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IRB 6640
ABB IRB 6640 User Manual
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4 Rep
air
4.4.1. R
eplacement
of turnin
g disk
263
3HAC0
26876-001
Revision:
F
© Copyright 2007-2010 ABB. All rights reserved.
6.
DANGER!
Make sur
e all safe
ty re
quirements are m
et
when perfo
rming th
e first tes
t run. The
se are
further d
etailed in
the sect
ion
DANGER - First
test ru
n may c
ause injur
y or dama
ge! on page
41
.
Action
Note
Continued
264
266
Table of Contents
Default Chapter
5
Table of Contents
5
Overview of this Manual
9
Product Documentation, M2004
13
How to Read the Product Manual
15
1 Safety
17
Introduction to Safety Information
17
General Safety Information
18
Safety in the Manipulator System
18
Safety Risks
19
Safety Risks During Installation and Service Work on Manipulators
19
CAUTION - Hot Parts May Cause Burns
21
Safety Risks Related to Tools/Workpieces
22
Safety Risks Related to Pneumatic/Hydraulic Systems
23
Safety Risks During Operational Disturbances
24
Risks Associated with Live Electric Parts
25
Safety Actions
26
Safety Fence Dimensions
26
Fire Extinguishing
27
Emergency Release of the Manipulator's Arm
28
Brake Testing
29
Risk of Disabling Function "Reduced Speed 250 MM/S
30
Safe Use of the Flexpendant
31
Work Inside the Manipulator's Working Range
32
Signal Lamp (Optional)
33
Safety Stops
34
What Is an Emergency Stop
34
Safety Related Instructions
36
Safety Signals in the Manual
36
Safety Symbols on the Manipulator Labels
38
DANGER - Moving Manipulators Are Potentially Lethal
42
DANGER - First Test Run May Cause Injury or Damage
43
WARNING - the Brake Release Buttons May be Jammed after Service Work
44
WARNING - the Unit Is Sensitive to ESD
45
WARNING - Safety Risks During Work with Gearbox Lubricants (Oil or Grease)
46
2 Installation and Commissioning
49
Introduction
49
Design 1 and Design 2 of IRB 6640
50
Robot Transportation Precautions
51
Securing the Robot
58
Unpacking
60
Pre-Installation Procedure
60
Working Range and Type of Motion
62
Risk of Tipping/Stability
65
On-Site Installation
66
Lifting the Robot with Fork Lift
66
Lifting Robot with Roundslings
70
Manually Releasing the Brakes
73
Lifting the Base Plate
75
Securing the Base Plate
76
Orienting and Securing the Robot
80
Fitting Equipment on Robot
83
Installation of Cooling Fan for Motors, Axes 1 and 2 (Option)
90
Installation of Foundry Plus Cable Guard (Option No. 908-1)
97
Loads
98
Restricting the Working Range
99
Introduction
99
Mechanically Restricting the Working Range of Axis 1
100
Mechanically Restricting the Working Range of Axis 2
102
Mechanically Restricting the Working Range of Axis 3
104
Electrical Connections
107
Robot Cabling and Connection Points
107
Making Robot Ready for Operation (Foundry Prime)
109
Additional Installation Procedure
109
Commissioning (Foundry Prime)
112
Making Robotready for Operation, (Cleanroom)
113
Additional Installation Procedure, Clean Room
113
3 Maintenance
115
Introduction
115
Maintenance Schedule and Expected Component Life
116
Specification of Maintenance Intervals
116
Maintenance Schedule
117
Expected Component Life
122
Inspection Activities
124
Inspection, Oil Level Gearbox Axis 1
124
Inspection, Oil Level Gearbox Axis 2
126
Inspection, Oil Level Gearbox Axis 3
128
Inspection, Oil Level Gearbox Axis 4
130
Inspection, Oil Level, Gearbox Axis 5
132
Inspection, Oil Level Gearbox Axis 6
134
Inspection, Balancing Device
139
Inspection, Cable Harness
144
Inspection of Air Hoses (Foundry Prime)
149
Inspection of Surface Treatment (Foundry Prime)
150
Inspection, Information Labels
151
Inspection, Mechanical Stop Pin, Axis 1
154
Inspection, Additional Mechanical Stops
156
Inspection, Damper Axes 2-5
159
Inspection, Signal Lamp (Option)
161
Replacement / Changing Activities
163
Type of Oil in Gearboxes
163
Oil Change, Gearbox Axis 1
167
Oil Change, Gearbox Axis 2
170
Oil Change, Gearbox, Axis 3
173
Oil Change, Gearbox, Axis 4
176
Oil Change, Gearbox, Axis 5
179
Oil Change, Gearbox Axis 6
182
Replacement of SMB Battery
185
Lubrication Activities
188
Lubrication of Spherical Roller Bearing, Balancing Device
188
Rust Preventive Measures, Sealing Axis 4 (Foundry Prime)
190
Rust Preventive Measures, Support Bearing in Wrist (Foundry Prime)
193
Cleaning Activities
195
Cleaning, Robot
195
4 Repair
197
Introduction
197
General Procedures
198
Performing a Leak-Down Test
198
Mounting Instructions for Bearings
199
Mounting Instructions for Seals
201
Exchange of Parts on Clean Room Robots
203
Complete Robot
205
Replacement of Cable Harness, Axes 1-6
205
Replacement of Cabling, Axis 5 Motor
216
Fitting Cable Package Attachments (Cleanroom)
218
Replacement of Cable Harness, Cleanroom
226
Replacement of Cable Harness, Axes 1-4 IRB 6640ID
239
Replacement of Cable Harness, Axes 5-6 - IRB 6640ID
247
Replacement of Complete Arm System
252
Upper and Lower Arm
262
Replacement of Turning Disk
262
Replacement of Complete Wrist Unit
266
Replacement of Complete Wrist Unit, IRB 6640ID
271
Replacement of Upper Arm
274
Replacement of Complete Lower Arm
281
Frame and Base
287
Replacement of SMB Unit
287
Replacement of Brake Release Unit
290
Replacement of Spherical Roller Bearing, Balancing Device
294
Replacement of Balancing Device (Design 1)
299
Replacement of Balancing Device (Design 2)
308
Unloading the Balancing Device Using Distance Tool
319
Restoring the Balancing Device Using Distance Tool
322
Unloading the Balancing Device Using Hydraulic Press Tool
324
Restoring the Balancing Device Using a Hydraulic Press Tool
327
Motors
330
Replacement of Motor, Axis 1
330
Replacement of Motor Axis 2
334
Replacement of Motor, Axis 3
339
Replacement of Motor, Axis 4
344
Replacement of Motor, Axis 5 IRB 6640
348
Replacement of Motor, Axis 5, IRB 6640ID
353
Replacement of Motor, Axis 6, IRB 6640
356
Replacement of Motor, Axis 6, IRB 6640ID
360
Gearboxes
363
Replacement Gearbox Axis 1
363
Replacement Gearbox Axis 2
370
Replacement of Gearbox, Axis 3
378
Replacement of Gearbox, Axis 6
384
5 Calibration Information
389
Introduction
389
Calibration Methods
390
Calibration Scale and Correct Axis Position
392
Calibration Movement Directions for All Axes
393
Updating Revolution Counters
394
Checking the Calibration Position
397
6 Decommissioning
399
Introduction
399
Environmental Information
400
Decommissioning of Balancing Device
401
7 Reference Information
403
Introduction
403
Applicable Safety Standards
404
Unit Conversion
406
Screw Joints
407
Weight Specifications
410
Standard Toolkit
411
Special Tools
412
Dismounting and Mounting Tool 3HAC028920-001
415
Lifting Equipment and Lifting Instructions
430
8 Spare Parts
431
Spare Parts and Exploded Views
431
9 Circuit Diagrams
433
About Circuit Diagrams
433
Index
435
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ABB IRB 6640 Specifications
General
Brand
ABB
Model
IRB 6640
Category
Robotics
Language
English
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