robot is specified in section Installation of cooling fan for motors, axes 1 and 2 (option) on page 88 .

Cabling between robot base and control cabinet, cooling fans.

The cables specified below are specific for the IRC5 controller and used when the robot is equipped with cooling fans. The cabling for the cooling fans runs all the way from the robot base to the inside of the cabinet.

If equipping the robot with cooling fans, use the cabling specified below. The cables for cooling fans listed below are used together with a distributing cable, also specified below.

Cable Art. no.

Connection point

Distributing cable

Harness - cooling, 7 m

3HAC022708-001 Robot base: R1.SW2/3

3HAC022723-001 Distributing cable: R1.FAN.SW2/3

Inside cabinet: A43.X10 and A43.X11

Harness - cooling, 15 m 3HAC022723-004 Distributing cable: R1.FAN.SW2/3








2.9.1. Additional installation procedure

2.9 Making robot ready for operation (Foundry Prime)

2.9.1. Additional installation procedure

General

Robots delivered with the Foundry Prime protection are specially designed to work in water jet cleaning cells with 100% humidity and alkaline detergent. To ensure that the protection offers the best reliability, some measures are needed during installation of the robot according to the procedures below.

NOTE!

For best reliability, it is of highest importance that the special maintenance instructions for the Foundry Prime robot are followed and documented.

Commissioning

• Never switch off the overpressure in motors and serial measurement compartment during cooling down of robot after it has been switched off.

• When turning off a cleaning cell we recommend that the humid air inside a cell is ventilated out, to avoid that the humid air is sucked into gearboxes for example, due to the raised vacuum when cooled down.

Environmental conditions

The table below details the environmental conditions.

Parameter Value

Humidity 100%

Washing detergent with pH

Washing detergent must contain rust inhibitor and be approved by ABB

Cleaning bath temperature

<9.0

<60°C, used in a typical waterjet cleaning application at suitable speed.

Air specification for pressurizing of robot

The air must be dry and clean, such as instrument air. The table below details the air specifications.

Parameter

Dew point

Solid particle size

Oil content

Pressure to robot

Value

<+2°C at 6 bar

<5 microns

<1 ppm (1 mg/m3)

0.2 - 0.3 bar

WARNING!

If the pressurized air contains oil, it could result in a brake failure in the motors and cause the robot arms to fall down, leading to personal injury or physical damage.



107



Continued

WARNING!

If the air pressure exceeds the specified, it could result in a brake failure in the motors and cause the robot arms to fall down, leading to personal injury or physical damage.

NOTE!

To secure the supply of air pressure, it is recommended to use a pressure sensor.

Pressurize the motors, balancing device and serial measurement board cavity

The robots are prepared with hoses to the motors and the serial measurement board cavity to enable pressurizing of them.

WARNING!

The robot must be pressurized also when it is switch off, to avoid that the humid environmental air is sucked into the motors when cooling down.

Action

1. Connect a compressed air hose to air connector on robot base.

Note xx0700000450

• A: Air connection, outside diameter = 6 mm.

Do this when the controller cables are connected.

2. Protect the screws on the Harting connector on the robot base from corrosion with Mercasol 3106.

3. Pressurize the robot.

4. Inspect the air system.

See

Air specification for pressurizing of robot on page 107 for correct pressure.

See

Inspection of air hoses (Foundry Prime) on page 147 .

Protecting robot from high pressure water

WARNING!

No part of the robot should be exposed to direct high pressure jet of water. The sealings between the moving parts on the wrist should not be exposed to direct or rebounding highpressure jet of water.

108





Continued

Protection points at the wrist joints

The illustration below shows points that are particularly sensitive to water spray.

xx0600002792

A

B

C

Axis 5, bearing support side

Axis 5, bearing gear side

Axis 6, mounting flange - gear house



2.9.2. Commissioning (Foundry Prime)

2.9.2. Commissioning (Foundry Prime)

General

The following should be taken in consideration when running a robot in a water jet application cell:

CAUTION!

Never switch off the overpressure in motors and serial measurement compartment during cooling down of robot after it has been switched off.

NOTE!

To reduce the risk for corrosion due to condensation in gearboxes, it is recommendable that the robot is running with high speed on each axes at least on one occasion each hour. This is to lubricate the gearbox cavities.

NOTE!

When turning off a cleaning cell we recommend that the humid air is ventilated out from the cell, to avoid that the humid air is sucked into gearboxes for example, due to the raised vacuum when cooled down.



2.10.1. Additional installation procedure, Clean room

2.10 Making robotready for operation, (Cleanroom)

2.10.1. Additional installation procedure, Clean room

General

Clean room robots are specially designed to work in a clean room environment.

Clean room robots are designed in order to prevent from particle emission from the robot. For example is maintenance work possible to perform without cracking the paint. The robot is painted with four layers of polyurethane paint. The last layer being a varnish over labels in order to simlify cleaning.

Clean room parts being replaced must be replaced with parts designed for use in Clean room environments.

Clean room class 5

Particle emission from the robot fulfill Clean room class 5 standard according to DIN EN ISO

14644-1.

Preparations before commissioning a Clean room robot

During transport and handling of a Clean room robot, it is likely that the robot has been contaminated with particles of different kinds. Therefore the robot must be minutely cleaned before installation.



2.10.1. Additional installation procedure, Clean room


3 Maintenance

3.1. Introduction

3 Maintenance


Structure of this chapter

This chapter details all maintenance activities recommended for the manipulator.

It is based on the maintenance schedule located at the beginning of the chapter. The schedule contains information about required maintenance activities including intervals and refers to procedures for the activities.

Each procedure contains all the information required to perform the activity, that is, required tools and materials.

The procedures are gathered in different sections and divided according to the maintenance activity.


Before any service work is commenced, it is extremely important that all safety information is observed!

There are general safety aspects that must be read through, as well as more specific safety information that describes the danger and safety risks when performing the procedures. Read the chapter

Safety on page 15 before performing any service work.

NOTE!

If the robot is connected to power, always make sure that the robot is connected to earth before starting any maintenance work!



• Product manual - IRC5 Compact

• Product manual - Panel Mounted Controller


3 Maintenance

3.2.1. Specification of maintenance intervals

3.2 Maintenance schedule and expected component life

3.2.1. Specification of maintenance intervals

Introduction

The intervals are specified in different ways depending on the type of maintenance activity to be carried out and the working conditions of the manipulator:

• Calendar time: specified in months regardless of whether the manipulator system is run or not

• Operating time: specified in operating hours. More frequent running of the manipulator means more frequent maintenance activities.

• SIS: specified by the robot's SIS (Service Information System). A typical value is given for a typical work cycle, but the value will differ depending on how hard each part is run. The SIS is further detailed in the Operating manual Service Information

System. Document number can be found in section References .


3 Maintenance

3.2.2. Maintenance schedule

3.2.2. Maintenance schedule

General

The robot must be maintained regularly to ensure proper function. The maintenance activities and intervals are specified in the table below.

Non-predictable situations also give rise to inspections of the robot. Any damages must be attended to immediately!

The inspection intervals do not specify the life of each component.

Values for these are specified in the section

Expected component life on page 120

Activities and intervals, standard equipment

The table below specifies the required maintenance activities and intervals:

Maintenance activity

Cleaning

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Equipment

Robot

Axis 1 gearbox, oil level






-

Interval

Every:

• 12 months

2)

Every:

12 months 2)

Every:

12 months

2)

Every:

12 months 2)

Every:

12 months

2)

Every:

12 months 2)

Balancing device Every:

• 6 months

Robot harness Every:

12 months

4)

Information labels Every:

• 12 months

Dampers

Mechanical stop, axis 1

Every:

• 12 months

Every:

• 12 months

Detailed in section

•

Cleaning, robot on page 193

•

Inspection, oil level gearbox axis 1 on page 122

•


•


•


•

Inspection, oil level, gearbox axis 5 on page 130

•


•

Inspection, balancing device on page 137

•

Inspection, cable harness on page 142

•

Inspection, information labels on page 149

•

Inspection, damper axes 2-5 on page 157

•

Inspection, mechanical stop pin, axis 1 on page 152



115

3 Maintenance


Continued


Equipment Interval Detailed in section

Changing

Changing

Changing

Changing

Changing

Axis 1 gearbox oil:

Kyodo Yushi TMO

150

Axis 2 gearbox oil:

Kyodo Yushi TMO

150

First change when

DTC

1)

reads:

6,000 hours

Second change when

DTC 1) reads:

24,000 hours

Following changes:

Every 24,000 hours

Do not mix with other oils!

•

Oil change, gearbox axis 1 on page 165

First change when

DTC 1) reads:

6,000 hours

Second change when

DTC

1)

reads:

24,000 hours

Following changes:

Every 24,000 hours


•


Axis 3 gearbox oil:

Kyodo Yushi TMO

150

First change when

DTC

1)

reads:

6,000 hours

Second change when

DTC

1)

reads:

24,000 hours

Following changes:

Every 24,000 hours


•

Oil change, gearbox, axis 3 on page 171

Every:

24,000 hours 2)

•


Axis 4 gearbox oil:

Mobilgear 600

XP320

Axis 5 gearbox oil :

Mobilgear 600

XP320

Every:

24,000 hours 2)

•


Changing Axis 6 gear oil:

Kyodo Yushi TMO

150

First change when

DTC

1)

reads:

6,000 hours

Second change when

DTC

1)

reads:

24,000 hours

Following changes:

Every 24,000 hours


•


•


Changing Axis 6 gear oil:

Mobilgear 600

XP320 (IRB

6640ID)

Every:

24,000 hours

2)

Overhaul Robot Every:

40,000 hours

Replacement SMB Battery pack Battery low alert

3)

•

•


Replacement of SMB battery on page 183

116



3 Maintenance


Continued


Equipment

Lubrication Balancing device bearing

Interval

Every:

12,000 hours 5)


•

Lubrication of spherical roller bearing, balancing device on page 186

•

•

•

•

•

1)

DTC = Duty Time Counter. Shows the operational time of the robot.

2)

If the robot is run at ambient temperatures higher than 50°C, the equipment may require maintenance more frequently.

3)

Battery low alert (38213 Battery charge low) is displayed when remaining backup capacity (robot powered off) is less than 2 months. Typical lifetime of a new battery is 36 months if the robot is powered off 2 days/week or 18 months if the robot is powered off 16 hours/day. The lifetime can be extended (approx. 3 times) for longer production breaks by a battery shutdown service routine. See Operating manual -

IRC5 with FlexPendantfor instructions.

4)

Replace when damage or cracks is detected or life limit is approaching as specified in section


.

5)

Always lubricate the front eye bearing after refitting the shaft of the balancing device.

Activities and intervals, optional equipment

The table below specifies the required maintenance activities and intervals for common optional equipment. The maintenance of other external equipment for the robot is detailed in separate documentation.


Inspection

Equipment

Signal lamp

Inspection

Interval Note

Mechanical stop axes 1-2-3

Every:

12 months


Inspection, signal lamp (option) on page 159

Inspection, additional mechanical stops on page 154



117

3 Maintenance


Continued

Activities and intervals, Foundry Prime

The table below specifies the required maintenance activities and intervals for Foundry

Prime.

118


Equipment Interval Detailed in section

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Inspection

Analysis

Changing

Changing

Changing

Changing

Changing

Changing

Replacement

Overhaul

Overhaul

Cable harness

Air hoses

Balancing device

Information labels

Dampers

Surface treatment

Mechanical stop, axis 1 Every:

Oil gearbox axis 6

Axis 1 gearbox, oil:

Kyodo Yushi TMO 150


Kyodo Yushi TMO 150


Kyodo Yushi TMO 150

Axis 4 gearbox oil:

Mobilgear 600 XP320

Axis 5 gearbox oil:

Mobilgear 600 XP320


Kyodo Yushi TMO 150

SMB Battery pack

Robot

Axis 6 gearbox

Every:

• 6 months

Every:

•

Every:

•

Every:

•

Every:

•

Every:

•

6 months

6 months

12 months

12 months

• 6 months

12 months

5)

Inspection, cable harness on page 142

Inspection of air hoses

(Foundry Prime) on page

147

•

Inspection, balancing device on page 137

•

Inspection, information labels on page 149

•

Inspection, damper axes 2-5 on page

157

Inspection of surface treatment (Foundry Prime) on page 148

•

Inspection, mechanical stop pin, axis 1 on page

152

Inspection, oil level gearbox axis 6 on page

132

Every:

• 3,000h or 6 months 2)

Every:

• 6,000 hours

Every:

• 6,000 hours



Every:

• 6,000 hours

Every:

• 12,000 hours

Oil change, gearbox, axis

3 on page 171


4 on page 174

Every:

• 12,000 hours


5 on page 177

Every:

• 3,000 hours or 6 months

1)

Battery low alert

3)


•

Replacement of

SMB battery on page 183

40,000 hours

Every:

• 24 months 4)


Replacement of gearbox, axis 6 on page 382



3 Maintenance


Continued


Equipment

Lubrication Balancing device, bearing

Rust preventing Wrist bearing

Rust preventive Axis 4 sealing

Interval

Every:

• 6 months

Every:

• 6 months

Every:

• 6 months


Rust preventive measures, support bearing in wrist (Foundry

Prime) on page 191

Rust preventive measures, sealing axis 4

(Foundry Prime) on page

188

•

•

•

•

1)

If the robot is working in cleaning cells that are not emptied when the robot is switched off, the oil may be replaced more frequently. See also

Analysis of water content in oil, gearbox axis 6 (Foundry Prime) on page 136 .

2)

Analyse water content in oil in gearbox axis 6 first time after 3,000 hours or 6 months. If the working conditions changes, analyse again after 3,000 hours or 6 months.

3)

Battery low alert (38213 Battery charge low) is displayed when remaining backup capacity (robot powered off) is less than 2 months. Typical lifetime of a new battery is 36 months if the robot is powered off 2 days/week or 18 months if the robot is powered off 16 hours/day. The lifetime can be extended (approx. 3 times) for longer production breaks by a battery shutdown service routine. See Operating manual -

IRC5 with FlexPendant for instructions.

5)

Damage to painted surfaces must be repaired as soon as possible to avoid corrosion.


3 Maintenance

3.2.3. Expected component life

3.2.3. Expected component life

General

The expected life of a specific component of the robot can vary greatly depending on how hard it is run.

NOTE!

For expected component life of Foundry Prime robots see

Expected component life - Foundry

Prime on page 121

.

Expected component life

Component

Cable harness

Normal usage

1)

Cable harness

Extreme usage

2)

Expected life

40,000 hours 3)

20,000 hours 3)

Note

Not including:

• SpotPack harnesses

• Optional upper arm harnesses

Not including:

• SpotPack harnesses

• Optional upper arm harnesses

Balancing device

Gearboxes

4)

40,000 hours 5)

40,000 hours

1)

Examples of "normal usage" in regard to movement: most material handling applicationsand limited use of bending backwards mode of axis 3.

2)

Examples of "extreme usage" in regard to movement: presstending, very severe palletizing applications, major use of axis 1 movement and major use of bending backwards of axis 3.

3)

Severe chemical, thermal or similar environments can result in shortened life expectancy.

4)

Depending on application, the lifetime can vary. The Service Information System (SIS), integrated in the robot software, can be used as a guidance for planning service of gearbox for the individual robot. This applies to gearboxes on axes 1, 2, 3 and 6. The lifetime of gearbox axes 4 and 5 is not calculated by SIS (See the Operating manual - Service Information

System). In some applications such as Foundry or Washing the robot can be exposed to chemicals, high temperature or humidity, which can have an effect on the lifetime of the gearboxes. Contact the local ABB Robotics Service team for more information.

5)

The given life for the balancing device is based on a test cycle of 4,000,000 cycles that starts from the initial position and goes to maximum extension, and back. Deviations from this cycle will result in differences in expected life!

The SIS for an M2004 system is described in the Operating manual - Service Information

System. Document number can be found in section References on page 8

.

120



3 Maintenance

3.2.3. Expected component life

Continued

Expected component life - Foundry Prime

The demanding nature of using Foundry Prime robots in a washing application, can shorten the life of the robot’s components compared to that of standard robots in a typical robotic application. See


for standard robots. Depending on the actual washing application, the life of an individual robot can vary or being redused.

The life of Foundry Prime robots in washing applications will depend on a number of factors.

The most important factors are:

• the washing detergent used

• the ambient environment

• installation, maintenenace, and repair procedures

• the operation cycle of the robot.


3 Maintenance

3.3.1. Inspection, oil level gearbox axis 1

3.3 Inspection activities

3.3.1. Inspection, oil level gearbox axis 1

Location of gearbox

The axis 1 gearbox is located between the frame and base. The oil plugs are shown in the figure below. xx0600003449

A

B

C

Oil plug, filling

Oil plug, inspection

Oil plug, draining


Equipment

Lubricating oil

Standard toolkit


-

Art. no.

3HAC032140-001

Note

Kyodo Yushi TMO 150

Note! Do not mix with other oils!

The content is defined in the

section Standard toolkit on page

409

.


122



3 Maintenance


Continued

Inspection, oil level gearbox, axis 1

The procedure below details how to inspect the oil level in gearbox axis 1.

Note

1.

Action

2.

WARNING!

Handling gearbox oil involves several safety risks. Before proceeding, please read the safety information in the section

WARNING - Safety risks during work with gearbox lubricants (oil or grease) on page 44 .

DANGER!




SMB.

3. Open the filler plug.

Shown in the figure Location of gearbox on page 122

.

4. Required oil level: max. 5 mm below the oil plug hole.

5. Add oil if required.

6. Refit the oil plug, inspection.


Required equipment on page 122

.

Further information about how to fill the oil may be found in the section

Filling oil, axis 1 on page 167 .



3 Maintenance




The axis 2 gearbox is located in the lower arm rotational center, underneath the motor attachment. xx0600003451

A

B

C


Oil plug, filling

Oil plug, draining


Equipment, etc.,

Lubricating oil

Standard toolkit

Other tools and procedures may be required. See references to these procedures in the step-by-step instructions below.

-

Art. no.

3HAC032140-001

Note

Kyodo Yushi TMO 150



Standard toolkit on page

409 .


124



3 Maintenance


Continued

Inspection, oil level gearbox 2


Note

1.

Action

2.

WARNING!



DANGER!




SMB.

3. Open the oil plug, filling. Shown in the figure

Location of gearbox on page 124 .

4. Measure the oil level at the oil plug, filling.

Required oil level: max. 5 mm below the oil plug hole.

Shown in the figure



6. Refit the oil plug, filling.



.

Filling of oil is detailed further in the

section Filling, oil on page 170 .



3 Maintenance




The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. xx0200000230

A

B

C

Gearbox axis 3

Oil plug, filling

Oil plug, draining


Equipment, etc.

Lubricating oil

Standard toolkit


-

Art. no.

3HAC032140-001

Note

Kyodo Yushi TMO 150




409

.


126



3 Maintenance


Continued


The procedure below details how to inspect the oil level in the gearbox axis 3.

Note

1.

Action

WARNING!

Handling gearbox oil involves several safety risks. Before proceeding, please read the safety

information in the section WARNING - Safety risks during work with gearbox lubricants (oil or grease) on page 44

.

2. Move the robot to the calibration position. Detailed in the section

Calibration scale and correct axis position on page 390

.

3.

DANGER!




SMB.

4. Open the oil plug, filling.

Shown in the figure Location of gearbox on page 126 .

5. Required oil level: max. 5 mm below the oil plug hole.


Art. no. is specified in Required equipment on page 126 .


Filling, oil on page 173 .

7. Refit the oil plug, filling. Tightening torque: 24 Nm.


3 Maintenance




The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure below. xx0200000231

A

B

Oil plug, filling

Oil plug, draining


Equipment, etc.

Lubricating oil

Standard toolkit


Art. no.

-

11712016-604

Note

Mobilgear 600 XP320



.


128



3 Maintenance


Continued



Note

1.

Action

WARNING!

Handling gearbox oil involves several safety risks. Before proceeding, please read the

safety information in the section WARNING -

Safety risks during work with gearbox lubricants (oil or grease) on page 44

.

2. Move the robot to the calibration position. Shown in the section


.

3.

DANGER!




SMB.

4. Open the oil plug, filling. Shown in the figure


5. Required oil level: maximum 10 mm below the oil plug hole.


7. Refit the oil plug.


Further information about how to fill the

oil may be found in the section Filling, oil on page 176

.



3 Maintenance

3.3.5. Inspection, oil level, gearbox axis 5

3.3.5. Inspection, oil level, gearbox axis 5


The axis 5 gearbox is located in the wrist unit as shown in the figure below. xx0200000232

A

B

Oil plug, filling

Oil plug, draining

130 xx0500002013

-

A

B

C

The figure above shows the wrist unit of IRB 6640ID

Wrist unit, axis 5

Oil plug, filling

Oil plugs, draining



3 Maintenance

3.3.5. Inspection, oil level, gearbox axis 5

Continued


Equipment etc.

Lubricating oil

Standard toolkit


Art. no. Note

-

11712016-604 Mobilgear 600 XP320






Note

1.

Action

WARNING!

Handling gearbox oil involves several safety risks.

Before proceeding, please read the safety

information in the section WARNING - Safety risks during work with gearbox lubricants (oil or grease) on page 44 .

2. Move the robot upper arm to a horizontal position.

3. Turn the wrist unit in a way that both oil plugs are facing upwards.

4.

DANGER!




SMB.


6. Measure the oil level.

Required oil level to the upper edge of the oil plug hole (a): 30mm.


.



3HAC026876-001 Revision: F xx0500002222



Filling, oil, axis 5 on page 179 .


131

3 Maintenance





A

B

C

Gearbox axis 6

Oil plug, filling

Oil plug, draining xx0400001092

A

B

C

Gearbox, axis 6

Oil plug, filling

Oil plug, draining

132



3 Maintenance



-

A

B

C


Gearbox, axis 6

Oil plugs, draining

Oil plug, filling

Type of wrist

To inspect oil level for wrist type 1, see Inspection, oil level gearbox 6, wrist type 1 on page

134

.

To inspect oil level for wrist type 2, see Inspection, oil level gearbox 6, wrist type 2 on page

135

.



Lubricating oil

Lubricating oil (IRB 6640ID)

Standard toolkit


-

3HAC032140-001 Kyodo Yushi TMO 150


11712016-604 Mobilgear 600 XP320



409 .




133

3 Maintenance


Continued

Inspection, oil level gearbox 6, wrist type 1

Use this procedure to inspect the oil level in gearbox axis 6, for wrist type 1.

Note

1.

Action

2.

WARNING!




.

DANGER!




3. Make sure the oil plug, filling is facing upwards and open it.

Shown in the figure


4. Turn axis to 85 degrees. Oil should now start to run over. To much oil will give overrun before 85 degrees, to little oil in axis means oil will not spill over until after 85 degrees.




Filling, oil, axis 6 on page

182

.


7.

WARNING!

Do not mix the oil types. If wrong oil is refilled, the gearbox must be rinsed as detailed in the section

Type of oil .

134



3 Maintenance


Continued

Inspection, oil level gearbox 6, wrist type 2

Use this procedure to inspect the oil level in gearbox axis 6, for wrist type 2.

Note

1.

Action

2.

WARNING!



DANGER!




SMB.

3. Make sure the oil plug, filling is facing upwards and open it.


.

4. Measure the oil level.

• 55 mm ± 5 mm

• 15 mm (IRB 6640ID)


6. Refit the oil plug, filling. xx0500002222



Filling, oil, axis 6 on page 182

.




135

3 Maintenance


Continued

Analysis of water content in oil, gearbox axis 6 (Foundry Prime)

When changing oil, check for water content in oil.

If: Then....

1. More than 2% water in oil:

• With more than 2% water content there is a risk for corrosion in the gearbox and reduced viscosity in the oil.

Replacement of gearbox axis 6 is required every two years

2. Less than 2% water in oil.

xx0600003155

• A: Water content in oil from gearbox axis 6

• B: Months or hours in operation

• C: Replacement of gearbox axis 6

Normal replacement interval is required for gearbox axis 6, as specified by SIS or typically 96 months (as on a standard robot).

xx0600003156

• A: Water content in oil from gearbox axis 6

• B: Months or hours in operation


3 Maintenance

3.3.7. Inspection, balancing device

3.3.7. Inspection, balancing device

General

Several points are to be checked on the balancing device during the inspection. This section details how to perform the inspection regarding:

• dissonance

• damage

• leakage

• contamination / lack of free space.

Inspection points, balancing device

The balancing device is located at the top rear of the frame as shown in the figure below. The figure also shows the inspection points, further detailed in the instructions.

xx0600003431

D

E

F

A

B

C

Balancing device

Piston rod (inside balancing device)

Fork / Link ear

Shaft

Retaining ring, bore

Attachments in cradle (rear bearing)



137

3 Maintenance


Continued


Equipment, etc. Spare part no.

Design 1:

Maintenance parts, shaft

Design 2:


Design 1:

Maintenance parts, cradle

Design 2:


Securing screw

Toolkit for maintenance

Standard toolkit


3HAC029054-001

3HAC033411-001

3HAC029288-001

3HAC033413-001

Art. no. Note

For maintenance of balancing device.

Includes:

• bearings, o-rings and seals (Front bearing).


Includes:

• bearings, o-rings and seals (Front bearing).


Includes:

• bearing, o-ring and sealing (Rear

bearing).


Includes:

• bearing, o-ring and sealing (Rear

bearing).

Securing screw in the shaft.

M16 x 180

Locking liquid must be used when fitting the screw

(Loctite 243)!

3HAC028920-001

3HAC15571-1 The content is defined in the section


.


138



3 Maintenance


Continued

Check for dissonance

The check points are shown in the figure

Inspection points, balancing device on page 137

.

1.

2.

3.

Check for dissonance from...

If dissonance is detected...

• bearing at the link ear

• bearings at the balancing devices attachments.

• balancing device (a tapping sound, caused by the springs inside the cylinder).

• piston rod

(squeaking may indicate worn plain bearings, internal contamination or insufficient lubrication).

... perform maintenance according to given instructions in Maintenance kit, bearings and seals. The replacement of the bearing at the ear is also detailed in section

Replacement of spherical roller bearing, balancing device on page 292 .

Art. no. for the kit and the documentation are specified in section


...replace the balancing device or consult ABB Robotics.

How to replace the device is detailed in section

Replacement of balancing device . This section also specifies the spare part number!

... perform maintenance according to given instructions in Maintenance kit, complete.

Art. no. for the kit and the documentation are specified in section


Check for damage

Check for damages, such as scratches, general wear, uneven surfaces or incorrect positions.

The check points are shown in the figure

Inspection points, balancing device on page 137

.

1.

Check for damage on...

If damage is detected...

• the piston rod (part of the piston rod that is visible at the front of the balancing device).

... perform maintenance according to given instructions in Maintenance kit, complete.

Art. no. for the kit and the documentation

are specified in section Required equipment on page 138 .



139

3 Maintenance


Continued

Check for leakage - Design 1

The front ear of the balancing device is lubricated with grease. After filling, excessive grease may normally be forced out between the shaft and the sealing ring in the sealing spacer. This is normal behaviour and must not be confused with incorrect leaks from the ear.

Leaks at the o-rings and/or sealings, are not acceptable and must be attended to immediately in order to avoid any damage to the bearing!

Check the o-rings in the front ear of the balancing device for leaks, as shown and detailed below.

140 xx0700000111

A

B

C

D

Shaft

Sealing ring (radial) 2 pcs

O-ring

Sealing spacer

Action Note

1. Clean the area at the front ear from old grease.

2. Run the robot for some minutes, in order to move the balancing device piston.

3. Check the o-rings at the front ear for leakage.

Replace the o-rings, if any leaks are detected.

Excessive grease from between the shaft and the sealing ring is normal and is not considered as a leak!

The o-rings are included in the

Maintenance kit, bearings and seals, already assembled with sealing spacers and sealing rings.

Art. no. for the kit is specified in


.

The replacement of the complete bearing is also detailed in section

Replacement of spherical roller bearing, balancing device on page

292 .



3 Maintenance


Continued

Check for leakage - Design 2

The front ear of the balancing device is lubricated with grease.

Leaks at o-rings, sealings etc. are not acceptable and must be attended to immediately to avoid damage to the bearing.

Check the o-rings and sealings in the front ear of the balancing device for leaks.

Action

1. Clean the area at the front ear from contamination.

2. Run the robot for some minutes, in order to move the balancing device piston.

3.

Note

DANGER!




SMB.

4. Check the o-rings at the front ear for leakage.

5. Replace o-rings if leaks are detected.

The o-rings are included in the

Maintenance kit, bearings and seals already assembled with sealing spacers and sealing rings. Art. no. for the kit is specified in


Replement of the complete bearing is also described in section

Replacement of spherical roller

bearing, balancing device.

Check for contamination / lack of free space

Action

1.

DANGER!




2. Check that there are no obstacles inside the frame, that could prevent the balancing

device from moving freely. See the figure Inspection points, balancing device on page

137 .

Keep the areas around the balancing device clean and free from objects, such as service tools.


3 Maintenance

3.3.8. Inspection, cable harness

3.3.8. Inspection, cable harness

Introduction

This section describes how to inspect the cable harness. The procedure is divided in two parts:

•

Inspection of axes 1-4 is described in: Location of cable harness, axes 1-4 on page 142

and

Inspection, cable harness 1-4 on page 144 .

•

Inspection of axes 5-6 is described in: Location of cabling axes 5-6 on page 145 and

Inspection, cable harness, axes 5-6 on page 146 .

Location of cable harness, axes 1-4

The robot cable harness, axes 1-4, is located as shown in the figure below.

142 xx0600003434

IRB 6640 standard

A

B

C

Lower arm

SMB/BU unit

Connectors at base



3 Maintenance



IRB 6640 Cleanroom variant.

C

D

A

B

E

Connectors at base

Velcro straps

Cable harness

Side bracket balancing cylinder

Gripping clamp (4 pcs)


Equipment, etc. Art. no. Note

Standard toolkit


Circuit diagram




3HAC025744-001 See the chapter Circuit diagram .



143

3 Maintenance


Continued

Inspection, cable harness 1-4

The procedure below details how to inspect the cable harness of axes 1-4.

Note

1.

Action

DANGER!




SMB.

2. Make an overall visual inspection of the cable harness, in order to detect wear and damage.

3. Check the connectors at the base.

Shown in the figure Location of cable harness, axes 1-4 on page 142 .

4.

NOTE!

If the robot is used in a Foundry Prime application, check the cables for cracks in insulation.

5. Check that velcro straps are properly attached to the side bracket balancing cylinder.

Location shown in the figure

Location of cable harness, axes 1-4 on page 142 .

NOTE!

For Cleanroom robots, check all cable attachments as well as velcro straps.

Make sure the cable harness is properly attached to the robot and isn’t damaged.

6. Replace the cable harness if wear, cracks or damage is detected.

Detailed in section

Replacement of cable harness, axes 1-6 on page 203 .

Detailed in section

Replacement of cable harness, Cleanroom on page 224

.

144



3 Maintenance


Continued

Location of cabling axes 5-6

The robot cable harness, axes 5-6, is located as shown in the figure below. xx0600003435

IRB 6640 standard

A

B

C

Cable harness axes 5-6

Cable attachment, rear of upper arm

Cable attachment, upper arm tube xx0800000045

IRB 6640 Cleanroom variant.

A

B

C

D

Gripping clamp

Cable guide

Cover

Connectors at connection plate ax 3



145

3 Maintenance


Continued

Inspection, cable harness, axes 5-6

The procedure below details how to inspect the cable harness of axes 5-6.

Note

1.

Action

DANGER!




SMB.

2. Make an overall visual inspection of the cable harness, in order to detect wear and damage.

3. Check the attachments at the rear of the upper arm and in the upper arm tube.

Shown in the figure

Location of cabling axes 5-6 on page 145 .

4.

NOTE!

For Cleanroom robots also check the

connectors at the division point. Make sure the connection plate axis 3 is not bent or in any other way damaged.

Shown in the figure

Location of cabling axes 5-6 on page 145 .

5.

NOTE!

For Cleanroom robots, check all cable attachments as well as velcro straps.

Also check that the cable harness is fitted correctly at the cable guide on the armhouse.

Make sure the cable harness is properly attached to the robot and isn’t damaged.

Shown in the figure

Location of cable harness, axes 1-4 on page 142

.

NOTE!

If the robot is used in a Foundry Prime application, check the cables for cracks in insulation.

6. Replace the cable harness if wear, cracks or damage is detected.

Detailed in section Replacement of cable harness, axes 1-6 on page 203

.

Detailed in section Replacement of cable harness, axes 5-6 - IRB 6640ID on page 245 .

Detailed in section Replacement of cable harness, Cleanroom on page 224

.


3 Maintenance

3.3.9. Inspection of air hoses (Foundry Prime)

3.3.9. Inspection of air hoses (Foundry Prime)

General

The air hoses on Foundry Prime robots must be inspected for leakage every six months.


Equipment, etc.

Leak detection spray

Pressure gauge

Cut off valve -

-

-

Art. no.

Procedure

For this test it is recommended that the air supply to the robot has a pressure gauge and a cutoff valve connected.

Action Note

1. Apply compressed air to the air connector on robot base, and raise the pressure with the knob until the correct value is shown on the pressure gauge.

Recommended pressure:

0.2-0.3 bar

2. Close the cut off valve.

3. The time is < 5 seconds:

• If the answer is YES:

Localize the leakage by following the procedures below.

• If the anser is NO: The system is OK. Remove the leak testing equipment.

4. Pressurize by opening the cut off valve.

5. Spray suspected leak areas with

leak detection spray.

Bubbles indicate a leak.

6. When the leak is localized: correct the leak.

xx0600002794

• A: Air Connection

• B: Cut off valve

• C: Pressure gauge

It should take at least 5 seconds for the pressure to reach 0 bar.


3 Maintenance

3.3.10. Inspection of surface treatment (Foundry Prime)

3.3.10. Inspection of surface treatment (Foundry Prime)

Introduction to inspection of surface treatment

Damage to painted surfaces must be repaired as soon as possible to avoid corrosion. All painted surfaces on the robot must be inspected.


Equipment, etc.

Touch up paint Foundry Prime, orange

Touch up paint Foundry Prime 2, grey

Spare part no

3HAC037052-001

3HAC035355-001

Inspection and repair of surface treatment

Use this procedure to inspect the surface treatment on Foundry Prime robots.

Info Action

1. Inspect all painted surfaces for damages.

2. Repair damages as described in the instruction included in the spare part kit.


3 Maintenance

3.3.11. Inspection, information labels

3.3.11. Inspection, information labels

Location of labels

The figures below show the location of the information labels to be inspected. xx0600003457

A

I

B

C

J

-

M

Warning label concerning high temperature (4 pcs)

Warning sign, symbol of flash (located on motor cover) (5 pcs)

Instruction label

Warning label, tools are not allowed around the balancing device during operation

Warning label concerning shutting off power

Serial no. from rating label

Information labels about type of oil, at gearboxes and at robot base



149

3 Maintenance



H

K

N

M

L

E

F

G

Instructional label concerning lifting the robot

Warning label concerning risk of tipping

Foundry logotype

Warning label concerning stored energy

Abs-Acc information sign

Label calibration

Serial no. from rating label

UL-label


Equipment

Labels and plate set

Label set, oil labels

Art. no.

See the chapter

Spare parts.

See the chapter

Spare parts.

Note

Includes all labels specified in the two previous figures!

Includes only the oil labels at the gearboxes and at the robot base.

Are fitted to the robot if the gearboxes include Kyodo Yushi TMO 150.

150



3 Maintenance


Continued

Inspection, labels

1.

Action Note

DANGER!




SMB.

2. Check the labels, located as shown in the figures.

3. Replace any missing or damaged labels. Art. no. is specified in



3 Maintenance

3.3.12. Inspection, mechanical stop pin, axis 1

3.3.12. Inspection, mechanical stop pin, axis 1

Location of mechanical stop pin

The mechanical stop axis 1 is located at the base as shown in the figure below.

xx0600003436

A

B




Equipment, etc.

Mechanical stop pin axis 1

Standard toolkit

Art. no. Note

-

3HAC024014-001 To be replaced when damaged.



152



3 Maintenance

3.3.12. Inspection, mechanical stop pin, axis 1

Continued

Inspection, mechanical stop pin

The procedure below details how to inspect the mechanical stop pin axis 1.

Note

1.

Action

DANGER!




SMB.

2. Inspect the mechanical stop pin, axis 1. Shown in the figure

Location of mechanical stop pin on page 152

.

3. If the mechanical stop pin is bent or damaged, it must be replaced!


NOTE!

The expected life of gearboxes can be reduced as a result of collisions with the mechanical stop.


3 Maintenance

3.3.13. Inspection, additional mechanical stops

3.3.13. Inspection, additional mechanical stops

Location of mechanical stops

The figures below shows the location of the additional mechanical stops on axes 1, 2 and 3 . xx0600002938

A

B

C

D

Additional stop, axis 1

Attachment screws and washers (2 pcs)

Fixed stop


154



3 Maintenance



C

D

A

B


Fixed stop, axis 3


Fixed stop, axis 2


Equipment etc. Art. no. Note

Mechanical stop set, axis 1 3HAC025204-003 Includes:

• Stop +15°/-7.5°

• Stop +7.5°/-15°

• Attachment screws plus washers

• Document for movable mechanical stop

Mechanical stop axis 2 3HAC020885-001 Includes:

• Mechanical stop pin

• Attachment screw and washer

• Document for mechanical stop pin

Mechanical stop set, axis 3 3HAC025290-003 Includes:

• Mechanical stop pin

• Attachment screw and washer

• Document for mechanical stop pin





155

3 Maintenance


Continued

Inspection, mechanical stops

The procedure below details how to inspect the additional mechanical stops on axes 1,2 and 3.

Note

1.

Action

DANGER!




2. Check the additional stops on axes 1, 2 and 3 for damage.

Shown in the figure

Location of mechanical stops on page 154

.

3. Make sure the stops are properly attached.

Correct tightening torque, mechanical stop axis 1:

120 Nm.

4. If any damage is detected, the mechanical stops must be replaced!

Correct attachment screws (lubricated with Molycote

1000):

• Axis 1: M12 x 40

• Axis 2: M16 x 50

• Axis 3: M16 x 60



3 Maintenance

3.3.14. Inspection, damper axes 2-5

3.3.14. Inspection, damper axes 2-5

Location of dampers

The figure below shows the location of all the dampers to be inspected. xx0600003440

A

B

C

D

Damper, axis 2 (2 pcs)

Damper, axis 3 (2 pcs)

Damper, axis 4 (1 pc)

Damper, axis 5 (2 pcs) (IRB 6640ID: 4 pcs)


A damper must be replaced if damaged!

Equipment Spare part/ art. no. Note

Damper axis 2

Damper axis 3

Damper axis 4

Damper axis 5

Damper 1, axis 5

Damper 2, axis 5

Standard toolkit

3HAC12991-1

3HAC12320-1

3HAC13564-1

3HAB4337-2

3HAC021325-001

3HAC021675-001

3HAC15571-1

IRB 6640ID (2 pcs)

IRB 6640ID (2 pcs)



.



157

3 Maintenance

3.3.14. Inspection, damper axes 2-5

Continued

Inspection, dampers

The procedure below details how to inspect the dampers, axes 2-5.

Note

1.

Action

DANGER!




2. Check all dampers for damage, and for cracks or existing impressions larger than 1 mm.

To inspect the damper axis 4, remove the two covers on top of the upper arm!

Shown in the figure

Location of dampers on page 157 .

3. Check attachment screws for deformation.

4. If any damage is detected, the damper must be replaced with a new one!



.


3 Maintenance

3.3.15. Inspection, signal lamp (option)

3.3.15. Inspection, signal lamp (option)

Location of signal lamp

The signal lamp is located as shown in the figure below. Note that the position can differ depending on how the customer harness for axis 4-6 is mounted. See assembly drawing on the current harness for alternative positioning.

xx0600003071

A

B

C

D

E

UL signal lamp

Clamp

Cable strap, outdoor

Motor, axis 3

Attachment screw, M6x8 quality 8-A2F(2 pcs)


Equipment, etc.

Signal lamp

Standard toolkit


-

Art. no.

3HAC10830-1

Note

To be replaced in case of detected damage.






159

3 Maintenance

3.3.15. Inspection, signal lamp (option)

Continued

Inspection, signal lamp

The procedure below details how to inspect the function of the signal lamp.

Action

1. Check that the signal lamp is lit when the motors are put in operation ("MOTORS ON").

2.

Note

DANGER!




3. If the lamp is not lit, trace the fault by:

• Checking whether the signal lamp is broken.

If so, replace it.

• Checking the cable connections.

• Measuring the voltage in connectors motor axis 3 (=24V).

• Checking the cabling. Replace cabling if a fault is detected.



.


3.4 Replacement / Changing activities

3.4.1. Type of oil in gearboxes

Location of gearboxes

The figure shows the location of the gearboxes on the robot.

3 Maintenance

3.4.1. Type of oil in gearboxes xx0600003442

C

D

A

B

E

F

Gearbox, axis 1

Gearbox, axis 2

Gearbox, axis 3

Gearbox, axis 4

Gearbox, axis 5

Gearbox, axis 6 xx0500002226

E

F

Axis 5 gearbox, IRB 6640ID

Axis 6 gearbox, IRB 6640ID



161

3 Maintenance

3.4.1. Type of oil in gearboxes

Continued

Type of oil - historically used

The gearboxes of the robot have historically been filled with different types of oils. Today only the types of oil specified in the table is recommended.

NOTE!

When there is a change of oil types in the gearbox, it needs to be rinsed. See

Rinsing the gearbox on page 164 .

CAUTION!

When filling gearbox oil, do not mix different types of oil as this may cause severe damage to the gearbox! Always use the type of oil specified in the table!

If oils are mixed, the gearbox must be thoroughly rinsed! See Rinsing the gearbox on page

164

.

Type of oil - currently used

The table show which types of oil are used in gearboxes.

Gearbox

Axis 1

Axis 2

Axis 3

Axis 4

Axis 5

Type of oil

Kyodo Yushi TMO 150

Kyodo Yushi TMO 150

Kyodo Yushi TMO 150

Mobilgear 600 XP320

Mobilgear 600 XP320

Axis 6IRB 6640 Kyodo Yushi TMO 150

Axis 6, IRB 6640ID Mobilgear 600 XP320

Art. no.

Amount

3HAC032140-001 6,100 ml

3HAC032140-001 5,800 ml

3HAC032140-001 2,500 ml

11712016-604

11712016-604

8,100 ml

IRB 6640:

6,700 ml

IRB 6640ID:

5,000 ml

3HAC032140-001 450 ml

11712016-604 6,000 ml

Labels next to oil plugs

Labels located next to the oil plugs of each gearbox show which type of oil it contains. All gearboxes must have the correct label clearly visible.

xx0800000230 xx0800000241

Labels located next to the oil plugs

162



3 Maintenance


Continued

Labels at robot base

Label located at robot base show the types of oil in all gearboxes.

xx0600003448

IRB 6640

Label at robot base, (example of label on robot base)

Mixed types of oil may cause severe damage!

When refilling or replacing oil in a gearbox it is important to first check which type of oil is recommended for use in the gearbox. As Kyodo Yushi TMO 150 (as well as Shell Tivela S

150) is not compatible with mineral oil, contamination with other types of oil in the gearboxes is not accepted. Equipment used in handling Kyodo Yushi (as well as Shell Tivela S 150) must be carefully cleaned before use!

If the type of oil needs to be changed, the gearbox must be thoroughly rinsed. See Rinsing the gearbox on page 164 .

NOTE!

When filling gearbox oil, do not mix different types of oil as this may cause severe damage to the gearbox! Always use the recommended oil!



163

3 Maintenance


Continued

Rinsing the gearbox

Depending on which types of oil are mixed and which type of oil shall be filled in the gearbox after rinsing, use the appropriate procedure.

The same applies if the type of oil shall be changed in the gearbox.

NOTE!

The explanation given for Kyodo Yushi TMO 150 also applies to Shell Tivela S 150.

The explanation given for Mobilgear 600 XP320 also applies to Mobil Gearlube X320.

Kyodo Yushi TMO 150 mixed with Optimol Optigear RMO 150/Optigear RO 150

Use this procedure to rinse the contaminated gearbox if the oil types Kyodo Yushi TMO 150 and Optimol Optigear RMO 150/Optigear RO 150 are mixed.

• Flush the gearbox properly three times with the correct type of oil. Use a service program when flushing.

• Refill the gearbox with the correct type of oil.

Kyodo Yushi TMO 150 mixed with Mobilgear 600 XP320

Use this procedure to rinse the contaminated gearbox if the gearbox shall contain Kyodo

Yushi TMO 150 and it is mixed with Mobilgear 600 XP320.

• Flush the gearbox properly three times with Kyodo Yushi TMO 150. Use a service program when flushing.

• Refill the gearbox with Kyodo Yushi TMO 150.

Equipment

Equipment

Label set

Oil change equipment

Art. no.

Note

See Spare Parts.

Includes small labels for each gearbox and the complete label to be fitted at the robot base.

NOTE!

The correct labels must be fitted to the robot in case of changing of oil types!

3HAC021745-001 Includes pump with outlet pipe.


3 Maintenance

3.4.2. Oil change, gearbox axis 1

3.4.2. Oil change, gearbox axis 1

Location of oil plugs

The axis 1 gearbox is located between the frame and base. The oil plugs for filling and inspection are shown in the figure below. xx0600003449

A

B

C

Oil plug, filling


Oil plug, draining


Equipment, etc.

Lubricating oil

Oil collecting vessel

Oil exchange equipment

Standard toolkit

Art. no. Amount Note

-

3HAC032140-001 6,000 ml Kyodo Yushi TMO 150

Note! Do not mix with other oil types!

Capacity: 8,000 ml.

3HAC021745-001 The content is defined in the

section Special tools on page

410

.



409

.



165

3 Maintenance


Continued

Draining oil, axis 1

The procedure below details how to drain the oil in gearbox axis 1.

When using the oil exchange equipment, follow the instructions enclosed with the kit. Art.

no. for the kit is specified in Required equipment on page 165 .

Note

1.

Action

2.

DANGER!




SMB.

WARNING!


WARNING -

Safety risks during work with gearbox lubricants (oil or grease) on page 44 .

3. Collect the drained oil in an oil vessel.

Vessel capacity is specified in


.

4. Remove the oil plug, filling, in order to drain the oil quicker!

Shown in the figure

Location of oil plugs on page 165

.

5. Open the oil plug, draining and drain the oil into the vessel.

NOTE!

The draining is time-consuming.

Elapsed time depends on the temperature of the oil.

6. Refit the oil plug, draining.

166



3 Maintenance


Continued

Filling oil, axis 1

The procedure below details how to fill the oil in gearbox axis 1.

Note

1.

Action

2.

DANGER!




WARNING!


Before proceeding, please read the safety information

in the section WARNING - Safety risks during work with gearbox lubricants (oil or grease) on page 44 .


Shown in the figure Location of oil plugs on page 165 .

4. Refill the gearbox with lubricating oil.

The amount of oil to be refilled depends on the amount previously being drained. The correct oil level

is detailed in section Inspection, oil level gearbox axis

1 on page 122

.

Art. no. and the total amount are

specified in Required equipment on page 165 .

5.

Detailed in section

Type of oil in gearboxes on page 161

.

NOTE!

Do not mix Kyodo Yushi TMO 150 with other oil types!

6. Refit the oil plug, filling. Tightening torque: 24 Nm.


3 Maintenance



Location of oil plugs

The gearbox, axis 2, is located in the lower arm rotational center, underneath the motor attachment. xx0600003451

A

B

C


Oil plug, filling

Oil plug, draining


Equipment, etc. Art. no.

Lubricating oil

Amount

3HAC032140-001 5,800 ml

Oil collecting vessel -


3HAC021745-001

Standard toolkit -

Note

Kyodo Yushi TMO 150


Capacity: 6,000 ml.



410

.


section Standard toolkit on page 409 .

168



Draining, oil

3 Maintenance


Continued

The procedure below details how to drain the oil in gearbox axis 2.



Note

1.

Action

2.

DANGER!




SMB.

WARNING!




.

3. Remove the oil plug, draining, and drain the gearbox oil using a hose with nipple and an oil collecting vessel.

Remove the oil plug, filling in order to drain the oil quicker!

Shown in the figure

Location of oil plugs on page 168

.

Vessel capacity is specified in Required equipment on page 168 .


NOTE!

Draining is time-consuming. Elapsed time varies depending on the temperature of the oil.




169

3 Maintenance


Continued

Filling, oil

The procedure below details how to fill oil into the gearbox, axis 2.



Note

1.

Action

2.

DANGER!




WARNING!


Before proceeding, please read the safety information in the section


3. Remove the oil plug, filling and the oil plug,

inspection.


The amount of oil to be refilled depends on the amount previously being drained. The correct oil level is detailed in section

Inspection, oil level gearbox axis 2 on page 124 .

5.

Shown in the figure

Location of oil plugs on page 168 .

Art. no. and total amount are


Detailed in section Type of oil in gearboxes on page 161

.

NOTE!

Don´t mix Kyodo Yushi TMO 150 with other oil types!

6. Refit the oil plug. Tightening torque: 24 Nm.


3 Maintenance

3.4.4. Oil change, gearbox, axis 3

3.4.4. Oil change, gearbox, axis 3


The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below. xx0200000230

A

B

C

Gearbox axis 3

Oil plug, filling

Oil plug, draining


Equipment, etc.

Lubricating oil



Standard toolkit

Art. no. Amount Note

-

-

3HAC032140-001 2,500 ml Kyodo Yushi TMO 150


3HAC021745-001 The content is defined in the


410

.

Capacity: 3,000 ml.



409

.



171

3 Maintenance


Continued

Draining, oil

The procedure below details how to drain oil from the gearbox, axis 3.



Note

1.

Action

2.

DANGER!




SMB.

WARNING!




.

3. Remove the oil plug, draining, and drain the gearbox oil using a hose with nipple and an oil collecting vessel.


Shown in the figure

Location of gearbox on page 171

.



.


NOTE!

Draining is time-consuming. Elapsed time varies depending on the temperature of the oil.


172



Filling, oil

3 Maintenance


Continued




Note

1.

Action

2.

DANGER!




WARNING!



WARNING - Safety risks during work with gearbox lubricants (oil or grease) on page 44

.

3. Remove the oil plug, filling.

Shown in the figure Location of gearbox on page 171 .


The amount of oil to be refilled depends on the amount previously drained. The correct oil level is detailed in

the section Inspection, oil level gearbox axis 3 on page 126

Art. no. and total amount are specified in


5.

Detailed in the section

Type of oil in gearboxes on page 161

.

NOTE!




3 Maintenance




The axis 4 gearbox is located in the rearmost part of the upper arm as shown in the figure below. xx0200000231

A

B

Oil plug, filling

Oil plug, draining



Lubricating oil 11712016-604

Oil exchange equipment 3HAC021745-001


Standard toolkit -

-

Amount Note

8,100 ml Mobilgear 600 XP 320


Special tools on page

410 .

Capacity: 9,000 ml.



.

174



Draining, oil

3 Maintenance


Continued

The procedure below details how to drain the oil in the gearbox, axis 4.



Note Action

1. Run the upper arm -45° from the calibration position.

2.

3.

DANGER!




SMB.

WARNING!

Handling gearbox oil involves several safety risks. Before proceeding, please read the safety


.

4. Drain the oil from the gearbox into a vessel by opening the oil plug, draining.



.



.

5. Run the upper arm back to its calibration position (horizontal position).

6. Refit the oil plug, draining.

Shown in the section Calibration scale and correct axis position on page 390


.



175

3 Maintenance


Continued

Filling, oil

The procedure below details how to fill the oil in the gearbox, axis 4.



Note

1.

Action

2.

DANGER!




WARNING!




.

3. Refill the gearbox with lubricating oil through the oil plug, filling.

Shown in the figure


The amount of oil to be refilled depends on the amount previously being drained. The correct oil level is detailed in the section

Inspection, oil level gearbox axis 4 on page 128 .

Art. no. and total amount are specified in


.



3 Maintenance





A

B

Oil plug, filling

Oil plug, draining xx0500002013

A

B

C

Wrist unit of IRB 6640ID

Oil plug, filling

Oil plug, draining



177

3 Maintenance


Continued


Equipment, etc.

Lubricating oil

Art. no.

11712016-604



Standard toolkit -

-

Amount Note

IRB 6640:

6,700 ml

IRB 6640ID:

5,000 ml

Mobilgear 600 XP 320


Special tools on page

410 .

Capacity: 7,000 ml.



.

Draining, oil, axis 5

The procedure below details how to change the oil in gearbox, axis 5.



Action

1. Run axis 4 to a position where the oil plug, draining, is facing downwards.

2.

Note

3.

DANGER!




SMB.

WARNING!




.

4. Drain the oil from the gearbox by opening the oil plug, draining.



.



.

5. Refit the oil plug, draining. Tightening torque: 24 Nm.

178



3 Maintenance


Continued

Filling, oil, axis 5

The procedure below details how to change the oil in gearbox, axis 5.



Action

1. Run axis 4 to a position where the oil plug, filling, is facing upwards.

2.

Note

3.

WARNING!



WARNING - Safety risks during work with gearbox lubricants (oil or grease) on page 44

.

DANGER!




SMB.

4. Refill the gearbox with lubricating oil through the oil plug, filling.

The amount of oil to be refilled depends on the amount previously being drained. The correct oil

level is detailed in the section Inspection, oil level, gearbox axis 5 on page 130 .


.

Art. no. and total amount are




3 Maintenance




The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below. xx0400001092

A

B

C

Gearbox, axis 6

Oil plug, filling

Oil plug, draining

180 xx0500002017

-

A

B

C


Gearbox, axis 6

Oil plug, draining

Oil plug, filling



3 Maintenance


Continued


Equipment, etc. Art. no. Amount Note

Lubricating oilIRB 6640ID 11712016-604

Lubricating oil IRB 6640


3HAC032140-001

3HAC021745-001

6,000 ml

450 ml

Mobilgear 600 XP320

Kyodo Yushi TMO 150

Note! Do not mix with other oil types.



410

.


Standard toolkit -

Vessel capacity:

500 ml

7,000 ml (IRB 6640ID)



Draining, oil, axis 6

The procedure below details how to drain oil from the gearbox, axis 6.



Action

1. IRB 6640:

Run the robot to a position where the oil plug,

draining of axis 6 gearbox is facing downwards and the oil plug, filling, is facing upwards.

IRB 6640ID:

Run the robot to a position where the oil plug,

draining is facing downwards.

2.

Note

Shown in the figure


3.

DANGER!




SMB.

WARNING!




.

4. Drain the oil from the gearbox into a vessel by removing the oil plug.

5. Refit the oil plug, draining.



.




181

3 Maintenance


Continued

Filling, oil, axis 6




Note

1.

Action

2.

DANGER!




WARNING!




.

3. Remove the oil plug, filling.


The amount of oil to be refilled depends on the amount previously drained. The correct oil level is

detailed in the section Inspection, oil level gearbox axis 6 on page 132

.

5.


.

Art. no. and the total amount are specified in



Type of oil in gearboxes on page 161 .

NOTE!




3 Maintenance

3.4.8. Replacement of SMB battery

3.4.8. Replacement of SMB battery

NOTE!

The SMB lithium battery lifetime can be extended significantly during a production break.

Activate sleep mode in IRC5 by a service routine that is described in Operating manual –

IRC5 with FlexPendant, chapter Battery shutdown service routine.

Location of SMB battery

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

xx0600003444

A

B

C

D

Cover, battery box

Battery pack

Cable, battery

Battery holder


Equipment, etc.

Battery pack

Standard toolkit

Circuit Diagram

-

Spare part no. Note

3HAC16831-1

-

3HAC025744-001

Battery includes protection circuits. Replace it only with a given spare part number or an ABB approved equivalent.



.




183

3 Maintenance


Continued

Removal, battery

The procedure below details how to remove the SMB battery.

Action

1. Move the robot to its calibration position.

Note

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

2.

3.

DANGER!




SMB.

esd

WARNING!

The unit is sensitive to ESD. Before handling the unit please read the safety information in the

section WARNING - The unit is sensitive to ESD! on page 43

4. Remove the SMB battery cover by unscrewing its attachment screws.

Shown in the figure Location of SMB battery on page 183

.

5. Pull out the battery and disconnect the battery

cable.


.

6. Remove the SMB battery.

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


.

184



3 Maintenance


Continued

Refitting, battery

The procedure below details how to refit the SMB battery.

Note

1.

Action

2.

DANGER!




SMB.

esd

WARNING!

The unit is sensitive to ESD. Before handling the unit please read the safety information in the section

WARNING - The unit is sensitive to

ESD! on page 43

3. Reconnect the battery cable to the SMB battery

pack and fit it to the frame.



.

4. Secure the SMB battery cover with its attachment screws.

5. Update the revolution counter.


.

Detailed in the chapter Calibration - section

Updating revolution counters on page 392

.

6.

DANGER!

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

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

41 .


3 Maintenance

3.5.1. Lubrication of spherical roller bearing, balancing device

3.5 Lubrication activities

3.5.1. Lubrication of spherical roller bearing, balancing device

Location of bearing (Design 1)

The spherical roller bearing is located at the front ear of the balancing device, as shown in the figure below.

Note! The balancing device must be mounted on the robot when lubricating the bearing!

186 xx0700000361

A

B

Lubrication hole on ear

Spherical roller bearing



Location of bearing (Design 2)

3 Maintenance

3.5.1. Lubrication of spherical roller bearing, balancing device

Continued



Grease

Lubrication nipple

Grease pump

Note

3HAA1001-294 Optimol PDO, 20 ml

M6. Normally not fitted to the link ear at delivery.

-

Lubrication, balancing device bearing

The procedure below details how to lubricate the spherical roller bearing.

Note

1.

Action

DANGER!


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

2. Lubricate the spherical roller bearing through the lubrication nipple in the ear with grease.

Fill until excessive grease is forced out between the shaft and the sealing spacer.

Art. no. and amount is specified in

Required equipment on page 187 !

Shown in the figure Location of bearing

(Design 1) on page 186 !

The balancing device must be mounted on the robot when lubricating the bearing!

3. Clean the area from any excessive grease and check the area once again after operation of the robot, in order to make sure there is no incorrect leakage from the o-rings.

Read more about the inspection in section Inspection, balancing device -

Check for leakage - Design 1 on page

140 .


3 Maintenance

3.5.2. Rust preventive measures, sealing axis 4 (Foundry Prime)

3.5.2. Rust preventive measures, sealing axis 4 (Foundry Prime)

Overview

The sealing axis 4 is located as shown in the illustration.

xx0500002869

A

B

Cover

Cable guide


Equipment

Brush

Rust preventive

Standard toolkit


Art. no.

Note

-

3HAC026621-001 Equivalent:

• Mercasol 3106



409

.


188



Procedure

3 Maintenance


Continued

The procedure describes how to apply rust preventive on sealing axis 1.

Note Action

1. Put the robot in a suitable position.

2.

DANGER!




3. Remove the cover at the rear end of the upper arm.

4. Remove the cable guide that covers the sealing.

xx0600002872

Parts:

• A: Cover

• B: Cable guide

5. Wipe the surface under the cable

guide.

xx0600002871

Parts:

• A: Cable guide



189

3 Maintenance


Continued

Action

6. Apply rust preventive on the radial

sealing and the rear part of the tube with a brush.

Note

7. Refit the radial sealing and cable

guide.

xx0600002868

Parts:

• A: Radial sealing and rear part of tube

• B: Cable guide


3 Maintenance

3.5.3. Rust preventive measures, support bearing in wrist (Foundry Prime)

3.5.3. Rust preventive measures, support bearing in wrist (Foundry Prime)

Location of bearing

The support bearing in the wrist is located as shown in the illustration.

xx0500002863

A

B

C


Equipment

Brush

Rust preventive

Standard toolkit

Bearing

Cable bracket

Cover

Art. no.

-

3HAC026621-001


Note

Equivalent:

• Mercasol 3106






191

3 Maintenance

3.5.3. Rust preventive measures, support bearing in wrist (Foundry Prime)

Continued

Greasing bearings

The procedure describes how to apply rust preventive on the support bearing.

Note Action

1. Put the robot and the upper arm in a suitable position.

2.

DANGER!




3. Dismantle the air hose from motor axis 6.

4. Tighten the hose clamp on motor axis 6, and remove the air hose.

5. Remove the cover.

6. Apply rust preventive on the bearing and cable

bracket with the brush.

7. Refit the cover.

8. Perform a leakdown test.

A xx0600002864

• A: Cover

See Location of bearing on page

191

.

See Inspection of air hoses

(Foundry Prime) on page 147

.


3 Maintenance

3.6.1. Cleaning, robot

3.6 Cleaning activities

3.6.1. Cleaning, robot

WARNING!

Turn off all electrical power supplies to the manipulator before entering the manipulators work space!

General

To secure high uptime it is important that the robot is cleaned regularly. The frequency of cleaning depends on the environment that the robot is working in.

Depending on the protection of the robot, different methods of cleaning of the robot are allowed. This section describes how to clean a robot with protection Standard, Foundry Plus,

Foundry Prime and Clean Room.

NOTE!

Always check the serial number sign for verification about the robot protection class.

Cleaning activities

This instruction specifies allowed cleaning methods for each protection class.

Cleaning method

Standard Foundry Plus Foundry Prime

Clean

Room

Vacuum cleaner.

Wipe with cloth.

Rinse with water.

Yes.

Yes. With light cleaning detergent.

High pressure water or steam according to chapter

Cleaning with water and steam below.

No.

Yes.

Yes. With light cleaning detergent or spirit.

Yes. It is highly recommended that water contains a rust prevention solution and that the robot is dried afterwards.

Yes. It is highly recommended that water contains a rust prevention solution.

Yes. It is highly recommended that water and steam contains rust preventive, without cleaning detergents.

Yes.

Yes.

Yes. With cleaning detergent approved by ABB, spirit or isopropyl alcohol.

Yes. With light cleaning detergent, spirit or isopropyl alcohol.

Yes. It is highly recommended that water contains a rust prevention solution.

No.

Yes. It is highly recommended that water and steam contains rust preventive. If cleaning detergents are used they must be approved by ABB for Foundry Prime robots.

No.



193

3 Maintenance

3.6.1. Cleaning, robot

Continued

Cleaning with water and steam

Cleaning methods that can be used for ABB robots with protection Standard, Foundry Plus,

Wash, Foundry Prime.

Equipment, etc. Note

Vacuum cleaner

Cloth with mild detergent

Water cleaner

Steam cleaner

• Max. water pressure at the nozzel: 700 kN/m 2 (7 bar)

(1)

• Fan jet nozzle should be used, min. 45° spread

• Distance from nozzle to encapsulation: min. 0.4 m

• Flow: max. 20 liters/min

(1)

.

• Water pressure at nozzle: max. 2,500 kN/m 2 (25 bar)

• Type of nozzle: fan jet, min. 45° spread

• Distance from nozzle to encapsulation: min. 0.4 m

• Water temperature: max. 80° C

1) Typical tap water pressure and flow

Cables

Movable cables need to be able to move freely:

• Remove waste material, for example sand, dust, and chips, if it prevents cable movement.

• Clean the cables if they have a crusty surface for example from dry release agents.

Do's and don'ts!

The section below specifies some special considerations when cleaning the robot.

Always!

• Always use cleaning equipment as specified above! Any other cleaning equipment may shorten the life of the robot.

• Always check that all protective covers are fitted to the robot before cleaning!

Never!

• Never point the water jet at connectors, joints, sealings or gaskets!

• Never use compressed air to clean the robot!

• Never use solvents that are not approved by ABB to clean the robot!

• Never spray from a distance closer then 0.4m!

• Never remove any covers or other protective devices before cleaning the robot!


4 Repair

4.1. Introduction

4 Repair


Structure of this chapter

This chapter details all repair activities recommended for the robot and any external units of the robot.

It is made up of separate procedures, each detailing a specific repair activity. Each procedure contains all the information required to perform the activity, for example spare parts numbers, required special tools and materials.

The procedures are gathered in sections, divided according to the component location on the robot.


All equipment required to perform a specific repair activity is listed together with the current procedure.

The equipment is also gathered in different lists in chapter Reference information .


Before any service work is commenced, it is extremely important that all safety information is read!

There are general safety aspects that must be read through, as well as more specific safety information that describes the danger and safety risks when performing specific steps in a procedure. Make sure to read through the chapter

Safety on page 15 before commencing any

service work.

NOTE!

If the robot is connected to power, always make sure that the robot is connected to earth before starting any repair work!




4 Repair

4.2.1. Performing a leak-down test

4.2 General procedures

4.2.1. Performing a leak-down test

General

After refitting any motor and gearbox, the integrity of all seals enclosing the gearbox oil must be tested. This is done in a leak-down test.


Equipment, etc.

Leakdown tester

Leak detection spray

Art. no.

3HAC0207-1

-

Note

Procedure

Action Note

1. Finish the refitting procedure of the motor or gear in question.

2. Remove the topmost oil plug on the gear in question and replace it with the leakdown tester.

Adapters, which are included in the leakdown tester kit, may be required.


3. Apply compressed air and raise the pressure with the knob until the correct value is shown on the manometer.

Recommended value:

0.2 - 0.25 bar (20 - 25 kPa)

4. Disconnect the compressed air supply.

5. Wait for approx. 8-10 minutes. No pressure loss may be detected.

If the compressed air is significantly colder or warmer than the gearbox to be tested, a slight pressure increase or decrease may occur. This is quite normal.

6. Was any pressure drop evident?

Localize the leak as detailed below.

Remove the leakdown tester and refit the oil plug.

The test is complete.

7. Spray suspected leak areas with leak detection spray.

Bubbles indicate a leak.

8. When the leak has been localized, take the necessary measures to correct the leak.


4 Repair

4.2.2. Mounting instructions for bearings

4.2.2. Mounting instructions for bearings

General

This section details how to mount and grease different types of bearings on the robot.

Equipment

Equipment, etc.

Grease

Art. no.

3HAB3537-1

Note

Used to grease the bearings, if not specified otherwise.

Assembly of all bearings

Follow the instructions below when mounting a bearing on the robot.

Action

1. To avoid contamination, let a new bearing remain in its wrapping until it is time for fitting.

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

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

Note

Assembly of tapered bearings

Follow the previous instructions for assembly of all bearings when mounting a tapered bearing on the robot.

In addition to those instructions, the procedure below must be carried out to enable the roller elements to adjust to the correct position against the race flange.

Action

1. Tension the bearing gradually until the recommended pre-tension is achieved.

Note

NOTE!

The roller elements must be rotated a specified number of turns before pre-tensioning is carried out and also rotated during the pretensioning sequence.

2. Make sure the bearing is properly aligned as this will directly affect the lifespan of the bearing.



197

4 Repair

4.2.2. Mounting instructions for bearings

Continued

Greasing of bearings

The bearings must be greased after assembly in accordance to the instructions below:

• The bearings must not be completely filled with grease. However, if space is available beside the bearing fitting, the bearing may be totally filled with grease when mounted, as excessive grease will be pressed out from the bearing when the robot is started.

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

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

Grease the different types of bearings as detailed below:

• Grooved ball bearings must be filled with grease from both sides.

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


4 Repair

4.2.3. Mounting instructions for seals

4.2.3. Mounting instructions for seals

General

This section details how to mount different types of seals onto the robot.

Equipment

Equipment, etc.

Grease

Art. no.

3HAB3537-1

Note

Used to lubricate the seals.

Rotating seals

The procedure below details how to fit rotating seals.

CAUTION!

Please observe the following before commencing any assembly of seals:

• Protect the sealing surfaces during transport and mounting.

• Keep the seal in its original wrappings or protect it well before actual mounting.

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

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

Action Note

1. Check the seal to ensure that:

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

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

2. Inspect the sealing surface before mounting. If scratches or damage are found, the seal must be replaced since it may result in future leakage.

3. Lubricate the seal with grease just before fitting. (Not too early - there is a risk of dirt and foreign particles adhering to the seal.)

Fill 2/3 of the space between the dust tongue and sealing lip with grease. The rubber coated external diameter must also be greased, unless otherwise specified.


Equipment on page 199 .

4. Mount the seal correctly with a mounting tool.

Never hammer directly on the seal as this may result in leakage.



199

4 Repair

4.2.3. Mounting instructions for seals

Continued

Flange seals and static seals

The procedure below details how to fit flange seals and static seals.

Action

1. 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).

If the flange surfaces are defective, the parts may not be used because leakage could occur.

2. Clean the surfaces properly and in accordance with ABB recommendations.

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

4. Tighten the screws evenly when fastening the flange joint.

O-rings

The procedure below details how to fit o-rings.

Action Note

1. Ensure that the correct o-ring size is used.

2. Check the o-ring for surface defects, burrs, shape accuracy, etc.

Defective o-rings may not be used.

3. Check the o-ring grooves.

The grooves must be geometrically correct and free from pores and contamination.

Defective o-rings may not be used.

4. Lubricate the o-ring with grease.

5. Tighten the screws evenly when assembling.


4 Repair

4.2.4. Exchange of parts on Clean room robots

4.2.4. Exchange of parts on Clean room robots

General

When exchanging parts on a Clean room robot, it is important to make sure that after the exchange, no particles will be emitted from the joint between the structure and the new part and that the easy cleaned surface is retained.


Equipment

Sealing compound

Tooling pin

Spirit

Knife

Lint free cloth

Spare parts

See the chapter Spare parts.

Note

Sikaflex 521 FC. Color white.

Width 6-9 mm, made of wood.

Etanol

Disassemble

Use this procedure when dismantling a part for exchanges on a Clean room robot.

Action

1. Cut the paint with a knife in the joint between the part that will be dismantled and the structure, to avoid that the paint cracks.

Description

2. Grind the paint edge left on the structure carefully to a smooth surface.

xx0900000121



201

4 Repair

4.2.4. Exchange of parts on Clean room robots

Continued

Assemble

Action

1. After the parts is mounted, clean the joint free from oil and grease.

2. Seal the joint with

Sikaflex 521FC.

Description

3. Smooth the joint with a tooling pint that has been placed in hot water before use. xx0900000122 xx0900000125

NOTE!

After all repair work, wipe the robot free from particles with spirit on a cloth.


4 Repair

4.3.1. Replacement of cable harness, axes 1-6

4.3 Complete robot

4.3.1. Replacement of cable harness, axes 1-6

General

This section details how to replace the cable harness that runs undivided from axis 1 to axis 6.

Replacement or cable harness for Foundry Prime

For replacement of cable harness on robots with option Foundry Prime, see Replacement of

cable harness, axis 1-6 - Option Foundry Prime, 3HAC037959-005 (available on ABB

Library).

Location of cable harness

The cable harness of axes 1-6 is run throughout the robot as shown in the figure below.

xx0700000102

E

F

G

C

D

A

B

Connectors at motor, axis 2 (R2.FB2, R2.MP2)

Connectors at motor, axis 1 (R2.FB1, R2.MP1)

Rear cover plate

Earth (attachment point is placed under the cover plate)

Cable harness

Cable holder

Velcro strap



203

4 Repair


Continued

N

O

P

R

K

L

H

J

M

Guide plate ax 2

Cable guide

Connector R1.MP

Connector R1.SMB

Cable protector (placed inside the lower arm)

Position for SMB and brake release units

Cable harness (cut away view)

Velcro strap (inside lower arm on metal clamp)

Cable gland (armhouse)


Equipment


Gasket

Standard toolkit

Spare part no.

See Spare parts chapter.

-

3HAC033489-001


Circuit diagram 3HAC025744-001

Note

Motor axis 6



.



204



4 Repair


Continued

Cable brackets of the upper arm xx0500002293

A

B

C

Cable bracket, wrist unit

Cable bracket, upper arm tube

Cable attachment, rear

Removal, cable harness - upper arm

The procedure below details how to remove the cable harness from the upper arm of the robot.

Action

1. In order to facilitate refitting of cable harness, run the robot to the specified position:

• Axis 1: 0 °

• Axis 2: 0 °

• Axis 3: 0 °

• Axis 4: 0 °

• Axis 5: +90 °

• Axis 6: no significance

2.

Note

Axes 2 and 3 may be tilted slightly to improve access.

DANGER!




SMB.

3. Remove the cover, wrist unit and the cover,

upper arm tube.

3HAC026876-001 Revision: F xx0200000214

A. Cover, wrist unit

B. Cover, upper arm tube


205

4 Repair


Continued

4.

Action Note

NOTE!

Axis 5 must be oriented in the correct position

(+90º) to allow the motor 6 cover to open!

5. Remove the cover of motor, axis 6 and disconnect all connectors beneath.

6. Loosen the cable bracket, wrist unit by undoing the three attachment screws.

Two of the attachment screws are visibly located at the rear of the bracket and the third is located at the bottom of the cable bracket, in the center.

Shown in the figure

Cable brackets of the upper arm on page 205 .

xx0200000254

• B: Attachment screws, rear of cable bracket (2 pcs)

• C: Attachment screw, bottom of cable bracket

7. Pick out the cabling from motor, axis 6.

8. Loosen the cable bracket, upper arm tube by undoing the two screws on top of the tube.

9. Disconnect the two connectors (R3.FB5 and

R3.MP5) inside the tube.

10. Remove eventual cable straps from the harness.

11. Remove the cable attachment, rear.

Shown in the figure


Shown in the figure

Location of cable harness on page 203 .

Shown in the figure


12. Remove the covers of motors axes 3 and 4 and disconnect all connectors beneath.

Pick out the cabling from the motors.

13. Gently pull the cable harness out from the upper arm tube.

14. Tie the connectors into bundles, to avoid damaging them during further removal.

15. Continue removing the cable harness as detailed in following procedure.

206



4 Repair


Continued

Removal, cable harness - lower arm, frame and base

The procedure below details how to remove the cable harness from the lower arm, frame and base.

Action Note

1. Remove the rear cover plate from the robot by removing its attachment screws.

Shown in the figure Location of cable harness on page 203 .

2. Disconnect the earth cable beneath the rear cover plate.

Position shown in the figure Location of cable harness on page 203 .

3. Disconnect connectors R1.MP and R1.SMB.


4. Remove the cable holder on the frame securing the cable harness.

5. Pull the cable and connectors up through the cable guide in the center of the frame.

6. Disconnect all connectors at motors 1 and 2.

7. Open the SMB cover carefully.

The cable between the battery and the SMBunit may stay connected, in order to avoid an update of the revolution counter. Be careful not to let the weight of the cover strain the cable!

In order to remove the cover completely, the connector R1.G must be disconnected! This causes a necessary updating of the revolution counter!

8. Disconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB4-6 from the SMB unit.

Disconnect X8, X9 and X10 from the brake release unit. xx0700000104



207

4 Repair


Continued

Action

9. Remove the cable gland by removing the four

attachment screws from inside the SMB recess.

Note

10. Remove the velcro strap and cable gland

11. Remove the cable gland securing the cables to the arm house. xx0700000109

• A: Cable gland

• B: Attachment screws, inside

SMB recess

208

12. Remove the velcro strap from the harness at the guide plate ax 2 at the lower arm.

13. Remove the cable harness from the cable guide plate ax 2.

14. Disconnect all connectors at motors 3 and 4.

15. Gently pull the cable harness out. xx0100000143

Shown in the figure

Location of cable harness on page 203

.



4 Repair


Continued

Refitting, cable harness - lower arm, frame and base

The procedure below details how to refit the lower end of the cable harness to the robot.

How to refit the upper end is detailed in section

Refitting, cable harness - upper arm on page

211

.

Action Note

1. Pull the cable and connectors down through the cable guide in the center of the frame.

2. Reconnect connectors R1.MP and R1.SMB at the base.

Shown in the figure


Make a note of the correct positions of the connectors!

3. Reconnect the earth cable.

Shown in the figure


Make sure the cables are not twisted with each other or with eventual customer harnesses!


4. Refit the rear cover plate to the robot with its attachment screws.

Position shown in the figure Location of cable harness on page 203 .

Shown in the figure


5. Reconnect all connectors at motors 1 and 2.

6. Secure the cable gland with four attachment

screws from inside the SMB recess.

Refit the velcro strap. (Shown in the figure

Location of cable harness on page 203 .)

3HAC026876-001 Revision: F xx0700000109

• A: Cable gland

• B: Attachment screws, inside

SMB recess


209

4 Repair


Continued

Action

7. Reconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB4-6 to the SMB unit.

Reconnect X8, X9 and X10 to the brake release unit.

Reconnect R1.G if it has been disconnected.

Note

8. Secure the SMB cover with its attachment screws.

9.

WARNING!

Before continuing any service work, please observe the safety information in section

WARNING - The brake release buttons may be jammed after service work on page 42

!

10. Pull the cable harness through the lower arm.

11. Refit the metal clamp on the inside of the lower arm. Then refit the cable harness to the metal clamp with the velcro strap and cable gland.

xx0700000104 xx0100000142

210 xx0700000472

• A: Position of velcro strap



4 Repair


Continued

Action

12. Refit the cable gland securing the cables to the arm house.

Note

NOTE!

The cable harness is delivered in a pretwisted state. Make sure not to affect this by twisting the cable harness further in any direction.

xx0100000143

Refitting, cable harness - upper arm

The procedure below details how to refit the upper end of the cable harness to the robot.

How to refit the lower end is detailed in section

Refitting, cable harness - lower arm, frame and base on page 209 .

Action Note

1. Before refitting the upper end of the cable harness, the lower end must first be refitted.

Detailed in section

Refitting, cable harness - lower arm, frame and base on page 209

.

2. Refit the cable gland securing the cables in the armhouse.


NOTE!

The cable harness is delivered pretwisted.

Make sure not to affect this by twisting the cable harness further in any direction.

xx0100000143


4. Secure the cable harness to the guide plate axis 2.




211

4 Repair


Continued

Action Note

5. Refit the velcro strap at the guide plate axis 2. Shown in the figure Location of cable harness on page 203 .

6. Gently insert the cable harness from the rear into the upper arm.

7. Connect the two connectors inside the upper arm tube, R2.FB5 and R3.MP5 and secure the

cable bracket with its two attacment screws to the tube.

Shown in the figure Cable brackets of the upper arm on page 205

.

8.

NOTE!

The position of axis 6 must be +90° for a correct installation of the cable harness.

9. Place the cabling to motor axis 6 correctly on the upper arm and gently pull the connectors through the hole on top of the wrist unit to motor axis 6.

In case of excess of cable length:

• put the excess cable in a loop in the area shown in the figure and secure with cable straps. Cables are longer in order to fit different upper arm lengths.

10. Fasten the cable bracket, wrist unit with its three attachment screws. Two screws are visible at the rear attachment point of the bracket and the third is located at the bottom of

the cable bracket, in the center.

xx0200000185

• A: Cable straps

11. Reconnect the connectors to motor, axis 6 and refit the motor cover. xx0200000254

• B: Attachment screws, rear attachment point of cable bracket


212



4 Repair


Continued

Action

12. Refit the cover, upper arm tube and the cover,

wrist unit.

Make sure the cabling is placed correctly when refitting the covers, and does not get jammed.

Note xx0200000214

Parts:

• A: Cover, wrist unit

• B: Cover, upper arm tube

13. If any cable straps have been removed, refit them to the harness.

14. Refit the cable attachment, rear.

Shown in the figure Cable brackets of the upper arm on page 205 .

15. If the connection between the SMB battery and the SMB unit has been broken, the revolution counters now must be updated!

Detailed in section

Updating revolution counters on page 392 .

16.

DANGER!

Make sure all safety requirements are met when performing the first test run. These are

further detailed in the section DANGER - First test run may cause injury or damage! on page

41

.


4 Repair

4.3.2. Replacement of cabling, axis 5 motor

4.3.2. Replacement of cabling, axis 5 motor

Location of cabling

The separate cables for the axis 5 motor are located inside the upper arm tube, as shown in the figure below.

xx0500002294

A

B

Motor axis 5 with connectors R4.FB5 and R4.MP5

Connectors R3.FB5 and R3.MP5


Equipment

Cable harness axis 5

Circuit diagram

Standard toolkit


Spare part no.

Note


3HAC025744-001




Removal, cabling axis 5 motor

The procedure below details how to remove the cabling from the axis 5 motor.

Note

1.

Action

DANGER!




SMB.

214



4 Repair

4.3.2. Replacement of cabling, axis 5 motor

Continued

Action

2. Remove the complete wrist unit.

3. Remove the cover of motor, axis 5.

4. Disconnect all connectors at motor, axis 5.

5. Remove the cable gland cover at the cable exit by unscrewing its two attachment screws.

6. Remove the cable, axis 5.

Note

Detailed in section:

• IRB 6640:

Removal, wrist unit on page 265 .

•

IRB 6640ID: Removal, wrist unit on page 270

.

Refitting, cabling axis 5 motor

The procedure below details how to refit the cabling to the motor of axis 5.

Note

1.

Action

DANGER!




SMB.

2. Reconnect all connectors at motor, axis 5.

3. Refit the cable gland cover at the cable exit with its two attachment screws.

4. Refit the cover of motor, axis 5.

5. Refit the complete wrist unit.

6. Recalibrate the robot.

Detailed in section:

• IRB 6640:

Refitting, wrist unit on page 266 .

•

IRB 6640ID: Refitting, wrist unit on page 270 .

Calibration is detailed in a separate calibration manual enclosed with the calibration tools.

General calibration information is included in the section Calibration information .

7.

DANGER!



41 .


4 Repair

4.3.3. Fitting cable package attachments (Cleanroom)

4.3.3. Fitting cable package attachments (Cleanroom)

Overview

This section details how to fit the cable attachments for the cable harness (Cleanroom). How to replace the cable harness itself is detailed in section

Replacement of cable harness,

Cleanroom on page 224

.

Location of cable harness attachments (Cleanroom)

The cable harness attachments are located as shown in the figure below.

xx0800000022

G

H

E

F

C

D

A

B

J

K

L

Shelf

Gripping clamp

Side bracket balancing cylinder

Lower bracket

Gripping clamp

Bracket for cable clamp

Gripping clamp

Gripping clamp

Bracket for cable clamp

Cable guide

Connection plate axis 3


Equipment

Locking liquid

Standard toolkit


-

-

Part no.

216

Note

Loctite 243






4 Repair


Continued

Fitting of cable package attachments - lower end

The procedure below details how to install the attachments at the lower end of the cable harness (Cleanroom).

Note

1.

Action

DANGER!




2. Fit the shelf to the frame with its attachment screws.

Lock screws with locking liquid.

Locking liquid is specified in


xx0800000006

Parts:

• A: Shelf

• B: Attachment screws

M10x16 quality 8.8-A3F (3 pcs)



217

4 Repair


Continued

Action Note

3. Fit the gripping clamp to the shelf with its attachment

screws.




218

4. Fit the side bracket, balancing cylinder with its

attachment screws.


The screws are supplied with the kit.

xx0800000008

Parts:

• A: Shelf

• B: Cover

• C: Attachment screws


• D: Washer 2 holes

• E: Gripping clamp



xx0800000010

Parts:

• A: Side bracket balancing cylinder





4 Repair


Continued

Action

5. Fit the gripping clamp to the lower bracket, balancing cylinder with its attachment screws.



Note



6. Then attach the lower bracket (with the gripping

clamp already fitted) to the side bracket balancing

cylinder with its attachment screws.



xx0800000010

Parts:

• A: Lower bracket

• B: Gripping clamp

• C: Washer 2 holes

• D: Attachment screws




xx0800000013

Parts:

• A: Side bracket balancing cylinder



• C: Lower bracket

• D: Gripping clamp



219

4 Repair


Continued

7.

Action

NOTE!

The lower bracket is fitted slightly different depending on robot variant. See figure to the right!

Note

8. Fit the two brackets for cable clamp on the lower arm with its attachment screws.


xx0800000014

• A: SW 2.55

• B: SW 2.75



xx0800000019

Parts:

• A: Bracket for cable clamp


M12x25 quality 8.8-A3F (2

+ 2 pcs)

220



4 Repair


Continued

Action Note

9. Fit the gripping clamp to the bracket for cable clamp with its attachment screws , M8x16 quality 8.8-A2F

(2 pcs) and washer 2 holes (2 pcs).

Lock screws with locking liquid.




xx0800000021

Parts:

• A: Gripping clamp

• B: Bracket for gripping clamp

Fitting of cable package attachments - upper end

The procedure below details how to install the attachments at the upper end of the cable harness (Cleanroom).

Note

1.

Action

DANGER!




2. Fit the bracket for cable clamp on top of the armhouse with its attachment screws.





3HAC026876-001 Revision: F xx0800000027

Parts:

• A: Armhouse



• C: Bracket for cable clamp


221

4 Repair


Continued

Action Note

3. Fit the gripping clamp to the bracket for cable clamp with:

• attachment screws (2 pcs)

• washer 2 holes

• washers (2 pcs)

• locking nuts M8 (2 pcs)





xx0800000023

Parts:

• A: Armhouse

• B: Locking nut M8

• C: Washer

• D: Bracket for cable clamp

• E: Gripping clamp

• F: Washer 2 holes

• G: Attachment screws


4. Fit the cable guide on the side of the armhouse with its attachment screws.





xx0800000025

Parts:

• A: Cable guide



222



4 Repair


Continued

Action

5. Fit the connection plate axis 3 with its attachment

screws.



Note



xx0800000026

Parts:

• A: Connection plate axis3




4 Repair

4.3.4. Replacement of cable harness, Cleanroom

4.3.4. Replacement of cable harness, Cleanroom

General

This section details how to replace the cable harness, Cleanroom.

Fitting of cable attachments is detailed in section

Fitting cable package attachments

(Cleanroom) on page 216

.

Location of cable harness, Cleanroom

The illustration below shows the location of the cable harness, Cleanroom.

G H

F

M

J

K

P

O

D

E N

C

B

L

R

S

T

A xx0800000054

N

O

P

R

K

L

M

D

E

F

A

B

C

G

H

J

Earth (placed under rear cover plate)

Rear cover plate

Velcro straps

Gripping clamp, shelf

Cover, shelf

Cover, armhouse

Bracket for metal clamp

Gripping clamp, armhouse

Cable harness, Cleanroom

Gripping clamps, lower arm

Gripping clamp, lower bracket

Cable guide

Connection plate, axis 3

Motor axis 3

Motor axis 4

Motor axis 2

224



4 Repair


Continued

S

T

Motor axis 1

Connectors at base


Equipment Spare part no.

Cable harness, Cleanroom See Spare parts chapter.

Gasket 3HAC033489-001

Standard toolkit -


Circuit diagram 3HAC025744-001

Note

Motor, axis 6





Removal cable harness - lower end

The procedure below details how to remove the lower end of the cable harness, Cleanroom.

Note

1.

Action

2.

DANGER!




CAUTION!

The cable package is sensitive to mechanical damage. They must be handled with care, especially the connectors, in order to avoid damaging them.


Shown in the figure Location of cable harness, Cleanroom on page 224 .

4. Disconnect connectors R1.MP and R1.SMB at the base.

5. Disconnect the earth cable.


6. Disconnect all connectors at motor axis 1 and motor

axis 2.




225

4 Repair


Continued

Action

7. Remove the cover on the shelf by removing its


Note

8. Remove the bracket on the cable harness from the

shelf by removing its attachment screws.

xx0800000049

Parts:

• A: Cover

• B: Shelf


M6x16 quality 8.8-A2F (4 pcs) xx0800000047

Parts:

• A: Cable bracket (part of cable harness)

• B: Shelf



226



4 Repair


Continued

Action

9. Open the gripping clamp and remove the cable harness from the shelf.

Note

10. Pull the cable harness and connectors carefully up through the cable guide in the center of the frame.

xx0800000050

Parts:


11. Open the SMB cover by removing its attachment screws.

The cable between the battery and the SMB unit may stay connected, in order to avoid an update of the revolution counter. xx0800000046

Parts:

• A: Cable harness

NOTE!

Be careful not to let the weight of the cover strain the cable!

NOTE!

In order to remove the SMB cover completely, the connector R1.G must be disconnected. This causes a necessary updating of the revolution counter!



227

4 Repair


Continued

Action

12. Disconnect connectors:

• R2.SMB, R1.SMB1-3, R1.SMB4-4 to the

SMB unit

• X8, X9, X10 to the brake release unit

Note

13. Remove the cable gland by removing its attachment


xx0700000104

228 xx0700000109

Parts:

• A: Cable gland

• B: Attachment screws,

(inside SMB recess), 4 pcs



4 Repair


Continued

Action

14. Open the gripping clamp on the lower bracket and remove the cable harness.

Note

15. Remove the velcro straps on the side bracket, balancing device.

xx0800000053

Parts:


16. Open the gripping clamp on the lower arm and remove the cable harness.

xx0800000052

Parts:

• A: Velcro starps

• B: Cable harness

17. Continue removal of the upper end of the cable harness.

xx0800000051

Parts:

• A: Gripping clamps



229

4 Repair


Continued

Removal cable harness - upper end

The procedure below details how to remove the upper end of the cable harness, Cleanroom.

Action Note

1. Remove the cover at the back of the upper arm tube by removing its attachment screws.

Shown in the figure

Location of cable harness, Cleanroom on page 224 .

2. Remove the cable harness from motor axis 5 and motor axis 6, as well as from the wrist.

This procedure is the same as for the standard cable harness of the robot.

3. Remove the cable clamp on the armhouse by removing its attachment screws.

Detailed in section Removal, cable harness - upper arm on page 205 .

Shown in the figure


4. Disconnect all connectors at motor axis 3 and motor axis 4.

Shown in the figure


5. Carefully pull out the cable harness from the upper arm tube.

6. Disconnect all connectors at the connection plate axis 3.

7. Open the the gripping clamp on the bracket for cable

clamp.

xx0800000055

Parts:

• A: Connectors (at connection plate axis 3)

230

8. Remove the cable harness from the robot.

xx0800000056

Parts:






4 Repair


Continued

Refitting cable harness - lower end

The procedure below details how to refit the lower end of the cable harness, Cleanroom.

Note

1.

Action

2.

DANGER!




CAUTION!

The cable package is sensitive to mechanical damage. They must be handled with care, especially the connectors, in order to avoid damaging them.

3. Push the cable harness and connectors carefully down through the cable guide in the center of the frame.

Make sure that the cables are not twisted with each other!

4. Reconnect the earth cable.

5. Reconnect the connectors R1.MP and R1.SMB at

base.

xx0800000046

Parts:

• A: Cable harness



6. Refit the rear cover plate with its attachment screws. Shown in the figure Location of cable harness, Cleanroom on page 224 .



231

4 Repair


Continued

Action

7. Fit the bracket on the cable package to the shelf with its attachment screws.

Note

8. Secure the cable harness to the gripping clamp on the shelf.

xx0800000047

Parts:

• A: Cable bracket (part of cable harness)

• B: Shelf



232 xx0800000050

Parts:


9. Reconnect all connectors at motor axis 1 and motor

axis 2.

Shown in the figure




4 Repair


Continued

Action

10. Refit the cover on the shelf with its attachment

screws.

Note

11. Secure the cable gland with its attachment screws from inside the SMB recess.

xx0800000049

Parts:

• A: Cover

• B: Shelf



3HAC026876-001 Revision: F xx0700000104

Parts:

• A: Cable gland


(inside SMB recess), 4 pcs


233

4 Repair


Continued

Action

12. Reconnect connectors:

• R2.SMB, R1.SMB1-3, R1.SMB4-6 to the

SMB unit

• X8, X9, X10 to the brake release unit

• R1.G battery cable (if it has been reconnected)

Note

13. Secure the SMB cover with its attachment screws.

14.

xx0700000104

WARNING!

Before continuing any service work, please observe

the safety information in section WARNING - The brake release buttons may be jammed after service work on page 42

!

15. Secure the cable harness to the gripping clamp on the lower bracket.

16. Secure the cable harness with the velcro straps to the side bracket balancing cylinder.

xx0800000053

Parts:


234 xx0800000052

Parts:

• A: Velcro straps




4 Repair


Continued

Action

17. Secure the cable harness to the gripping clamps on the lower arm.

Note xx0800000051

Parts:

• A: Gripping clamps

18. Continue refitting of the upper end of the cable harness.

Refitting cable harness - upper end

The procedure below details how to refit the upper end of the cable harness, Cleanroom.

Action

1. Start refitting of the cable harness by refitting the lower end.

2. Secure the cable harness to the gripping clamp on the bracket for cable clamp.

Note

Detailed in section Refitting cable harness - lower end on page 231

above.

3. Place the cable harness in the cable guide on the upper armhouse.

xx0800000056

Parts:







235

4 Repair


Continued

Action

4. Reconnect all connectors on the connection plate axis 3.

Note xx0800000055

Parts:

• A: Connectors (at connection plate axis 3)

5. Reconnect all connectors at motor axis 3 and motor

axis 4.

Shown in the figure


6. Fit the metal clamp to the armhouse with its attachment screws.

236 xx0800000057

Parts:

• A: Metal clamp

7. Carefully insert the cable harness from the rear, into the upper arm tube.

8. Continue refitting the cable harness to motor axis 5 and motor axis 6 as well as to the wrist.

This procedure is the same as for the standard cable harness of the robot.

Detailed in section

Refitting, cable harness - upper arm on page 211 .

9. Fit the cover at the back of the upper arm tube with its attachment screws.

Shown in the figure


10.

DANGER!


DANGER - First test run may cause injury or damage! on page 41 .


4 Repair

4.3.5. Replacement of cable harness, axes 1-4 IRB 6640ID

4.3.5. Replacement of cable harness, axes 1-4 IRB 6640ID

Location of cable harness

The cable harness for axes 1-4 is run throughout the base, frame and lower arm as shown in the figure below.

xx0700000470

G

H

J

K

L

M

A

B

C

D

E

F

R

S

T

U

N

O

P

Connectors at motor axis 2 (R2.FB2, R2.MP2)

Connectors at motor axis 1(R2.FB1, R2.MP1)

Rear cover plate

Earth (attachment point is placed under the cover plate)

Cable harness

Cable holder

Velcro strap

Guide plate axis 2

Cable guide

Connector R1.MP

Connector R1.SMB

Cable protector (placed inside the lower arm)

Position for SMB and brake release units

Cable harness (cut away view)

Velcro strap (inside lower arm)

Cable gland (armhouse)



Cable division point (R2.M5/6, R2.FB5/6)



237

4 Repair


Continued


Equipment, etc.


IRB 6640ID - 200/2.55


IRB 6640ID - 170/2.75

Locking liquid

Spare part no. Art. no.



Note

Standard toolkit -

Loctite 638

Used to secure the attachment screws for the attachment plate inside the frame.





Circuit Diagram See the chapter Circuit diagram .

Removal, cable harness, axes 1-4

The procedure below details how to remove the cable harness, axes 1-4.

Action Note

1. In order to facilitate refitting of cable harness, run the robot to the specified position:

• Axis 1: 0 °

• Axis 2: 0 °

• Axis 3: 0 °

• Axis 4: 0 °

• Axis 5: +90 °



2.

DANGER!





4. Disconnect the earth cable.

Shown in the figure


.

Attachment point is shown in the

figure Location of cable harness on page 237

!

238



4 Repair


Continued

Action Note

5. Disconnect connectors R1.MP and R1.SMB. Attachment points are shown in the figure


.

6. Pull the cable and connectors up through the cable guide in the center of the frame.

7. Disconnect all connectors at motors 1 and 2. Specified and shown in the figure

Location of cable harness on page 237 !

8. Open the SMB cover carefully.

The cable between the battery and the SMB-unit may stay connected, in order to avoid an update of the revolution counter. Be careful not to let the weight of the cover strain the cable!

In order to remove the cover completely, the connector R1.G must be disconnected! This causes a necessary updating of the revolution counter!

9. Disconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB4-6 from the SMB unit.

Disconnect X8, X9 and X10 from the brake release unit.

0700000104



239

4 Repair


Continued

Action

10. Remove:

• the cable gland by removing the four attachment screws from inside the SMB recess.

Note

11. Remove the cable gland securing the cables inside the lower arm.

12. Remove the cable gland securing the cables to the arm house. xx0700000109

• A: Cable gland


(inside SMB recess)

240

13. Remove the velcro strap from the harness at the cable fixing bracket at the arm house.

xx0100000143.wmf

Shown in the figure Location of cable harness on page 237

.



4 Repair


Continued

Action Note

14. Disconnect connector R2.M5/6 at the cable division point.


!

15. Disconnect all connectors at motor 3 and motor 4. Specified and shown in the figure

Location of cable harness on page 237 !

16. Gently pull the cable harness out.

Refitting, cable harness, axes 1-4

The procedure below details how to refit the cable harness, axes 1-4.

Note

1.

Action

DANGER!




SMB.

2. In order to facilitate refitting of cable harness, move the robot to the specified position:

• Axis 1: 0 degrees




• Axis 5: +90 degrees


3. Pull the cable and connectors down through the cable guide in the center of the frame.


Make sure the cables are not twisted with each other or with eventual customer harnesses!


4. Reconnect connectors R1.MP and R1.SMB at the rear cover plate.


Attachment point is shown in the


.

5. Reconnect the earth cable. Attachment point is shown in the


!

6. Refit the rear cover plate to the robot with its attachment screws.



.

Specified and shown in the figure

Location of cable harness on page

237

!



241

4 Repair


Continued

Action

8. Secure the cable gland with four attachment


Note

9. Reconnect connectors R2.SMB, R1.SMB1-3,

R1.SMB4-6 to the SMB unit.

Reconnect X8, X9 and X10 to the brake release unit.

Reconnect R1.G if it has been disconnected. xx0700000109

• A: Cable gland

• B: Attachment screws, inside SMB recess

242

10. Secure the SMB cover with its attachment screws. xx0700000104



4 Repair


Continued

Note

11.

Action

WARNING!


WARNING - The brake release buttons may be jammed after service work on page 42

!

12. Pull the cable harness through the lower arm.

13. Refit the cable gland securing the cables inside the lower arm.

14. Refit the cable gland securing the cables to the arm house.

Make sure not to twist the harness! xx0100000142 xx0100000143

15. Reconnect all connectors at motor 3 and motor 4. Specified and shown in the figure

Location of cable harness on page

237

!

16. Reconnect the connector R2.M5/6 gently at the cable division point.

Be careful not to bend the attachment plate when fastening the screws!


!

M6, 2 pcs.

17. Secure the cable harness to the upper arm house by refitting the velcro strap to the cable bracket at the upper arm house.


!

18. Refit the cable harness to the guide plate axis 2.


.

19. Refit the velcro strap at the guide plate axis 2.


.



243

4 Repair


Continued

Action

20. If the connection between the SMB battery and the SMB unit has been broken, the revolution counters must now be updated!

21.

Note

Detailed in the Calibration chapter -

section Updating revolution counters on page 392 .

DANGER!




4 Repair

4.3.6. Replacement of cable harness, axes 5-6 - IRB 6640ID

4.3.6. Replacement of cable harness, axes 5-6 - IRB 6640ID

Location of cable harness, axes 5-6

The cable harness of axes 5-6 is run inside the upper arm, as shown in the figure below.

xx0500001896

C

D

A

B

E

F

Cover, upper arm tube

Hood, upper arm housing

Attachment screws and washers (3 pcs), hood, upper arm housing

Connectors at motor axis 5; R3.FB5 and R3.MP5

Connectors at motor axis 6; R3.FB6 and R3.MP6

Connector at cable harness division point; R2.M5/6



245

4 Repair


Continued


Equipment

Product manual -

SpotPack/DressPack

Spare part no.

Art. no.

Cable harness axes 5-6 See Spare parts chapter.

Cable grease

Standard toolkit

Note

3HAC 14807-1 Optitemp RB 1



Art. no. is specified in section References.

Removal, cable harness axes 5-6

The procedure below details how to remove the cable harness from the upper arm.

Note Action

1. Run the robot to its calibration position.

2.

DANGER!




3. Remove the process cabling from the upper arm, if any.

How to remove the DressPack harness from the upper arm and wrist unit is detailed in the Product manual -

SpotPack/DressPack.

4. Remove the cover from the upper arm tube and the hood from the upper arm housing.

Shown in the figure Location of cable harness, axes 5-6 on page 245

.

5. Disconnect all the connectors at the axis 5 and 6 motors, and the connector at the cable harness division point.

The connectors are specified and shown

in the figure Location of cable harness, axes 5-6 on page 245

.

6. Remove the two cable clamps (A) from the bracket at the back of the upper arm housing.

246 xx0500001903



4 Repair


Continued

Action

7. Remove the cable bracket from the upper arm housing by removing the three

attachment screws (B).

Leave the cabling fitted to the bracket.

Note

8. Loosen the cable clamp (C) inside of the upper arm tube.

xx0500001905

9. Remove all velcro straps and cable ties holding the cabling inside the wrist unit.

10. Pull out the cabling from the wrist unit and the upper arm tube. Be careful not to damage the connectors!

xx0500001904



247

4 Repair


Continued

Cable layout, wrist unit

The figure below shows how to run and attach the cabling inside the wrist unit.

xx0500002014

A Location inside the wrist unit where to strap the cabling, next to the axis 5 motor.

Refitting, cable harness axes 5-6

The procedure below details how to refit the cable harness to the upper arm.

Note

1.

Action

DANGER!




SMB.

2. Make sure all the cable clamps and brackets are attached properly to the new cable harness.

Spare part no. is specified in


.

3. Insert the cable harness through the upper arm tube and pull out the motor connectors at the wrist unit.

4. Secure the cable clamp (C) inside the upper arm tube.

248 xx0500001904



4 Repair


Continued

Action Note

5. Place the cabling inside the wrist unit according

to the cable layout shown in the figure Cable layout, wrist unit on page 248

and fasten it with velcro straps.

Reconnect the connectors to the axis 5 and 6 motors.

Shown in the figure


.

6. Wind the cabling in a spiral with four free turns.

Secure the fifth turn with two clamps (A and B) to the bracket.

NOTE!

The cable clamps should be positioned approximately 1 m from the connector R2.M5/6.

NOTE!

Adjust the clamps to make the bend of the fifth turn equal with the others, creating a symmetrical spiral.

7. Grease the cabling with cable grease.

8. Refit the cover to the upper arm tube and the

hood to the upper arm housing.

9. Reconnect the connector R2.M5/6 at the cable harness division point.

10. Update the revolution counters!

xx0500001909

• A: Attachment point for the power cable, R3.MP.

• B: Attachment point for the signal cable, R3.FB.



.

Shown in the figure


.

Shown in the figure


.



.

11.

DANGER!


DANGER - First test run may cause injury or damage! on page 41

.


4 Repair

4.3.7. Replacement of complete arm system

4.3.7. Replacement of complete arm system

Location of arm system

The complete arm system is defined as the complete robot except for the base and gearbox axis 1. This is shown in the figure below.

A more detailed view of the component and its position may be found in chapter Upper arm including wrist unit, motors ax. 3- 6 (IRB 6640 and IRB 6640ID) .

Detailed in section Lower arm to upper arm .

250 xx0700000352

F

G

D

E

A

B

C

Upper arm

Lower arm

Frame

Base

Gearbox, axis 1

Attachment screws base M12x80, quality 12.9 Gleitmo (16 pcs)

Motor, axis 1



4 Repair


Continued


Equipment, etc.

Holder for bits

Guide pins M12x200

Roundsling 2 m

Roundsling 1,5 m

Hoisting block

Lifting chain

Standard toolkit


-

-

-

Art. no.

3HAC029090-001

3HAC13056-3

Note

Bits SW10 included

Used to guide the complete arm system when refitting.

Always use the guide pins in pairs!

In order to make the refitting easier, it is recommended to use guide pins of different lengths.

Lifting capacity 2,000 kg

Lifting capacity 1,000 kg

Lifting capacity 500 kg

Used to adjust the length of the lifting chain.

Used together with the hoisting block.




Removal, arm system

The procedure describes how to lift and remove the complete arm system.

Action Note

1. Make sure the robot is positioned as shown in figure to the right. If it is not, position it that way.

Release the brakes if necessary, as detailed in section

Manually releasing the brakes on page 71 .

2. Run the overhead crane to a position above the robot. xx0700000351



251

4 Repair


Continued

Action Note

3. Fit the lifting device and adjust it as detailed in the enclosed

instructions.

Also fit a hoisting block to the

roundsling put around the lower arm. Used to adjust the balance of the arm system in order to lift it completely level.

Art. no. is specified in Required equipment on page

251

.

Make sure the lift is done completely level! How to adjust the lift is described in the enclosed instruction to the lifting device! Read the instructions before lifting!

252 xx0700000349

• A: Lifting eye (on armhouse)

• B: Lifting chain

• C: Hoisting block

• D: Lifting chain

• E: Roundsling (put in a loop around the wrist on the inside)

• F: Roundsling (used to eliminate any load through the brake on motor axis 3)

• G: Position for roundsling F, put behind the mechanical stop pin.

• H: Roundsling (put in a loop around the lower arm)

4.

NOTE!


In order to prevent from particle emission while lifting, put for example a 20 mm thick cellular

plastic sheet around the places on the robot where the lifting equipment may rub against the paint.



• Wrist

• Lower arm/Frame xx0800000061


• A: Upper arm

• B: Wrist

• C: Lower arm/Frame

• D: Lower arm



Note

4 Repair


Continued

5.

Action

DANGER!




6. Drain the oil from gearbox axis

1.

7. Loosen the cable connectors from the base and pull up the cabling from the base, through the hole in the center of the frame.

8. Remove the motor, axis 1.

Detailed in section

Oil change, gearbox axis 1 on page

165

.

Detailed in section

Replacement of cable harness, axes 1-6 on page 203

.

Detailed in section


Cleanroom on page 224

.

Detailed in section

Replacement of motor, axis 1 on page 328 .

9. Remove the calibration plate from the bottom of the frame.

10. Unfasten the arm system from the base by unscrewing its

16attachment screws. xx0700000380

Parts:

• A: Calibration plate

Shown in the figure Location of arm system on page

250

.

3HAC026876-001 Revision: F xx0600003070

Parts:

• A: Serrated lock washer

• B: Gearbox axis 1

• C: Attachment scxrews M12x80


253

4 Repair


Continued

11.

Action Note

CAUTION!

The complete arm system weighs 1250 kg! All lifting equipment used must be sized accordingly!

12. Lift the arm system carefully and secure it in a safe area.

Always move the robot at very low speeds, making sure it does not tip.

Continue lifting even if the arm system turns out to be unbalanced despite earlier adjustments! The risk of damaging the interfaces is bigger if the load is lowered unbalanced!

Make sure all hooks and attachments stay in the correct position while lifting the arm system and that the lifting device does not wear against sharp edges.

254



4 Repair


Continued

Refitting, arm system

The procedure describes how to lift and refit the complete arm system.

Note

1.

Action

2.

DANGER!




SMB.

NOTE!


In order to prevent from particle emission while lifting, put for example a 20 mm thick

cellular plastic sheet around the places on the robot where the lifting equipment may rub against the paint.



• Wrist

• Lower arm/Frame xx0800000061


• A: Upper arm

• B: Wrist

• C: Lower arm/Frame

• D: Lower arm



255

4 Repair


Continued

Action Note

3. Fit the lifting device as detailed in the figure to the right.

Also fit a hoisting block to the roundsling put around the lower arm. Used to adjust the balance of the arm system in order to lift it completely level.



Make sure the lift is done completely level! How to adjust the lift is described in the enclosed instruction to the lifting device.

Read the instructions before lifting!

Releasing the brakes are detailed in

section Manually releasing the brakes on page 71 .

256 xx0700000349

Parts:





• E: Roundsling (put in a loop around the wrist on the inside)

• F: Roundsling (used to eliminate any load through the brake on motor axis 3)

• G: Position for roundsling F, put behind the mechanical stop pin

• H: Roundsling (put in a loop around the lower arm

4.

CAUTION!

The complete arm system weighs 1250 kg!


5. Lift the complete arm system and move it at very low speed, making sure it does not tip!

Make sure the lift is done completely level.

Adjust the length of the chains as detailed in enclosed instruction or with a hoisting block.

Make sure all the hooks and attachments stay in the correct position while lifting the robot!



4 Repair


Continued

Action Note

6. Fit the two guide pins to the holes in gearbox axis 1, as shown in the figure to the right.

Dimension is specified in Required equipment on page 251 .

xx0600003095

The figure below shows the gearbox, axis

1.

• A : Attachment holes for guide pins, M12 in gearbox axis 1.

• B : Hole for attachment screw.

7. Look through the empty mounting hole of motor 1 to assist in aligning the assembly during refitting of the arm system.

Lower the arm system with guidance from the guide pins previously fitted to the gearbox axis 1. Fit the guide pins in the corresponding holes in the frame as shown in the figure to the right.

This is a complex task to be performed with utmost care in order to avoid injury or damage!

NOTE!

The refitting must be made completely level!

Make sure the lifting device is adjusted prior to refitting of arm system.

8.

NOTE!

Check that the serrated lock washers are turned the correct way. See figure!

xx0600003093

• A : Holes in frame for guide pins, shown from above.

3HAC026876-001 Revision: F xx0600003070

Parts:


• B: Gearbox axis 1

• C: Attachment screws M12x80 quality 12.9 gleitmo (16 pcs)


257

4 Repair


Continued

Action

9. Refit 14 of the 16 attachment screws before the arm system is completely lowered.

Note

NOTE!

Use a torque wrench with a holder for bits

recommended in Required equipment on page 251

.

10. Remove the guide pins and secure the arm system to the base with its 16attachment screws and washers.

Shown in the figure Location of arm system on page 250

.

M12 x 80, 12.9 quality gleitmo. Tightening torque: 105 Nm.

Reused screws may be used, providing they are lubricated as detailed in the

section Screw joints on page 405

before fitting.

11. Refit the calibration plate at the bottom of the frame.

258

12. Refit the motor axis 1.

13. Refit the cabling in the base.

xx0700000380

Parts:

• A: Calibration plate

Detailed in section Replacement of motor, axis 1 on page 328 .

Detailed in section


Detailed in section

Replacement of cable harness, Cleanroom on page 224 .

14. Perform a leak-down test of the gearbox axis

1.

Detailed in section

Performing a leakdown test on page 196

.

15. Refill the gearbox axis 1 with lubricating oil.

Detailed in section

Oil change, gearbox axis 1 on page 165 .

16. Recalibrate the robot. Calibration is detailed in a separate calibration manual enclosed with the calibration tools.




17.

Action

DANGER!


DANGER -

First test run may cause injury or damage! on page 41

.

4 Repair


Continued

Note


4 Repair

4.4.1. Replacement of turning disk

4.4 Upper and lower arm

4.4.1. Replacement of turning disk

Location of turning disk

The turning disk is located in the front of the wrist housing as shown in the figure below.


xx0300000473

A

B

E

Turning disk (type 1)

Wrist unit

Attachment screws (6 pcs) , turning disk xx0200000217

A

B

C

D

F

Turning disk (type 2)

Wrist unit

Oil plug, draining

Oil plug, filling

Attachment screws (12 pcs)

260



4 Repair


Continued


Equipment, etc. Spare part no. Art. no. Note

Turning disk, diam. 200 See Spare parts chapter.

Turning disk, dia. 200 See Spare parts chapter.

O-ring

Wrist, type 1

O-ring

Wrist, type 2

3HAB3772-65

(1pc)

21520431-20

(6 pcs)

3HAB3772-64

(1 pc)

3HAB3772-61

(12 pcs)

Grease

Standard toolkit


O-rings are not included!

O-rings are not included.

Must be replaced when replacing the turning disk!

Must be replaced when replacing the turning disk!

-

3HAB3537-1 Used to lubricate the o-rings.




Removal, turning disk

The procedure below details how to remove the turning disk.

Note

1.

Action

DANGER!




2. Remove any equipment fitted to the turning disk.

3. Run the robot to a position where the oil plug, draining of axis 6 gearbox faces downwards.

Shown in the figure Location of turning disk on page 260

.

4. Drain the oil from gearbox axis 6.

5. Remove the turning disk by unscrewing its


See section:

•

Oil change, gearbox axis

6 on page 180

Shown in the figure Location of turning disk on page 260

.



261

4 Repair


Continued

Refitting, turning disk

The procedure below details how to refit the turning disk.

Action

1. Lubricate the turning disk o-ring with grease.

Fit the o-ring to the rear of the turning disk.

Also fit the 12 o-rings, when refitting the attachment screws.

Note

Art. no. is specified in Required equipment on page 261

.

262

2. Secure the turning disk with its attachment

screws. xx0200000218

• A: Sealing surface, o-ring

The number of attachment screws depends on which wrist type is used:

6 pcs, M14 x 25

Tightening torque: 174 Nm.

12 pcs, M12 x 30, 12.9 quality Gleitmo.

Tightening torque: 100 Nm.

Reused screws may be used, providing they are lubricated as detailed in the section

Screw joints on page 405

before fitting.

3. Perform a leak-down test of the gearbox axis 6. Detailed in the section

Performing a leak-down test on page 196 .

4. Refill the gearbox 6 with oil. Detailed in the section


5. Refit any equipment removed during disassembly to the turning disk.



6.

Action

DANGER!



41

.

4 Repair


Continued

Note


4 Repair

4.4.2. Replacement of complete wrist unit

4.4.2. Replacement of complete wrist unit

Wrist unit for robot models IRB 6640ID

This section is valid for robot models IRB 6640. How to replace the wrist of the models IRB

6640ID is detailed in section

Replacement of complete wrist unit, IRB 6640ID on page 269 .

Location of wrist unit

The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.


Upper arm inc. wrist unit, motors ax. 3- 6 .

264 xx0700000343

F

G

D

E

I

H

A

B

C

Wrist unit

Turning disk

Cover, wrist unit

Cover, upper arm tube

Connectors, upper arm tube, with cable bracket (R3.FB5, R3.MP5)

Cable bracket

Attachment piont for lifting tool, wrist unit

Wrist unit attachment screws and washers

Upper arm tube



4 Repair


Continued


Equipment etc.

Wrist

Guide pins M12 x 200

Spare part no. Art. no.


3HAC13056-3

Lifting tool, wrist unit

Standard toolkit

3HAC13605-1

-

Note

Always use guide pins in pairs!




Other tools and procedures may be required. See references to these procedures in the stepby-step instructions below.

Circuit diagram 3HAC025744-001 See the chapter Circuit diagram .

Removal, wrist unit

The procedure below details how to remove the complete wrist unit.

Action

1. Remove all equipment fitted to the turning disk.

2. Turn axis 4 to a position where the cover, upper

arm tube and wrist unit, faces upwards. Turn axis 5 to +90°.

Note xx0200000185

3.

DANGER!




SMB.

4. Remove the cover, wrist unit.

5. Remove the cover, upper arm tube.

Shown in the figure

Location of wrist unit on page 264 .

Shown in the figure

Location of wrist unit on page 264 .

6. Remove the cover of motor, axis 6 and disconnect all connectors beneath.



265

4 Repair


Continued

Action Note

7. Loosen the cable bracket, wrist unit on top of the wrist by undoing the three attachment screws.

Two of the attachment screws are visibly located at the rear of the bracket and the third located at the bottom of the cable bracket, in the center.

Shown in the figure Location of wrist unit on page 264 .

xx0200000254

• B: Attachment screws, rear of cable bracket (2 pcs)


8. Pick out the cabling from motor, axis 6 and place it safely on the tube.

9. Fit the lifting tool to the wrist unit.


10.

CAUTION!

The complete wrist unit weighs 130 kg! All lifting equipment used must be sized accordingly!

11. Slightly raise the wrist unit to unload the screw joint, facilitating removing the attachment screws.

12. Remove the wrist unit attachment screws and

washers.

13. Pull the wrist unit out, lift it away and place it on a secure surface.


14. Disconnect the motor axis 5 by disconnecting the two connectors in the upper arm tube

(R3.FB5, R3.MP5).


Refitting, wrist unit

The procedure below details how to refit the complete wrist unit.

Note

1.

Action

266

DANGER!




SMB.

2. Fit two guide pins, M12 in the upper arm tube, in two of the holes for the wrist unit attachment screws.



.

Shown in the figure Location of wrist unit on page 264

.



Action

3. Fit the lifting tool to the wrist unit.

4.

4 Repair


Continued

Note

Art. no. is specified

Location of wrist unit on page 264

.

CAUTION!


5. Lift the wrist unit and guide it to the upper arm tube with help of the guide pins.

Make sure the cabling from motor, axis 5 is safely run into the arm tube and does not get jammed.

6. Reconnect the motor axis 5 by connecting the two connectors inside the upper arm tube

(R3.FB5, R3.MP5) and secure the cable bracket with the two attachment screws to the tube.


.

7. Secure the wrist unit with 10 of the 12

attachment screws and washers.


.

12 pcs: M12 x 50, 12.9 quality Gleitmo.




before fitting.

8. Remove the guide pins and secure the two remaining attachment screws as detailed above.

9. Remove the lifting tool from the wrist unit.

10.

NOTE!

Axis 5 must be oriented in the correct position

(+90º).

11. Place the cabling to motor axis 6 correctly on the upper arm and gently pull the connectors through the hole on top of wrist unit to motor, axis 6.

In case of excess of cable length:

• put the excess cable in a loop in the area shown in the figure and secure with with cable straps. Cables are longer in order to fit different upper arm lengths. xx0200000185

Parts:

• A: Cable straps



267

4 Repair


Continued

Action Note

12. Fasten the cable bracket at top of the wrist unit with three attachment screws. Two of them are visible at the rear attachment point and the third is located on the bottom of the cable bracket, in the center.


.

xx0200000254

• B: Attachment screws, rear attachment point of cable bracket (2 pcs)


13. Reconnect the connectors to motor, axis 6 and refit the motor cover.

14. Refit the cover, upper arm tube.

15. Refit the cover, wrist unit.

16. Recalibrate the robot!

17. Refit any equipment previously removed from the turning disk.

18.


.


.



DANGER!



41 .


4 Repair

4.4.3. Replacement of complete wrist unit, IRB 6640ID

4.4.3. Replacement of complete wrist unit, IRB 6640ID

Wrist unit for robot models IRB 6640ID

This section is only valid for robot models IRB 6640ID. How to replace the wrist unit on the models IRB 6640 is detailed in section

Replacement of complete wrist unit on page 264

.

Location of wrist unit

The wrist unit is located in the frontmost part of the upper arm as shown in the figure below.


xx0500001567

A

B

C

Wrist unit

Attachment screws and washers, wrist unit

Upper arm tube


Equipment

Wrist, process



Roundslings

Standard toolkit


Circuit diagram

Product manual -

DressPack/SpotPack

Spare part no.

Art. no.


-

-

3HAC13056-3

3HAC13056-3

Note

Always use guide pins in pairs!

The content is defined in

the section Standard toolkit on page 409 .


-


Art. no. is specified in section References.



269

4 Repair


Continued

Removal, wrist unit

The procedure below details how to remove the complete wrist unit from the robot.

Note

1.

Action

DANGER!




2. Remove all equipment fitted to the turning disk.

3. Remove the integrated spotpack cabling.

How to remove the DressPack harness from the upper arm and wrist unit is detailed in the Product

manual - DressPack/SpotPack.

4. Disconnect the connectors from motors, axes 5 and

6. Loosen the cabling from the wrist unit.

5. Support the weight of the wrist unit with lifting slings.

6.

CAUTION!


7. Slightly raise the wrist unit to unload the screw joint, facilitating removal of the attachment screws.

8. Remove the attachment screws and washer from the wrist unit.

9. Lift away the wrist unit and place it on a secure surface. Be careful not to damage the cabling and the motor connectors while running them through the wrist during removal!

Refitting, wrist unit

The procedure below details how to refit the complete wrist unit to the robot.

Note

1.

Action

270

DANGER!




2. Fit the two guide pins in the upper arm tube, in two of the attachment holes for the wrist unit.


Required equipment on page 269Required equipment on page 269

.



4 Repair


Continued

Note

3.

Action

CAUTION!


4. Attach the lifting slings to the wrist unit and lift it to the upper arm tube.

5. Insert the cabling and connectors through the wrist unit and match the wrist against the upper arm tube with guidance from the guide pins.

6. Secure the wrist unit with 10 of the 12 attachment

screws and washers.

Shown in the figure Location of wrist unit on page 269Location of wrist unit on page 269 .

12 pcs; M12 x 50, 12.9 quality

UNBRAKO. Tightening torque:

115 Nm.



before fitting.

7. Remove the guide pins and secure the two remaining attachment screws as detailed above.

8. Reconnect the motor connectors to the motors, axes

5 and 6. Fasten the cabling as shown in the cable layout in the figure

Cable layout, wrist unit on page

248

.



General calibration information is included in the section

Calibration information .

10. Refit any equipment previously removed from the turning disk.

11.

DANGER!




4 Repair

4.4.4. Replacement of upper arm

4.4.4. Replacement of upper arm

Location of upper arm

The upper arm is located on top of the robot as shown in the following figure. The complete upper arm includes the wrist unit but this section also describes how to remove the upper arm when there is no wrist unit mounted.

Note! The lifting device is attached differently depending on whether the wrist unit is mounted on the upper arm or not. The attachment points are shown in the following figure.

A more detailed view of the component and its position may be found in chapter Exploded views in the Product manual, reference information .

272 xx0700000345

F

G

D

E

A

B

C

Attachment hole for lifting eye, M12 (if the wrist unit is mounted)

Attachment for lifting device, upper arm, 2 pcs (if there is no wrist unit mounted)

Oil plug, draining, gearbox axis 3

Motor, axis 3

Motor, axis 4

Attachment screws and washers, upper arm

Sealing, axes 2/3 (between lower arm and gearbox axis 3)



4 Repair


Continued



Sealing, axis 2/3

Rotation tool

3HAC17212-1 Always use a new sealing when refitting the upper arm!

3HAC12703-1 To be replaced if damaged.

Washer, axis 3 (3 pcs)

Guide pins, sealing axis 2/3 80 mm 3HAC14628-1 For guiding "Sealing, axis 2/3".

Guide pins, sealing axis 2/3 100 mm 3HAC14628-2 For guiding "Sealing, axis 2/3".

Power supply 24 VDC, max 1,5A

For releasing the brakes.

3HAC17105-1 Used to rotate the motor shaft beneath the motor cover, when brakes are released with 24 VDC power supply.

Lifting eye VLBG M12

Lifting device, upper arm

Lifting tool (chain)

Standard toolkit


3HAC16131-1

3HAC15994-1

3HAC15556-1 To be used together with lifting eye, M12 and lifting device, upper arm.

- The content is defined in the


409

.


Removal, upper arm

The procedure below details how to remove the upper arm.

Action Note

1. Remove all equipment fitted to turning disk.

2. Move the upper arm to a horizontal position.

Rotate axis 4 so that the attachment hole for lifting

eye is faced upwards!

Shown in the figure

Location of upper arm on page 272 .

3. Rotate axis 5 to position +90°

4.

DANGER!




5. Upper arm including wrist unit:

Fit the lifting eye, VLBG M12 to the attachment hole

for lifting eye on the upper arm tube.



.

Shown in the figure




273

4 Repair


Continued

Action Note


Fit one of the pieces included in lifting device, upper

arm to the front attachment for lifting device on the upper arm.

Upper arm without wrist unit:

Fit the lifting device, upper arm to both attachments

for lifting device.


Attachment point is shown in the figure


NOTE!

The different attachment points, depends on whether the wrist unit is mounted or not!

7. Fasten the lifting tool (chain) onto the lifting eye, the lifting device and an overhead crane.



Detailed in section Oil change, gearbox, axis 3 on page 171

.

9. Remove the cover on top of the motors, axis 3 and

4 and disconnect all connectors inside the motors.

10. Remove the cable harness upper arm and place it in a way that it will not be damaged in the proceeding procedure of removing the upper arm.

Detailed in section Removal, cable harness - upper arm on page 205

.

Detailed in section Replacement of cable harness, Cleanroom on page 224 .

11.

12.

CAUTION!

The complete upper arm weighs 380 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel!

274

NOTE!


In order to prevent from particle emission while lifting, put for example a 20 mm thick cellular plastic sheet around the places on the robot where the lifting equipment may rub against the paint.

13. Raise the lifting equipment to take the weight of the upper arm.

14. In order to release the brake of the axis 3 motor, connect the 24 VDC power supply.

Connect to connector R2.MP3

• +: pin 2

• -: pin 5

NOTE!

When releasing the brake, the position of the upper arm is adjusted to the position given by the lifting equipment.



4 Repair


Continued

Action Note

15. Carefully remove the attachment screws and washers, upper arm.

16. Lift the upper arm and place it on a secure surface.

Make sure the lift is done completely level! In case of necessary adjustments, use the shortening loops on the lifting tool (chain), but make sure to place the chain the right way through the loops!

Shown in the figure


17. Remove the sealing, axis 2/3 from the lower arm. Shown in the figure


Refitting, upper arm

The procedure below details how to refit the upper arm.

Note

1.

Action

DANGER!




SMB.

2. Fit the two guide pins, sealing axis 2/3 in two of the attachment screw holes on gearbox 3, see figure to the right.

Guide the new sealing, axis 2/3 into position on gearbox 3, using the guide pins.

Always use a new sealing when reassembling!



.

3HAC026876-001 Revision: F xx0200000166

A. Holes for the guide pins (sealing axis 2/3).

B. Holes for the upper arm attachment screws (33 pcs).

C. Holes for the gearbox attachment screws (not affected in this instruction).


275

4 Repair


Continued

Action Note


Fit the lifting eye, VLBG M12 to the attachment

hole, lifting eye on the wrist unit.


Shown in the figure

Location of upper arm on page 272

.


Fit one of the pieces included in the lifting

device, upper arm to the front attachment for

the lifting device on the upper arm.

Upper arm without wrist unit:

Fit the lifting device, upper arm to the both

attachments for the lifting device on the upper arm.


Attachment points are shown in the

figure Location of upper arm on page

272

.

NOTE!

The different attachment points, depends on whether the wrist unit is mounted or not!

5. In order to release the brake of the axis 3 motor, connect the 24 VDC power supply, after removing the motor cover.


• +: pin 2

• -: pin 5

6. Fasten the lifting tool (chain) onto the lifting eye, the lifting device and an overhead crane.


7.

8.

CAUTION!

The complete upper arm weighs 380 kg without any additional equipment fitted! Use a suitable lifting device to avoid injury to personnel!

NOTE!


In order to prevent from particle emission while lifting, put for example a 20 mm thick cellular plastic sheet around the places of the robot where the lifting equipment may rub against the paint.

9. Lift the upper arm and move to its mounting position.

Make sure the lift is done completely level!

276



4 Repair


Continued

Action Note

10. Fit in the gearbox attachment holes with the attachment holes on the lower arm with the guide pins.

It may be necessary to turn the gear by rotating the motor pinion with a rotation tool, motor beneath the motor cover.



.

xx0200000165

The rotation tool is used beneath the motor cover, directly on the motor shaft as shown in figure above.

• A: Rotation tool

11. Fit the three washers to be placed beneath the attachment screws.

Shown in the figure Location of upper arm on page 272

.

12. Insert 31 of the 33 attachment screws, upper

arm into the attachment holes in the lower arm.

Do not remove the guide pins until the attachment screws are tightened as detailed below.

Shown in the figure Location of upper arm on page 272

.

Removing the plastic mechanical stops may be required before fitting the upper arm.

If guide pins are removed before the screws are tightened, the sealing can be involuntarily moved into wrong position.

13. Secure the lower arm to gearbox axis 3, with the attachment screws.

33 pcs: M12 x 50; 12.9 quality

UNBRAKO, tightening torque: 120 Nm.



before fitting.

14. Remove the guide pins and fit the two remaining attachment screws. Tighten them as detailed above!

15. Disconnect the brake release voltage and remove the rotation tool from the motor.

16. Remove the lifting devices.

17. Refit any cabling removed during the removal process.

18. Reconnect all connectors inside motors, axis 3 and 4. Refit the motor covers.

19. Perform a leakdown test. Detailed in section

Performing a leakdown test on page 196

.

20. Refill the gearbox with oil. Detailed in section

Oil change, gearbox, axis 3 on page 171 .



277

4 Repair


Continued

Action


22.

DANGER!



41 .

Note




4 Repair

4.4.5. Replacement of complete lower arm

4.4.5. Replacement of complete lower arm

Location of lower arm

The lower arm is located as shown in the figure below.


xx0700000347

C

D

A

B

Lower arm

Pivot point, axis 2

Front shaft, balancing device

Attachment for lifting equipment, balancing device


Equipment, etc.

Lifting tool, lower arm

Rotation tool

Grease

Isopropanol

Standard toolkit


Art. no.

3HAC027794-001

3HAC17105-1

3HAB3537-1

11771012-208

-

Note

Used to rotate the motor pinion and gear if necessary, when brakes are released.

For lubrication of the shaft hole.

For cleaning of the shaft.






279

4 Repair


Continued

Removal, lower arm

The procedure below details how to remove the complete lower arm.

Note

1.

Action

DANGER!




SMB.

2. Remove the upper arm.

3. Disconnect and remove the cables from inside the lower arm.

Release any cable attachments.

Detailed in section

Removal, upper arm on page 273 .

Detailed in section

Replacement of cable harness, axes 1-6 on page

203

.

280

NOTE!

For Cleanroom robots it is necessary to remove the complete cable harness from base, frame and lower arm. The removal procedure is

detailed in section Replacement of cable harness, Cleanroom on page

224

.

4. Apply the shackle to the balancing device and raise to unload the weight of the device.



Attachment is shown in the figure

Location of lower arm on page 279

.

5. Unload the balancing device in order to make the piston rod and front ear adjustable when pulling the front shaft out.

Method 1 detailed in section

Unloading the balancing device using hydraulic press tool. on page

322

Method 2 detailed in section

Unloading the balancing device using distance tool on page 317

.

6. Remove the securing screw from the balancing device front shaft.

Shown in the figure Location of lower arm on page 279 .

7. Apply the puller tool, balancing device shaft to the shaft of the balancing device, through the hole in the frame.

The shaft has a M20 thread diameter, as shown in the figure to the right.

Pull the shaft out using the puller tool and the hydraulic pump.



NOTE!

The dimension of the shaft puller tool is M20. Do not mix up with the shaft press tool used when mounting the shaft.

8. Lower the balancing device until it rests safely against the bottom of the frame.



4 Repair


Continued

Action

9. Move the lower arm backwards to the lowest position possible.

Note

The figure shows IRB 6600 but the position of the lower arm shall be the same.

xx0300000015

10.

NOTE!



11. Apply the lifting tool to the lower arm.

12. Drain the oil from gearbox 2.


Detailed in section


13.

CAUTION!

The lower arm weighs 160 kg! All lifting equipment used must be sized accordingly!

14. Raise the tool to unload the lower arm.

15. Remove the lower arm shaft and all additional components, as detailed in section Removal, lower arm shaft .

16. Remove the attachment screws and washers that attach the lower arm to the gearbox axis 2.

17. Lift the lower arm and place it on a secure surface.



281

4 Repair


Continued

Refitting, lower arm

The procedure below details how to refit the lower arm.

Note

1.

Action

DANGER!




SMB.

2. Fit two guideing pins in two opposite attachment holes of the lower arm.

282 xx0700000348

3.

NOTE!



4. Apply the lifting tool to the lower arm.

Art. no. is specified in Required equipment on page 279

.

5.

CAUTION!

The lower arm weighs 160 kg! All lifting equipment used must be sized accordingly!

6. Lift the lower arm and move it to its mounting position.



4 Repair


Continued

Action Note

7. In case the hole pattern of the lower arm and the gearbox axis 2 does not match, use power supply to release the motor axis 2 brakes and rotate the pinion and gear with the rotational tool.

Connect power supply to connector

R2.MP2

• +: pin 2

• -: pin 5 xx0200000165

The rotation tool (A) is used beneath the motor cover, directly on the motor shaft as shown in figure above.


8. Disconnect the power supply, if used.

9. Secure the lower arm with 18 of the

20attachment screws and washers in gearbox, axis 2.

20 pcs: M16 x 50, tightening torque:

300 Nm.

Reused screws may be used, providing they are lubricated as

detailed in the section Screw joints on page 405

before fitting.

10. Remove the guidings and secure the two remaining screws as detailed above!

11. Remove the lifting tool from the lower arm.

12. Refit and restore the balancing device.

13. Refit the upper arm.

14. Perform a leak-down test.

15. Refill the gearbox with oil.

Detailed in section Refitting of balancing device .

Detailed in section

Refitting, upper arm on page 275

.

Detailed in section Performing a leakdown test on page 196 .

Detailed in section Oil change, gearbox axis 2 on page 168

.

16. Refit and reconnect all cables inside the lower arm.

Resecure any cable attachments.

Detailed in section Refitting, cable harness, axes 1-4 on page 241 .

Detailed in section Replacement of cable harness, Cleanroom on page

224 .

17. Recalibrate the robot! Calibration is detailed in a separate calibration manual enclosed with the calibration tools.




283

4 Repair


Continued

18.

Action

DANGER!



41

.

Note


4 Repair

4.5.1. Replacement of SMB unit

4.5 Frame and base

4.5.1. Replacement of SMB unit

Replacement of SMB unit for Foundry Prime

For replacement of SMB unit on robots with option Foundry Prime, see Replacement of SMB

unit - Option Foundry Prime, 3HAC037959-014 (available on ABB Library).

Location of SMB unit

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

xx0700000121

A

B

C

D

SMB cover

Pins

Battery cable

SMB unit


Equipment, etc. Spare part no. Art. no.

SMB unit

Standard toolkit

3HAC022286-001

-

Circuit Diagram

Note

-

3HAC025744-001



.




285

4 Repair


Continued

Removal, SMB unit

The procedure below details how to remove the SMB unit.

Action

1. Move the robot to the calibration position.

2.

Note

3.

DANGER!




esd

WARNING!


WARNING - The unit is sensitive to ESD! on page 43

4. Remove the SMB cover by unscrewing its attachment screws.

5. Remove the connectors X8, X9 and X10 from the brake release board, if need of more space.

Shown in the figure Location of

SMB unit on page 285

.

6. Remove the nuts and washers from the pins securing the board.



.

7. Gently disconnect the connectors from the SMB unit when pulling the board out.

Connectors R1.SMB1-3,

R1.SMB4-6 and R2.SMB

8. Disconnect the battery cable from the SMB unit.



.

286



Refitting, SMB unit

The procedure below details how to refit the SMB unit.

Note

1.

Action

4 Repair


Continued

2.

DANGER!




SMB.

esd

WARNING!

The unit is sensitive to ESD. Before handling the unit please read the safety information in the

section WARNING - The unit is sensitive to ESD! on page 43

3. Connect the battery cable to the SMB unit. Shown in the figure

Location of SMB unit on page 285 .

4. Connect all connectors to the SMB board and fit the SMB unit onto the pins.



.

Shown in the figure


R1.SMB1-3, R1.SMB4-6 and R2.SMB

5. Secure the SMB unit to the pins with the nuts and washers.

6. If disconnected, reconnect the connectors X8, X9 and X10 to the brake release board.

7. Secure the SMB cover with its attachment screws.

8. Update the revolution counter!

Shown in the figure


Detailed in chapter Calibration -


9.

DANGER!

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

detailed in the section DANGER - First test run may cause injury or damage! on page 41

.


4 Repair

4.5.2. Replacement of brake release unit

4.5.2. Replacement of brake release unit

Location of brake release unit

The brake release unit is located together with the SMB unit on the left hand side of the frame, right next to the gearbox, axis 2, as shown in figure below. xx0700000123

C

D

A

B

E

F

Brake release unit

Push button guard

Battery cover

Battery

SMB cover

Battery cable


Equipment, etc. Art. no. Note

Brake release unit with buttons 3HAC16035-1 Located together with the SMB-unit at the left-hand side of the frame.



.



288



4 Repair


Continued

Removal, brake release unit

The procedure below details how to remove the brake release unit.

Note

1.

Action

2.

DANGER!




SMB.

esd

WARNING!

The unit is sensitive to ESD. Before handling the unit please read the safety information in

the section WARNING - The unit is sensitive to ESD! on page 43

3. Remove the push button guard from the SMB cover.

Shown in the figure Location of brake release unit on page 288

.

The guard must be removed to ensure a correct refitting of the brake release unit.

4. Let the battery stay connected, to avoid the need of synchronization of the robot!

5. Disconnect the connectors X8, X9 and X10 from the brake release unit.


.

6. Remove the brake release unit from the bracket by removing the four attachment screws. xx0200000129

• A: Connector X8

• B: Connector X9

• C: Connector X10

• D: Push buttons

Location of the brake release unit is

shown in the figure Location of brake release unit on page 288

.



289

4 Repair


Continued

Refitting, brake release unit

The procedure below details how to refit the brake release unit.

Note

1.

Action

2.

DANGER!




SMB.

esd

WARNING!


WARNING - The unit is sensitive to

ESD! on page 43

3. Fasten the brake release unit on the bracket with the attachment screws.

Make sure the unit is positioned as straight as possible on the bracket! The push buttons can otherwise get jammed when the SMB cover is refitted.


.



4. Connect the connectors X8, X9 and X10 to the brake release unit.

290 xx0200000129

• A: Connector X8

• B: Connector X9

• C: Connector X10

• D: Push buttons

5. Refit the SMB cover with its attachment screws.

The push button guard must not be mounted on the cover before the check described below is made!


.



4 Repair


Continued

Note

6.

Action

WARNING!


WARNING - The brake release buttons may be jammed after service work on page 42 !

7. Refit the push button guard to the SMB cover. Shown in the figure

Location of brake release unit on page 288 .

8. If the battery has been disconnected the revolution counter must be updated.

Detailed in the Calibration chapter -


9.

DANGER!



41 .


4 Repair

4.5.3. Replacement of spherical roller bearing, balancing device

4.5.3. Replacement of spherical roller bearing, balancing device

Overview

There are some differences in the two designs of the robot IRB 6640, design 1 has:

• one ear on the lower arm as shown in the figure for design 1.

Design 2 has:

• two ears on the lower arm as shown in the figure for design 2

The difference is described in section

Design 1 and Design 2 of IRB 6640 on page 48

.

Location of bearing, Design 1

The bearings are located in the balancing device, as shown in the figure below.

292 xx0900000072

A

B

C

D

Washer

Sealing ring, radial (2 psc)


O-ring



H

J

E

F

K

L

M

N

Location of bearing, Design 2

4 Repair


Continued

Shaft


VK-cover

VK-cover


Cradle bearing kit

Hex socket head cap screw M16x70

Sealing washer xx0900000066

C

D

E

A

B

F

G

H

Shaft

Washer


VK-cover

Washer

Radial sealing with dust lip 50x68x8


Radial sealing with dust lip 50x68x8



293

4 Repair


Continued

J

K

L

M

N

O

P

Q

O-ring

End cover

Radial sealing (not used in clean room applications)

Cradle bearing kit


Washer


VK-cover


Equipment


Grease

Toolkit


Spare part no.

Art. no.

See Spare parts

Note

3HAB3537-1

Includes the parts shown in the figure above.

For lubrication of the components.

3HAC028920-001 The tools in the set are shown in the section

Dismounting and mounting tool

3HAC028920-001 on page 413


Tool set up 3HAC028920-001

The set up of the press tool used for the process of removal and refitting of spherical bearing

is described in section Dismounting and mounting tool 3HAC028920-001 on page 413 .

294



4 Repair


Continued

Removal, spherical roller bearing

Use this procedure to remove the spherical roller bearing from the balancing device front ear.

Note

1.

Action

DANGER!




2. Remove the balancing device from the robot.

3. Remove the both sealing spacers with a screwdriver or any equal tool.

4. Remove the sperical roller bearing, using the dismounting and mounting tool

3HAC028920-001.

Detailed in section

Replacement of balancing device (design 1) on page 297

or in Replacement of balancing device

(design 2) on page 306 .

Shown in the figure Location of bearing,

Design 1 on page 292 and

Location of bearing, Design 2 on page 293

Described in section Removal front bearing Design 1 on page 419 or

Removal front bearing Design 2 on page

422 .

Refitting, spherical roller bearing

Use this procedure to refit the spherical roller bearing to the balancing device front ear.

Note

1.

Action

DANGER!




2. Grease the inside walls of the front ear.

3. Press in the sealing washer and the sealing.

3HAC026876-001 Revision: F xx0900000115


295

4 Repair


Continued

Action Note

4. Refit the new bearing and sealings.

5. Apply grease to the new sealing rings and orings and fit them.

Sealing and o-ring are showed in the

figure Location of bearing, Design 1 on page 292

and Location of bearing, Design

2 on page 293 .

6. Refit the end cover.

Described in section

Refitting front bearing and sealing Design 1 on page

421

or in Refitting front bearing with sealing Design 2 on page 424 .

End cover shown in figure

Location of bearing, Design 1 on page 292 or

Location of bearing, Design 2 on page

293

.

7. Refit the balancing device to the robot.

Detailed in section Replacement of balancing device (design 1) on page

297

or Replacement of balancing device

(design 2) on page 306

.

8. Lubricate the spherical roller bearing in the ear.

Detailed in section Lubrication of spherical roller bearing, balancing device on page 186

NOTE!

The balancing device must be mounted on the robot when lubrication is performed!

9. Make sure no incorrect leakage occurs. It could indicate damaged o-rings.

Further information is available in section

Check for leakage - Design 1 on page

140

.

10.

DANGER!


DANGER -


.


4 Repair

4.5.4. Replacement of balancing device (design 1)

4.5.4. Replacement of balancing device (design 1)

Replacement balancing device for Foundry Prime

For replacement of balancing device on robots with option Foundry Prime, see Replacement

of balancing device (design 1) - Option Foundry Prime, 3HAC037959-006 (available on

ABB Library).

Location of balancing device

The balancing device is located on rear top of the frame as shown in the figure below.

xx0800000477

A

B

C

Balancing device

Cradle bearing




297

4 Repair


Continued


Equipment

Spare part no.

Balancing device See Spare parts


See Spare parts


See Spare parts

Locking screw

Bearing grease

Grease

Grease pump


Shackle

Press tool, balancing device

Distance tool

Dismantle and mounting tool

Hydraulic cylinder

Hydraulic pump,

80 MPa

Standard toolkit

Art. no.

Note

M16x60 quality 12.9 Gleitmo

For securing the lower arm.

3HAB3537-1

-

3HAA1001-294

To lubricate spherical roller bearing.

3HAC15556-1

3HAC020997-001

3HAC020902-001 For unloading and restoring the balancing device.

-

3HAC030662-001

3HAC028920-001 For dismantle and mounting of shaft and bearings.

3HAC11731-1 To be used with these tools:

• 3HAC028920-001

• 3HAC020902-001

3HAC13086-1 To be used with the hydraulic cylinder 3HAC11731-1.



409

.

Loctite 577

Sikaflex 521FC

298



4 Repair


Continued

Removal balancing device, (design 1)

The procedure below details how to remove the balancing device.

Action Note

1. Remove all equipment, if any, on or close to the balancing device.

2. For Clean Room robots - remove the lower end of the cable harness.

3. Fit the lifting tool with shackle to the balancing device and raise to unload the weight.

Detailed in section


Cleanroom on page 224 .

CAUTION!

The balancing device weights

210 kg! All lifting equipment used must be sized accordingly!

4. Secure the upper arm using a lifting sling or using the locking screw (A) in the frame.

xx0900000092 xx0800000249

5. Method 1:

Unload the balancing device with the press tool in order to make the piston rod and front ear adjustable when pulling the shaft out.

Method 2:

Unload the balancing device with the distance tool in order to make the piston rod and front ear adjustable when pulling the shaft out.

Art. no. is specified in Required equipment .

Method 1: Detailed in section

Unloading the balancing device using hydraulic press tool. on page

322 .

Method 2: Detailed in section




4 Repair


Continued

6.

Action Note

DANGER!




7. Remove the VK cover in order to reach the shaft .

Hit the VK cover gently at the bottom part of it with a plastic hammer or similar and tilt it out.

8. Remove the retaining ring, bore.

9. Remove the front shaft using the


3HAC028920-001.



3HAC028920-001 on page 413

300

10. Remove the VK cover in order to reach the shaft holding the balancing device.

Hit the VK cover gently at the bottom part of it with a plastic hammer or similar and tilt it out.

11. Wipe off all residual grease inside the hole.

12. Remove the Hex socket head cap screw M16x70 securing the piston rod shaft.

xx0900000095



4 Repair


Continued

Action

13. Remove the retaining ring, bore

(A) securing the shaft.

Note

14. Remove both the cradle bearings and the balancing device shafts, using the dismounting and mounting tool

3HAC028920-00.

xx0900000079

15. Perform the following procedure of pulling out the shafts on both sides of the cradle.

16. Lift the balancing device gently backwards to a secure area.

xx0900000074



301

4 Repair


Continued

Refitting

The procedure below details how to refit the balancing device.

Action

1. Fit the shackle

3HAC020540-001 to the balancing device.

Note

Where to attach the shackle is shown in the figure.

302

2.

CAUTION!

The balancing device weighs 210 kg! All lifting equipment used must be sized accordingly!

3. Refit one of the two retaining rings.

4. Grease the cradle

5. Use the tool 3HAC028920-

001 to refit the cradle bearings and the balancing device shafts.

xx0900000094 xx0900000060



Action

6. On the side where the retaining ring, bore is mounted.

Refit the cradle bearings and the balancing device shafts to the retaining

ring, bore.

7. On the side where the retaining ring, bore is not mounted, refit the cradle bearings and the balancing device shafts completely.

8. It should look like this.

Note

4 Repair


Continued

9. Mount new radial sealings.

xx0900000083

NOTE!

The radial sealings is not used in Clean room applications.

xx0900000093



303

4 Repair


Continued

Action

10. Use Loctite on the threads on the balancing device.

Note

CAUTION!

Do not use Loctite on the threads of the Hex socket head cap screw M16x70.

xx0900000088

11. Perform the following procedure of refitting the shafts on both sides of the cradle before refitting of the shaft at the piston rod shaft front eye.

12. Lift the balancing device to the back of the robot.

13. Fit the balancing device on the side where the shaft is in final position and fix it lightly using the Hex socket head cap screw

M16x70.

14. On the other side, use the

Hex socket head cap screw M16x70 to refit the cradle bearings and the balancing device shafts to the final position.

Tighten the Hex socket head cap screw M16x70 on both sides. Tightening torque 300Nm.

304



Action

15. Lock the cradle bearings using the retaining ring, bore (A).

Note

4 Repair



16. Mount new VK- covers on both sides.

17. Raise the balancing device to a position where the shafts may be refitted.

18. Lubricate the shaft with

grease.

19. Refit the front shaft using the tool 3HAC028920-001.

40ml

20. Refit the attachment screw securing the shaft.

Attachment screw M16x70 quality 12.9 Gleitmo

Tightening torque:300 Nm

21. Refit the retaining ring,

bore.

22. Refit the VK cover.

20ml 23. Lubricate the bearing in the ear with grease through the lubricating nipple, with a grease

pump.

Fill until excessive grease pierces between the shaft and the sealing spacer.

24. For Clean Room robots - refit the lower end of the cable harness.

25. Restore the balancing device.

Detailed in section Replacement of cable harness,


Method 1: described in section Restoring the balancing device using a hydraulic press tool. on page 325

Method 2: described in section Restoring the balancing device using distance tool on page 320


4 Repair


4.5.5. Replacement of balancing device (design 2)

Replacement balancing device for Foundry Prime

For replacement of balancing device on robots with option Foundry Prime, see Replacement

of balancing device (design 2) - Option Foundry Prime, 3HAC037959-007 (available on

ABB Library).

Location of balancing device

The balancing device is located on rear top of the frame as shown in the figure below.

xx0900000075

A

B

C

Balancing device

Cradle bearing



Equipment

Balancing device



Locking screw

Spare part no.

Art. no.

See Spare parts

See Spare parts

See Spare parts

Bearing grease

Grease

Grease pump

Brush

3HAB3537-1

3HAA1001-294

Note

M16x60 quality 12.9 Gleitmo.

For securing of the lower arm.

306



4 Repair


Continued

Equipment

Rust preventive


Shackle


Distance tool


Hydraulic cylinder

Hydraulic pump, 80

MPa

Standard toolkit

Spare part no.

Art. no.

Note

3HAC026621-001 Mercasol 3106

3HAC15556-1

3HAC020997-001

3HAC020902-001 For unloading and restoring the balancing device,

(Method 1)


(Method 2)

3HAC028920-001 For dismantle and mounting of shaft and bearings.

3HAC11731-1

3HAC13086-1

To be used with these tools:

• 3HAC028920-001

• 3HAC020902-001

To be used with the hydraulic cylinder 3HAC11731-1.



Loctite 577

Sikaflex 521FC

Removal balancing device, (design 2)

The procedure below details how to remove the balancing device

Action

1. Remove all equipment, if any, on or close to the balancing device.

2. For Clean room robots - remove the lower end of the cable harness.

3. Fit the lifting tool to the balancing device and raise to unload the weight.

Note

CAUTION!

The balancing device weights 210 kg! All lifting equipment used must be sized accordingly!

xx0900000092



307

4 Repair


Continued

Action

4. Secure the upper arm using a lifting sling or using the locking screw (A) in the frame.

Note

308 xx0800000249

5. Method 1:

Unload the balancing device with the press tool in order to make the piston rod and front ear adjustable when pulling the shaft out.


Unloading the balancing device using hydraulic press tool. on page 322

6. Method 2:

Unload the balancing device with the distance tool in order to make the piston rod and front ear adjustable when pulling the shaft out.

7.



DANGER!




SMB.

8. Remove the protection

plug covering the shaft in the center of the piston rod shaft front eye.

NOTE!

The protection plug used in Clean Room applications must also be refitted after the refitting of the balancing device! do not loose it!

9. Remove the Hex socket head cap screw M16x70 securing the piston rod shaft front eye.



4 Repair


Continued

Action

10. Remove the front shaft using the tool

3HAC028920-001.

Note

Described in section Dismounting and mounting tool

3HAC028920-001 on page 413 .

xx0900000080

• A) Protection plug (only Clean Room)

• B) Hex socket head cap screw M16x70

• C) Washer

• D) Shaft

• E) Distance tool

11. Remove the VK cover in order to reach the shafts holding the balancing device. Hit the VK-cover at the bottom part of it with a hammer or similar and tilt it out

NOTE!

It is almost impossible to remove the VK-cover without damage, new VK-covers are needed.

12. Remove the hex socket head cap screw M16x70 securing the shaft.

13. Wipe off all residual grease inside the hole.



309

4 Repair


Continued

Action

14. Remove the retaining ring, bore (A) securing the shaft and bearing.

Note

15. Remove both the cradle bearings and the balancing device shafts, using the dismounting and mounting tool

3HAC028920-00.

Tool configuration in

section Removal rear shafts Design 1 and 2 on page 425

xx0900000079

16. Remove the balancing device.

xx0900000074

310



4 Repair


Continued

Refitting balancing device, Design 2

Action Note

1. Grease the cradle.

2. Refit one of the two retaining rings.

3. Use the tool

3HAC028920-001 to refit the cradle bearings and the balancing device shafts.



3HAC028920-001 on page 413

.

4. On the side where the retaining ring, bore is mounted.

Refit the cradle bearings and the balancing device shafts to the retaining

ring, bore.

xx0900000061 xx0900000084



311

4 Repair


Continued

Action

5. On the side where the retaining ring, bore is not mounted, refit the cradle bearings and the balancing device shafts

completely.

Note

6. It should look like this.

xx0900000085

7. Mount new radial sealings.

NOTE!

The radial sealings is not used in Clean room applications.

xx0900000083 xx0900000093

312



Action

8. Fit the lifting tool to the balancing device.

Note

4 Repair



9. Use Loctite on the threads on the balancing device.

CAUTION!

The balancing device weighs 210 kg! All lifting equipment used must be sized accordingly!

NOTE!

Do not use Loctite on the threads of the Hex socket head cap screw M16x70

10. Perform the following procedure of refitting the shafts on both sides of the cradle before refitting of the shaft at the piston rod shaft front eye.

11. Lift the balancing device in to the cradle.

xx0900000088



313

4 Repair


Continued

Action Note

12. Fit the balancing device on the side where the shaft is in final position and fix it lightly using the

Hex socket head cap screw M16x70.

13. On the other side, use the

Hex socket head cap screw M16x70 to refit the cradle bearings and the balancing device shafts to the final position.

Tightening torque 300Nm.

14. Lock the cradle bearings using the retaining ring, bore (A).

15. Mount new VK- covers on both sides.

xx0900000089

314



4 Repair


Continued

Action Note

16. Refit the front shaft using the tool 3HAC028920-

001.



3HAC028920-001 on page 413

.

NOTE!

Grease the shaft for easier assemble.

xx0900000080

• A) Protection plug (Clean room)

• B) Hex socket head cap screw M16x70

• C) Washer

• D) Shaft

• E) Distance tool

17. Refit the Hex socket head cap screw M16x70, use

Loctite.

Tightening torque 50Nm

18. Restore the balancing device.

Method 1 Described in section Restoring the balancing device using a hydraulic press tool. on page 325

Method 2 Described in section Restoring the balancing device using distance tool on page 320 .

19. Fill the cradle bearings with 70 ml, Optimol PDO.

NOTE!

The inner hole is used for lubrication, and the outer hole is used for air outlet.

3HAC026876-001 Revision: F xx0900000090


315

4 Repair


Continued

Action

20. Fill the spherical roller bearing with 20 ml,

Optimol PDO.

Note xx0900000102


4 Repair

4.5.6. Unloading the balancing device using distance tool

4.5.6. Unloading the balancing device using distance tool

Overview

This section details how to unload the balancing device using a distance tool 3HAC030662-

001. This method is used when the balancing device is reusable.

DANGER!

There is a high tensioned spring inside the balancing device, incorrect handling may cause injuries and damage property.

DANGER!

Do not remove the press tool from a dismounted balancing device.

Distance tool xx0800000478

A Distance tool 3HAC030662-001



317

4 Repair


Continued

Unloading procedure

Action

1. Jog the robot lower arm to a maximal forward position.


2. Remove the cover plate on the back of the balancing device.

3. Mount the press tool on the back of the balancing device using the four screws.

xx0800000479

318 xx0800000480

• A . Press tool



4 Repair


Continued

Action

4. Jog the robot lower arm backward until the pressure from the balancing device release.


5.

CAUTION!

Secure the upper arm before removing the shaft.

xx0800000481


4 Repair

4.5.7. Restoring the balancing device using distance tool

4.5.7. Restoring the balancing device using distance tool

DANGER!


DANGER!

Do not remove the press tool 3HAC030662-001 from a dismounted balancing device.


Equipment

End Cover Gasket

Distance tool

Spare part no.

Art. no.

Note

See Spare parts To be replaced if damaged!


(Method 2)

Standard toolkit

Loctite 577

Sikaflex 521FC

Restoring procedure

Action

1. Jog the lower arm forward to release the pressure from the press tool.


320

2. Remove the press tool.

3. Mount a new end cover gasket if needed.

xx0800000482



4 Repair

4.5.7. Restoring the balancing device using distance tool

Continued

Action Note/Illustration

4. Mount the cover on the back of the cylinder using the four screws.

Apply Sikaflex 521FC on the end cover gasket.

5. Use Loctite 577 on the four screws.

xx0900000104

Tightening torque 47Nm


4 Repair

4.5.8. Unloading the balancing device using hydraulic press tool.

4.5.8. Unloading the balancing device using hydraulic press tool.

Prerequisite

This section details how to unload the balancing device using the hydraulic press tool.

The lower arm must be secured before unloading the balancing device! How to secure the lower arm is detailed in the current repair activity, for example removal of the balancing device.

DANGER!


Press tool and hydraulic cylinder

The figure below shows the hydraulic cylinder mounted on the press tool.

The press tool includes two press devices that are used to different models of the balancing device.

322 xx0200000174

E

F

G

A

B

C

D

Press block

Hydraulic cylinder

Press device

Bolt, press device

Moving pin with marking

Bolt (4 pcs)

Pin, attached to the fix plate



4 Repair


Continued


Equipment, etc.


Hydraulic cylinder

Hydraulic pump, 80 MPa

Standard toolkit

Art. no.

Note

-

3HAC020902-001 Includes

• press device 3HAC15767-2

• press device 3HAC18100-1

Choose the correct device, depending on model of balancing device.

3HAC11731-1

3HAC13086-1

To be used with the press tool.

To be used with the hydraulic cylinder.



.

Using the correct press device

The different designs of the balancing device require different versions of the press device, included in the complete press tool. The table below specifies which press device to use to which balancing device.

The article number of the balancing device may be found on a label at the rear of the balancing device.

Balancing device Press device

Art. no: 3HAC18100-1 xx0300000599 xx0700000475

Unloading the balancing device

The procedure below details how to use the press tool in order to unload the balancing device.

How to remove the press tool, is detailed in section

Restoring the balancing device using a hydraulic press tool. on page 325 .

Action Note

1. Fit the moving pin to the current press device. Choose the correct press device,

according to the table Using the correct press device on page 323

.

The moving pin is shown in the figure

Press tool and hydraulic cylinder on page 322

.



323

4 Repair


Continued

Action Note

2. Fit the correct press device and moving pin to the press tool. Secure with the bolt, press device.

Shown in the figure Press tool and hydraulic cylinder on page 322 .

NOTE!

Make sure the bolt is secured properly!

3. Remove the rear cover of the balancing device, by unscrewing the attachment screws.

DANGER!

DO NOT! remove any other screws then the rear cover attachment screws.

4. Fit the press tool to the rear of the balancing device with enclosed bolts. Tighten them properly!

5. Fit the hydraulic cylinder to the press tool. xx0700000422

• E: Rear cover attachment screws, 4 pcs



See the figure Press tool and hydraulic cylinder on page 322

.



See the figure Press tool and hydraulic cylinder on page 322

.

6. Connect the hydraulic pump to the cylinder. Art. no. is specified in


7. Increase the pressure and press until the marking on the moving pin indicates the correct position (in level with the pressure block).

See the figure


.

Do not apply more pressure than necessary, it could damage bearings and sealings at the shaft.

8. Turn the fix plate to position "Closed" in order to lock the tool in loaded condition.

See the figure


.

9. Unload the hydraulic cylinder.

10. The hydraulic cylinder may now be removed from the tool, when necessary.


4 Repair

4.5.9. Restoring the balancing device using a hydraulic press tool.

4.5.9. Restoring the balancing device using a hydraulic press tool.

Overview

This section details how to restore the balancing device and how to remove the press tool from the device.

DANGER!


Press tool and hydraulic cylinder

The figure below shows the hydraulic cylinder mounted on the press tool.

The press tool includes two press devices that are used to different models of the balancing device.

xx0200000174

F

G

D

E

A

B

C

Press block

Hydraulic cylinder

Press device

Bolt, press device

Moving pin with marking

Bolt (4 pcs)

Pin, attached to the fix plate



325

4 Repair


Continued


Equipment, etc.

Art. no.

Note

Hydraulic cylinder 3HAC11731-1 To be used with press tool.

Hydraulic pump, 80 MPa 3HAC13086-1 To be used with hydraulic cylinder.

Locking liquid Loctite 577

Used to secure the attachment screws of the rear cover at the end of the balancing device.

Standard toolkit 3HAC15571-1

The content is defined in the section Standard toolkit on page 409 .

Sikaflex 521FC

Restoring the balancing device

The procedure below details how to restore the balancing device, that is removing the press tool.

Action Note

1. Refit the hydraulic cylinder to the press tool, in case it has been removed.

Shown in the figure Press tool and hydraulic cylinder on page 325 .

2. Press with the cylinder and the hydraulic pump until the fix plate is movable again. Turn the pin on the fix plate to position "Open".

Shown in the figure Press tool and hydraulic cylinder on page 325 !

Do not apply more pressure than necessary, it could damage bearings and sealings at the shaft.

3. Unload the cylinder and make sure the moving

pin indicates that the tool has returned to its starting position.

Shown in the figure Press tool and hydraulic cylinder on page 325 !

4. Remove the hydraulic cylinder.

5. Remove the press tool by unscrewing the bolts. Shown in the figure Press tool and hydraulic cylinder on page 325 !

6. Refit the gasket to the rear of the balancing device.

7. Refit the rear cover to the balancing device with its attachment screws, using locking liquid.

Apply sikaflex 521FX on the cover.

326 xx0700000422

• E: 4 pcs: M10x30, tightening torque: 50 Nm.



.



8.

Action

4 Repair


Continued

Note

DANGER!

The rear cover of the balancing device is a safety device for the piston rod during operation!

Make sure the cover is properly secured before commissioning of the robot!


4 Repair

4.6.1. Replacement of motor, axis 1

4.6 Motors

4.6.1. Replacement of motor, axis 1

NOTE!

This procedure requires calibration of the robot.

Use the Calibration Pendulum tool 3HAC15716-1.

Replacement of motor axis 1 for Foundry Prime

For replacement of motor axis 1 on robots with option Foundry Prime, see Replacement of

motor, axis 1 - Option Foundry Prime, 3HAC037959-008 (available on ABB Library).

Location of motor

The motor axis 1 is located as shown in the figure below.

xx0700000085

A Motor, axis 1



Motor, axis 1 See Spare parts

Art. no.

O-ring

Grease

Removal tool, motor

M12x

Lifting tool, motor ax 1,

4, 5

21522012-430

3HAB3537-1

3HAC14973-1

3HAC14459-1

Note

Includes

• motor

• pinion

• o-ring 21522012-

430

Must be replaced when reassemling the motor.

Used to lubricate the oring.

Always use the removal tools in pairs!

328



4 Repair


Continued

Note Equipment, etc. Spare part no.

Extension 300mm for bits 1/2"

Power supply -

Art. no.

3HAC12342-1

Standard toolkit -

Calibration Pendulum toolkit


Circuit Diagram

3HAC15716-1

24 VDC, max. 1,5 A




.

Complete kit that also includes operating manual.



Removal, motor axis 1

The procedure below details how to remove motor, axis 1.

Note

1.

Action

DANGER!




2. Remove the cover for connector access on top of the motor by unscrewing its four attachment screws.


NOTE!

Make sure the gasket is not damaged! xx0200000199

• A: Cable gland cover

4. Disconnect all connectors beneath the motor cover.

5. Apply lifting tool, motor axis 1, 4, 5 to the motor.




329

4 Repair


Continued

Action Note

6. In order to release the brakes, connect the 24 VDC power supply.


• +: pin 2

• -: pin 5

7. Remove the motor by unscrewing its four

8.

attachment screws and plain washers.

Shown in the figure Location of motor on page 328

.

CAUTION!

The motor weighs 25 kg! All lifting equipment used must be sized accordingly!

9. Lift the motor to get the pinion away from the gear and disconnect the brake release voltage.

10. Remove the motor by gently lifting it straight up.

Refitting, motor axis 1

The procedure below details how to refit motor, axis 1.

1.

Action Note

330

DANGER!




2. Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the o-ring with grease.

Art no. is specified in Required equipment on page 328 .

3.

CAUTION!


4. Apply the lifting tool, motor axis 1, 4, 5 to the motor. Art no. is specified in Required equipment on page 328 .

5. In order to release the brake, connect the 24 VDC power supply.


• +: pin 2

• -: pin 5

6. Fit the motor, making sure the motor pinion is properly mated to gearbox of axis 1.

Make sure the motor is turned the correct way, that is connection of motorcable as shown in the figure

-

Location of motor on page 328 .

Make sure the motor pinion does not get damaged!

7. Fit the clutch on the pinion on the motor.

8. Secure the motor with its four attachment screws and plain washers.

M10 x 40, tightening torque: 50

Nm.



4 Repair


Continued

Action Note

9. Disconnect the brake release voltage.

10. Reconnect all connectors beneath the motor cover.


Make sure the cover is tightly sealed!

12. Refit the motor cover with its four attachment screws.


13. Recalibrate the robot! Calibration is detailed in a separate calibration manual enclosed with the calibration tools.


14.

DANGER!



.


4 Repair

4.6.2. Replacement of motor axis 2

4.6.2. Replacement of motor axis 2



motor axis 2 - Option Foundry Prime, 3HAC037959-009 (available on ABB Library).


The motor, axis 2, is located on the left-hand side of the robot as shown in the figure below.

xx0700000086

A Motor, axis 2



Motor including pinion

O-ring

Mercasol 3106

Loctite 574

Grease

Locking screw

Removal tool, motor

M12x

Guide pins M10 x

150

Lifting tool, motor ax

2, 3, 4


21522012-430

Note

21522012-430

Includes

• motor

• pinion

• o-ring 2152 2012-

430

Must be replaced when reassembling motor!

3HAC026621-001 Option Foundry Prime

3HAB3537-1

3HAA1001-266

3HAC14973-1

3HAC15521-2

Option Foundry Prime

For lubricating the o-ring.

M16 x 60

For securing the lower arm.


For guiding the motor.

Guides are to be used in pairs!

3HAC026061-001

332




Extension bar, 300 mm for bits 1/2"

Power supply

3HAC12342-1

-

Rotation tool 3HAC17105-1

4 Repair


Continued

Note

Standard toolkit

Calibration

Pendulum toolkit


Circuit diagram

-

3HAC15716-1

24 VDC, 1.5 A


Used to rotate the motor pinion when mating it to the gear when brakes are released with 24VDC power supply.






Removal, motor

The procedure below details how to remove the motor, axis 2.

Action Note

1. Move the robot to a position close enough to its calibration position, to allow the lock screw to be inserted into thehole for lock screw .

Shown in the figure Location of motor on page

332

.

2.

DANGER!




3. Lock the lower arm by inserting the

lock screw into the hole.

Art. no. and dimension is specified in Required equipment on page 332

.

4. Drain the oil from gearbox, axis 2.

Detailed in the section Oil change, gearbox axis 2 on page 168 .

5. Remove the cover on top of the motor by unscrewing its four attachment screws.



333

4 Repair


Continued

Action Note

6. Remove the cable gland cover at the cable exit by unscrewing its two attachment screws.

Shown in the figure

Location of motor on page

332

.

Make sure the gasket is not damaged!


8.

Use the lock screw to lock the lower arm, as detailed above!

DANGER!

Secure the weight of the lower arm properly before releasing the brakes of motor, axis 2!

When releasing the holding brakes of the motor, the lower arm will be movable and may fall down!



• +: pin 2

• -: pin 5

10. Remove the motor by unscrewing its four attachment screws and plain washers.

11. Fit the two guide pins in two of the motor attachment holes.


Shown in the figure


332

.

12. If required, press the motor out of position by fitting the removal tool,

motor to the remaining motor attachment holes.


Shown in the figure


332

.


13. Remove the removal tools and fit the lifting tool, motor axis 2, 3, 4 to the motor.


14. Lift the motor to get the pinion away from the gear.


15. Remove the motor by gently lifting it straight out and place it on a secure surface. Disconnect the brake release voltage.

334



4 Repair


Continued

Refitting, motor

The procedure below details how to refit the motor axis 2.

Note

1.

Action

DANGER!




SMB.



3. In order to release the brake, remove the cover on top of the motor and connect the 24

VDC power supply.


• +: pin 2

• -: pin5

4. Fit the lifting tool, motor axis 2, 3, 4 to the motor.


5. Fit the two guide pins in the two lower motor attachment holes.


Shown in the figure

Location of motor on page 332

.

6. Lift the motor and guide it onto the guide pins, as close to the correct position as possible without pushing the motor pinion into the gear.

Make sure that the motor is turned the right direction, that is the cables facing downwards.

7. Remove the lifting tool and allow the motor to rest on the guide pins.

8. Use the rotation tool in order to rotate the motor pinion when mating it to the gear (see the figure to the right). Fit the motor, making sure the motor pinion is properly mated to the gear of gearbox axis 2 and that it does not get damaged.


9. Remove the guide pins.

3HAC026876-001 Revision: F xx0200000165

The rotation tool is used beneath the motor cover, directly on the motor shaft as shown in the figure above.

• A: Rotation tool


335

4 Repair


Continued

Action Note

10. Secure the motor with four attachment screws and plain washers.

M10 x 40, tightening torque: 50 Nm.



before fitting.



Connect in accordance with markings on connectors.

13. Refit the cable gland cover at the cable exit with its two attachment screws.


.

14. Refit the cover on top of the motor with its four attachment screws.


15. Remove the lock screw from the hole for lock screw.


.

16. Perform a leak down test.



Detailed in Performing a leak-down test on page 196 .

Detailed in the section Oil change, gearbox axis 2 on page 168

.



19.

DANGER!



41 .


4 Repair







The motor axis 3 is located on the left hand side of the robot as shown in the figure below. xx0200000186

A

B

C

Motor axis 3

Cable gland cover, motor axis 3

Motor attachment holes (4 pcs)




O-ring

Mercasol 3106

Loctite 574

Mechanical stop axis 3

21522012-430

Grease


Art. no.

3HAC0266621-

001

3HAC12708-1

3HAB3537-1

Note

Includes

• motor

• pinion

• o-ring 21522012-430


Option: Foundry Prime

Option: Foundry Prime

May be used to fix axis 3.

Use attachment screws 3HAB

3409-86 (M16 x 60).




337

4 Repair


Continued


Removal tool, motor M12x

Lifting tool, motor ax 2, 3, 4

Bolts M16x60

(for mechanical stop axis 3)

Washers (for mechanical stop axis 3)

Guide pins M10 x

100

Guide pins M10 x

150


Rotation tool

3HAC14973-1

3HAC026061-001

3HAB3409-86

3HAA1001-186

3HAC15521-1

3HAC15521-2

3HAC12342-1

3HAC17105-1

Power supply

Standard toolkit

Calibration

Pendulum toolkit


Circuit Diagram

-

-

3HAC15716-1

Note




Used to rotate the motor pinion when mating it to the gear when brakes are released with 24 VDC power supply.

24 VDC, max. 1.5 A




.




338



4 Repair


Continued

Removal, motor


Action

1. Unload the upper arm of the robot by either:

• Use a fork lift to rest the upper arm onto.

• Use lifting slings and an overhead crane to rest the upper arm.

• Use a mechanical stop to rest the upper arm. Fit the mechanical stop in the attachment hole (A) with tightening torque: 115 Nm.

Note xx0300000051

Fit the mechanical stop to the third and final attachment hole (A), below the fixed stop (B) in the upper arm. See the figure above!

2.

DANGER!




3. Drain the oil from gearbox axis 3. Detailed in section

Oil change, gearbox, axis 3 on page 171 .

4. Remove any equipment hindering access to motor axis 3.


6. Remove the cable gland cover at the cable exit by unscrewing its two securing screws.

Shown in the figure Location of motor on page 337 .



8. Unscrew the motors four attachment screws and plain

washers .


9. Fit the two guide pins in two of the motor attachment screw holes.


10. Press the motor out of position by fitting removal tool, motor to the remaining motor attachment screw holes.



11. Apply the lifting tool, motor axis 2 ,3,

4 to the motor.




339

4 Repair


Continued

12.

Action Note

CAUTION!


13. Lift the motor to get the pinion away from the gear.

14. Remove the motor by gently lifting it straight out and disconnect the brake release voltage.

Make sure the motor pinion is not damaged!



1.

Action Note

DANGER!




SMB.

2. Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate it with

grease.

Art no. is specified in


.

3. Fit the lifting tool, motor axis 2, 3, 4 to the motor. Art no. is specified in


.

4. Fit the two guide pins in the two lower motor attachment holes.

Art no. is specified in


.

Shown in the figure

Location of motor on page 337

5.

CAUTION!


6. Lift the motor and guide it onto the guide pins, as close to the correct position as possible without pushing the motor pinion into the gear.

7. Remove the lifting tool and allow the motor to stay on the guide pins.



• +: pin 2

• -: pin 5

340



4 Repair


Continued

Action

9. Use the rotation tool in order to rotate the motor pinion when mating it to the gear!

Fit the motor, making sure the motor pinion is properly mated to the gear of gearbox, axis 3.

Note

Art no. is specified in Required equipment on page 337

.


Make sure the motor is turned the right direction, that is the cables facing forwards. xx0200000165


• A: Rotation tool.




4 pcs: M10 x 40, tightening torque:

50 Nm.


Connect in accordance with markings on connectors.





16. Remove the equipment used to unload the upper arm.



Detailed in the section Performing a leak-down test on page 196

.



Detailed in the section Oil change, gearbox, axis 3 on page 171 .



20.

DANGER!


detailed in the section DANGER - First test run may cause injury or damage! on page 41 .


4 Repair







The motor axis 4 is located on the left-hand side of the upper arm as shown in the figure below. xx0200000202

A

B

C

Motor, axis 4

Cable gland cover, motor axis 4

Motor attachment holes (4 pcs)


Equipment, etc.

Spare part no.

Art. no.


O-ring

Mercasol 3106

Loctite 574

Grease

Removal tool. motor

M10x

Guide pins M8 x 100

Guide pins M8 x 150

See Spare parts

21522012-430

Note

Includes

• motor

• pinion

• o-ring 21522012-430



3HAC3537-1

3HAC14972-1

3HAC15520-1

3HAC15520-2


Used to lubricate the o-ring.




342



4 Repair


Continued

Equipment, etc.

Spare part no.

Art. no.


Rotation tool

3HAC12342-1

3HAC17105-1

Power supply

Standard toolkit

Calibration

Pendulum toolkit


Circuit Diagram

-

-

3HAC15716-1

Note

Used to rotate the motor pinion when mating it to the gear when brakes are released with 24 VDC power supply.

24 VDC, max. 1,5 A




.






Action Note

1. Move the robot to a position where the upper arm is pointed straight up.

This position enables the motor to be replaced without draining the gear oil, which in turn saves time.

Any other position of the upper arm requires a draining of oil from the gearbox for axis 4.

Draining of oil is described in section

Draining, oil on page 175 .

2.

DANGER!




SMB.

3. Remove the cable gland cover at the cable exit of the motor by unscrewing its two attachment screws.


.





343

4 Repair


Continued

Action Note


6. In order to release the brake, connect the 24

VDC power supply.

7. Unscrew the motors four attachment screws and plain washers.




• +: pin 2

• -: pin 5

9. If required, press the motor out of position by fitting removal tool, motor to the motor attachment screw holes.



.



11. Remove the motor by gently lifting it straight out.




Note

1.

Action

DANGER!





3. In order to release the brakes, connect the

24 VDC power supply.

4. Fit the two guide pins in two of the motor attachment holes.

5. Fit the motor with guidance of the pins, making sure the motor pinion is properly mated to the gear of gearbox 4.



.

Connect to connector R2.MP4:

• +: pin 2

• -: pin 5



.



344



4 Repair


Continued

Action Note

6. Use the rotation tool in order to rotate the motor pinion when mating it to the gear!

Fit the motor, making sure the motor pinion is properly mated to the gear, axis 4.




Make sure the motor is turned the right direction, that is the cables facing forwards. xx0200000165


• A: Rotation tool.




4 pcs: M8 x 25, tightening torque: 24 Nm.






.

13. Perform a leak-down test if the gearbox has been drained.

Detailed in the section Performing a leakdown test on page 196

.

14. Refill the gearbox with oil if drained.



Filling, oil on page

176 .



16.

DANGER!


DANGER -


.


4 Repair

4.6.5. Replacement of motor, axis 5 IRB 6640

4.6.5. Replacement of motor, axis 5 IRB 6640




Reused pinion

The pinion in the motor, axis 5, is matched with the beveral gear for axis 5. When the motor is replaced the pinion must therefore be removed from the dismounted motor and fitted onto the new motor shaft as detailed in this section.


The motor axis 5 is located inside the upper arm tube, but attached to the wrist unit, as shown in the figure below.


xx0200000204

A

B

C

Motor, axis 5

Upper arm tube

Wrist unit



Motor See Spare parts

346

Set of shim, motor 3HAC7941-28

Note

Does not include pinion.

Use the pinion from the motor to be replaced.

Includes o-ring 21522012-

430.

Used to obtain the correct distance between motor flange and outer surface of motor pinion.



4 Repair


Continued


O-ring

Loctite 574

Grease

Isopropanol

Mineral oil

Removal tool, motor

M10x

Oil injector / max

500 MPa

Extension bar 300 mm for bits 1/2"

Motor press pinion

21522012-430

Note

3HAC3537-1

11771012-208

CS 320




For cleaning motor pinion and motor pinion hole.

For lubrication of pinion shaft and pinion hole.

3HAC14972-1

3HAC021590-001 For pressing out the pinion, motor 5.

3HAC12342-1


Measuring tool

Guide pins M8 x 100

Guide pins M8 x 150

Power supply

Standard toolkit


Circuit Diagram

3HAC021883-001 For pressing the pinion on to the new motor.

6896134-GN

3HAC15520-1

3HAC15520-2

-



24 VDC, 1.5 A



section Standard toolkit on page 409

.



Removal, motor, axis 5


Note

1.

Action

DANGER!




SMB.





.


347

4 Repair


Continued

Action Note

3. Remove the wrist unit.

Detailed in the section Removal, wrist unit on page 265 .

4. Place the wrist unit safely on a workbench, in a fixture or similar.



7. Disconnect all connectors beneath the motor cover and remove theseparate cable of the axis 5 motor.


Connect to either:

- connector R4.MP5 (in the motor):

• + : pin 2

• - : pin 5

- connector R3.MP5 (on the separate cable, if not removed):

• +: pin C

• -: pin D



11. If required, press the motor out of position by fitting removal tool, motor, M10 to the motor attachment screw holes.

Art. no. is specified in Required equipment on page 346 equipment on page 346 .

.

Art. no. is specified in Required

Always use the removal tools in pairs and diagonally!



13. Remove the motor by gently lifting it straight out. Keep track of the shims between the motor flange and the wrist housing.

14. Measure the distance between the motor flange, included eventual shims, and the outer surface of the pinion, with measuring tool.


Make a note of the distance.

15. Press out the pinion from the dismounted motor, with the equipment included in the oil injector kit.

Replacing the complete wrist unit is detailed in section


.


NOTE!

If the pinion is damaged the complete wrist unit must be replaced!

348



4 Repair


Continued

Refitting, motor, axis 5


Note

1.

Action

DANGER!




SMB.

2. Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the o-ring with grease.

3. Clean the pinion and the pinion hole in the motor, with isopropanol.



.



.

Replacing the complete wrist unit is detailed in section


.

NOTE!

If the pinion is damaged the complete wrist unit must be replaced!

4. Apply a thin film of mineral oil to the pinion shaft and the pinion hole in order to make the pinion run smoothly and to achieve an even friction torque when assembling the pinion.



.

5. Place the motor and pinion in the press fixture. Art. no. is specified in


.

6. Press the pinion onto the new motor and check the pressing force.

For an axis diameter of 15.5 mm, use min. pressing force: 18.5 kN and max. pressing force: 39.5 kN.

If the pressing 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!

7. Measure the distance between the motor flange and the outer surface of the pinion with the measuring tool.

Modify the distance with shims in order to obtain the same distance as measured when dismounting the old motor (+ 0-0,05 mm).



.


VDC power supply.

9. Fit the two guide pins in two of the motor attachment holes.

Connect to either:

- connector R4.MP5 (in the motor):

• +: pin 2

• -: pin 5

- connector R3.MP5 (on the separate cable, if not removed):

• +: pin C

• - : pin D



.



349

4 Repair


Continued

Action Note

10. Fit the motor, with guidance from the pins, making sure the motor pinion is properly mated to the gear of axis 5.



4 pcs: M8 x 25; tightening torque: 24

Nm.


13. Refit theseparate cable of the axis 5 motor and reconnect all connectors beneath the motor cover.





17. Refit the wrist unit.

Detailed in the section Performing a leak-down test on page 196

.

Detailed in the section Refitting, wrist unit on page 266 .

18. Refill the gear with oil.


Detailed in the section Oil change, gearbox, axis 5 on page 177 .



20.

DANGER!



41 .


4 Repair

4.6.6. Replacement of motor, axis 5, IRB 6640ID

4.6.6. Replacement of motor, axis 5, IRB 6640ID

Location of motor, axis 5

The motor of axis 5 is located on the bottom side of the wrist, when axis 4 is placed in calibration position.

xx0500001573

A

B

C

Motor, axis 5

Motor connectors, R3.MP5 and R3.FB5

Wrist side with the axis 5 gearbox


Equipment


O-ring

Grease

Power supply

Spare part no.

See Spare parts

3HAB3772-22

Allen key and socket

Standard toolkit


Circuit diagram -

Art. no.

Note

Includes o-ring 3HAB 3772-

22.

-

-

-

3HAB 3537-1 For lubricating the o-ring.

24 VDC, 1.5A


A specific length is required for accessing the attachment screws of the motor. The dimensions are shown in the figure

Removal tools, motor attachment screws on page 352

.







351

4 Repair


Continued

Removal tools, motor attachment screws

The figure below shows the required dimensions of the tools, in order to access the attachment screws of the motor.

xx0500002271

A

B

C

Allen key, No 6

Socket, max Ø16 mm

Torque wrench



1.

Action Note

352

DANGER!




2. Move axis 4 +90º so that the gearbox of axis 5 is faced downwards. This makes it possible to remove the motor without draining the gearbox oil.

3. Disconnect the motor connectors from the axis 5 motor. Shown in the figure Location of motor, axis 5 on page 351 .

4. In order to release the brakes, connect the 24 VDC power supply to the motor.

Connect to connector

R3.MP5:

• + : pin C

• - : pin D

5. Remove the three attachment screws of the motor.

Dimensions of the tools are specified in the figure

Removal tools, motor attachment screws on page

352

.

6. Remove the motor by gently lifting it straight out. Lift carefully to get the pinion away from the gear.




4 Repair


Continued


The procedure below details how to refit the motor, axis 5.

Note

1.

Action

DANGER!




SMB.

2. Make sure the o-ring on the circumference of the

motor is seated properly. Replace it if damaged.

Lightly lubricate the o-ring with grease.

Article numbers are specified in


.

3. In order to release the brakes, connect the 24

VDC power supply to the motor.


• + : pin C

• - : pin D

4. Fit the motor, making sure the motor pinion is properly mated to the gear of axis 5.

5. Secure the motor with the three attachment screws and washers.

6. Disconnect the brake release and reconnect the

motor connectors.

Shown in the figure Location of motor, axis 5 on page 351

.


3 pcs: M8x25. Tightening torque: 24

Nm.

Dimensions of the tools are specified

in the figure Removal tools, motor attachment screws on page 352 .

8. Refill the axis 5 gearbox with oil, if previously drained.


Detailed in section Performing a leakdown test on page 196

.

Filling is detailed in section Filling, oil, axis 5 on page 179 .



10.

DANGER!



.


4 Repair

4.6.7. Replacement of motor, axis 6, IRB 6640

4.6.7. Replacement of motor, axis 6, IRB 6640


For replacement of motor axis 6 on robots with option Foundry Prime, see Replacement of

motor axis 6 - Option Foundry Prime, 3HAC037959-013 (available on ABB Library).


The motor axis 6 is located in the center of the wrist unit as shown in the figure below.


xx0700000126

A

B

C

Gearbox, axis 6

Motor, axis 6

Attachment screws (4 pcs)


354

Equipment, etc. Spare part no. Art. no. Note


O-ring

Gasket

Gasket, cover

Removal tool, motor

M10x


Guide pins M8 x 100

Guide pins M8 x 150

See Spare parts

21522012-430

3HAC033206-001

3HAC033489-001


Must be replaced when replacing motor

3HAC14972-1 Always use the removal tools in pairs!

3HAC12342-1

Must be replaced when opening cover.

3HAC15520-1

3HAC15520-2

Includes:

• motor

• pinion

• o-ring 21522012-430





4 Repair


Continued

Equipment, etc.

Power supply

Grease

Standard toolkit



Circuit Diagram

Spare part no. Art. no. Note

24 VDC, 1.5 A


3HAB3537-1 For lubricating the o-ring.



3HAC15716-1 Complete kit that also includes operating manual.


3HAC025744-

001


Removal, motor


Action Note

1. Move the robot to a position where the motor in axis

6 is pointed straight up. This position enables the motor to be replaced without draining the gear oil, which in turn saves time.


2.

DANGER!




3. Remove the rear motor cover by unscrewing the five attachment screws.

4. Disconnect all connectors beneath the cover.



• +: pin 2

• -: pin 5



355

4 Repair


Continued

Action


Note xx0600003038

• A: Tilthouse

• B: Motor, axis 6

• C: Attachment screws (4 pcs)

7. If required, press the motor out of position by fitting

removal tool, motor to the motor attachment screw holes.



.


8. Lift the motor carefully to get the pinion away from the gear and disconnect the brake release voltage.


9. Remove the motor by gently lifting it straight out.



Action Note

1. Make sure the o-ring on the circumference of the motor is seated properly. Lightly lubricate the oring with grease.



.


VDC power supply.


• +: pin 2

• -: pin 5

3. Fit the two guide pins in two of the motor attachment holes.



.

356



4 Repair


Continued

Action Note

4. Fit the motor, with guidance from the pins, making sure the motor pinion is properly mated to the gear of gearbox, axis 6.

Make sure the pinion on the motor shaft is not damaged! xx0600003038

• A: Tilthouse

• B: Motor, axis 6



6. Secure the motor with its four attachment screws and plain washers.

4 pcs: M8 x 25, tightening torque: 24

Nm.



9. Refit the cover on top of the motor with its five attachment screws.





11.

DANGER!



.


4 Repair


4.6.8. Replacement of motor, axis 6, IRB 6640ID

Replacement motor axis 6 for Foundry Prime



Location of motor, axis 6

The motor of axis 6 is located on top of the wrist, when axis 4 is placed in calibration position.

xx0500001574

A

B

C

Motor, axis 6

Motor connectors, R3.MP6 and R3.FB6

Wrist side with axis 6 gearbox inside


Equipment Spare part no.

Art. no.

Motor including pinion See Spare parts

Grease

O-ring

Power supply

3HAB3772-22

-

Note

Includes o-ring 3HAB3772-22.

3HAB 3537-1 For lubricating the o-ring.

Allen key and socket

Standard toolkit -

-

24 VDC, 1.5 A


A specific length is required for accessing the attachment screws of the motor. The dimensions are shown in the

figure Removal tools, motor attachment screws on page

352

.



358



4 Repair


Continued

Equipment


Circuit diagram

Spare part no.

Art. no.

-

Note


See chapter Circuit diagram in the Product manual, reference information .



Action

1. Move axis 4 -90º so that the axis 6 gearbox is facing downwards. This enables the motor to be replaced without draining the gearbox oil from axis 6.

2.

Note

DANGER!




3. Disconnect the motor connectors.

4. In order to release the brakes, connect the 24 VDC power supply to the motor.

Shown in the figure

Location of motor, axis 6 on page 358 .

Connect to connector

R3.MP6:

• + : pin C

• - : pin D

5. Unfasten the motor by unscrewing its three attachment screws and washers.


Removal tools, motor attachment screws on page

352

.

6. Remove the motor by gently lifting it straight out. Lift carefully to get the pinion away from the gear.




359

4 Repair


Continued


The procedure below details how to refit the motor, axis 6.

Note

1.

Action

DANGER!




SMB.

2. Make sure the o-ring on the circumference of the motor is seated properly. Ligthly lubricate with grease.

3. In order to release the brakes, connect the 24

VDC power supply to the motor.

The article numbers are specified in


.


• + : pin C

• - : pin D

4. Fit the motor, making sure the motor pinion is properly mated into the gear of axis 6.

5. Secure the motor with its three attachment screws and washers.

3 pcs, M8x25. Tightening torque: 24

Nm.



.


7. Reconnect the motor connectors.


9. Refill the axis 6 gearbox with oil, if previously drained.


Shown in the figure Location of motor, axis 6 on page 358

.

Detailed in section Performing a leakdown test on page 196 .

Detailed in section Filling, oil, axis 6 on page 182

.



11.

DANGER!




4 Repair

4.7.1. Replacement gearbox axis 1

4.7 Gearboxes

4.7.1. Replacement gearbox axis 1

Replacement gearbox axis 1 for Foundry Prime

For replacement of gearbox axis 1 on robots with option Foundry Prime, see Replacement

gearbox axis 1 on IRB 6640 - Option Foundry Prime, 3HAC037959-001 (available on ABB

Library).

Location of gearbox axis 1 xx0600003068

A

B

C

D

E

F

G

Gearbox, axis 1 RV 320C-191.35

Attachment screw, M12x80 quality 12.9 gleitmo (16 pcs)

Attachment screw, M16x60 quality 12.9 gleitmo (12 pcs)

Base

Frame

Protection pipe axis 1

O-ring



361

4 Repair


Continued


Equipment, etc.

Spare part no.

Gearbox, axis 1 See Spare parts

O-ring

O-ring (3 pcs)

Support, base and gear axis 1

Guide pins

(M16x300)

Guide pins

(M16x250)

Lifting tool

3HAB3772-97

Lifting eye (2 pcs)

Grease

Standard tools


3HAB3772-93

Art. no.

Note

Includes:

• gearbox

• o-ring

Replace only when damaged.

380.6x3.53

23x3.6

Consists of 4 pcs.

3HAC15535-1

3HAC13120-5

3HAC13120-4

3HAC15556-1 Used to lift gearbox axis 1 and frame.

3HAC025333-005 Used together with lifting tool 3HAC15556-1.

-

3HAB3537-1

Always use guiding pins in pairs.

Always use guiding pins in pairs

For lubricating o-rings.


the section Standard toolkit on page 409

.


362



4 Repair


Continued

Removal

The procedure below details how to remove the gearbox axis 1.

Note

1.

Action

DANGER!




2. Remove motor, axis 1.

Detailed in section

Replacement of motor, axis 1 on page 328

.

3. Remove the lower end of thecable harness.

Secure the cable harness to the robot in a safe way, that it will not be damaged in the continued removal procedure.

Detailed in section


NOTE!

For Cleanroom robots the procedure is detailed in section


.

4. Remove the complete armsystem.

Detailed in section

Replacement of complete arm system on page 250 .

5. Lift the robot (without the base) and put it safely on its side on the floor.

6. Remove the robot´s attachments screws in order to unfasten the base from the foundation.

Detailed in section

Orienting and securing the robot on page 78 .

7. Fit two lifting eyes on each side of the gearbox and secure it with a roundsling.

8. Attach the lifting tool to the gearbox.



Required equipment on page 362 equipment on page 362 .

.

Required

9.

CAUTION!

The complete gearbox unit and base weighs

241 kg together! (Base: 133 kg, gearbox unit: 108 kg.) All lifting equipment used must be sized accordingly!

10. Lift the robot base with gearbox axis 1, to allow fitting the support, base and gear axis

1 on each side of the base.


11. Fit the support, base and gear axis 1.

Make sure the base remains in a stable position before performing any work underneath the base!



363

4 Repair


Continued

Action

12. Unscrew the 12 attachment screws and washers securing the gearbox to the base.

Note

13.

CAUTION!

The gearbox weighs 108 kg! All lifting equipment used must be sized accordingly!

14. Remove the gearbox.

xx0600003069

• A: Gearbox, axis 1

• B: Attachment screw, M16x60

364



Refitting

4 Repair


Continued

The procedure below details how to remove the gearbox axis 1.

Action Note

1. If the base not already is resting on the

support base and gear, axis 1, this should be done first.

Mounting of the support base and gear,

axis 1 is detailed in section

Removal on page 363 .

2. Make sure the o-ring is fitted to the gearbox as shown in the figure to the right.

Lightly lubricate the o-ring with grease.



.

xx0200000055

• A : O-ring (Gearbox shown from the side)

3. Fit the three o-rings (23x3.6).

5. Fit two lifting eyes on each side of the

6. Fit two guide pins in two of the attachment holes, parallel to each other.

7.

gearbox and secure it with a roundsling.

Use some grease to attach them.

4. Refit the protection pipe axis 1 in the center of gearbox 1 with its attachment screws.

Shown in the figure

Location of gearbox axis 1 on page 361

.



.

CAUTION!


8. Lift the gearbox on to the guide pins and lower it carefully to its mounting position.



365

4 Repair


Continued

Action

9. Refit the gearbox to the base with its attachment screws and washers.

Note

Shown in the figure


.

M16x60 quality 12.9 (12 pcs)


366 xx0600003069

• A: Gearbox, axis 1

• B: Attachment screw, M16x60

10.

CAUTION!

The complete gearbox unit and base weighs

241 kg together! (Base: 133 kg, gearbox unit: 108 kg.) All lifting equipment used must be sized accordingly!

11. Lift the robot base and gearbox 1 to allow removing the support, base and gear.

12. Secure the base to the mounting site.

13. Refit the complete armsystem.

14. Refit the robot to the base with its attachment screws and serrated lock washers.

Detailed in section Orienting and securing the robot on page 78 .

Detailed in section Replacement of complete arm system on page 250

.

Shown in the figure


.

M12x80 quality 12.9 (16 pcs)


NOTE!

The orientation of the serrated lock washer must be fitted as is shown in the figure to the right!

xx0600003069


• B: Gearbox, axis 1

• C: Attachment screw, M12x80



4 Repair


Continued

Action

15. Refit the lower end of thecable harness.

Note

Detailed in section Replacement of cable harness, axes 1-6 on page 203

.

NOTE!



.

16. Refit motor, axis 1.

17. Fill oil in gearbox axis 1.


Detailed in section Replacement of motor, axis 1 on page 328

.

Detailed in section Oil change, gearbox axis 1 on page 165

.



19.

DANGER!


DANGER -


.


4 Repair


4.7.2. Replacement gearbox axis 2




Library).

Location of gearbox axis 2

The gearbox axis 2 is located in the lower arm rotational center.

xx0700000357

C

D

A

B

Attachment screws, M16x50 quality Gleitmo (20 pcs)


Gearbox, axis 2

Motor, axis 2


Equipment, etc

Gearbox, axis 2

Spare part no.

See Spare parts

Art. no.

368

O-ring (339.3x5.7)

Grease

Lifting tool

Roundsling

Guide pins (M12x250)

Guide pins (M12x200)

Crank

Standard toolkit

3HAB3772-91

Note

Includes:

• gearbox

• o-ring



Equivalent:

• Mercasol 3106

3HAB3537-1 For lubricating o-rings.

3HAC025214-001 For lifting gearbox

-

3HAC13056-4 Always use in pairs.

-

3HAC13056-3 Always use in pairs.

3HAC020999-001 Used to turn the gear in correct position.

The content is defined

in the section Standard toolkit on page 409

.



Removal

Equipment, etc


Spare part no.

Art. no.

4 Repair


Continued

Note


The procedure below details how to remove gearbox axis 2.

Action Note

1. Unload the balancing device.

2. Remove the front shaft using the tool 3HAC028920-001.

Method 1 described in section

Unloading the balancing device using hydraulic press tool. on page 322

Method 2 described in section


.

Described in section Replacement of balancing device (design 1) on page 297 for design 1.

Described in section Replacement of balancing device (design 2) on page 306 for design 2.

3. Jog the robot to the position ax.2 (-

60°) and ax.3 (+60°).

4.

CAUTION!

The upper and lower arms (incl. gearboxes axes 2 and 3) weighs

455 kg. All lifting equipment used must be sized accordingly!

xx0700000351



369

4 Repair


Continued

Action

5. Fit the lifting tool on the upper and lower arms as shown in the figure to the right.

Secure the robot in an overhead crane.

Note

6. Jog ax.3 to reach lifting center and straighten the lifting slings.

xx0700000350

Parts:





• E: Lifting chain

• F: Roundsling (put in a loop around the wrist on the inside)

• G: Roundsling (put in a loop around the lower arm)

370 xx0900000112





4 Repair


Continued

8.

Action Note

DANGER!




9. Remove the lower end of the cable harness.

Detailed in the section Replacement of cable harness, axes 1-6 on page 203 .

NOTE!




10. Let the removed part of the cable harness hang loose and take care not to damage it during the removal process.

11. Remove the attachment screws

M16x60 (12 pcs) securing the lower arm to gearbox axis 2.

Shown in the figure Location of gearbox axis 2 on page 368

.

12. Remove the upper and lower arms and put them down on the floor.

13. Remove motor axis 2.

Detailed in the section Replacement of motor axis 2 on page 332

.

14. Remove two attachment screws

(M12x60) parallel to each other.

15. Fit two guide pins in the holes, parallel to each other.

16.

CAUTION!




371

4 Repair


Continued

Action

17. Fit the lifting tool for lifting the gearbox in the uppermost hole and secure it with a roundsling.

Note


368 .

372

18. Remove the attachment screws

M12x60 (32 pcs) securing the gearbox to the frame.

19. Remove the gearbox and put it in a place where it will not/cannot be damaged.

Shown in the figure Location of gearbox axis 2 on page 368

.

20. Wipe away residual oil and paint.

xx0900000114

The figure shows IRB6640.



Refitting

The procedure below details how to refit gearbox axis 2.

Action

1. Make sure the o-ring is fitted to the gearbox. Lightly lubricate it with grease.

Note

4 Repair



• A : O-ring 3HAB3772-91

2.

CAUTION!


3. Fit the lifting tool for lifting the gearbox in the uppermost hole of the gearbox and secure it with a roundsling.


368 .

3HAC026876-001 Revision: F xx0900000114

The figure shows IRB6640.


373

4 Repair


Continued

Action Note

4. Fit two guide pins in two of the attachment holes, parallel to each other.

5. Lift the gearbox on to the guide pins and push it in mounting position.

6. Refit the gearbox with its attachment screws.

M12x60 (32 pcs)


7.

CAUTION!

The upper and lower arms

(incl. gearboxes axes 2 and 3) weighs 455 kg. All lifting equipment used must be sized accordingly!

8. Fit the lifting tool on the upper and lower arms and secure the robot in an overhead crane.

374

9. Use a crank in the gearbox in order to find the holes for the attachment screws.

xx0700000350

Parts:





• E: Lifting chain

• F: Roundsling (put in a loop around the wrist on the inside)

• G: Roundsling (put in a loop around the lower arm)



4 Repair


Continued

Action Note

10. Refit the lower arm to the gearbox axis 2 with its attachment screws.

11. Refit motor axis 2.

M16x50 (20 pcs)


Detailed in the section Replacement of motor axis 2 on page 332

.

12. Refit the lower end of the cable harness.


Replacement of cable harness, axes 1-6 on page 203

.

NOTE!


Replacement of cable harness, Cleanroom on page

224 .

13. Fill the gearbox axis 2 with oil. Detailed in the section Oil change, gearbox axis 2 on page 168

.




15.

DANGER!

Make sure all safety requirements are met when performing the first test run.

These are further detailed in

the section DANGER - First test run may cause injury or damage! on page 41 .


4 Repair

4.7.3. Replacement of gearbox, axis 3

4.7.3. Replacement of gearbox, axis 3




Library).


The axis 3 gearbox is located in the upper arm rotational center as shown in the figure below.


376 xx0200000194

C

D

A

B

Gearbox, axis 3

Motor, axis 3

Upper arm





Equipment, etc.

Gearbox

Spare part no.

Art. no.


4 Repair


Continued

O-ring 3HAB3772-68

Grease

Sealing, axis 2/3

Mechanical stop axis

3

3HAC17212-1

3HAB3537-1

3HAC12708-1

Note

Includes

• gearbox

• o-ring.

Does not include the sealing, axis 2/3!

1 pc on the gearbox.

Replace if damaged.

For lubricating the o-rings.

A new sealing must be used on each assembly!

Used to secure the upper arm. Use attachment screws 3HAB3409-86

(M16 x 60).

Washers (for mechanical stop axis

3)

Bolt, M16x60 (for mechanical stop axis

3)

Lifting eye M12



Guide pins, sealing ax

2/3, 80mm

Guide pins, sealing ax

2/3, 100mm

Standard toolkit



3HAA1001-186

3HAB3409-86

-

3HAC025333-005

3HAC13056-3

3HAC13056-4

3HAC14628-1

3HAC14628-2

3HAC15716-1

For guiding the gearbox.

Use guides in pairs!

For guiding the gearbox.


For guiding the sealing, axis 2/3.


For guiding the sealing, axis 2/3.



the section Standard toolkit on page 409

.





377

4 Repair


Continued

Removal, gearbox axis 3

The procedure below details how to remove gearbox, axis 3.

Note

1.

Action

DANGER!




2. Secure the upper arm in a horizontal position using round slings.

3. Remove the motor, axis 3.


377

.

Detailed in section Removal, motor on page 339

.

4. Remove the upper arm.

NOTE!

When removing the motor axis 3, the brake on axis

3 is released. Make sure the upper arm is secured and disabled to move!

Detailed in section Removal, upper arm on page

273

.

On reassembly a new sealing must be used! Art. no. is specified in

Required equipment on page

377

.

5. Remove the sealing, axis 2/3 between the gearbox and lower arm.

6. Place the upper arm safely on a workbench, in a fixture or similar.

7. Remove the attachment screws, gearbox.

8. Fit the two guide pins in 180° relation to each other in the gearbox attachment screw holes.

Shown in the figure

Location of gearbox on page

376

.


377

.

378



4 Repair


Continued

Action Note

9. If required, use screws in the holes

(A) shown in the figure to the right to press the gearbox free.



377

.

10.

CAUTION!


11. Remove the gearbox, with guidance from the guide pins, using an overhead crane or similar. xx0200000201

• A: M12 holes for pressing the gearbox out

• B: Attachment screw holes, gearbox - upper arm

• C: Attachment screw holes, gearbox - lower arm



379

4 Repair


Continued

Refitting, gearbox axis 3

The procedure below details how to refit gearbox, axis 3.

Note

1.

Action

DANGER!




2. Turn the upper arm in such a position that the gear mating surface faces upwards.

3. Fit two guide pins in 180° relation to each other in the holes in the upper arm, used for the gearbox attachment screws.

4.


377

.

CAUTION!


5. Make sure the o-rings are fitted to the gearbox. Apply grease to the o-rings to make sure they stick in their grooves during assembly.

Replace if damaged!


377

.

380

6. Lift the gearbox to its mounting position.

7. Turn the gearbox to align the attachment screw holes with those in the upper arm. xx0200000173

• A: O-ring, gearbox axis 3



4 Repair


Continued

Action

8. Fit the gearbox onto the guide pins and slide it into position.

9. Remove the lifting tool.

10. Secure the gearbox with 22 of the 24 gearbox attachment screws.

Remove the guide pins and tighten the remaining two screws.

11. Refit the upper arm with a new

sealing, axis 2/3 .

12. Refit the motor.


Note

Make sure the o-rings are seated properly and the gearbox correctly oriented!

24 pcs: M12 x 60.


Reused screws may be used, providing they are

lubricated as detailed in the section Screw joints on page 405 before fitting.



377

.

Detailed in section

Refitting, upper arm on page 275

.

Detailed in section

Refitting, motor on page 340

.



14.

DANGER!


DANGER - First test run may cause injury or damage! on page 41

.


4 Repair


4.7.4. Replacement of gearbox, axis 6




Library).


The axis 6 gearbox is located in the center of the wrist unit as shown in the figure below.

382 xx0200000219

A

B

C

D

-

Gearbox, axis 6

Attachment screws and washers, gearbox (18 pcs)

Oil plug, draining

Oil plug, filling

O-ring (not shown in figure)



4 Repair


Continued



Gearbox

Gearbox, wrist type 1

See Spare parts

Gearbox, wrist type 2 See Spare parts

Washers

O-ring (type 1)

152.0x3.53

O-ring (type 1)

131.0x2.0

3HAB3772-58

3HAB3772-65

O-ring (type 1), 6 pcs

15.5x1.5

21520431-20

3HAB3772-57 O-ring (type 2)

164.7x3.53

O-ring (type 2)

150.0x2.0

3HAB3772-64

O-ring (type 2) 12 pcs

13.1x1.6

3HAB3772-61

Grease

Standard toolkit



3HAB3537-1

-

3HAC15716-1

Note

Includes o-ring 3HAB3772-58

Includes o-ring 3HAB3772-57

3HAA1001-172 Not included in gearbox!

Replace only when damaged!

Must be replaced when reassembling gearbox.









.





383

4 Repair


Continued

Removal, gearbox

The procedure below details how to remove gearbox, axis 6.

1.

Action Note

DANGER!




SMB.

2. Drain the oil from gearbox, axis 6.

3. Remove the turning disk.




Removal, turning disk on page 261 .

4. Remove the gearbox by unscrewing its 18


5. If required, apply M8 screws to the holes shown in the figure beside to press the gearbox out.

Shown in the figure


.

6. Remove the gearbox axis 6 by lifting it out carefully. xx0200000220

• A: M8 holes for pressing out the gearbox

Be careful not to damage the motor pinion!

384



4 Repair


Continued

Refitting, gearbox

The procedure below details how to refit gearbox, axis 6.

Note

1.

Action

DANGER!




2. Make sure the o-ring is fitted to the rear of the gearbox. Lubricate the o-ring with grease.



. xx0100000132

• A: O-ring, gearbox axis 6

3. Release the holding brake of motor axis 6. Detailed in the section


.

4. Insert the gearbox, axis 6 into the wrist unit. Art. no. is specified in


.

Shown in the figure


.

Make sure the gears of the gearbox mate with the gears of the motor!

5. Secure the gearbox with the attachment screws and washers.

Shown in the figure


.

8 pcs or 18 pcs (depending on wrist version): M8 x 40, 12.9 quality Gleitmo,



Screw joints on page 405 before

fitting.

6. Refit the turning disk. Detailed in the section

Refitting, turning disk on page 262 .



385

4 Repair


Continued

Action

7. Perform a leak-down test.



10.

DANGER!


DANGER

- First test run may cause injury or damage! on page 41 .

Note

Detailed in the section Performing a leakdown test on page 196

.





5 Calibration information

5.1. Introduction



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 the documentation enclosed with the calibration tools.

When to calibrate

The system must be calibrated if any of the following situations occur.

The resolver values are changed

If resolver values are changed, the robot must be recalibrated using the calibration methods supplied by ABB. Calibrate the robot carefully with standard calibration. The different

methods are briefly described in the section Calibration methods on page 388 , and further

detailed in separate calibration manuals.

If the robot has Absolute Accuracy calibration, it is also recommended but not always necessary to calibrate for new absolute accuracy.

The resolver values will change when parts affecting the calibration position are replaced on the robot, for example motors, or parts of the transmission.

The revolution counter memory is lost

If the revolution counter memory is lost, the counters must be updated. See


. 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 is rebuilt, for example after a crash or when the robot is 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.



5.2. Calibration methods

5.2. Calibration methods

Overview

This section specifies the different types of calibration and the calibration methods that are supplied by ABB.

Types of calibration

Type of calibration

Description Calibration method

Standard calibration

Absolute Accuracy calibration

(optional)

The calibrated robot is positioned at home position, that is the axes’ positions (angles) are set to 0º.

Standard calibration data is found on the SMB

(serial measurement board) in the robot.

For robots with RobotWare 5.04 or older the calibration data is delivered in a file, calib.cfg, supplied with the robot at delivery. The file identifies the correct resolver/motor position corresponding to the robot home position.

Calibration Pendulum

(standard 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 calibration data is found on the SMB (serial measurement board) in the robot.

For robots with RobotWare 5.05 or older the

Absolute Accuracy calibration data is delivered in a 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.

A robot calibrated with Absolute Accuracy 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

388




5.2. Calibration methods

Continued

Calibration methods

Each calibration method is detailed in a separate manual. Below is a brief description of the methods available.

Calibration Pendulum - standard method

Calibration Pendulum is the standard method for calibration of all ABB robots (except IRB

6400R, IRB 640, IRB 1400H and IRB 4400S) and is also the most accurate method for the standard type of calibration. It is the recommended method in order to achieve proper performance.

Two different routines are available for the Calibration Pendulum method:

• Calibration Pendulum II

• Reference Calibration

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including the operating manual for Calibration Pendulum, which describes the method and the different routines further.

CalibWare - Absolute Accuracy calibration

To achieve a good positioning in the Cartesian coordinate system, Absolute Accuracy calibration is used as a TCP calibration. The CalibWare tool guides through the calibration process and calculates new compensation parameters. This is further detailed in the application manual Absolute Accuracy Calibware Field 5.0.

If a 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 the section

Special tools on page 410 .

The calibration equipment for Calibration Pendulum is delivered as a complete toolkit, including Operating manual - Calibration Pendulum, which describes the method and the routines further.



5.3. Calibration scale and correct axis position

5.3. Calibration scale and correct axis position

Introduction

This section specifies the calibration scale positions and/or correct axis position for all robot models.

Calibration scales/marks, IRB 6640 and IRB 6640ID

The figure below shows the positions of the calibration marks on the robot.

390 xx0700000340

C

D

A

B

E

F

Calibration mark axis 1








5.4. Calibration movement directions for all axes

5.4. Calibration movement directions for all axes

Overview

When calibrating, the axis must consistently be run towards the calibration position in the same direction in order to avoid position errors caused by backlash in gears and so on.

Positive directions are shown in the graphic below.

This is normally handled by the robot calibration software.

Calibration movement directions, 6 axes

Note! The graphic shows an IRB 7600. The positive direction is the same for all 6-axis robots, except the positive direction of axis 3 for IRB 6400R which is in the opposite direction! xx0200000089



5.5. Updating revolution counters

5.5. Updating revolution counters

General

This section details how to perform a rough calibration of each robot axis, that is updating the revolution counter value for each axis using the pendant.

Step 1 - Manually running the robot to the calibration position

This procedure details the first step when updating the revolution counter, that is, manually running the robot to the calibration position.

Action Note

1. Select axis-by-axis motion mode.

2. Jog the robot to place the calibration marks within the tolerance zone.

IRB 140, 1400, 2400, 4400, 6600ID/

6650ID, 6640ID: Axes 5 and 6 must be positioned together!

Shown in the section Calibration scale and correct axis position on page 390

.

3. When all axes are positioned, store the revolution counter settings.

Described in the section

Step 2 - Storing the revolution counter setting with the FlexPendant on page 393

(RobotWare 5.0).

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 6640 -180/2.55

IRB 6640 - 235/2.55, 205/

2.75, 185/2.8, 130/3.2

IRB 6640ID - 170/2.75, 200/

2.55

Axis 4

Yes

Yes

Yes

Axis 6

No

Yes

No

If the calibration marks seem to be wrong (even if the motor calibration data is correct), try to rotate the axis one turn, update the revolution counter and check the calibration marks again (try both directions, if needed).

392





Continued

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.

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.

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.



393



Continued

6.

Action

CAUTION!

If a revolution counter is incorrectly updated, it will cause incorrect robot positioning, which in turn may cause damage or injury!

Check the calibration position very carefully after each update.

See the section Checking the calibration position on page 395

.



5.6. Checking the calibration position

5.6. Checking the calibration position

General

Check the calibration position before beginning any programming of the robot system. This may be done:

• Using a MoveAbsJ instruction with argument zero on all axes.

• Using the Jogging window on the FlexPendant.

Using a MoveAbsJ instruction on the FlexPendant, IRC5

Use this procedure to create a program that runs all the robot axes to their zero position.

Action Note

1. On ABB menu tap Program Editor.

2. Create a new program.

3. Use MoveAbsJ in the Motion&Proc menu.

4. Create the following program:

MoveAbsJ [[0,0,0,0,0,0],

[9E9,9E9,9E9,9E9,9E9,9E9]]\

NoEOffs, v1000, z50, Tool0

5. Run the program in manual mode.

6. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!

The calibration marks are shown in the section

Calibration scale and correct axis position on page 390 .

How to update the revolution counters is detailed in section

Updating revolution counters on page 392 .

Using the Jogging window on the FlexPendant

This section describes how to jog the robot to all axes zero position.

Action Note

1. Tap Jogging in the ABB menu.

2. Tap Motion mode to select group of axes to jog.

3. Tap to select the axis to jog, axis 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.

5. Check that the calibration marks for the axes align correctly. If they do not, update the revolution counters!

The calibration marks are shown in the section


.

How to update the counters is detailed in section


.



5.6. Checking the calibration position


6 Decommissioning

6.1. Introduction



Introduction

This section contains information to consider when taking a product, robot or controller, out of operation.

It deals with how to handle potentially dangerous components and potentially hazardous materials.

General

All used grease/oils and dead batteries must be disposed of in accordance with the current legislation of the country in which the robot and the control unit are installed.

If the robot or the control unit is partially or completely disposed of, the various parts must be grouped together according to their nature (that is, all iron together and all plastic together), and disposed of accordingly. These parts must also be disposed of in accordance with the current legislation of the country in which the robot and control unit are installed.



6.2. Environmental information

6.2. Environmental information

Hazardous material

The table specifies some of the materials in the robot and their respective use throughout the product.

Dispose of the components properly to prevent health or environmental hazards.

Material

Batteries, NiCad or Lithium

Copper

Cast iron/nodular iron

Steel

Neodymium

Plastic/rubber (PVC)

Oil, grease

Aluminium

Example application

Serial measurement board

Cables, motors

Base, lower arm, upper arm

Gears, screws, base-frame, and so on.

Brakes, motors

Cables, connectors, drive belts, and so on.

Gearboxes

Covers, sync. brackets

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 onto soil. Incineration must be carried out under controlled conditions in accordance with local regulations.

Also note that:

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

• Spillage may penetrate the soil causing ground water contamination.



6.3. Decommissioning of balancing device

6.3. Decommissioning of balancing device

General

There is much energy stored in the balancing device. Therefore a special procedure is required to dismantle it. The coil springs inside the balancing device exert a potentially lethal force unless dismantled properly.

The device must be dismantled by a decommissioning company.


Equipment

Standard toolkit

Cutting torch


Art. no.

-

Note



.

For opening housing and cutting coils


DANGER!

Do not under any circumstances, deal with the balancing device in any other way than that detailed in the product documentation! For example, attempting to open the balancing device is potentially lethal!

Action on field, decommissioning

The procedure below details the actions to perform on field, when the balancing device is to be decommissioned.

Action Note

1. Remove the balancing device from the robot. Detailed in section Removal of balancing device .

2. Send the device to a decommissioning company.

Make sure the decommissioning company is well informed about the stored energy built up by high tensioned compression springs and that the device contains some grease.

The following procedure contains useful information about decommissioning.



399


6.3. Decommissioning of balancing device

Continued

Decommissioning at decommissioning company, balancing device

The instruction below details how to decommission the balancing device. Contact ABB

Robotics for further consultation.

Note

1.

Action

DANGER!

There is stored energy built up by high tensioned compression springs inside the balancing device! The device also contains some grease!

2. Place the device on a workbench or similar. Make sure it is clamped in position with a vice or similar.

3. Open a hole in the side of the housing as shown in the figure.

Use a cutting torch. The measurements shown below are maximum values!

200

m m

40

0 m m xx0700000391

4. Cut the coils of the three springs inside the housing as specified below:

• Outer spring: cut at least five coils!

• Middle spring: cut at least four coils!

• Inner spring: cut at least four coils!

Use a cutting torch.

5. Double-check the number of coils cut and make sure all the tension in the springs is removed.


7 Reference information

7.1. Introduction



General

This chapter includes general information, complementing the more specific information in the different procedures in the manual.



7.2. Applicable safety standards

7.2. Applicable safety standards

Standards, EN ISO

The manipulator system is designed in accordance with the requirements of:

Standard

EN ISO 12100 -1

EN ISO 12100 -2

EN ISO 13849-1

EN ISO 13850

EN ISO 10218-1 1

EN ISO 9787

EN ISO 9283

Description

Safety of machinery - Basic concepts, general principles for design - Part 1: Basic terminology, methodology

Safety of machinery - Basic concepts, general principles for design - Part 2: Technical principles

Safety of machinery, safety related parts of control systems -

Part 1: General principles for design

Safety of machinery - Emergency stop - Principles for design

Robots for industrial environments - Safety requirements -Part 1

Robot

Manipulating industrial robots, Coordinate systems and motion nomenclatures

Manipulating industrial robots, Performance criteria and related test methods

Classification of air cleanliness

Ergonomics of the thermal environment - Part 1

EMC, Generic emission

EN ISO 14644-1 2

EN ISO 13732-1

EN IEC 61000-6-4

(option 129-1)

EN IEC 61000-6-2

EN IEC 60974-1

3

EN IEC 60974-10 3

EN IEC 60204-1

IEC 60529

EMC, Generic immunity

Arc welding equipment - Part 1: Welding power sources

Arc welding equipment - Part 10: EMC requirements

Safety of machinery - Electrical equipment of machines - Part 1

General requirements

Degrees of protection provided by enclosures (IP code)

1. There is a deviation from paragraph 6.2 in that only worst case stop distances and stop times are documented.

2. Only robots with Protection Clean Room.

3. Only valid for arc welding robots. Replaces EN IEC 61000-6-4 for arc welding robots.

European standards

Standard

EN 614-1

EN 574

EN 953

Description

Safety of machinery - Ergonomic design principles - Part 1:

Terminology and general principles

Safety of machinery - Two-hand control devices - Functional aspects - Principles for design

Safety of machinery - General requirements for the design and construction of fixed and movable guards

402




7.2. Applicable safety standards

Continued

Other standards

Standard

ANSI/RIA R15.06

ANSI/UL 1740

(option 429-1)

CAN/CSA Z 434-03

(option 429-1)

Description

Safety Requirements for Industrial Robots and Robot Systems

Safety Standard for Robots and Robotic Equipment

Industrial Robots and Robot Systems - General Safety Requirements



7.3. Unit conversion

7.3. Unit conversion

Converter table

Use the table below to convert units used in this manual.

Quantity

Length

Weight

Pressure

Force

Moment

Volume

Units

1 m

1 kg

1 bar

1 N

1 Nm

1 L

3.28 ft

2.21 lb

100 kPa

0.738 lbf

0.738 lbf-tn

0.264 US gal

39.37 in

14.5 psi



7.4. Screw joints

7.4. Screw joints

General

This section details how to tighten the various types of screw joints on the robot.

The instructions and torque values are valid for screw joints comprised of metallic materials and do not apply to soft or brittle materials.

UNBRAKO screws

UNBRAKO is a special type of screw recommended by ABB for certain screw joints. It features special surface treatment (Gleitmo as described below) and is extremely resistant to fatigue.

Whenever used, this is specified in the instructions, and in such cases, no other type of

replacement screw is allowed. Using other types of screws will void any warranty and may potentially cause serious damage or injury.

Gleitmo treated screws

Gleitmo is a special surface treatment to reduce the friction when tightening the screw joint.

Screws treated with Gleitmo may be reused 3-4 times before the coating disappears. After this the screw must be discarded and replaced with a new one.

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

Screws lubricated in other ways

Screws lubricated with Molycote 1000 should only be used when specified in the repair, maintenance or installation procedure descriptions.

In such cases, proceed as follows:

1. Apply lubricant to the screw thread.

2. Apply lubricant between the plain washer and screw head.

3. Screw dimensions of M8 or larger must be tightened with a torque wrench. Screw dimensions of M6 or smaller may be tightened without a torque wrenchif this is done by trained and qualified personnel..

Lubricant Art. no.

Molycote 1000 (molybdenum disulphide grease) 11712016-618



405


7.4. Screw joints

Continued

Tightening torque

Before tightening any screw, note the following:

• Determine whether a standard tightening torque or special torque is to be applied.

The standard torques are specified in the tables below. Any special torques are specified in the Repair, Maintenance or Installation procedure descriptions. Any special torque specified overrides the standard torque!

• Use the correct tightening torque for each type of screw joint.

• Only use correctly calibrated torque keys.

• Always tighten the joint by hand, and never use pneumatic tools.

• Use the correct tightening technique, that is do not jerk. Tighten the screw in a slow, flowing motion.

• Maximum allowed total deviation from the specified value is 10%!

The table below specifies the recommended standard tightening torque for oil-lubricated

screws with slotted or cross-recess head screws.

Dimension

M2.5

M3

M4

M5

M6

Tightening torque (Nm)

Class 4.8, oil-lubricated

0.25

0.5

1.2

2.5

5.0

The table below specifies the recommended standard tightening torque for oil-lubricated

screws with Allen head screws.

M5

M6

M8

M10

M12

M16

M24

Dimension


(Nm)


6

10

24

47

82

200

725


(Nm)



(Nm)


-

-

34

67

115

290

960

-

-

40

80

140

340

1150

406




7.4. Screw joints

Continued

The table below specifies the recommended standard tightening torque for Molycote-

lubricated screws with Allen head screws.

Dimension


Class 10.9, Molycote-lubricated


Class 12.9, Molycote-lubricated

M8

M10

M12

M16

M20

M24

28

55

96

235

790

35

70

120

280

550

950

The table below specifies the recommended standard tightening torque for water and air

connectors when one or both connectors are made of brass.

Dimension

1/8

1/4

3/8

1/2

3/4


Nm - Nominal

12

15

20

40

70


Nm - Min.

8

10

15

30

55


Nm - Max.

15

20

25

50

90



7.5. Weight specifications

7.5. Weight specifications

Definition

In installation, repair and maintenance procedures, weights of the components handled are sometimes specified. All components exceeding 22 kg (50 lbs) are highlighted in this way.

To avoid injury, ABB recommends the use of lifting equipment when handling components with a weight exceeding 22 kg. A wide range of lifting tools and devices are available for each manipulator model.

Example

Below is an example of how a weight specification is presented, inside a procedure table:

Action Note

CAUTION!




7.6. Standard toolkit

7.6. Standard toolkit

General

All service (repairs, maintenance and installation) procedures contain lists of tools required to perform the specified activity.

All special tools required are listed directly in the procedures while all the tools that are considered standard are gathered in the Standard toolkit and defined in the table below.

This way, the tools required are the sum of the Standard toolkit and any tools listed in the instruction.

Contents, standard toolkit

Qty Tool

1

1

1

1

1

1

1

1

1

2

1

1

Ring-open-end spanner 8-19 mm

Socket head cap 5-17 mm

Torx socket no: 20-60

Box spanner set

Torque wrench 10-100 Nm

Torque wrench 75-400 Nm

Ratchet head for torque wrench 1/2

Hexagon-headed screw M10x100

Socket head cap no: 14, socket 40 mm bit L 100 mm




Rem.

To be shortened to 12 mm



7.7. Special tools

7.7. Special tools

General

All service instructions contain lists of tools required to perform the specified activity. The required tools are a sum of standard tools, defined in the section

Standard toolkit on page 409 ,

and of special tools, listed directly in the instructions and also gathered in this section.

Basic tools

The table below specifies the tools that are used for the current robot model. This toolkit is necessary primarly when removing and refitting the motors.

The tools are also listed directly in the instructions.

Description


Guide pins M8 x 100

Guide pins M8 x 150



Lifting tool, wrist unit





Qty

Rotation tool

Mechanical stop axis 3

Bolts M16 x 60 (for mechanical stop axis 3)

Washers (for mechanical stop axis 3)

Standard toolkit (content described in section

Standard toolkit on page 409 )

2

1

1

2

2

1

1

2

2

1

2

1

2

2

2

Art. no.

3HAC12342-1

3HAC15520-1

3HAC15520-2

3HAC15521-1

3HAC15521-2

3HAC13605-1

3HAC14459-1

3HAC026061-001

3HAC14972-1

Fits motors, axes 4, 5 and 6.

3HAC14973-1

Fits motors axes 1, 2 and 3.

3HAC17105-1

3HAC12708-1

3HAB3409-86

3HAA1001-186

3HAC15571-1

Special tools

410

The table below specifies the special tools required during several of the service procedures.

The tools may be ordered separately and are also specified directly in concerned instructions in the Product manual, procedures .

Description

Allen key No. 6 special

Distance tool

Gearbox crank, axis 2


Qty

1

1

1

1

Art. no.

For more information see section

Replacement of motor axis 5:

•


3HAC030662-001

3HAC020999-001

3HAC022637-001




7.7. Special tools

Continued

Description






Guide pins, sealing ax 2/3, 100mm

Guide pins, sealing ax 2/3, 80mm

Holder for bits (Stahlwille 736/40 S 5/16")

Hydraulic cylinder

Hydraulic pump, 80 MPa

Lifting device, upper arm

Lifting device. lower arm

Lifting device, gearbox axis 3

Lifting eye

Lifting eye VLBG M12

Lifting eye M16


Lifting tool, gearbox axis 2

Measuring tool

Motor press pinion

Oil injector / max 500 MPa

Press gear axis 1


Shackle, balancing device

Support, base

Tool set balancing device

Qty

1

1

1

1

1

1

1

1

1

2

1

2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Art. no.

3HAC13056-2

3HAC13056-3

3HAC13056-4

3HAC13120-4

3HAC13120-5

3HAC14628-2

3HAC14628-1

3HAC029090-001

3HAC11731-1

3HAC13086-1

3HAC15994-1

3HAC027794-001

3HAC032724-001

3HAC025333-001

3HAC16131-1

3HAC14457-4

3HAC15556-1

3HAC025214-001

6896134-GN

3HAC021883-001

3HAC021590-001

3HAC026594-001

3HAC020902-001

3HAC020997-1

3HAC15535-1

3HAC028920-001

Calibration equipment, Levelmeter (alternative method)

The table below specifies the calibration equipment required when calibrating the robot with the alternative method, Levelmeter Calibration.

Note Description

Angel bracket

Calibration bracket

Calibration tool ax1

Levelmeter 2000 kit

Measuring pin

Sensor fixture

Sensor plate

Sync. adapter

Turn disk fixture

Art. no.

68080011-LP

3HAC13908-9

3HAC13908-4

6369901-347

3HAC13908-5

68080011-GM

3HAC0392-1

3HAC13908-1

3HAC68080011-GU

Includes one sensor.



411


7.7. Special tools

Continued

Calibration equipment, Calibration Pendulum

The table below specifies the calibration equipment needed when calibrating the robot with the Calibration Pendulum method.

Description Art. no.

Note

Calibration Pendulum toolkit 3HAC15716-1 Complete kit that also includes operating manual.

Oil exchange equipment

The table below specifies the recommended equipment for oil exhange.

Description Art. no.


Note

Includes:

• vacuum pump with regulator, hose and coupling

• couplings and adapters

• pump (manual) with hose and coupling

• graduated measuring glass

• oil gun

• user instructions.



7.8. Dismounting and mounting tool 3HAC028920-001

7.8. Dismounting and mounting tool 3HAC028920-001

General

This section details how to configure the tool 3HAC028920-001 for dismounting and mounting the balancing device on the IRB 6640 Design 1 and Design 2. The difference in the

design is described in Design 1 and Design 2 of IRB 6640 on page 48

.

The following setups for the tool are described:

•

Tool description on page 414

•

Removal front shaft design 1 and 2 on page 415

•

Removal front bearing Design 1 on page 419

•

Refitting front bearing and sealing Design 1 on page 421

•

Removal front bearing Design 2 on page 422

•

Refitting front bearing with sealing Design 2 on page 424

•

Removal rear shafts Design 1 and 2 on page 425

•

Refitting rear shafts Design 1 on page 426

•

Refitting rear shafts Design 2 on page 427



413



Continued

Tool description

414 xx0900000024

7

8

5

6

2

3

4

Item Mark Description

1

B

F

C

A

D

Hydraulic cylinder not included in tool 3HAC028920-001 (ordered separately).

Press tool D=103

Press tool D=54

Threaded bar, M16

Adapter M16/M20

Knurled nut D=80

Slide hammer / Distance

Nut M16





Continued

Item Mark Description

9

10

11

12

13

E

K

G

J

H

Press tool D=85

Press tool D=100

Press tool D=110

Press tool D=90

Press tool D=62

Removal front shaft design 1 and 2

The following configuration is used for removal of the front shaft Design 1 and 2. In the figure only Design 1 is shown.

Configuration:

• 8

• C

• 4

• B

1) Assemble the adapter B into the shaft.

2) Assemble the threaded bar,

M16 into the adapter.

3) Assemble the

Slide hammer /

Distance on to the threaded bar,

M16.

4) Assemble the nut M16.

xx0900000026

3HAC026876-001 Revision: F xx0900000027


415



Continued

Alternative configuration:

• 4

• F

• 1

• A

• B

1) Assemble the adapter B into the shaft.


M16 into the adapter.

3) Assemble the

Press tool

D=103 on to the threaded bar,

M16.

4) Assemble the hydraulic press

5) Assemble the knurled nut

D=80 xx0900000028 xx0900000029

416





Continued

Refitting front shaft design 1 and 2

The following configuration is used for refitting of the front shaft Design 1 and 2.

Configuration:

• 8

• C

• 4 xx0900000063 xx0900000091



417



Continued


M16 (4).

2) Assemble the

Slide hammer /

Distance (C) on to the threaded bar, M16.

3) Assemble the nut M16 (8).

xx0900000065 xx0900000064

418





Continued

Removal front bearing Design 1

The following configuration is used for removal of the front bearing Design 1.

Configuration:

• D

• A

• C

• 8

• 4

1) Assemble the press tool D=54

(D) onto the threaded bar (4).


M16 with the press tool through the assembled bearing.

3) Assemble the

Press tool

D=103 on to the threaded bar,

M16.

4) Assemble the

Slide hammer /

Distance.

5) Assemble the nut M16.

xx0900000031

3HAC026876-001 Revision: F xx0900000032


419



Continued

Alternative configuration

• D

• A

• 1

• F

• 4


(D) onto the threaded bar (4).



3) Assemble the

Press tool

D=103 (A) on to the threaded bar,

M16.


(1).

5) Assemble the

Knurled nut

D=80 (F).

xx0900000033 xx0900000034

420





Continued

Refitting front bearing and sealing Design 1

The following configuration is used for refitting of the front bearing and sealing Design 1

Configuration:

• 4

• F

• E

• C

• 8

1) Insert the threaded bar (4) through the new bearing and place it in the ear

2) Assemble the

Knurled nut D=80

(F).

3) Assemble the

Press tool D=85

(E).

4) Assemble the

Slide hammer /

Distance (C).

5) Assemble the

Nut M16 (8) xx0900000036 xx0900000037



421



Continued

Removal front bearing Design 2

The following configuration is used for removal of the front bearing Design 2.

Configuration:

• H

• A

• C

• 8

• 4 xx0900000038


(H) onto the threaded bar (4).



3) Assemble the

Press tool D=103

(A) on to the threaded bar,

M16.

4) Assemble the

Slide hammer /

Distance (C).


xx0900000039

422



Alternative configuration:

• H

• A

• 1

• F

• 4





(H) onto the threaded bar (4).



3) Assemble the

Press tool D=103


M16.


(1).

5) Assemble the

Knurled nut

D=80 (F).

xx0900000041



423



Continued

Refitting front bearing with sealing Design 2

The following configuration is used for refitting of the front bearing with sealing Design 2.

Configuration:

• 4

• F

• J

• 7

• 8

1) Insert the threaded bar (4) through the new bearing and place it in the ear

2) Assemble the

Knurled nut

D=80 (F).

3) Assemble the

Press tool D=90

(J).

4) Assemble the

Slide hammer /

Distance (C).

5) Assemble the

Nut M16 (8) xx0900000042 xx0900000043

424





Continued

Removal rear shafts Design 1 and 2

The following configuration is used for removal of the rear shafts Design 1 and 2.

Configuration:

• B

• A

• J

• C

• 8

• 4

1) Assemble the adapter (B) into the shaft.

2) Assemble the threaded bar (4) and the adapter

(B)

3) Assemble the

Press tool D=103


M16.

4) Assemble the

Slide hammer /

Distance (C).


xx0900000044 xx0900000045



425



Continued

Refitting rear shafts Design 1

The following configuration is used for refitting of the rear shafts Design 1.

Configuration:

• 4

• F

• G

• C

• 8

1) Insert the threaded bar (4) through the new bearing.

2) Assemble the

Knurled nut

D=80 (F).

3) Assemble the

Press tool D=110

(G).

4) Assemble the

Slide hammer /

Distance (C).

5) Assemble the

Nut M16 (8).

xx0900000047 xx0900000060

426 xx0900000048





Continued

Refitting rear shafts Design 2

The following configuration is used for refitting of the rear shafts Design 2.

Configuration:

• 4

• K

• G

• C

• 8 xx0900000049

1) Insert the threaded bar (4) through the new bearing.

2) Assemble the

Press tool

D=100 (K).

3) Assemble the

Press tool

D=110 (G).

4) Assemble the

Slide hammer /

Distance (C).

5) Assemble the

Nut M16 (8) xx0900000061

3HAC026876-001 Revision: F xx0900000050

427


7.9. Lifting equipment and lifting instructions

7.9. Lifting equipment and lifting instructions

General

Many repair and maintenance activities require different pieces of lifting equipment, which are specified in each procedure.

The use of each piece of lifting equipment is not detailed in the activity procedure, but in the instruction delivered with each piece of lifting equipment.

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


8 Spare parts

8.1. Spare parts and exploded views

8 Spare parts

8.1. Spare parts and exploded views

Introduction

Spare parts and exploded views are not included in the manual but delivered as a separate document on the documentation DVD. Article number 3HAC038330-001 .


8 Spare parts

8.1. Spare parts and exploded views


9 Circuit diagrams

9.1. About circuit diagrams


9.1. About circuit diagrams

Overview

The circuit diagrams are not included in this manual but delivered as separate documents on the documentation DVD. See below for correct article numbers.

Controllers

Product

IRC5 with Drive System 04

IRC5 with Drive System 09

IRC5 Panel Mounted Controller

IRC5 Compact

Article numbers for circuit diagrams

3HAC024480-004

3HAC024480-005

3HAC026871-005

3HAC031403-003

Manipulators

Product

IRB 120

IRB 140

IRB 260

IRB 360

IRB 660

IRB 1410

IRB 1600

IRB 2400

IRB 2600

IRB 4400/4450S

IRB 4600

IRB 6400RF

IRB 6600 type A

IRB 6600 type B

IRB 6620

IRB 6620LX

IRB 6640

IRB 6650S

IRB 6660

IRB 7600

Article numbers for circuit diagrams

3HAC031408-003

3HAC6816-3

3HAC025611-001

3HAC028647-009

3HAC025691-001

3HAC2800-3

3HAC021351-003

3HAC6670-3

3HAC029570-007

3HAC9821-1

3HAC9821-1

3HAC029038-003

3HAC8935-1

3HAC025744-001

3HAC025744-001

3HAC025090-001

3HAC025090-001

3HAC025744-001

3HAC025744-001

3HAC029940-001 (DressPack)

3HAC025744-001

3HAC025744-001



431


9.1. About circuit diagrams

Continued


Index

A

Absolute Accuracy, calibration

389

B balancing device bearing, replacement

292

brake release unit, replacement

288

brakes testing function

27

C cable harness axes 1-4, replacement

237

cable harness axes 1-6, replacement

203

cabling axis 5, replacement

214

cabling between robot and controller

105

cabling, robot

105

cabling, robot axes 1-4

238

calibrating roughly

392

calibration

Absolute Accuracy type

388

marks/scales

390

rough

392

standard type

388

when to calibrate

387

calibration manuals

389

calibration position

392

checking

395

jogging to, FlexPendant

395

scales

390

calibration, Absolute Accuracy

389

CalibWare

388

carbon dioxide extinguisher

25

complete arm system, replacement

250

connecting the robot and controller, cabling

105

connection external safety devices

16

D danger levels

34

direction of axes

391

E emergency stop definition

32

devices

33

enabling device

29

ESD damage elimination

43

sensitive equipment

43

wrist strap connection point

43

F fire extinguishing

25

FlexPendant jogging to calibration position

395

MoveAbsJ instruction

395

updating revolution counters

393

foundation loads

59

requirements

59


G gearbox axis 3, replacement

376

gearbox axis 6, replacement

382

H hold-to-run

29

I inspecting oil levels axis 6

132

installation mechanical stop axis 1

98

mechanical stop axis 2

100


102

L labels manipulator

36

lifting equipment

408

lifting upper arm attachment points for lifting device

272

loads on foundation

59

lower arm, replacement

279

M manipulator labels

36

symbols

36


98

axis 2

100

axis 3

102

motion of axes

61

motor axis 1, replacement

328


332


337


342


346


354

MoveAbsJ instruction

FlexPendant

395

N negative directions, axes

391

O oil change safety risks

44

operating conditions, robot

59

P paint surface damages

148

position, robot

390

positive directions, axes

391

protection classes

59

protection standards

402

R range of movement

61

repair painted surface

148

433

Index replacement bearing, balancing device

292

brake release unit

288

cable harness axes 1-4

237

cable harness axes 1-6

203

cabling axis 5

214

complete arm system

250

gearbox axis 3

376

gearbox axis 6

382

lower arm

279

motor axis 1

328

motor axis 2

332

motor axis 3

337

motor axis 4

342

motor axis 5

346

motor axis 6

354

turning disk

260

upper arm

272

wrist unit

264

requirements on foundation

59

responsibility and validity

16

restricting working range axis 1

98

working range axis 2

100

working range axis 3

102

revolution counters storing on FlexPendant

393

updating

392

risk of tipping

63

robot operating conditions

59

protection class

59

storage conditions

59

weight

58

robot position

390

S safety brake testing

27

emergency stop

32

ESD

43

fence dimensions

24

fire extinguishing

25

FlexPendant

29

introduction

15

manipulator system

16

moving manipulators

40

reduced speed function

28

release manipulator arm

26

service

16

signal lamp

31

signals

34

signals in manual

34

symbols

34

symbols on manipulator

36

test run

41

working range

30

wrist strap

43

434 safety equipment mechanical stop

98


100


102

signal lamp

159

safety risk electric parts

23

hot parts

19

hydraulic system

21

installation

17

oil change

44

operational disturbance

22

pneumatic system

21

tools

20

voltage

23

safety risks service work

17

work pieces

20

safety signals in manual

34

safety standards

402

scales on robot

390

securing the robot to foundation, attachment screws

78

securing, base plate

74

securing, robot

78

securing, upper arm

339

serial measurement board unit, replacement

285

signal lamp

31

signals safety

34

special tools

410

stability

63

standards

ANSI

403

CAN

403

EN

402

EN IEC

402

EN ISO

402

protection

402

safety

402

storage conditions, robot

59

symbols safety

34

sync marks

390

T testing brakes

27

tightening torque mechanical stop axis 1

99


101

tools calibration equipment, Levelmeter

411

Calibration Pendulum equipment

412

for service

410

oil exchange equipment

412

turning disk replacement

260

type of motion

61


U updating revolution counters

392

upper arm, replacement

272

V validity and responsibility

16

W weight balancing device

302

,

313

base plate

73

,

77

complete arm system

254

,

256

gearbox

379

,

380

lower arm

281

,

282

motor

330

,

340

upper arm

274

,

276

wrist unit

266

,

267

,

270

,

271

weight, robot

58

working range

60

restricting axis 1

98

restricting axis 2

100

restricting axis 3

102

wrist unit, replacement

264

Index



ABB Robotics

S-721 68 VÄSTERÅS

SWEDEN

Telephone: +46 (0) 21 344000

ABB IRB 6640 Product Manual

Product manual

Articulated robot

1 Safety

2 Installation and commissioning

3 Maintenance

4 Repair

5 Calibration information

6 Decommissioning

7 Reference information

8 Spare parts

9 Circuit diagrams

Related manuals

Table of contents

ABB IRB 6640 Product Manual

Product manual

Articulated robot

1 Safety

2 Installation and commissioning

3 Maintenance

4 Repair

5 Calibration information

6 Decommissioning

7 Reference information

8 Spare parts

9 Circuit diagrams

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ABB

IRB 8700 - 550/4.20

ABB

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ABB

IRB 340 M2000, M2004

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IRB 1200-5/0.9

ABB

IRB 6640 Foundry Prime

Omron

ZX-T Series CR_UGD4_XL

ABB Robotics

IRB 120

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CR_UGD4_XXL1300H _R

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Table of contents