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ABB IRB 6640 Foundry Prime, Product Manual

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4.6.5 Replacing motor axis 5

Introduction

This section describes how to replace motor axis 5.

The section consists of these parts:

•

Removing motor axis 5 on page 372

•

Removing the pinion on motor axis 5 on page 374

•

Refitting the pinion on motor axis 5 on page 375

•

Refitting motor axis 5 on page 376

•

Connecting motor axis 5 on page 377

•

Connecting motor axis 5 on page 377

Reused pinion

Note

The pinion in motor axis 5 is matched with the bevel gear for axis 5. When the
motor is replaced the pinion therefore must be removed from the dismounted
motor and be fitted to the new motor.

Location of motor axis 5

The motor axis 5 is located inside the upper arm tube, but attached to the wrist
unit. See figure!

xx0200000204

Motor axis 5 (inside upper arm tube)

A

Upper arm tube

B

Wrist unit

C

Continues on next page

370

Product manual - IRB 6640 Foundry Prime

3HAC040586-001 Revision: N

© Copyright 2011-2018 ABB. All rights reserved.

4 Repair

4.6.5 Replacing motor axis 5

Summary of Contents for IRB 6640 Foundry Prime

Page 1: ...ROBOTICS Product manual IRB 6640 Foundry Prime ...

Page 2: ...Trace back information Workspace R18 1 version a9 Checked in 2018 03 22 Skribenta version 5 2 025 ...

Page 3: ...Product manual IRB 6640 Foundry Prime 235 2 55 IRB 6640 Foundry Prime 185 2 8 IRC5 Document ID 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved ...

Page 4: ...BB 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 Keep for future reference Additional copies of this manual may be obtained from AB...

Page 5: ... 1 Safety signals in the manual 43 1 4 2 Safety symbols on product labels 49 2 Installation and commissioning 49 2 1 Introduction 50 2 2 Installation and operational requirements for Foundry Prime robots 54 2 3 Design 1 and Design 2 of IRB 6640 56 2 4 Robot transportation precautions 60 2 5 Securing the robot with a transport support 62 2 6 Unpacking 62 2 6 1 Pre installation procedure 66 2 6 2 Wo...

Page 6: ...s 1 mechanical stop pin 161 3 3 13 Inspecting the additional mechanical stops 164 3 3 14 Inspecting the damper on axes 2 5 166 3 3 15 Inspecting the signal lamp option 168 3 4 Changing activities 168 3 4 1 Type of lubrication in gearboxes 170 3 4 2 Changing oil axis 1 gearbox 173 3 4 3 Changing oil axis 2 gearbox 176 3 4 4 Changing oil axis 3 gearbox 179 3 4 5 Changing oil axis 4 gearbox 182 3 4 6...

Page 7: ...raulic press tool 336 4 5 4 6 Restoring the balancing device using a hydraulic press tool 339 4 6 Motors 339 4 6 1 Replacing motor axis 1 346 4 6 2 Replacing motor axis 2 354 4 6 3 Replacing motor axis 3 362 4 6 4 Replacing motor axis 4 370 4 6 5 Replacing motor axis 5 379 4 6 6 Replacing motor axis 6 387 4 7 Gearboxes 387 4 7 1 Replacing gearbox axis 1 405 4 7 2 Replacing gearbox axis 2 419 4 7 3...

Page 8: ...ories and lifting instructions 487 8 Spare parts 487 8 1 Spare part lists and illustrations 489 9 Circuit diagrams 489 9 1 Circuit diagrams 491 Index 8 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved Table of contents ...

Page 9: ...rganized in the following chapters Contents Chapter 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 Safety Required information about lifting and installation of the robot Installation and commis sioning Step b...

Page 10: ...ng manual IRC5 with FlexPendant 3HAC16578 1 Operating manual Calibration Pendulum 3HAC050944 001 Operating manual Service Information System 3HAC051016 001 Application manual Additional axes and stand alone controller 3HAC042927 001 Technical reference manual Lubrication in gearboxes 3HAC050948 001 Technical reference manual System parameters 3HAC050996 001 Application manual Electronic Position S...

Page 11: ...Changed the length of guide pins and changed pictures of the gearbox see Replacing gearbox axis 1 on page 387 Added guide pins and added an alternate method of lifting the arm system see Replacing gearbox axis 2 on page 405 The interval for inspecting the balancing device is changed see Maintenance schedule on page 122 This revision includes the following updates B Removed row with axis 1 sealing ...

Page 12: ...This revision includes the following updates J Information regarding air flow added Published in release R16 2 This revision includes the following updates K New activities in maintenance schedule Minor changes Corrections due to updates in terminology Published in release R17 1 The following updates are made in this revision L Drying time for Mercasol added Removed article number for press fixtur...

Page 13: ...ery cable to serial measurement board Published in release R18 1 The following updates are made in this revision N Added sections in General procedures on page 214 Safety restructured New spare part number brake release board was DSQC563 Information about myABB Business Portal added Added Nickel in Environmental information Product manual IRB 6640 Foundry Prime 13 3HAC040586 001 Revision N Copyrig...

Page 14: ...information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists Circuit diagrams or references to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Applicati...

Page 15: ...anuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters Product manual IRB 6640 Foundry Prime 15 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved Product documentation Continued ...

Page 16: ...d 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 Note Illustration Action Art no is specif...

Page 17: ...omponents Motors balancing device and the serial measurement board cavity shall be pressurized on Foundry Prime robots during operation and shut down The overpressure can be dropped when atmospheric humidity has reached the same level as the surrounding environment For more information see Pressurized components on page 50 Cleaning Special procedures are needed when cleaning the Foundry Prime robo...

Page 18: ...This page is intentionally left blank ...

Page 19: ...out by in experienced or non qualified personnel Foreign objects Force majeure Nation region specific regulations To protect personnel the complete system must be designed and installed in accordance with the safety requirements set forth in the standards and regulations of the country where the robot is installed To be observed by the supplier of the complete system The integrator is responsible ...

Page 20: ...ermine the maximum speed from the maximum velocities of the robot axes and from the position at which the robot is working in the work cell see 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 robot Safe handling Users shall not be exposed to hazards including slipping ...

Page 21: ...s through welding riveting or drilling of new holes into the castings The strength could be affected CAUTION Ensure that a gripper is prevented from dropping a work piece if such is used Product manual IRB 6640 Foundry Prime 21 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 1 Safety 1 1 1 Limitation of liability Continued ...

Page 22: ...e protective stops and emergency stops are described in the product manual for the controller 22 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 1 Safety 1 1 2 Protective stop and emergency stop ...

Page 23: ... Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator or controller Product manual IRB 6640 Foundry Prime 23 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 1 Safety 1 2 1 Fire extinguishing ...

Page 24: ...quire using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the robot does not increase the pressure on the trapped person further increasing any injury 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 24 Product manual I...

Page 25: ... before proceeding work Note Switch off all main power switches in a MultiMove system Spot welding cabinet Wait for 5 minutes to let the capacitors discharge after the power has been switched off DANGER Even if the main switch is switched off the capacitors can cause electric shock if not given the time to discharge Product manual IRB 6640 Foundry Prime 25 3HAC040586 001 Revision N Copyright 2011 ...

Page 26: ...ock Make sure that no one else can turn on the power to the controller and robot while you are working with the system A good method is to remove the power cable to the controller If the robot is installed at a height hanging or other than standing directly on the floor there may be additional risks than those for a robot standing directly on the floor Energy stored in the robot for the purpose of...

Page 27: ...ns to the robot Connection of external safety devices Apart from the built in safety functions the robot is also supplied with an interface for the connection of external safety devices An external safety function can interact with other machines and peripheral equipment via this interface This means that control signals can act on safety signals received from the peripheral equipment as well as f...

Page 28: ...equipment is cor rectly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system parameter 2 The hold to run fu...

Page 29: ... is powered up 2 Verify that any safety equipment installed to secure the position or restrict the robot motion during service activity is removed 3 Verify that the fixture and work piece are well secured if applicable 4 Install all safety equipment properly 5 Make sure all personnel are standing at a safe distance from the robot and is out of its reach behind safety fences or similar 6 If mainten...

Page 30: ...or Canada Pay attention to the rotating axes of the robot Keep away from axes to not get entangled with hair or clothing Also be aware of any danger that may be caused by rotating tools or other devices mounted on the robot or inside the cell Keep clear of moving parts so that limbs hands or fingers do not get trapped or crushed by the robot To prevent anyone else from taking control of the robot ...

Page 31: ...ator switches to the MOTORS OFF state To ensure safe use of the teach pendant 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 robot to move Anyone entering the working space of the robot must always hold the teach pendant This is to prevent a...

Page 32: ...isks 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 main supply main switch The transformers The power unit The control power supply 230 VAC The rectifier unit 262 400 480 VAC and 400 70...

Page 33: ...even if the robot system is in the OFF position Power supply cables which are in motion during the working process may be damaged Product manual IRB 6640 Foundry Prime 33 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 1 Safety 1 3 6 Risks associated with live electric parts Continued ...

Page 34: ...n Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Product manual IRC5 Panel Mounted Controller Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of static ...

Page 35: ...and at some distance to feel if heat is radiating from the potentially hot component before actually touching it Wait until the potentially hot component has cooled if it is to be removed or handled in any other way Do not put anything on hot metal surfaces e g paper or plastic Product manual IRB 6640 Foundry Prime 35 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 1 Safety 1...

Page 36: ... be released in the complete pneumatic or hydraulic systems before starting to repair them Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics All pipes hoses and connections have to be inspected regularly for leaks and damage Damage must be repaired immediately Splashed oil may cause injury or fire Safe design Gravity may cause any part...

Page 37: ...ribed below 1 Run each robot axis to a position where the combined weight of the robot arm and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the robot does not change position as the motors are switched off then the brake function is adequate Product manual IRB 6640 Foundry Prime 37 3HAC040586 001 Revisio...

Page 38: ...fire may follow depending upon the circumstances Note Appropriate disposal regulations must be observed Safe handling Use safety glasses when handling the batteries In the event of leakage wear rubber gloves and chemical apron In the event of fire use self contained breathing apparatus Do not short circuit recharge puncture incinerate crush immerse force discharge or expose to temperatures above t...

Page 39: ...ion Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling hot lubricant heated up to 90 C Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction Allergic reaction ...

Page 40: ...o heat up the oil Warm oil drains quicker than cold oil Heat up the oil After filling verify that the level is correct 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 Specified amount de pends on drained volume Whe...

Page 41: ... the instructions are not followed that can lead to serious injury pos sibly 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 WARNING xx0100000002 Warns for electrical hazards which could result in severe persona...

Page 42: ...0100000004 Describes where to find additional information or how to do an operation in an easier way TIP xx0100000098 42 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 1 Safety 1 4 1 Safety signals in the manual Continued ...

Page 43: ...rman and French Symbols on safety labels Description Symbol Warning xx0900000812 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...

Page 44: ... disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page 44 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All ri...

Page 45: ... if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 6640 Foundry Prime 45 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 46: ...xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page 46 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 47: ... Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page Product manual IRB 6640 Foundry Prime 47 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels Continued ...

Page 48: ...s part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts 48 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 1 Safety 1 4 2 Safety symbols on product labels...

Page 49: ...portant 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 page19 before performing any installation work Note If the IRB 6640 Foundry Prime is connected to power always make sure that the robot is connected...

Page 50: ...oxes Pressurized components The motors the balancing device and the serial measurement board cavity must be pressurized on Foundry Prime robots during operation and shut down The overpressure can be dropped when atmospheric humidity has reached the same level as the surrounding environment At the installation of the Foundry Prime robot a pressure sensor and pressure relief valve not included must ...

Page 51: ...Air flow Pressurizing equipment ABB recommends a safety valve if not included set at 0 4 bar pressure sensor set at 0 2 0 3 bar or regulator set for maximum 0 3 bar to be attached on the pressure side of the air system Example of products Description Equipment Festo SDE1 series Pressure sensor Festo LRP series Pressure regulator Connect air hose to over pressure limiter unit Note ABB recommends th...

Page 52: ...t be avoided ABB recommends using a tool design with integrated covers that protect the wrist from direct or indirect high pressure water jet Note Make sure that the special Foundry Prime painting of the robot is not broken during testing installation or repair work Use the touch up kit available for Foundry Prime article number 3HAC035355 001 to repair any damages in the paint Continues on next p...

Page 53: ...he surrounding environment Will avoid that humid air is trapped into gearboxes or other cavities due to raised vacuum when cooling down Will give the robot a chance to dry as most rust preventive components in washing detergents have a decaying effect i e the rust preventive effect is reduced after a time Please refer to the Product Specification of the washing detergent in question for decaying e...

Page 54: ... 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 xx0800000401 Continues on next page 54 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 3 Design 1 and Design 2 of IRB 6640 ...

Page 55: ... 2 xx0800000402 Product manual IRB 6640 Foundry Prime 55 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 3 Design 1 and Design 2 of IRB 6640 Continued ...

Page 56: ...gly 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 described in section Risk of tipping stability on page 69 Always read and follow the instructions in section Pre installation procedure on page 62 Method 2...

Page 57: ...ort position with a transport support on page 58 Always use the recommended transport support described in sub section Recommended transport support on page 59 IRB 6640 Foundry Prime A B D C xx0800000037 Transport Support A Hexagon socket head cap screw M16x140 B Threaded bar M10x200 C Nut M10 D Continues on next page Product manual IRB 6640 Foundry Prime 57 3HAC040586 001 Revision N Copyright 201...

Page 58: ...ool must follow these instructions IRB 6640 Foundry Prime xx0800000040 Continues on next page 58 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 4 Robot transportation precautions Continued ...

Page 59: ...upport when transporting a robot with tool IRB 6640 Foundry Prime xx0800000039 Product manual IRB 6640 Foundry Prime 59 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 4 Robot transportation precautions Continued ...

Page 60: ...GER 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 Fitting the transport support Illustration for fitting the transport support A B xx0800000062 Continues on next page 60 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation a...

Page 61: ...t position with a transport support on page 58 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 78 3 CAUTION Do not attempt to tighten any attachment screws without first releasing the brakes This can seriously damage the robot Tighten all the attachment screws A and B in the figure with the brake re...

Page 62: ...ht robot on page 62 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 64 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 65 7 Before taking the robot to its installation site make sure that the site conforms to Loads on foundation robot on pa...

Page 63: ... the various forces and torques working on the robot during different kinds of operation 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 WARNING The robot installation is restricted to the mounting options given in following load table s Floor mounted Max load emergency stop Endurance load in o...

Page 64: ...rpreted as the frequency of the robot mass inertia robot assumed stiff when a foundation translational torsional elasticity is added i e the stiffness of the pedestal where the robot is mounted The minimum resonance frequency should not be interpreted as the resonance frequency of the building floor etc For example if the equivalent mass of the floor is very high it will not affect robot movement ...

Page 65: ...ximum ambient humidity Protection classes robot The table shows the available protection types of the robot with the corresponding protection class Protection class Protection type IP 67 Manipulator protection type Foundry Prime Product manual IRB 6640 Foundry Prime 65 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 6 1 Pre installation proc...

Page 66: ...illustration below xx0600003396 F E D C B A Robot variant 1814 mm 1119 mm 903 mm 2550 mm 286 mm 3015 mm IRB 6640 2 55 1999 mm 1252 mm 961 mm 2755 mm 268 mm 3219 mm IRB 6640 2 75 2061 mm 1324 mm 1004 mm 2800 mm 533 mm 3261 mm IRB 6640 2 8 2445 mm 1604 mm 1067 mm 3200 mm 713 mm 3665 mm IRB 6640 3 2 1814 mm 1549 mm 903 mm 2550 mm 286 mm 3015 mm IRB 6640ID 2 55 1999 mm 1682 mm 961 mm 2755 mm 268 mm 32...

Page 67: ...tion Axis Movement range can be set to 170 to 170 Rotation motion 1 220º to 220º option 561 1 85º to 65º Arm motion 2 70º to 180º Arm motion 3 IRB 6640ID the range of move ment is the combined value for axis 4 and 6 together 300 to 300 Wrist motion 4 IRB 6640 Bend motion 5 120 to 120 IRB 6640ID 100º to 100º Continues on next page Product manual IRB 6640 Foundry Prime 67 3HAC040586 001 Revision N C...

Page 68: ...nt 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 Working range and type of motion on page 66 68 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 6 2 Working range ...

Page 69: ...ition Do not change the robot position before securing it to the foundation Shipping and transportation position This figure shows the robot in its shipping position and transportation position Ax2 A x 3 Ax5 45 1 0 80 Z Y X xx0600003400 WARNING The robot is likely to be mechanically unstable if not secured to the foundation Product manual IRB 6640 Foundry Prime 69 3HAC040586 001 Revision N Copyrig...

Page 70: ...t truck Preparations before fitting the fork lift pockets Note Action DressPack if used can stay fitted as long as the tool fitted on the turning disk is removed Remove any tools fitted on the axis 6 turning disk Note No tool is permitted to be fitted on the robot when lifting the robot with the fork lift accessory 1 Ax2 Ax 3 Ax5 45 10 80 Z Y X xx0600003400 Jog the robot to its shipping position S...

Page 71: ... The fork lift accessory is fitted on the robot as shown in the figure xx0600002910 Fork lift pocket A Attachment screw M20x60 quality 8 8 2 pcs x4 B Continues on next page Product manual IRB 6640 Foundry Prime 71 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 7 1 1 Fitting the fork lift accessory Continued ...

Page 72: ... bot with its attachment screws Note Before fitting any attachment screws make sure they are not damaged in any way Replace dam aged screws 1 Verify that all four fork lift pockets are properly secured before lifting 2 72 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 7 1 1 Fitting the fork lift accesso...

Page 73: ... truck Lifting the robot with fork lift truck Note Action Note No load is permitted on the robot Make sure that the robot is in shipping position 1 DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 2 Verify that all four fork lift pockets are properly secured before lifting 3 Continues on next page Product manual IRB 6640 Foundry Prime 73 3HAC040586 001 ...

Page 74: ...f lifting with fewer than four fork lift pockets fitted there is a risk of accidents 4 IRB 6640 Ax2 A x3 Ax5 45 10 80 xx0600003401 IRB 460 xx1000001159 Continues on next page 74 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 7 1 2 Lifting the robot with fork lift truck Continued ...

Page 75: ...ircum stances be present under the suspended load 7 Note Move the robot with low speed Move the robot slowly to its new position 8 Secure the robot to the foundation DANGER Do not power the robot up until it is se cured properly to the foundation 9 Remove the fork lift accessories 10 Product manual IRB 6640 Foundry Prime 75 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 In...

Page 76: ...lower arm behind the side bracket balancing cylinder Attach roundslings to robot according to fig ure Attachment points on page 77 2 Note If the robot is equipped with fork lift pockets an extra weight of 90 kg must be added to the robot weight CAUTION The IRB 6640 Foundry Prime robot weighs 1 340 kg IRB6640 1 405 kg IRB6640ID All lifting accessories used must be sized accordingly 3 WARNING Person...

Page 77: ...acity 2 000 kg A 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 B Lifting eye M20 4 pcs Note Fit lifting eyes in the rear holes C Holes for lifting eyes in the robotbase Rear holes D Product manual IRB 6640 Foundry Prime 77 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commi...

Page 78: ... 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 79 1 DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpec ted ways Make sure no personnel is near or beneath the ro bot 2 Rel...

Page 79: ...ons Note Action DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 1 xx0600002937 Supply 0V on pin 12 and 24V on pin 11 2 Product manual IRB 6640 Foundry Prime 79 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 7 3 Manually releasing the brakes Continued ...

Page 80: ...ifting accessories used must be sized accordingly 1 Shown in figure Hole configur ation on page 80 Fit lifting eyes in specified holes 2 Fit lifting slings to the eyes and to the lifting accessory CAUTION Lift and move the base plate very slowly If the base plate starts to swing it is a risk for injuries or damage 3 80 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 ...

Page 81: ... 3 Ø 45P7 A A Ø1 5 4x 6 3 4 8 2 1 6 3x45º B B 2 1 3 3x R1 3 x 4 3x 90º C C 4 5 K 7 0 5 0 47 0 25 c 2x R22 5 1 6 D 2 c 5 2 5 º Common Zone E F G H xx1000001053 Common tolerance zone accuracy all over the base plate from one contact surface to the other E F G H Continues on next page Product manual IRB 6640 Foundry Prime 81 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Inst...

Page 82: ...ernative clamping 4x Ø18 A Continues on next page 82 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 7 5 Securing the base plate Continued ...

Page 83: ...ling bolts in the base plate A A A B B B B xx1500000312 Orienting grooves 3 pcs A Levelling bolts attachment holes 4 pcs B Continues on next page Product manual IRB 6640 Foundry Prime 83 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 7 5 Securing the base plate Continued ...

Page 84: ... is defined in section Standard tools on page 465 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Base plate This section details how to secure the base plate to the foundation Note Action Make sure the foundation is levelled 1 Continues on next page 84 Pr...

Page 85: ...ing grooves and leveling bolts on page 83 Fit the base plate and use the levelling bolts to level the base plate 6 If required fit strips of sheet metal underneath the base plate to fill any gaps 7 Secure the base plate to the foundation with screws and sleeves 8 Maximum allowed deviation all over the base plate from one contact surface to the other 0 3 mm Recheck the four contact surfaces on the ...

Page 86: ...rews Note Remove before the robot base is fitted C Base plate attachment screws D 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 M24 x 100 Suitable screws lightly lubricated Quality 8 8 Quality Thickness 4 mm Suitable washer Outer diameter 44 mm Inner diameter 25 mm 725 Nm Tightening torque Continue...

Page 87: ...e is correctly fitted onto the guide sleeves Guide the robot gently using two M24 screws while lowering it into its mounting position 4 Specified in Attachment screws on page 86 Fit the bolts and washers in the base attach ment holes 5 Shown in figure Illustration robot fitted to base plate on page 86 Note Lightly lubricate screws before as sembly Tighten bolts in a criss cross pattern to ensure t...

Page 88: ...3403 Cross section guide sleeve hole This illustration shows the cross section of the guide sleeve holes xx0600003404 88 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 7 6 Orienting and securing the robot Continued ...

Page 89: ...nt 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 Cleanro...

Page 90: ...5 xx0600003406 C B A Robot variant 40 mm 13 mm 400 mm IRB 6640 2 55 30 mm 13 mm 500 mm IRB 6640 2 75 40 mm 13 mm 400 mm IRB 6640 2 8 30 mm 13 mm 500 mm IRB 6640 3 2 40 mm 13 mm 400 mm IRB 6640ID 2 55 30 mm 13 mm 500 mm IRB 6640ID 2 75 Continues on next page 90 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissionin...

Page 91: ...eanroom robots xx0600003414 B A Robot variant 200 mm 1142 mm IRB 6640 2 55 200 mm 1142 mm IRB 6640 2 75 200 mm 1392 mm IRB 6640 2 8 200 mm 1592 mm IRB 6640 3 2 290 mm 1142 mm IRB 6640ID 290 mm 1142 mm IRB 6640ID xx1000000158 Continues on next page Product manual IRB 6640 Foundry Prime 91 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 7 7 Fi...

Page 92: ...for fitting extra equipment on the frame are shown below xx0600003416 Continues on next page 92 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 7 7 Fitting equipment on robot Continued ...

Page 93: ... disc There are different versions of the turning disc as shown in the illustrations below xx0200000397 Turning disk type 1 Continues on next page Product manual IRB 6640 Foundry Prime 93 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 7 7 Fitting equipment on robot Continued ...

Page 94: ...ews with quality 12 9 Standard screws with quality 8 8 may be used when fitting other equipment to the mounting holes 94 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 7 7 Fitting equipment on robot Continued ...

Page 95: ...01 to repair damages to paint surfaces Pre installation procedure Operation conditions robot Value Parameter 5 C Minimum ambient temperature 50 C Maximum ambient temperature 100 at constant temper ature gaseous only Maximum ambient humidity Protect attachment bolts and washers at the base Protect the attachment bolts and washers M24x100 at the base from physical obstructions and splashes with appr...

Page 96: ...References Load diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must be defined in the software Operating manual IRC5 with FlexPendant Stopping time and braking distances The performance of the motor brake depends on if there are any loads attached to the robot For more information see product specification for the robot 96 Product ...

Page 97: ...vered with the signal lamp 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 Product manual IRB 6640 Foundry Prime 97 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 7 10 Signal lamp option ...

Page 98: ...mation see the recommended solution Installing the over pressure limiter on wall on page 99 or the alternative solution Installing the over pressure limiter unit on robot base on page 102 Note An extra warning label is supplied with the robot and must be applied on the robot base if the over pressure unit is installed on the robot base Continues on next page 98 Product manual IRB 6640 Foundry Prim...

Page 99: ...0001149 Required equipment Note Article number Equipment etc For spare part number see Spare parts on page 487 Over pressure unit Content is defined in section Standard tools on page 465 Standard toolkit CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page219 Continues on next page Produ...

Page 100: ...it 3 xx1700001906 Connect the air hose from the unit to the connect or plug on the robot base 4 Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 29 5 Continues on next page 100 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights rese...

Page 101: ...rking area 1 xx1700001150 Disconnect the air hose from the unit 2 xx1700001906 Disconnect the air hose from the the robot base 3 xx1700001151 Remove the unit from the wall 4 Product manual IRB 6640 Foundry Prime 101 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 7 11 1 Installing the over pressure limiter on wall Continued ...

Page 102: ... Note An extra warning label is supplied with the robot and must be applied on the robot base if the over pressure unit is installed on the robot base Location of the over pressure limiter unit xx1700001821 Required equipment Note Article number Equipment etc For spare part number see Spare parts on page 487 Over pressure unit Content is defined in section Standard tools on page 465 Standard toolk...

Page 103: ...the extra warning label onto the robot and near the over pressure limiter unit clearly visible for the operator 2 xx1700001822 Remove the top cover from the robot base 3 xx1700001823 Disconnect the air hose from the plug on the connector plate Note If the robot is equipped with a perforated plate and not a connector plate then remove the perfor ated plate by hitting it with a plastic mallet before...

Page 104: ...bot base 6 xx1700001902 Connect the air hose to the unit 7 xx1700001903 Refit the top cover 8 Continues on next page 104 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 7 11 2 Installing the over pressure limiter unit on robot base Continued ...

Page 105: ...DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 xx1700001904 Disconnect the air hose from unit 2 xx1700001905 Remove the top cover from the robot base 3 Continues on next page Product manual IRB 6640 Foundry Prime 105 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and...

Page 106: ...1700001901 Remove the unit from the robot base 5 106 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 7 11 2 Installing the over pressure limiter unit on robot base Continued ...

Page 107: ...chanical 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 Product manual IRB 6640 Foundry Prime 1...

Page 108: ...Mechanical stops axis 1 The illustration shows the mounting position of the stop pin and one of the additional mechanical stops available for axis 1 xx0600002938 Movable mechanical stop A Attachment screw plus washer M12 x 40 quality 12 9 2 pcs B Fixed mechanical stop C Mechanical stop pin axis 1 D Continues on next page 108 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright...

Page 109: ...ring the robot working area 1 Tightening torque 120 Nm Fit the additional mechanical stop to the frame according to the figure Mechanical stops axis 1 on page 108 2 The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters Adjust the software working range limitations system parameter configuration to corres pon...

Page 110: ...crews washers and assembly drawings 3HAC13787 1 Mechanical stop set axis 2 Content is defined in section Standard tools on page 465 Standard toolkit Art no is specified in section Refer ences on page 10 Technical reference manu al System parameters Installation mechanical stops axis 2 Use the procedure to fit the mechanical stops for axis 2 to the robot An assembly drawing is also enclosed with th...

Page 111: ...mitations must be redefined to correspond to the changes in the mechanical limitations of the working range 3 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 4 Product manual IRB 6640 Foundry Prime 111 3HAC040586 001 Revision N ...

Page 112: ...llustration shows the mounting position of the mechanical stops on axis 3 The figure shows IRB 7600 but the principle is the same xx0300000048 Additional mechanical stops A Fixed mechanical stop B Attachment screw M16x60 quality 12 9 C Continues on next page 112 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commission...

Page 113: ... 3HAC13128 1 Mechanical stop set axis 3 Content is defined in section Standard tools on page 465 Standard toolkit Art no is specified in section Refer ences on page 10 Technical reference manu al System parameters Continues on next page Product manual IRB 6640 Foundry Prime 113 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 2 Installation and commissioning 2 8 4 Mechanically...

Page 114: ...nged Upper joint bound and Lower joint bound are described in Technical reference manual System parameters Note The software working range limitations system parameters must be redefined to correspond to the changes in the mechanic al limitations of the working range 3 WARNING If the mechanical stop pin is deformed after a hard collision it must be replaced Deformed movable stops and or additional...

Page 115: ... power supply to and control of the external axes motors as well as feedback from the servo system External axes cables option See the Application manual Additional axes and stand alone controller M2004 see document number in Refer ences on page 10 Robot cables These cables are included in the standard delivery They are completely pre manufactured and ready to plug in Connection point robot Connec...

Page 116: ...r for static floor cables A B xx1600002016 Diameter A Diameter x10 B Grounding and bonding point on manipulator There is a grounding bonding point on the manipulator base The grounding bonding point is used for potential equalizing between control cabinet manipulator and any peripheral devices xx1500001603 116 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB ...

Page 117: ...ed with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 100 mm s 20 20 3 Work cy...

Page 118: ...This page is intentionally left blank ...

Page 119: ...ore comprehensive More frequent Sample activities for check of lubrication Conditional for example water content in gearbox control decide replacement intervals Preventive measures every 6 months secure the uptime of the robot Inspection of oil level in gearboxes Surface treatment Cable harness Balancing device Activity to lubricate gearboxes cavities and gears Run each axis on high speed at least...

Page 120: ...use or failure to fulfil operational and maintenance requirements will not be approved 120 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 1 Introduction for Foundry Prime robots Continued ...

Page 121: ...al value is given for a typical work cycle but the value will differ depending on how hard each part is run The SIS used in M2004 is further described in the Operating manual Service Information System Overhaul Depending on application and operational environment a complete overhaul may be necessary in average around 40000 hours ABB Connected Services and its Assessment tools can help you to ident...

Page 122: ...pe Foundry Prime Interval Equipment Maintenance activ ity Every 6 months i Surface treatment Inspection Every 2 months Balancing device Inspection Every 6 months If required ii Cable harness Including rubber blocks and straps Inspection If required ii Cable harness Replacement Every 6 months Air hoses Inspection Every 6 months If corroded Replace support shaft with bearing See Re placement of supp...

Page 123: ...ded Balancing device bearings Solid oil bearings rear and front Lubrication Every 6 months Apply Mercasol on output shaft Axis 2 gear Rust preventing Every 6 months Apply Mercasol on output shaft Axis 3 gear Rust preventing Every 6 months Apply Mercasol on support shaft with bearing axis 5 Rust preventing Every 6 months Axis 1 sealing Rust preventing Every 6 months Axis 4 sealing Rust preventing E...

Page 124: ...be replaced See the replacement instruction for more details vi The battery low alert 38213 Battery charge low is displayed when remaining backup capacity robot powered off is less than 2 months The 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 h day The lifetime can be extended with a battery shutdown service rou...

Page 125: ...ected life v Depending on application the lifetime can vary The Service Information System SIS that is integrated in the robot software can be used as guidance when planning gearbox service 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...

Page 126: ...nce and repair procedures the operation cycle of the robot 126 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 2 3 Expected component life Continued ...

Page 127: ...ith other oils See Type and amount of oil in gearboxes on page 168 Lubricating oil Content is defined in section Standard tools on page 465 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page Product manual IRB 6640 Foundry Prime 127 3H...

Page 128: ...Make sure that the oil temperature is 25 C 10 C 3 Shown in figure Location of gear box on page 127 Open the oil plug inspection 4 A B C xx1400002785 A Oil plug hole B Required oil level C Gearbox oil Measure the oil level Required oil level 0 10 mm 5 Where to find type of oil and total amount is detailed in Type of lub rication in gearboxes on page168 Adjust the oil level if required 6 Further inf...

Page 129: ...edures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Inspecting the oil level in axis 2 gearbox Use this procedure to inspect the oil level in the axis 2 gearbox Note Action WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information i...

Page 130: ... 4 A B C xx1400002785 A Oil plug hole B Required oil level C Gearbox oil Measure the oil level Required oil level 0 15 mm 5 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 168 Adjust the oil level if required 6 Filling of oil is detailed further in the section Filling oil on page 174 Tightening torque 24 Nm Refit the oil plug 7 130 Product manu...

Page 131: ...g draining C Required equipment Note Art no Equipment etc Note Do not mix with other oils See Type and amount of oil in gearboxes on page 168 Lubricating oil Content is defined in section Standard tools on page 465 Standard toolkit Continues on next page Product manual IRB 6640 Foundry Prime 131 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 3 Inspecting th...

Page 132: ...for axes on page 442 Move the robot to a position according to the il lustration in Location of gearbox on page 131 2 DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot Before entering the robot working area 3 This is a precaution to reduce the temperature dependency of the measurement Make sure that the oil temperature is 25 C 10 C 4 Shown in the figure ...

Page 133: ...if required 7 Further information about how to fill the oil may be found in the section Filling oil on page 178 Tightening torque 24 Nm Refit the oil plug 8 Product manual IRB 6640 Foundry Prime 133 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 3 Inspecting the oil level in axis 3 gearbox Continued ...

Page 134: ...e tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Inspecting the oil level in axis 4 gearbox Use this procedure to inspect the oil level in the axis 4 gearbox Note Action WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section Safety risks durin...

Page 135: ...f gear box on page 134 Open the oil plug filling and inspection 5 A B C xx1400002785 A Oil plug hole B Required oil level C Gearbox oil Measure the oil level Required oil level 0 10 mm 6 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 168 Adjust the oil level if required 7 Further information about how to fill the oil may be found in the sectio...

Page 136: ...figure xx0200000232 The figure above shows the wrist unit of IRB 6600 and IRB 6650 Oil plug filling and inspection A Oil plug draining B Continues on next page 136 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 5 Inspecting the oil level in axis 5 gearbox ...

Page 137: ... to these procedures in the step by step instructions below Inspecting the oil level in axis 5 gearbox Use this procedure to inspect the oil level in the axis 5 gearbox Note Action WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety inform ation in the section Safety risks during work with gearbox lubricants oil or grease on page 39 1 Move the robot ...

Page 138: ... and inspection 6 xx0500002222 Measure the oil level Required oil level to the upper edge of the filling and inspection oil plug hole a 24 36 mm 7 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 168 Adjust the oil level if required 8 Further information about how to fill the oil may be found in the section Filling oil axis 5 on page 183 Tighten...

Page 139: ...1 Axis 6 gearbox A Oil plug filling and inspection B Oil plug draining C xx0400001092 Type 2 Axis 6 gearbox A Oil plug filling and inspection B Oil plug draining C Continues on next page Product manual IRB 6640 Foundry Prime 139 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 6 Inspecting the oil level in axis 6 gearbox ...

Page 140: ...age 142 Required equipment Note Art no Equipment See Type and amount of oil in gearboxes on page 168 Lubricating oil Content is defined in section Standard tools on page 465 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page 140 Produc...

Page 141: ...ce the temperature dependency of the measurement Make sure that the oil temperature is 25 C 10 C 4 A xx1300000244 Open the oil plug filling and inspection 5 Turn axis 6 so that the oil plug draining faces up wards 6 This is a precaution to avoid vacu um effects by allowing air to enter at the top of the gearbox Note If equipment that covers the oil plug draining is fitted on the robot so that the ...

Page 142: ...l plugs 11 WARNING Do not mix oil types If wrong oil is refilled the gearbox must be rinsed as detailed in Technical reference manual Lubrication in gearboxes 12 Inspecting the oil level in axis 6 gearbox wrist type 2 Use this procedure to inspect the oil level in the axis 6 gearbox for wrist type 2 Note Action WARNING Handling gearbox oil involves several safety risks Before proceeding please rea...

Page 143: ...ple an oil stick or a cable tie to gently poke the oil surface This will avoid surface tension from stopping air to enter into the gearbox 7 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 168 Adjust the oil level if required 8 Further information about how to fill the oil may be found in the section Filling oil axis 6 on page 186 Tightening to...

Page 144: ...ing device is located at the top rear of the frame as shown in the figure The figure also shows the inspection points further described in the instructions xx0600003431 Balancing device A Piston rod inside balancing device B Fork Link ear C Shaft D Retaining ring bore E Attachments in cradle rear bearing F Continues on next page 144 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N C...

Page 145: ...ard tools on page 465 3HAC15571 1 Standard toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step in structions below Check for dissonance The check points are shown in the figure Inspection points balancing device on page 144 If dissonance is detected Check for dissonance from perform ma...

Page 146: ...n points balancing device on page 144 If damage is detected Check for damage on perform maintenance according to given instructions in Maintenance kit complete the piston rod part of the piston rod that is visible at the front of the balancing device 1 Art no for the kit and the documentation are specified in section Required equip ment on page 145 Check for leakage Design 1 The front ear of the b...

Page 147: ...detected Excessive grease from between the shaft and the sealing ring is normal and is not considered as a leak 3 Art no for the kit is specified in Re quired equipment on page 145 The replacement of the complete bearing is also detailed in section Replacement of spherical roller bear ing balancing device on page 297 Check for leakage Design 2 The front ear of the balancing device is lubricated wi...

Page 148: ...king area 3 Check the o rings at the front ear for leakage 4 The o rings are included in the Main tenance kit bearings and seals already assembled with sealing spacers and sealing rings Art no for the kit is specified in Required equip ment on page 145 Replace o rings if leaks are detected 5 Replacement of the complete bearing is also described in section Replace ment of spherical roller bearing b...

Page 149: ...tacles inside the frame that could prevent the balancing device from moving freely See the figure Inspection points balancing device on page 144 2 Keep the areas around the balancing device clean and free from objects such as service tools Product manual IRB 6640 Foundry Prime 149 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting the balancing dev...

Page 150: ... cable harness axes 1 4 on page 151 and Inspection cable harness 1 4 on page 152 Inspection of axes 5 6 is described in Location of cabling axes 5 6 on page153 and Inspection cable harness axes 5 6 on page 153 Continues on next page 150 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the cable harness ...

Page 151: ...0003434 Lower arm A SMB BU unit battery pack RMU 3HAC16831 1 is shown note that there are different battery versions B Connectors at base C Continues on next page Product manual IRB 6640 Foundry Prime 151 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the cable harness Continued ...

Page 152: ... and damage 2 Shown in the figure Location of cable harness axes 1 4 on page 151 Check the connectors at the base 3 Note If the robot is used in a Foundry Prime applic ation check the cables for cracks in insula tion 4 Location shown in the figure Location of cable harness axes 1 4 on page151 Check that velcro straps are properly attached to the side bracket balancing cylinder Note For Clean Room ...

Page 153: ...NGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 1 Make an overall visual inspection of the cable harness in order to detect wear and damage 2 Shown in the figure Location of cabling axes 5 6 on page 153 Check the attachments at the rear of the up per arm and in the upper arm tube 3 Continues on next page Product manual IRB 6640 ...

Page 154: ...racks in insula tion 4 See Replacing cable harness axes 1 6 on page 222 Replace the cable harness if wear cracks or damage is detected 5 See Replacement of cabling axis 5 mo tor on page 237 154 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the cable harness Continued ...

Page 155: ...hown on the pressure gauge 1 0 2 0 3 bar 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 Close the cut off valve 2 The time is 5 seconds If the answer is YES Localize the leakage by following the procedures below If the answer is NO The system is OK Remove the leak testing equipment 3 Pressurize by opening the cut off...

Page 156: ...ticle number Equipment Mercasol Recommended drying time is 24h 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush 3HAC035355 001 Foundry Prime touch up kit Inspection and repair of surface treatment Use this procedure to inspect the surface treatment on Foundry Prime robots Information Action Inspect all painted surfaces for damages 1 Repair damages as desc...

Page 157: ...sign symbol of flash located on motor cover 5 pcs B Instruction label C Warning label tools are not allowed around the balancing device during operation I Warning label concerning shutting off power J Serial no from rating label M Information labels about type of oil at gearboxes and at robot base Continues on next page Product manual IRB 6640 Foundry Prime 157 3HAC040586 001 Revision N Copyright ...

Page 158: ...d equipment Visual inspection no tools are required Inspecting labels Note Action DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 1 Inspect the labels located as shown in the figures 2 Article numbers for the labels and plate set is specified in Spare parts on page 487 Replace any missing or damaged labels 3 158 Product manual...

Page 159: ...pin The axis 1 mechanical stop is located as shown in the figure xx0600003436 Mechanical stop pin axis 1 A Fixed mechanical stop B Required equipment Visual inspection no tools are required Continues on next page Product manual IRB 6640 Foundry Prime 159 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 12 Inspecting the axis 1 mechanical stop pin ...

Page 160: ... robot working area 1 Inspect the axis 1 mechanical stop pin 2 If the mechanical stop pin is bent or damaged it must be replaced Note The expected life of gearboxes can be reduced after collision with the mechanical stop 160 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 12 Inspecting the axis 1 mechanical stop pin Cont...

Page 161: ...stops on axes 1 2 and 3 xx0600002938 Additional stop axis 1 A Attachment screws and washers 2 pcs B Fixed stop C Mechanical stop pin axis 1 D Continues on next page Product manual IRB 6640 Foundry Prime 161 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 3 13 Inspecting the additional mechanical stops ...

Page 162: ...nical stop Attachment screw and washer Document for mechanical stop 3HAC13787 1 Mechanical stop axis 2 Includes Mechanical stop pin Attachment screw and washer Document for mechanical stop pin 3HAC025290 003 Mechanical stop set axis 3 Content is defined in section Standard tools on page 465 Standard toolkit Continues on next page 162 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N ...

Page 163: ...maged 2 Make sure the stops are properly attached 3 Correct tightening torque additional mechanical stops Axis 1 120 Nm Article number is specified in Required equipment on page162 If any damage is detected the mechanical stops must be replaced Correct attachment screws Axis 1 M12 x 40 quality 12 9 Axis 2 M16 x 50 Axis 3 M16 x 60 4 Product manual IRB 6640 Foundry Prime 163 3HAC040586 001 Revision ...

Page 164: ...Note Spare part art no Equipment 3HAC12991 1 Damper axis 2 3HAC12320 1 Damper axis 3 3HAC13564 1 Damper axis 4 3HAB4337 2 Damper axis 5 IRB 6640ID 2 pcs 3HAC021325 001 Damper 1 axis 5 IRB 6640ID 2 pcs 3HAC021675 001 Damper 2 axis 5 Content is defined in section Standard tools on page 465 3HAC15571 1 Standard toolkit Continues on next page 164 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Re...

Page 165: ...ampers 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 2 Check attachment screws for deformation 3 Art no is specified in Required equipment on page 164 If any damage is detected the damper must be re placed with a new one 4 Product manual IRB 6640 Foundry Prime 165 3HAC040586 001 Revision N Copyright 201...

Page 166: ...nal lamp A Clamp B Cable strap outdoor C Motor axis 3 D Attachment screw M6x8 quality 8 A2F 2 pcs E Required tools and equipment Note Article number Equipment To be replaced if damage is detected See Spare parts on page 487 Signal lamp kit Content is defined in section Stand ard tools on page 465 Standard toolkit Continues on next page 166 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revis...

Page 167: ...e number is specified in Re quired tools and equipment on page 166 If the lamp is not lit trace the fault by inspecting whether the signal lamp is broken If so replace it inspecting cable connections measuring the voltage in the connectors of motor axis 3 24V inspecting the cabling Replace the cabling if a fault is detected 3 Product manual IRB 6640 Foundry Prime 167 3HAC040586 001 Revision N Copy...

Page 168: ...tarting any inspection maintenance or changing activities of lubrication always contact the local ABB Service organization for more information For ABB personnel Always check ABB Library for the latest revision of the manual Technical reference manual Lubrication in gearboxes in order to always get the latest information of updates about lubrication in gearboxes A new revision will be published on...

Page 169: ...se the suggested dispenser or a similar one Orion OriCan article number 22590 pneumatic Nipple for quick connect fitting with o ring Product manual IRB 6640 Foundry Prime 169 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 4 1 Type of lubrication in gearboxes Continued ...

Page 170: ...quipment etc Note Do not mix with other oils See Type and amount of oil in gear boxes on page 168 See Type and amount of oil in gearboxes on page 168 Lubricating oil Capacity 8 000 ml Oil collecting vessel Content is defined in section Special tools on page 466 3HAC021745 001 Oil exchange equip ment Content is defined in section Standard tools on page 465 Standard toolkit Continues on next page 17...

Page 171: ... read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 39 2 Vessel capacity is specified in Re quired equipment on page 170 Collect drained oil in an oil vessel 3 Shown in figure Location of oil plugs on page 170 Remove oil plug filling in order to drain oil quicker 4 Note Draining is time consuming Elapsed time depends on the temperature...

Page 172: ...2 Shown in figure Location of oil plugs on page 170 Open the oil plug filling 3 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 168 Refill the gearbox with clean lubricating oil The correct oil level is detailed in section Inspecting the oil level in axis 1 gearbox on page 127 4 Note Do not mix Kyodo Yushi TMO 150 with other oil types 5 Tighten...

Page 173: ... gearboxes on page 168 Lubricating oil Capacity 6 000 ml Oil collecting vessel Content is defined in section Special tools on page 466 3HAC021745 001 Oil exchange equip ment Content is defined in section Standard tools on page 465 Standard toolkit CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing p...

Page 174: ...ining and drain the gearbox oil using a hose with nipple and an oil collecting vessel CAUTION Drain as much oil as possible See Safety risks during work with gearbox lubricants oil or grease on page 39 4 Vessel capacity is specified in Required equipment on page 173 Note Draining is time consuming Elapsed time varies depending on the temperat ure of the oil Tightening torque 24 Nm Refit the oil pl...

Page 175: ...on 3 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 168 Refill the gearbox with clean lubricating oil The correct oil level is detailed in section Inspect ing the oil level in axis 2 gearbox on page 129 4 Note Don t mix Kyodo Yushi TMO 150 with other oil types 5 Tightening torque 24 Nm Refit the oil plug 6 Product manual IRB 6640 Foundry Prime...

Page 176: ...Note Do not mix with other oil types See Type and amount of oil in gear boxes on page 168 See Type and amount of oil in gearboxes on page 168 Lubricating oil Content is defined in section Special tools on page 466 3HAC021745 001 Oil exchange equipment Capacity 3 000 ml Oil collecting vessel Continues on next page 176 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 20...

Page 177: ... oil involves several safety risks Before proceeding please read the safety information in the section Safety risks during work with gearbox lubricants oil or grease on page 39 2 Remove the oil plug filling 3 Shown in the figure Location of gearbox on page 176 Remove the oil plug draining and drain the gearbox oil using a hose with nipple and an oil collecting vessel CAUTION Drain as much oil as p...

Page 178: ...e section Safety risks during work with gearbox lubricants oil or grease on page 39 2 Shown in the figure Location of gearbox on page 176 Remove the oil plug filling 3 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 168 Refill the gearbox with clean lubricating oil The correct oil level is detailed in section Inspecting the oil level in axis 3 ...

Page 179: ...ating oil Content is defined in section Special tools on page 466 3HAC021745 001 Oil exchange equipment Capacity 9 000 ml Oil collecting vessel Content is defined in section Standard tools on page 465 Standard toolkit CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page219 Continues on n...

Page 180: ...l from the gearbox into a vessel by opening the oil plug draining 5 Vessel capacity is specified in Re quired equipment on page 179 This is detailed in section Synchroniz ation marks and synchronization pos ition for axes on page 442 Run the upper arm back to its calibration posi tion horizontal position 6 Tightening torque 24 Nm Refit the oil plug draining 7 Filling oil The procedure below detail...

Page 181: ...ll the gearbox with clean lubricating oil The correct oil level is detailed in section In specting the oil level in axis 4 gearbox on page 134 3 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 168 Tightening torque 24 Nm Refit the oil plug filling 4 Product manual IRB 6640 Foundry Prime 181 3HAC040586 001 Revision N Copyright 2011 2018 ABB All ...

Page 182: ...Lubricating oil Content is defined in sec tion Special tools on page 466 3HAC021745 001 Oil exchange equipment Capacity 7 000 ml Oil collecting vessel Content is defined in sec tion Standard tools on page 465 Standard toolkit CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page219 Contin...

Page 183: ...n of gearbox on page 182 Drain the oil from the gearbox by opening the oil plug draining 5 Vessel capacity is specified in Re quired equipment on page 182 Tightening torque 24 Nm Refit the oil plug draining 6 Filling oil axis 5 The procedure below details how to change the oil in gearbox axis 5 When using the oil exchange equipment follow the instructions enclosed with the kit Art no for the kit i...

Page 184: ...ing oil The correct oil level is detailed in section Inspect ing the oil level in axis 5 gearbox on page 136 4 Where to find type of oil and total amount is detailed in Type and amount of oil in gearboxes on page 168 Tightening torque 24 Nm Refit the oil plug filling 5 184 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 4 ...

Page 185: ...earboxes on page 168 Lubricating oil Content is defined in section Special tools on page 466 3HAC021745 001 Oil exchange equip ment Vessel capacity Oil collecting vessel 500 ml 7 000 ml IRB 6640ID Content is defined in section Standard tools on page 465 Standard toolkit CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the r...

Page 186: ...section Safety risks during work with gearbox lubricants oil or grease on page 39 3 Vessel capacity is specified in Re quired equipment on page 185 Drain the oil from the gearbox into a vessel by removing the oil plug 4 The amount of oil to be refilled de pends on the amount previously drained Measure the amount of oil drained Tightening torque 24 Nm Refit the oil plug draining 5 Filling oil axis ...

Page 187: ...ge 168 Refill the gearbox with clean lubricating oil The correct oil level is detailed in section Inspect ing the oil level in axis 6 gearbox on page 139 4 Detailed in the section Type of lubrication in gearboxes on page 168 Note Do not mix Kyodo Yushi TMO 150 with other oil types 5 Tightening torque 24 Nm Refit the oil plug 6 Detailed in the section Inspecting the oil level in axis 6 gearbox on p...

Page 188: ...hs if the robot is powered off 16 h day The lifetime can be extended for longer production breaks with a battery shutdown service routine See Operating manual IRC5 with FlexPendant for instructions WARNING See instructions for batteries Safety risks during handling of batteries on page38 Location of SMB battery The SMB battery SMB serial measurement board is located on the left hand side of the fr...

Page 189: ...e battery It is important that the SMB unit uses the correct battery Make sure to order the correct spare parts Do not exchange battery contacts Note Spare part no Equipment etc Battery includes protection circuits Only re place with a specified spare part or an ABB approved equivalent For spare part no see Spare parts on page 487 Battery unit Content is defined in section Standard tools on page 4...

Page 190: ... disassembling parts See Cut the paint or surface on the robot before replacing parts on page 219 4 Shown in figure Location of SMB battery on page 188 Remove the SMB battery cover by unscrewing the attachment screws CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 5 Shown in figure Location of SMB battery...

Page 191: ...ote RMU batteries are installed together with a battery holder to be properly secured inside the recess See figure 4 Shown in figure Location of SMB battery on page 188 A B D C xx1300000307 A Battery pack RMU B Battery holder C Battery cable D Strap Strap the battery cable to the holder Shown in figure Location of SMB battery on page 188 Secure the SMB battery cover with its attachment screws 5 Se...

Page 192: ...e first test run These are further detailed in the section First test run may cause injury or damage on page 29 8 192 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 4 8 Replacing the SMB battery Continued ...

Page 193: ...0003155 More than 3 water in oil With more than 3 water content there is a risk for corrosion in the gearbox and reduced viscosity in the oil 1 A Water content in gearbox oil B Months or hours in operation C Replacement of gearbox Normal replacement interval is required for the gearbox A B 3 6 12 18 24 30 3000 6000 9000 12000 15000 xx0600003156 Less than 3 water in oil 2 A Water content in gearbox...

Page 194: ...be mounted on the robot when lubricating the bearing xx0700000731 Securing screw and lubricating hole A Roller bearing B Location of bearing Design 2 Note The spherical roller bearing of design 2 with solid oil does not need any scheduled lubrication Continues on next page 194 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance ...

Page 195: ...t etc Optimol PDO 20 ml 3HAC042534 001 Grease M6 Lubrication nipple Normally not fitted to the link ear at delivery Grease pump Continues on next page Product manual IRB 6640 Foundry Prime 195 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 6 1 Lubrication of spherical roller bearing balancing device Continued ...

Page 196: ...ain after operation of the robot in order to make sure there is no incorrect leakage from the o rings 5 Lubrication balancing device bearing Design 2 The procedure below details how to lubricate the spherical roller bearing Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot Before entering the robot working area 1 M6 Replace the upper securing...

Page 197: ...ge Design 1 on page 146 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 6 Product manual IRB 6640 Foundry Prime 197 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 6 1 Lubrication of spherical roller bearing balancing device Continued ...

Page 198: ...hown in the illustration View from above xx0700000445 Cable guide A Required equipment Note Art no Equipment Brush Continues on next page 198 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 6 2 Rust preventive measures bearing axis 1 Foundry Prime ...

Page 199: ...structions below Procedure The following procedure details how to apply the rust preventive on bearing axis 1 Note Action DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 1 xx0700000445 Remove the cable guide 2 Parts A Cable guide Wipe the surface under the cable guide 3 Continues on next page Product manual IRB 6640 Foundry Pr...

Page 200: ...g Refit the cable guide 5 xx1000000372 Apply Sikaflex 521FC outside the cable guide as shown in the figure 6 A Sikaflex 521FC B Cable guide 200 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 6 2 Rust preventive measures bearing axis 1 Foundry Prime Continued ...

Page 201: ... toolkit These procedures include references to the tools re quired Other tools and procedures may be required See refer ences to these procedures in the step by step instruc tions below Procedure The procedure describes how to apply rust preventive on sealing axis 1 Note Action Put the robot in a suitable position 1 Continues on next page Product manual IRB 6640 Foundry Prime 201 3HAC040586 001 R...

Page 202: ...the upper arm 3 Parts A Cover B Cable guide xx0600002871 Remove the cable guide that covers the sealing 4 Parts A Cable guide Wipe the surface under the cable guide 5 Continues on next page 202 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 6 3 Rust preventive measures sealing axis 4 Foundry Prime Continued ...

Page 203: ... brush 6 Parts A Radial sealing and rear part of tube B Cable guide Refit the radial sealing and cable guide 7 Product manual IRB 6640 Foundry Prime 203 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 6 3 Rust preventive measures sealing axis 4 Foundry Prime Continued ...

Page 204: ...903 001 Rust preventive Content is defined in section Standard tools on page 465 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below Continues on next page 204 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights...

Page 205: ...e air hose 4 A xx0600002864 Remove the cover with gasket 5 A Cover See Location of bearing on page 204 Apply rust preventive on the bearing and cable bracket with the brush 6 Refit the cover with gasket Note Replace gasket if damaged 7 Refit the hose clamp 8 Connect the air hose to motor axis 6 9 See Inspection of air hoses Foundry Prime on page 155 Perform a leakdown test 10 Product manual IRB 66...

Page 206: ... equipment Note Article number Equipment Brush Required consumables Note Article number Consumable Equivalent Mercasol 3HAC034903 001 Rust preventive isopropyl alcohol Continues on next page 206 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 6 5 Apply Mercasol on output shaft axis 2 ...

Page 207: ...re supply to the robot before entering the robot working area 2 B A xx1500001660 clean the surface on the output shaft with isopropanol 3 A Gear axis 2 B Output shaft Apply rust preventive on the out put shaft with a brush 4 Product manual IRB 6640 Foundry Prime 207 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 6 5 Apply Mercasol on output shaft axis 2 Conti...

Page 208: ...bles Note Article number Consumable Equivalent Mercasol 3HAC034903 001 Rust preventive Procedure The procedure describes how to remove and apply rust preventive output shaft axis 3 Note Action Put the robot in a suitable position 1 Continues on next page 208 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 6 6 Apply Mercaso...

Page 209: ...A xx1500001661 clean the surface on the output shaft with isopropanol 3 A Gear axis 2 B Output shaft Apply rust preventive on the out put shaft with a brush 4 Product manual IRB 6640 Foundry Prime 209 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 3 Maintenance 3 6 6 Apply Mercasol on output shaft axis 3 Continued ...

Page 210: ...vities on page 127 2 Write down the oil level 3 Inspect the oil level again after for example 6 months 4 If the oil level is decreased then replace the gearbox Oil spills discolors painted surfaces Oil spills on painted surfaces of the robot can result in discoloration Note After all repair and maintenance work involving oil always wipe the robot clean from all surplus oil Special cleaning conside...

Page 211: ...Instructions for rinsing with water ABB robots with protection types Standard Foundry Plus Wash or Foundry Prime can be cleaned by rinsing with water water cleaner 1 The following list defines the prerequisites Maximum water pressure at the nozzle 700 kN m2 7 bar I Fan jet nozzle should be used min 45 spread Minimum distance from nozzle to encapsulation 0 4 meters Maximum flow 20 liters minI I Typ...

Page 212: ...me very corrosive Approved cleaners and detergents All cleaners and detergents must be approved by ABB before use Contact ABB Robotics Sales Support to get the latest released list of approved cleaners and detergents Temperature of cleaning bath Maximum temperature 60ºC Ambient temperature must not be higher than 50 C Note Make sure that the special Foundry Prime painting of the robot is not broke...

Page 213: ...ific repair activity are listed in the respective procedures The details of equipment are also available in different lists in the chapter Reference information on page 457 Safety information There are general safety information and specific safety information The specific safety information describes the danger and safety risks while performing specific steps in a procedure Make sure to read thro...

Page 214: ...sure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that no pressu...

Page 215: ...tresses during the assembly work 3 Assembly of tapered bearings Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing gradually until the recomm...

Page 216: ...uring 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 following description 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 216 Product manual IRB 6640 Fou...

Page 217: ...e correct type provided with cutting edge There is no damage to the sealing edge feel with a fingernail 1 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced since it may result in future leakage 2 Article number is specified in Equipment on page217 Lubricate the seal with grease just before fitting Not too early there is a risk of dirt and foreig...

Page 218: ...n fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damaged or deformed o rings may not be used Check the o ring for surface defects burrs shape accuracy or deformation 2 Defective o rings may not be used Check the o ring grooves 3 The grooves must be geometrically correct ...

Page 219: ... used on all Foundry Prime robots re gardless of the original color of the robot 3HAC035355 001 Touch up paint Foundry Prime Foundry Prime 2 Foundry Prime 3 Grey Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edge that is left on the structure to a s...

Page 220: ...001 Use Touch up paint Foundry Prime grey to paint the joint Note Always read the instruction in the product data sheet in the paint repair kit for Foundry Prime 6 Apply Mercasol on all screw heads and set screws after tightening 7 220 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 2 4 Cut the paint or surface on the robot bef...

Page 221: ...e robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action Make sure the power is turned off 1 Remove the push button guard if necessary 2 Verify that the push buttons of the brake release unit are working by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a button gets jammed in ...

Page 222: ...roughout the robot as shown in the figure below xx0700000102 Connectors at motor axis 2 R2 FB2 R2 MP2 A Connectors at motor axis 1 R2 FB1 R2 MP1 B Rear cover plate C Earth attachment point is placed under the cover plate D Cable harness E Continues on next page 222 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 1 Replacing c...

Page 223: ...er arm on metal clamp P Cable gland armhouse R xx0700000107 Required parts Note Spare part no Equipment Includes Gaskets axes 1 5 See Spare parts chapter Cable harness axes 1 6 Motors axes 1 5 3HAC3438 1 Gasket Motor axis 6 3HAC033489 001 Gasket cover Continues on next page Product manual IRB 6640 Foundry Prime 223 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 ...

Page 224: ...AC026621 001 Rust preventive Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC Brush CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page219 Cable brackets of the upper arm xx0500002293 Cable bracket wrist unit A Cable bracket upper arm tube B Cable attachment rear C ...

Page 225: ...bot working area 2 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before repla cing parts on page 219 3 xx0200000214 Remove the cover wrist unit and the cover upper arm tube 4 A Cover wrist unit B Cover upper arm tube Note Axis 5 must be oriented in the correct position 90º to allow the motor 6 cover to open 5 R...

Page 226: ...ect all connectors beneath 13 Pick out the cabling from the motors Gently pull the cable harness out from the up per arm tube 14 Tie the connectors into bundles to avoid damaging them during further removal 15 Continue removing the cable harness in lower arm frame and base 16 Removing the cable harness frame and base Use this procedure to remove the cable harness from the frame and base Note Actio...

Page 227: ...ution counter Be careful not to let the weight of the cover strain the cable Note In order to remove the cover completely the connector R1 G must be disconnected This causes a necessary updating of the revolution counter xx0700000104 Disconnect connectors R2 SMB R1 SMB1 3 R1 SMB4 6 from the SMB unit Disconnect X8 X9 and X10 from the brake re lease unit 9 Continues on next page Product manual IRB 6...

Page 228: ... recess 10 A Cable gland B Attachment screws inside SMB recess 4 pcs Remove the velcro strap and cable gland 11 Continues on next page 228 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 1 Replacing cable harness axes 1 6 Continued ...

Page 229: ...otors 4 Gently pull the cable harness out 5 Refitting the cable harness lower arm frame and base Use this procedure to refit the cable harness on the lower arm frame and base of the robot How to refit on the upper arm is described in section Refitting the cable harness upper arm on page 233 Note Action For art no see Additional equipment Foundry Prime on page 224 Note Apply rust preventive around ...

Page 230: ...econnect connectors R1 MP and R1 SMB at the base 5 Shown in the figure Location of cable harness on page 222 Make a note of the correct positions of the connectors Position shown in the figure Location of cable harness on page 222 Reconnect the earth cable 6 Shown in the figure Location of cable harness on page 222 Refit the rear cover plate to the robot with its attachment screws 7 Reconnect all ...

Page 231: ...at the SMB BU units before the harness is fitted 10 Parts A Position for cover in SMB re cess B Sikaflex 521FC C Cover Continues on next page Product manual IRB 6640 Foundry Prime 231 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 1 Replacing cable harness axes 1 6 Continued ...

Page 232: ...SMB unit R2 SMB R1 SMB1 3 R1 SMB4 6 Reconnect connectors to the Brake release unit X8 X9 X10 Reconnect R1 G if it has been disconnected 12 Secure the SMB cover with its attachment screws 13 If cabling is used for 7th axis option refit the connector R2 FB7 to the SMB cover and tighten with 6 Nm Continues on next page 232 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011...

Page 233: ...ess upper arm Use this procedure to refit the cable harness on the upper arm of the robot How to refit the cable harness on lower arm frame and base is described in section Refitting the cable harness lower arm frame and base on page 229 Note Action How to refit see section Refitting the cable harness lower arm frame and base on page 229 Before refitting the upper end of the cable harness the lowe...

Page 234: ...gure Location of cable harness on page 222 Refit the velcro strap at the guide plate axis 2 6 Gently insert the cable harness from the rear into the upper arm 7 Shown in the figure Cable brackets of the upper arm on page 224 Connect the two connectors inside the upper arm tube R2 FB5 and R3 MP5 and secure the cable bracket with its two attachment screws to the tube 8 Note The position of axis 6 mu...

Page 235: ...ent screw bottom of cable bracket 1 pc Foundry robots Reconnect the connectors to motor axis 6 and refit the motor cover 12 It is recommended to use a new gasket on cover xx0200000214 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 13 Parts A Cover wrist unit Tightening torque 14 Nm Add Loctite to s...

Page 236: ...now must be updated 17 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 29 18 236 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 1 Replacing cable harness axes 1 6 Continued ...

Page 237: ...n page 465 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Removal cabling axis 5 motor The procedure below details how to remove the cabling from the axis 5 motor Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply...

Page 238: ...king area 1 Clean the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 219 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 Detailed in section IRB 6640 Refitting wrist unit on page 266 Refit the complete wrist unit 6 Seal and paint the j...

Page 239: ...irst test run These are further detailed in the section First test run may cause injury or damage on page 29 9 Product manual IRB 6640 Foundry Prime 239 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 2 Replacement of cabling axis 5 motor Continued ...

Page 240: ... found in Spare parts on page 487 xx0700000352 Upper arm A Lower arm B Frame C Base D Gearbox axis 1 E Attachment screws base M12x80 quality 12 9 Gleitmo 16 pcs F Motor axis 1 G Required equipment Note Art no Equipment etc Bits SW10 included 3HAC029090 001 Holder for bits Continues on next page 240 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights r...

Page 241: ...beginning the repair work of the robot see the table Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the F...

Page 242: ...the brakes if necessary as detailed in section Manually releasing the brakes on page 78 xx0700000351 Run the robot to the position shown in the figure to the right 2 Run the overhead crane to a position above the robot 3 Continues on next page 242 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of complete arm s...

Page 243: ...described below 4 A Lifting eye on arm house 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 inserted through hole in the frame H Roundsling put in a loop around the lower arm Continues on next page Product manual IRB 6640 Foundry Prime 24...

Page 244: ...ake on motor axis 3 F Position for roundsling E inserted through hole in the frame DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot Before entering the robot work ing area 6 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 219 7 Detailed i...

Page 245: ... on page339 Remove the motor axis 1 11 xx0700000380 Parts A Calibration plate Remove the calibration plate from the bottom of the frame 12 A xx1200000668 A Mechanical stop pin Remove the mechanical stop pin from the frame 13 Continues on next page Product manual IRB 6640 Foundry Prime 245 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 3 Replacement of complete a...

Page 246: ...fully 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 unbal anced despite earlier adjust ments The risk of damaging the interfaces is bigger if the load is lowered unbalanced 17 Refitting arm system The procedure describes how to lift and refit the complete arm system Note Action DANGER Turn o...

Page 247: ...method of lifting the complete armsystem described below Releasing the brakes are detailed in sec tion Manually releasing the brakes on page 78 H B C D E F A G xx0700000349 A Lifting eye on arm house 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 mo tor axis 3 G Position for rou...

Page 248: ...ing used to eliminate any load through the brake on mo tor axis 3 G Position for roundsling F inser ted through hole in the frame H Roundsling put in a loop around the lower arm CAUTION The complete arm system weighs 1250 kg All lifting equipment used must be sized ac cordingly 5 Lift the complete arm system and move it at very low speed making sure it does not tip 6 Make sure the lift is done com...

Page 249: ...9 This is a complex task to be performed with utmost care in order to avoid injury or damage xx0600003093 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 axis 1 gearbox axis 1 Fit the guide pins in the corresponding holes in the frame as shown in the...

Page 250: ...oviding they are lubricated as detailed in section Screw joints on page 461 before fitting xx0700000380 Refit the calibration plate at the bottom of the frame 14 Parts A Calibration plate Refit the mechanical stop pin to the frame 15 Detailed in section Replacing motor axis 1 on page 339 Refit the axis 1 motor 16 Detailed in section Performing a leak down test on page 214 Perform a leak down test ...

Page 251: ...ate the robot 21 General calibration information is included in section Calibration information on page 439 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 29 22 Product manual IRB 6640 Foundry Prime 251 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserve...

Page 252: ... air hose xx0600003025 Hose lengths and parts See hose lengths and parts in the figure and the following tables D E xx0700000449 Continues on next page 252 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 4 Replacement of air nipple and hose Foundry Prime ...

Page 253: ... length 100 mm 1T Hose length 50 mm 1U Parts Pneumatic hose A Y plug connector B T plug connector C Check valve D Straight fitting E Location on the robot Balancing cylinder rear end a Motor axis 1 b Battery cover c Motor axis 2 d Length Pos 1S e Motor axis 6 f Rubber clamp on attachment plate tilthouse g Rubber clamp on wrist cover h Motor axis 5 j Motor axis 3 k Motor axis 4 m Bulkhead plug conn...

Page 254: ...me air nipples and hose The pos no in following procedures correspond to the illustration in Hose lengths and parts on page 252and the table in Required equipment on page 254 Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the ro bot Before entering the robot working area 1 Locate the damaged hose or air connector and continue to replace the damaged ...

Page 255: ...quipment on page 254 1C xx1500000355 Balancing device Note Always install the check valve with the ar row pointing upwards 5 Item in illustration is detailed in Hose lengths and parts on page 252 Continues on next page Product manual IRB 6640 Foundry Prime 255 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 4 Replacement of air nipple and hose Foundry Prime Conti...

Page 256: ...ment on page 254 xx0700000460 Axis 1 2 6 xx0700000461 xx0700000462 A Air hose beneath velcro strap Continues on next page 256 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 4 Replacement of air nipple and hose Foundry Prime Continued ...

Page 257: ...se Tube shaft 8 1P Lay the hose in a spiral in the tube shaft Continues on next page Product manual IRB 6640 Foundry Prime 257 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 4 Replacement of air nipple and hose Foundry Prime Continued ...

Page 258: ...to the nipple of axis 6 S see Replacement of air nipple and hose Foundry Prime on page 252 9 258 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 3 4 Replacement of air nipple and hose Foundry Prime Continued ...

Page 259: ...x0300000473 Turning disk type 1 A Wrist unit B Attachment screws 6 pcs turning disk E xx0200000217 Turning disk type 2 A Wrist unit B Oil plug draining C Oil plug filling D Attachment screws 12 pcs F Continues on next page Product manual IRB 6640 Foundry Prime 259 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 1 Replacing the turning disk ...

Page 260: ...cation of turning disk on page 259 Run the robot to a position where the oil plug drain ing of axis 6 gearbox faces downwards 1 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 2 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing...

Page 261: ...ment screws 2 xx1400000995 Foundry Plus Apply Loctite 574 flange sealant on the contact surface 3 The number of attachment screws de pends on which wrist type is used Secure the turning disk with its attachment screws 4 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 sec tio...

Page 262: ...disk 7 Seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 219 8 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 29 9 262 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 20...

Page 263: ...ver upper arm tube D Connectors upper arm tube with cable bracket R3 FB5 R3 MP5 E Cable bracket F Attachment point for lifting tool wrist unit G Wrist unit attachment screws and washers H Upper arm tube I Required equipment Note Art no Equipment etc For spare part number see Spare parts on page 487 Wrist unit Continues on next page Product manual IRB 6640 Foundry Prime 263 3HAC040586 001 Revision ...

Page 264: ...m Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action might be required prior to beginning the repair work of the robot see the table Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on ...

Page 265: ...ll electric power supply to the robot hydraulic pressure supply to the robot Before entering the robot working area 4 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before repla cing parts on page 219 5 Shown in the figure Location of wrist unit on page 263 Remove the cover wrist unit 6 Shown in the figure Locat...

Page 266: ...263 Remove the wrist unit attachment screws and washers 14 Pull the wrist unit out lift it away and place it on a secure surface 15 Shown in the figure Location of wrist unit on page 263 Disconnect the motor axis 5 by disconnecting the two connectors in the upper arm tube R3 FB5 R3 MP5 16 Refitting wrist unit The procedure below details how to refit the complete wrist unit Note Action DANGER Turn ...

Page 267: ...2 9 quality Gleitmo Tightening torque 115 Nm Reused screws may be used providing they are lubricated as detailed in sec tion Screw joints on page461 before fit ting 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 to allow the motor 6 cover to open 11 xx02...

Page 268: ...ots with protection type Foundry Plus and Foundry Prime check the gasket If damaged or not previously installed fit a new gasket 16 Tightening torque 14 Nm 10 Screw 3HAB3409 25 with Loctite Washer 3HAC062379 001 Article number for the gasket is spe cified in Required equipment on page 263 Seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing par...

Page 269: ...Content is defined in section Standard tools on page 465 Standard toolkit CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page219 Consumables Note Article number Consumable Mercasol 3HAC034903 001 Rust preventive Loctite 243 3HAB7116 1 Locking liquid Loctite 574 1234 0011 116 Sealant Con...

Page 270: ...00000254 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 5 B Attachment screws rear of cable bracket 2 pcs C Attachment screw bot tom of cable bracket Open the cover on top of the axis 6 motor and disconnec...

Page 271: ...x1500001693 Apply rust protection Mercasol on the edge on the new support shaft with bearing 1 xx1500001692 Apply Loctite on surface A and Mercasol on sur face B 2 A Loctite 574 B Mercasol Continues on next page Product manual IRB 6640 Foundry Prime 271 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 3 Replacement of support shaft with bearing axis 5 Continued ...

Page 272: ...bearing 6 Reconnect cabling 7 Refit cover to axis 6 motor 8 xx1500001685 Refit cover with gasket to wrist unit Use M6x20 in hole closest to robot axis 6 Note Reconnect the over pressure air hose to axis 6 motor before tightening the cover Note Replace gasket if damaged 9 272 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 3 R...

Page 273: ...w to remove the upper arm when there is no wrist unit mounted Note The lifting accessory 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 Continues on next page Product manual IRB 6640 Foundry Prime 273 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 4 Replacemen...

Page 274: ...plug draining gearbox axis 3 C Motor axis 3 D Motor axis 4 E Attachment screws and washers upper arm F Sealing axes 2 3 between lower arm and gearbox axis 3 G Required equipment Note Art no Equipment Always use a new sealing when refitting the upper arm 3HAC17212 1 Sealing axis 3 Continues on next page 274 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All ...

Page 275: ... Lifting tool chain Content is defined in section Standard tools on page 465 Standard toolkit These procedures include refer ences to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which ...

Page 276: ...h calibration routine to use and take actions accordingly prior to beginning the repair procedure 1 Remove all equipment fitted to turning disk 2 Shown in the figure Location of upper arm on page 273 Move the upper arm to a horizontal position Rotate axis 4 so that the attachment hole for lifting eye is faced upwards 3 Rotate axis 5 to position 90 4 DANGER Turn off all electric power supply to the...

Page 277: ...procedure of removing the upper arm 12 CAUTION The complete upper arm weighs 380 kg without any additional equipment fitted Use a suitable lifting accessory to avoid injury to personnel 13 Raise the lifting equipment to take the weight of the upper arm 14 Connect to connector R2 MP3 pin 2 pin 5 In order to release the brake of the axis 3 motor connect the 24 VDC power supply Note When releasing th...

Page 278: ...e lifting eye VLBG M12 to the attachment hole lifting eye on the wrist unit 3 Shown in the figure Location of upper arm on page 273 Art no is specified in Required equip ment on page 274 Upper arm including wrist unit Fit one of the pieces included in the lifting ac cessory upper arm to the front attachment for the lifting accessory on the upper arm 4 Attachment points are shown in the figure Loca...

Page 279: ...ealing can be involuntarily moved into wrong pos ition 33 pcs M12 x 50 12 9 quality UN BRAKO tightening torque 120 Nm Secure the lower arm to gearbox axis 3 with the attachment screws 11 Reused screws may be used providing they are lubricated as detailed in sec tion Screw joints on page461 before fit ting Remove the guide pins and fit the two remaining attachment screws Tighten them as detailed ab...

Page 280: ...ed in section Calibration informa tion on page 439 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 29 21 280 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 4 Replacement of upper arm Continued ...

Page 281: ... no Equipment etc Tool that may be rented from ABB Robot ics 3HAC027794 001 Lifting accessory lower arm Used to rotate the motor pinion and gear if necessary when brakes are released 3HAC17105 1 Rotation tool For lubrication of the shaft hole 3HAB3537 1 Grease For cleaning of the shaft 11771012 208 Isopropanol Content is defined in section Standard tools on page 465 Standard toolkit Continues on n...

Page 282: ...rence values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Pendulum Calibration in Operating manu al Calibration Pendulum If no previous reference values exist and no new reference values can be create...

Page 283: ...front ear adjustable when pulling the front shaft out 7 Method 2 detailed in section Unload ing the balancing device using dis tance tool on page 327 Shown in the figure Location of lower arm on page 281 Remove the securing screw from the balancing device front shaft 8 Lower the balancing device until it rests safely against the bottom of the frame 9 The figure shows IRB 6600 but the position of t...

Page 284: ...joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 219 2 xx0700000348 Fit two guideing pins in two opposite attach ment holes of the lower arm 3 Art no is specified in Required equip ment on page 281 Apply the lifting tool to the lower arm 4 CAUTION The lower arm weighs 160 kg All lifting equip ment used must be sized accordingly 5 Lift the lower ...

Page 285: ... See section Replacing the balancing device design 1 on page 302 Refit and restore the balancing device 12 See section Refitting upper arm on page 278 Refit the upper arm 13 See section Performing a leak down test on page 214 Perform a leak down test 14 See section Changing oil axis 2 gear box on page 173 Refill the gearbox with oil 15 Detailed in section Replacing cable harness axes 1 6 on page 2...

Page 286: ...first test run These are further detailed in the section First test run may cause injury or damage on page 29 19 286 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 4 5 Replacement of complete lower arm Continued ...

Page 287: ...hown in the figure SMB unit DSQC633A with battery pack 3HAC16831 1 with 2 pole battery contact xx0700000121 SMB cover A Guide pins 2 pcs B Battery cable 2 pole contact C SMB unit DSQC633A D Continues on next page Product manual IRB 6640 Foundry Prime 287 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 1 Replacing the SMB unit ...

Page 288: ...quipment Note There are different variants of SMB units and batteries The variant with the 3 pole battery contact has longer lifetime for the battery It is important that the SMB unit uses the correct battery Make sure to order the correct spare parts Do not replace the battery contact Continues on next page 288 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 AB...

Page 289: ... hydraulic pressure supply to the robot before entering the robot working area 2 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 219 3 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ES...

Page 290: ...n the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 219 2 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 34 3 Shown in the figure Location of SMB unit on page 287 Connect the battery cable to the SMB unit Make sure the lock on the ba...

Page 291: ...en performing the first test run These are further detailed in the section First test run may cause injury or damage on page 29 12 Replacement of SMB unit Foundry Prime Robots working with Foundry Prime and that have the special tightness for this application require special repair routines to maintain the tightness level The repair must be done according to the previous repair procedure with the ...

Page 292: ...nder on top of the screw heads 6 Perform a leakdown test according to Inspection of air hoses Foundry Prime on page 155 7 See Updating revolution counters on page 444 Update the revolution counter 8 DANGER Make sure all safety requirements are met when performing the first test run These are further de tailed in the section First test run may cause injury or damage on page 29 9 292 Product manual ...

Page 293: ... F Required equipment Note Article number Equipment etc DSQC1050 3HAC065020 001 Brake release board Content is defined in section Standard tools on page 465 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page Product manual IRB 6640 Foun...

Page 294: ...the figure Location of brake release board on page 293 Remove the push button guard from the SMB cover 4 The guard must be removed to ensure a correct refitting of the brake release board Take a picture or make notes of how the robot cabling is positioned in regard to the brake release board 5 X9 X8 X10 xx1700000978 Disconnect the connectors X8 X9 and X10 from the brake release board 6 Location of...

Page 295: ...brake release board on page 293 Art no is specified in Required equip ment on page 293 5 Verify that the robot cabling is positioned cor rectly according to previously taken pic ture notes WARNING Screened cables must not get in contact with the brake release board after installation Eliminate all risks of contact between screened cables and the brake release board 6 Shown in the figure Location o...

Page 296: ...the battery has been disconnected the revolu tion counter must be updated 12 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 29 13 296 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 2 Replacing the ...

Page 297: ...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 54 Location of bearing Design 1 The bearings are located in the balancing device as shown in the figure below xx0900000072 Continues on next page Product manual IRB 6640 Foundry Prime 297 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 3 Replac...

Page 298: ...t head cap screw M16x70 M Sealing washer N Location of bearing Design 2 The bearings are located in the balancing device as shown in the figure below xx0900000066 Continues on next page 298 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 3 Replacement of spherical roller bearing balancing device Continued ...

Page 299: ...1 Grease The tools in the set are shown in the section Dis mounting and mounting tool 3HAC028920 001 on page 469 3HAC028920 001 Toolkit These procedures include references to the tools re quired Other tools and proced ures may be required See references to these procedures in the step by step in structions below Tool set up 3HAC028920 001 The set up of the press tool used for the process of remova...

Page 300: ...Remove the both sealing spacers with a screwdriver or any equal tool 4 Described in section Removal front bear ing Design 1 on page475 or Removal front bearing Design 2 on page 478 Remove the sperical roller bearing using the dismounting and mounting tool 3HAC028920 001 5 Refitting spherical roller bearing Use this procedure to refit the spherical roller bearing to the balancing device front ear N...

Page 301: ... the balancing device to the robot 8 Detailed in section Lubrication of spherical roller bearing balancing device on page 194 Lubricate the spherical roller bearing in the ear Note The balancing device must be mounted on the robot when lubrication is performed 9 This is detailed in section Check for leak age Design 1 on page 146 Make sure no incorrect leakage occurs It could indicate damaged o rin...

Page 302: ...Location of balancing device The balancing device is located on the rear top of the frame as shown in the figure xx0800000477 Balancing device A Cradle bearing B Spherical roller bearing C Required equipment Note Art no Spare part no Equipment See Spare parts chapter Balancing device Continues on next page 302 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB ...

Page 303: ...pump 80 MPa Content is defined in section Standard tools on page 465 Standard toolkit Option Foundry Prime Brush Option Foundry Prime 3HAC034903 001 Rust preventive Equivalent Mercasol Option Foundry Prime 12340011 116 Loctite 577 Option Foundry Prime 3HAC026759 001 Sikaflex 521FC CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surfa...

Page 304: ...balancing device using hydraulic press tool on page 333 Method 2 Unloading the balancing device using distance tool on page 327 Use one of the methods to unload the balan cing device in order to make the piston rod and front ear adjustable when pulling the shaft out Method 1 Unload the balancing device with the press tool Method 2 Unload the balancing device with the distance tool 5 DANGER Turn of...

Page 305: ...ool 9 Remove the VK cover in order to reach the shaft holding the balancing device Tip Hit the VK cover gently at the bottom part of it with a plastic hammer or similar and tilt it out 10 Wipe off all residual grease inside the hole 11 Remove the hex socket head cap screw M16x70 securing the piston rod shaft 12 xx0900000079 Remove the retaining ring bore securing the shaft 13 A Retaining ring bore...

Page 306: ... 1 on a standard robot Information Action Clean the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 219 1 For art no see Required equipment on page 302 xx0900000094 Fit the shackle to the balancing device 2 CAUTION The balancing device weighs 210 kg All lifting equipment used must be sized accord ingly 3 Refit one of the two retaining ring bore...

Page 307: ...g ring bore 7 Perform this on the side where the retaining ring bore is not mounted Refit the cradle bearings and balan cing device shafts completely 8 xx0900000083 It should look like this See figure 9 A Shows a correct fitting xx0900000088 Use Loctite 577 on the threads on the balan cing device CAUTION Do not use Loctite on the threads of the hex socket head cap screw M16x70 10 A Loctite 577 Con...

Page 308: ... art no see Required equipment on page 302 Refit the front shaft using the dismantle and mounting tool 19 Tightening torque 300 Nm Secure the shaft with its attachment screw 20 M16x70 quality 12 9 Gleitmo Refit the retaining ring bore 21 Refit the VK cover 22 Amount 20 ml Lubricate the bearing in the ear with grease through the lubricating nipple with a grease pump 23 Fill until excessive grease p...

Page 309: ...e balancing device Information Action DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 1 For art no see Required equipment on page 302 xx0700000452 Apply Mercasol to the shafts and holes 2 For a cut away view see below xx0700000453 A Mercasol surface on the balan cing device B Mercasol on hole in the shaft C Mercasol on shaft C...

Page 310: ...rfaces in rod bracket C Machined surfaces on shaft DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page29 4 310 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 4 1 Replacing the balancing device design 1 ...

Page 311: ...g device design 1 on page 302 Location of balancing device The balancing device is located on rear top of the frame as shown in the figure below xx0900000075 Balancing device A Cradle bearing B Spherical roller bearing C Continues on next page Product manual IRB 6640 Foundry Prime 311 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 4 2 Replacing balancing device ...

Page 312: ... steel C VK cover D Washer E Radial sealing with dust lip 50x68x8 F Spherical roller bearing G Radial sealing with dust lip 50x68x8 H O ring J End cover K Maintenance set Cradle Radial sealing Not used in Clean Room applications L Cradle bearing kit M Continues on next page 312 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 ...

Page 313: ... Loctite 577 M16x60 quality 12 9 Gleitmo Locking screw For securing of the lower arm 3HAB3537 1 Bearing grease 3HAC042534 001 Grease Grease pump 3HAC15556 1 Lifting tool chain 3HAC020997 001 Shackle For unloading and restoring the balan cing device Method 1 3HAC020902 001 Press tool balancing device For unloading and restoring the balan cing device Method 2 3HAC030662 001 Distance tool For dismant...

Page 314: ...fe and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page219 Removing balancing device design 2 Use this procedure to remove the balancing device design 2 Note Action CAUTION Always cut the paint with a knife and grind the paint edge when disas sembling parts See Cut the paint or surface on the robot before repla cing parts on pag...

Page 315: ...g equipment used must be sized accordingly 3 For art no see Required equipment tools etc on page313 xx0800000249 Secure the lower arm using a lifting sling or using the locking screw in the frame 4 A Locking screw Continues on next page Product manual IRB 6640 Foundry Prime 315 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 4 2 Replacing balancing device design ...

Page 316: ...ng service work on axis 2 Use one of the two methods de scribed Described in section Unloading the balancing device using hydraulic press tool on page 333 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 7 Described in section Unloading the balancing device using distance tool on page 327 Method 2 Unload th...

Page 317: ...l 12 A Protection plug B Hex socket head cap screw M16x70 C Washer D Front shaft E Press tool or Distance tool Note It is almost impossible to remove the VK cover without damage New VK covers are needed Remove the VK cover in order to reach the shafts holding the balan cing device Hit the VK cover at the bottom part of it with a hammer or similar and tilt it out 13 See the figure in Location of pa...

Page 318: ... 481 Note Make sure that the M16 threads in the rear shaft are clean before fitting the tool 17 Remove the balancing device 18 Preparation of the spare part Use this procedure for the preparation of the spare part Note Action xx1000000627 Remove the transport protection at the loc ation of the rear shafts 1 A Transport protection Continues on next page 318 Product manual IRB 6640 Foundry Prime 3HA...

Page 319: ...aces of the piston rod ear 3 A Mercasol The figure shows the principal method xx0900000121 Cut the paint with a knife in the joint between the rear cover and the balancing unit housing 4 Note Keep the cover for refitting on the new balancing unit Remove the cover with the air nipple 5 Continues on next page Product manual IRB 6640 Foundry Prime 319 3HAC040586 001 Revision N Copyright 2011 2018 ABB...

Page 320: ...the cradle and lubricate with grease 2 Use new parts maintenance parts cradle Refit one of the two retaining rings 3 For art no see Required equipment tools etc on page 313 How to use the tool see section Dismount ing and mounting tool 3HAC028920 001 on page 469 xx0900000061 Use the dismantle and mounting tool and refit new rear shaft units in both locations Note Adjust the shaft unit in order to ...

Page 321: ...0900000085 On the side where the retaining ring bore is not fitted refit the rear shaft unit com pletely into the frame 6 xx0900000083 The rear shaft unit to the right shows a correct fitting 7 Continues on next page Product manual IRB 6640 Foundry Prime 321 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 4 2 Replacing balancing device design 2 Continued ...

Page 322: ...ealing ring xx0900000093 Fit new radial sealings on both shafts Note The radial sealings are not used in Cleanroom applications 9 For art no see Required equipment tools etc on page 313 xx0900000094 Fit the lifting tool to the balancing device 10 CAUTION The balancing device weighs 210 kg All lifting equipment used must be sized accord ingly Continues on next page 322 Product manual IRB 6640 Found...

Page 323: ...adle 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 quality 8 8 steel 14 On the other side use the hex socket head cap screw M16x70 quality 8 8 steel to refit the rear shaft unit to its final posi tion 15 xx0900000089 Lock the shaft unit by fitting the retaining ring bore 16 Tightening torque 300 Nm Secure ...

Page 324: ...ex socket head cap screw M16x70 C Washer D Shaft E Press tool or Distance tool Tightening torque 200 Nm Refit the hex socket head cap screw M16x70 quality 8 8 steel 21 Use Loctite 2701 Method 1 Described in section Restoring the balancing device using a hydraulic press tool on page 336 Restore the balancing device in one of the methods 22 Method 2 Described in section Restoring the balancing devic...

Page 325: ...Additional equipment Foundry Prime on page 314 xx1000000632 Apply rust preventive Mercasol around the edge of the cover as a protection of the broken paint layers 26 A Mercasol xx0900000090 Fill the cradle bearings with 70 ml Optimol PDO Note The inner hole is used for lubrication The outer hole is used for air outlet 27 Continues on next page Product manual IRB 6640 Foundry Prime 325 3HAC040586 0...

Page 326: ...f the link ear Refit the M6 screw with sealing washers 28 Seal and paint the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 219 29 326 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 4 2 Replacing balancing device design 2 Continued ...

Page 327: ...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 distance tool from a dismounted balancing device Continues on next page Product manual IRB 6640 Foundry Prime 327 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 4 3 Unloading the balancing device using di...

Page 328: ...e tool 3HAC030662 001 A Continues on next page 328 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 4 3 Unloading the balancing device using distance tool Continued ...

Page 329: ...UTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 219 Continues on next page Product manual IRB 6640 Foundry Prime 329 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 4 3 Unloading the balancing device using distance tool Continued ...

Page 330: ...ing the four screws 3 A Distance tool xx0800000481 Jog the robot lower arm backward to calib ration position 0 4 330 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 4 3 Unloading the balancing device using distance tool Continued ...

Page 331: ...if damaged See Spare parts End Cover Gasket For unloading and restoring the balancing device Meth od 2 3HAC030662 001 Distance tool Standard toolkit Loctite 577 Sikaflex 521FC CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page219 Continues on next page Product manual IRB 6640 Foundry P...

Page 332: ...et if needed 3 Apply Sikaflex 521FC on the end cover gasket xx0900000104 Fit the cover on the back of the cylinder with the four screws 4 Tightening torque 47Nm Use Loctite 577 on the four screws 5 332 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 4 4 Restoring the balancing device using distance tool Continued ...

Page 333: ...igh tensioned spring inside the balancing device incorrect handling may cause injuries and damage property 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 Press block A Hydraulic cylinder B Continues on next page Product manual I...

Page 334: ...nife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page219 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 balan...

Page 335: ...34 Fit the press tool to the rear of the balancing device with enclosed bolts Tighten them properly 4 See the figure Press tool and hydraulic cylinder on page 333 Art no is specified in Required equip ment on page 334 Fit the hydraulic cylinder to the press tool 5 See the figure Press tool and hydraulic cylinder on page 333 Art no is specified in Required equip ment on page 334 Connect the hydraul...

Page 336: ...ol 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 Press block A Hydraulic cylinder B Press device C Bolt press device D Moving pin with marking E Continues on next page 336 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Co...

Page 337: ...ss tool and hydraulic cylinder on page 336 Refit the hydraulic cylinder to the press tool in case it has been removed 1 Shown in the figure Press tool and hydraulic cylinder on page 336 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 2 Do not apply more pressure than ne cessary it could damage bearings and sealings ...

Page 338: ...cified in Required equipment on page 337 DANGER The rear cover of the balancing device is a safety device for the piston rod during opera tion Make sure the cover is properly secured before commissioning of the robot 8 338 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 5 4 6 Restoring the balancing device using a hydraulic pre...

Page 339: ...w motor axis 1 on page 342 Refitting motor axis 1 on page 343 Connecting motor axis 1 on page 344 Refitting the concluding parts on page 345 Location of motor axis 1 The motor axis 1 is located as shown in the figure xx0700000085 Motor axis 1 A Required parts Note Spare part no Part Includes motor pinion o ring See chapter Spare parts Motor axis 1 Continues on next page Product manual IRB 6640 Fou...

Page 340: ...r manual 3HAC15716 1 Calibration Pendulum toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below See Circuit dia gram Circuit diagram Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 11...

Page 341: ...on page 219 2 The figure shows the principal method xx0900000121 Cut the paint with a knife in the joint between the motor and the structure in order to avoid that the paint cracks 3 The figure shows a Foundry Prime motor A C D B xx0600002874 Remove the cover for connector access on top of the motor 4 Parts A Attachment screws 4 pcs B Air hose only Foundry Prime C Cover D Motor Continues on next p...

Page 342: ... used must be sized accordingly 10 See the figure in Location of motor axis 1 on page 339 Unscrew the attachment screws and wash ers of the motor and lift it in order to get the pinion away from the gear 11 Disconnect the 24 VDC power supply 12 Remove the motor by carefully lifting it straight up 13 Preparation of the frame before fitting the new motor axis 1 Use this procedure for the preparation...

Page 343: ... the circumference of the motor is seated properly Lubricate the o ring with some grease 2 CAUTION The motor weighs 25 kg All lifting equip ment used must be sized accordingly 3 For art no see Required equipment tools etc on page 340 Apply the lifting tool motor axes 1 4 5 to the motor 4 See section Manually releasing the brakes on page 78 In order to release the brakes connect the 24 VDC power su...

Page 344: ...to connect motor axis 1 Note Action For art no see Required parts on page 339 xx0200000199 Fit a new gasket on the cable gland 1 Part A Position of Cable cland cover Connect in accordance with markings on connectors Reconnect all connectors of motor axis 1 2 Make sure the cover is tightly sealed Refit the cable gland cover at the cable exit with its attachment screws 3 Make sure the cover is tight...

Page 345: ...cing parts on page 219 2 See section Inspection of air hoses Foundry Prime on page 155 Perform an air leak test 3 Calibration is detailed in a separate calib ration manual enclosed with the calibra tion tools Recalibrate the robot 4 General calibration information is included in section Calibration information on page 439 DANGER Make sure all safety requirements are met when performing the first t...

Page 346: ...oncluding parts on page 353 Location of motor axis 2 The motor axis 2 is located on the left hand side of the robot as shown in the figure xx0700000086 Motor axis 2 A Required parts Note Spare part no Equipment Includes motor pinion o ring See chapter Spare parts Motor axis 2 Must be replaced when reassembling the motor 21522012 430 O ring Continues on next page 346 Product manual IRB 6640 Foundry...

Page 347: ...Rotation tool Content is defined in section Standard tools on page 465 Standard toolkit Complete kit which also includes user manual 3HAC15716 1 Calibration Pendulum toolkit These procedures include references to the tools required Other tools and proced ures may be required See references to these proced ures in the step by step instructions below See Circuit dia gram Circuit diagram Additional e...

Page 348: ...nt with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 219 3 See the figure above Lock the lower arm in position by inserting the lock screw into the hole and securing it 4 For art no and dimension see Required equipment tools etc on page 347 See section Changing oil axis 2 gearbox on page 173 Drain the oil from ge...

Page 349: ...ows a Foundry Prime motor A C D B xx0600002874 Remove the cover of the motor for connect or access 8 Parts A Attachment screws B Air hose only Foundry Prime C Cover D Motor Note Keep the old cover with the air nipple fitted 9 Make sure the gasket is not damaged Remove the cable gland cover at the cable exit 10 Disconnect all connectors on motor axis 2 11 Continues on next page Product manual IRB 6...

Page 350: ...moval tool in pairs If required press the motor out of position by fitting the removal tool motor to the re maining attachment holes for the motor 16 For article number see Required equipment tools etc on page 347 Remove the removal tool motor and fit the lifting tool motor axes 2 3 4 to the motor 17 Remove the motor by carefully lifting it straight up making sure the motor pinion does not get dam...

Page 351: ... see Required parts on page 346 Make sure the o ring on the circumference of the motor is seated properly Lubricate the o ring with some grease 3 See section Manually releasing the brakes on page 78 To release the brakes connect the 24 VDC power supply Connect to connector R2 MP2 pin 2 pin 5 4 For article number see Required equipment tools etc on page 347 Fit the lifting tool axes 2 3 4 to the mo...

Page 352: ...ers 11 4 pcs Tightening torque 50 Nm Reused screws can be used providing they are lubricated as described in section Screw joints on page461before fitting Disconnect the 24 VDC power supply 12 Connecting motor axis 2 Use this procedure to connect all connectors on motor axis 2 Note Action For article number see Required parts on page 346 Install a new gasket in the cable gland 1 Connect in accorda...

Page 353: ... robot before replacing parts on page 219 4 Calibration is detailed in a separate calibration manual enclosed with the calibration tools Recalibrate the robot 5 General calibration information is in cluded in section Calibration informa tion on page 439 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may c...

Page 354: ...1 Location of motor axis 3 The motor axis 3 is located on the left hand side of the robot as shown in the figure xx0200000186 Motor axis 3 A Cable gland cover motor axis 3 B Attachment screws 4 pcs C Required parts Note Spare part no Equipment Includes motor pinion o ring See chapter Spare parts Motor Must be replaced when reassembling motor 21522012 430 O ring 3HAC3438 1 Gasket Continues on next ...

Page 355: ...eleasing the brakes Content is defined in section Standard tools on page 465 Standard toolkit Complete kit which also includes user manual 3HAC15716 1 Calibration Pendulum toolkit These procedures include references to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below See Circuit dia gram Circuit diagram Additio...

Page 356: ...the mechanical stop B Fixed stop DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 3 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 219 4 Remove any equipment hindering access to motor axis 3 5 Figure showing the...

Page 357: ... page 78 To release the brakes connect the 24 VDC power supply Connect to connector R2 MP3 pin 2 pin 5 12 See the figure in Location of motor axis 3 on page354 Unscrew the attachment screws securing the motor 13 For art no see Required equipment tools etc on page 355 Fit guide pins in the screw holes for the at tachment screws 14 For art no see Required equipment tools etc on page 355 Always use r...

Page 358: ... this procedure for the preparation of the upper arm housing before refitting motor axis 3 Note Action Grind the paint edge on the surface carefully to get a smooth surface 1 Clean the surface from contamination such as oil and dirt 2 For article number see Additional equipment Foundry Prime on page 355 xx1000000562 Apply Loctite 574 on the surface as shown in the figure 3 Part A Loctite 574 Conti...

Page 359: ...see Required equipment tools etc on page 355 Shown in the figure in Location of motor axis 3 on page354 Fit guide pins in the two lower holes for motor attachment screws 5 CAUTION The motor weighs 27 kg All lifting equip ment used must be sized accordingly 6 Lift the motor onto the guide pins and guide it as close to the correct position as possible without pushing the motor all the way into the g...

Page 360: ...re to connect all connectors motor axis 3 Note Action For article number see Required parts on page 354 Fit a new gasket in the cable gland 1 Connect in accordance to markings on connectors Reconnect all connectors on motor axis 3 2 Make sure the cable gland cover is tightly sealed Refit the cable gland cover at the cable exit with its attachment screws 3 Shown in the figure in Location of motor a...

Page 361: ...robot before replacing parts on page 219 4 Calibration is detailed in a separate calib ration manual enclosed with the calibra tion tools Recalibrate the robot 5 General calibration information is in cluded in section Calibration information on page 439 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may c...

Page 362: ...on of motor axis 4 The motor axis 4 is located on the left hand side of the upper arm as shown in the figure xx0200000202 Motor axis 4 A Cable gland cover B Attachment screws 4 pcs C Required parts Note Spare part no Part Includes motor M10NB pinion o ring See chapter Spare parts Motor Must be replaced when reassembling motor 21522012 430 O ring Option Foundry Prime 3HAC3438 1 Gasket Continues on ...

Page 363: ...hich also includes user manual 3HAC15716 1 Calibration Pendulum toolkit These procedures include references to the tools required Other tools and procedures may be required See refer ences to these procedures in the step by step instructions below See Circuit dia gram Circuit diagram Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sik...

Page 364: ...quired 1 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 2 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 219 3 See the figure in Location of motor axis 4 on page362 Remove the cable gland cover at the cable ex...

Page 365: ...d cover with the air nipple fitted 8 Disconnect all connectors on motor axis 4 9 See section Manually releasing the brakes on page 78 To release the brake connect the 24 VDC power supply Connect to connector R2 MP4 pin 2 pin 5 CAUTION Axis 4 might move when the brake is re leased and the balance of the axis is settled 10 See the figure in Location of motor axis 4 on page362 Unscrew the motors atta...

Page 366: ...int edge on the surface carefully in order to get a smooth surface 1 Clean the surface from contamination such as oil and dirt 2 For article number see Additional equipment Foundry Prime on page 363 xx1000000617 Apply Loctite 574 on the surface as shown in the figure 3 Part A Loctite 574 Refitting motor axis 4 Use this procedure to refit motor axis 4 Note Action DANGER Turn off all electric power ...

Page 367: ...t the 24 VDC power supply Connect to connector R2 MP4 pin 2 pin 5 7 For article number see Required equipment tools etc on page 363 xx0200000165 Use the rotation tool in order to rotate the motor pinion when mating it to the gear 8 Part A Rotation tool Fit the motor in its position making sure that the motor pinion is properly mated to the gear of gearbox axis 4 the motor pinion does not get dam a...

Page 368: ...housing outside the motor flange as a protection of the broken paint layers 1 Parts A Mercasol on cover and motor housing B Attachment screws 4 pcs C Mercasol on upper arm housing outside motor flange See the figure above Apply rust preventive Mercasol on the at tachment screws of the motor 2 See the figure above Apply rust preventive Mercasol over the joint between the cover and the motor housing...

Page 369: ...ction Calibration information on page 439 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page29 7 Product manual IRB 6640 Foundry Prime 369 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 6 4 Replacing motor axis 4 Continued ...

Page 370: ...pinion Note The pinion in motor axis 5 is matched with the bevel gear for axis 5 When the motor is replaced the pinion therefore must be removed from the dismounted motor and be fitted to the new motor Location of motor axis 5 The motor axis 5 is located inside the upper arm tube but attached to the wrist unit See figure xx0200000204 Motor axis 5 inside upper arm tube A Upper arm tube B Wrist unit...

Page 371: ...pressing the pinion on to the new motor Press fixture for pinion 6896134 GN Measuring tool Always use the removal tool in pairs 3HAC14972 1 Removal tool motor 300 mm 3HAC12342 1 Extension bar for bits 1 2 For guiding the motor 3HAC15520 1 Guide pins For guiding the motor 3HAC15520 2 Guide pins 24 VDC max 1 5 A Power supply For releasing the brakes Content is defined in section Standard tools on pa...

Page 372: ...he paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 219 2 See section Changing oil axis 5 gearbox on page 182 Drain the oil from gearbox axis 5 3 xx0900000121 Cut the paint layer with a knife in the joint between the wrist unit and the upper arm tube to avoid that the paint cracks 4 See section Replacement of complete wrist unit on page 2...

Page 373: ...te cable of motor axis 5 11 To release the brakes connect the 24VDC power supply 12 Connect in one of these ways to connector R4 MP5 in the motor pin 2 pin 5 or to connector R3 MP5 on the separate cable to motor axis 5 if not removed pin C pin D Unscrew the attachment screws of motor axis 5 and remove screws and plain wash ers 13 For article number see Required equipment tools etc on page 371 Fit ...

Page 374: ...motor flange including shims and the outer sur face of the pinion with the measuring tool Make a note of measured distance 1 For article number see Required equipment tools etc on page 371 Press out the pinion from the removed mo tor with the equipment included in the oil injector kit 2 See section Replacement of complete wrist unit on page 263 Note If the pinion is damaged the complete wrist unit...

Page 375: ...on the motor with Isopropanol 2 See section Replacement of complete wrist unit on page 263 Note If the pinion is damaged the complete wrist unit must be replaced 3 For article number see Required equipment tools etc on page 371 Apply a thin film of mineral oil to the shaft of the pinion and in the hole for the pinion on the motor to make the pinion run smoothly when being fitted 4 This is necessar...

Page 376: ... 0 05 mm 8 Refitting motor axis 5 Use this procedure to refit motor axis 5 Note Action Clean the joints that have been opened See Cut the paint or surface on the robot before replacing parts on page 219 1 How to remove the pinion is described in Removing the pinion on motor axis 5 on page 374 How to fit the pinion is described in Refitting the pinion on motor axis 5 on page 375 Note The pinion of ...

Page 377: ... and guide it carefully into the gear making sure that the motor pinion is properly mated to the gear of gearbox axis 5 the motor pinion does not get dam aged 7 M8x25 Secure the motor with its attachment screws and plain washers 8 4 pcs Tightening torque 24 Nm For article number see Additional equipment Foundry Prime on page 371 Apply rust preventive Mercasol on attach ment screws and washers afte...

Page 378: ... Prime C Attachment screws D Motor housing axis 5 See section Performing a leak down test on page 214 Perform a leak down test 2 See section Replacement of complete wrist unit on page 263 Refit the wrist unit 3 See section Changing oil axis 5 gearbox on page 182 Refill gearbox axis 5 with oil 4 Calibration is detailed in a separate calib ration manual enclosed with the calibra tion tools Recalibra...

Page 379: ...of the wrist unit as shown in the figure xx0700000126 Gearbox axis 6 A Motor axis 6 B Attachment screws 4 pcs C Required parts Note Spare part no Part Includes Motor Pinion O ring See chapter Spare parts Motor including pinion Must be replaced when reassembling the motor 21522012 430 O ring Must be replaced when replacing mo tor 3HAC048560 001 Gasket Must be replaced when opening cover 3HAC033489 ...

Page 380: ...ctions be low See chapter Circuit diagram Circuit diagram Additional equipment Foundry Prime Note Art no Equipment Mercasol 3HAC034903 001 Rust preventive 3HAC026759 001 Sikaflex 521FC 12340011 116 Loctite 574 Brush CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page219 Removing motor a...

Page 381: ...od xx0900000121 Cut the paint layer with a knife in the joint between the rear motor cover and motor housing in order to avoid the paint layer cracking 4 xx0600002885 Parts A Motor housing B Attachment screws 5 pcs C Air nipple only Foundry Prime D Rear motor cover E Gasket Remove the rear motor cover 5 Keep the old rear motor cover with the air nipple 6 Continues on next page Product manual IRB 6...

Page 382: ...osition by fitting the removal tool motor to the at tachment holes of the motor 9 xx0600003038 Remove the motor by carefully lifting it straight up away from the gear Make sure the motor pinion is not damaged 10 Parts A Tilthouse B Motor axis 6 C Attachment screws 4 pcs Disconnect the 24 VDC power supply 11 Continues on next page 382 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N ...

Page 383: ...chined surface for motor flange previously cleaned 2 For article number see Additional equipment Foundry Prime on page 380 Preparation of motor axis 6 before fitting Use this procedure for the preparation of a new motor axis 6 Note Action For article number see Required parts on page 379 xx1000000625 Only applicable if a new spare part is used Fit a new gasket on the motor by removing the protecti...

Page 384: ...umber see Required parts on page 379 Make sure the o ring on the circumference of the motor is seated properly Lubricate the o ring with grease 2 To release the brake connect the 24 VDC power supply 3 Connect the connector R3 MP6 pin 2 pin 5 For article number see Required equipment tools etc on page 380 Fit guide pins in two of the holes for the motors attachment screws 4 Continues on next page 3...

Page 385: ...ews 7 4 pcs Tightening torque 24 Nm For article number see Additional equipment Foundry Prime on page 380 Apply rust preventive Mercasol on the at tachment screws and plain washers after tightening 8 Disconnect the 24 VDC power supply 9 Reconnect all connectors on motor axis 6 10 Refit the cover on top of the motor 11 Make sure the cover is tightly sealed Continues on next page Product manual IRB ...

Page 386: ...acing parts on page 219 13 Calibration is detailed in a separate calib ration manual enclosed with the calibra tion tools Recalibrate the robot 14 General calibration information is included in section Calibration information on page 439 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or d...

Page 387: ...of the spare part before refitting on page 394 Refitting gearbox axis 1 on the base Foundry Prime on page 397 Refitting base with gearbox on the mounting site on page 397 Refitting the complete arm system to the base Foundry Prime on page 398 Refitting protection pipe and cable guide Foundry Prime on page 401 Refitting the concluding parts Foundry Prime on page 404 Continues on next page Product m...

Page 388: ...t Note Art no Spare part no Equipment Includes O ring 3HAB3772 93 See Spare parts on page 487 Gearbox 3HAC024286 001 Cable guide 3HAC11581 4 Radial sealing M16x60 3HAB3409 86 Hex socket head cap screw Gleitmo 12 9 12 pcs 17x215x3 3HAA1001 186 Washer 12 pcs Continues on next page 388 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair...

Page 389: ...C15535 1 Support base and gear axis 1 Used to lift gearbox axis 1 and frame 3HAC15556 1 Lifting tool 2 pcs 3HAC025333 005 Lifting eye Used together with lifting tool 3HAC15556 1 For lubricating o rings 3HAB3537 1 Grease Content is defined in section Standard tools on page 465 Standard tools These procedures include references to the tools re quired Other tools and proced ures may be required See r...

Page 390: ...es to be lubricated with grease B Radial sealing C O ring 3 pcs D Protection pipe axis 1 E Continues on next page 390 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing gearbox axis 1 Continued ...

Page 391: ...m 3 See section Orienting and securing the robot on page 86 Remove the robot s attachment bolts in order to unfasten the base from the founda tion 4 For art no see Required equipment on page 388 Fit two M12 lifting eyes on each side of the gearbox 5 For art no see Required equipment on page 388 Attach the lifting tool to the lifting eyes 6 CAUTION The complete gearbox unit and base weighs 241 kg t...

Page 392: ... 12 attachment screws and washers securing the gearbox to the base 10 A Gearbox axis 1 B Attachment screw M16x60 CAUTION The gearbox weighs 108 kg All lifting equipment used must be sized accordingly 11 Remove the gearbox 12 See the figure in Cutaway view of gearbox axis 1 on page 390 Remove the cable guide and radial sealing 13 See the figure in Cutaway view of gearbox axis 1 on page 390 Remove t...

Page 393: ...s 1 Use this procedure for preparation of the base before refitting the gearbox axis 1 Note Action xx1000000336 Clean the joint surface on the base carefully and check that the corresponding surface on the frame also is clean 1 A Guidance edge B Joint surface C Mercasol Clean the painted surface outside the guid ance edge 2 See the figure above Remove old corrosion coating from the guidance edge c...

Page 394: ...rime is painted as shown in the figure 1 A Painted surfaces B Unpainted surface C Gearbox A xx1200000674 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 2 A O ring Continues on next page 394 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing g...

Page 395: ...x 521FC B Center tube of gearbox xx1000000333 Apply Mercasol on surfaces on the gearbox unit as described in the figure 4 A Mercasol B Gearbox Continues on next page Product manual IRB 6640 Foundry Prime 395 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing gearbox axis 1 Continued ...

Page 396: ...t 30 mm below the upper edge of the center tube 6 A Upper edge of center tube B Upper edge of the protection pipe C About 30 mm Use 2x M6x50 screws to fix the protection pipe in this temporary position Note The two M6x50 screws shall be replaced by two stainless M6x16 when the sealing ring has been installed Continues on next page 396 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N...

Page 397: ...n of the base before refitting gearbox axis 1 on page393 Check that both joint surfaces are clean Clean if necessary 2 Note Make sure that the lifting eyes will not damage the o ring Fit M16 guide pins in two corresponding attachment holes on the gearbox 3 Note Make sure that the lifting chain will not damage the gear wheel during the lifting procedure Place the gearbox unit carefully on the guide...

Page 398: ... lifting eyes 5 Refitting the complete arm system to the base Foundry Prime Use this procedure to refit the complete arm system to the base on Foundry Prime robots Note Action xx0600003095 Fit two M12 guide pins in the holes shown in the figure 1 A Holes for M12 guide pins in gearbox axis 1 2 pcs B Holes for attachment screws 16 pcs Fit the lifting equipment on the complete arm system as described...

Page 399: ...washers are turned the right way as shown in the figure Note Use new washers and attachment screws 4 A Serrated lock washer B Gearbox axis 1 C Attachment screws M12x80 quality 12 9 16 pcs Use new attachment screws Fit the 16 attachment screws before the arm system is completely lowered 5 Remove the guide pins and replace them with the remaining attachment screws 6 Lower the arm system into its pla...

Page 400: ...ace is cramped 8 A Attachment screw B Holder for bits xx1000000363 Apply Mercasol on the attachment screws and washers Note Mercasol shall be applied after the attach ment screws has been tightened 9 A Attachment screw B Mercasol Continues on next page 400 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing gearbox ax...

Page 401: ...f center tube B Upper edge of the protection pipe C About 30 mm xx1000000365 Lubricate the surfaces of the center tube with grease as shown in the figure 2 A Surfaces to be lubricated with grease B Center tube For art no see Required equipment on page 388 xx1000000366 Install the sealing ring with the press tool Use a plastic mallet 3 A Plastic mallet B Press tool Continues on next page Product ma...

Page 402: ...tion pipe to the correct position as shown in the figure by pushing it up inside the center tube Note The protection pipe is accessible from in side the base 5 A Groove B Correct position of protection pipe C Protection pipe D Center tube Continues on next page 402 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 1 Replacing g...

Page 403: ...e figure 7 A Mercasol B Protection pipe C Sealing ring xx1000000371 Install a new cable guide by pressing it down into position as shown in the figure Note The cable guide shall be locked in position by the groove 8 A Groove B Cable guide C Protection pipe D Center tube Continues on next page Product manual IRB 6640 Foundry Prime 403 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights res...

Page 404: ...ection Changing oil axis 1 gearbox on page 170 Fill oil in gearbox axis 1 3 Calibration is detailed in a separate calib ration manual enclosed with the calibra tion tools Recalibrate the robot 4 General calibration information is in cluded in section Calibration information on page 439 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in...

Page 405: ...f the spare part before refitting of gearbox axis 2 on page 413 Refitting gearbox axis 2 to the frame on page 415 Refitting the armsystem to gearbox axis 2 on page 417 Refitting the cable harness on page 418 Concluding refitting procedure on page 418 Location of gearbox axis 2 The gearbox axis 2 is located in the lower rotational center xx0700000357 Attachment screws M16x50 quality 12 9 Gleitmo 20...

Page 406: ...needing to use a hoisting block 3HAC16131 1 Lifting eye VLBG M12 3HAC028920 001 Dismantling and mounting tool M12x250 3HAC13056 4 Guide pins Always use in pairs M12x200 3HAC13056 3 Guide pins Always use in pairs M16x130 3HAC022637 001 Guide pins Always use in pairs M16x150 3HAC13056 2 Guide pins Always use in pairs Used to turn the gear in the correct position 3HAC020999 001 Crank Content is defin...

Page 407: ...nformation Action Method 1 is described in section Unloading the balancing device using hydraulic press tool on page 333 Method 2 is described in section Unloading the balancing device using distance tool on page 327 Unload the balancing device 1 For art no see Required equipment on page 406 How to use the tool is described in sec tions Replacing the balancing device design 1 on page 302 Replacing...

Page 408: ...rms as shown in the figure and secure the robot in an overhead crane 5 Parts A Lifting eye armhouse B Lifting chain C Hoisting block D Lifting chain 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 Continues on next page 408 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights res...

Page 409: ... C Shackle and lifting eye VLBG M12 D Lifting chain E Roundsling put in a loop around the wrist on the inside F Roundsling 1 5 m xx0900000112 Raise the crane to reach lifting center and straighten the chains 7 Release the brakes of axis 2 to let the weight of the arm system settle in the lifting accessories 8 Continues on next page Product manual IRB 6640 Foundry Prime 409 3HAC040586 001 Revision ...

Page 410: ...e cable harness frame and base on page 226 Remove the lower end of the cable harness 3 Loosen the cable attachment from the lower arm and pull up the cabling carefully 4 Let the removed part of the cable harness hang loose but be careful not to damage it during the continued removal process M16x50 Remove the attachment screws securing the lower arm to axis 2 gearbox 5 See the figure in Location of...

Page 411: ...ment used must be sized accordingly 5 See the figure in Location of gearbox axis 2 on page 405 Remove the remaining attachment screws M12x60 6 For art no see Required equipment on page 406 xx1000000378 Fit the lifting tool for lifting the gearbox and secure with a roundsling in an overhead crane or similair 7 Parts A Lifting tool Remove the gearbox 8 Use two M12 screws to push out the gear box if ...

Page 412: ...t surface B Surface for o ring C Machined surface See figure above Clean the joint surface carefully by remov ing old corrosion coating and or flange sealing from the surface 2 See figure above Clean the surface for the o ring 3 See figure above Apply Mercasol on the machined surface Note Make sure there is no Mercasol on the joint surface 4 Continues on next page 412 Product manual IRB 6640 Found...

Page 413: ...ed line B Guidance edge Preparation of the spare part before refitting of gearbox axis 2 Use this procedure to make the necessary preparations of the spare part before refitting gearbox axis 2 Note Action xx1000000380 Check that the spare part is painted as shown in the figure 1 A Unpainted surfaces B Painted surfaces Continues on next page Product manual IRB 6640 Foundry Prime 413 3HAC040586 001 ...

Page 414: ...um 0 5 mm on the unpainted sur face of the gearbox as shown in the figure Make sure the surface is covered properly it should not be possible to see through the layer of Mercasol 3 Parts A Mercasol on unpainted surface B Gearbox axis 2 Continues on next page 414 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 2 Replacing gear...

Page 415: ...box axis 2 Note Action CAUTION The gearbox weighs 98 kg All lifting equip ment used must be sized accordingly 1 For art no see Required equipment on page 406 xx1000000378 Fit the lifting tool in the uppermost hole of the gearbox axis 2 and secure it with a roundsling in an overhead crane or similair 2 Part A Lifting tool Continues on next page Product manual IRB 6640 Foundry Prime 415 3HAC040586 0...

Page 416: ...Use new attachment screws and washers 5 For art no see Required equipment on page 406 xx1000000384 Install 2x M12x12 set screws in the threaded holes in the flange of the gearbox 6 Parts A Screw head B Set screw 2 pcs opposite each other See figure above Apply Mercasol on all screw heads and set screws after tightening 7 Continues on next page 416 Product manual IRB 6640 Foundry Prime 3HAC040586 0...

Page 417: ...side G Roundsling put in a loop around the lower arm For art no see Required equipment on page 406 Use a crank in the gearbox in order to find the holes for the attahment screws 3 Tightening torque 300 Nm Secure the lower arm to gearbox axis 2 with its attachment screws and washers Note Use new attachment screws and washers 4 See the figure in Location of gearbox axis 2 on page 405 For art no see ...

Page 418: ...rocedure for the concluding procedure of refitting Note Action See section Changing oil axis 2 gearbox on page 173 Fill gearbox axis 2 with oil 1 Calibration is detailed in a separate calib ration manual enclosed with the calibra tion tools Recalibrate the robot 2 General calibration information is included in section Calibration information on page 439 DANGER Make sure all safety requirements are...

Page 419: ...ge 424 Preparations of upper arm before refitting of gearbox axis 3 on page 425 Preparations of spare part before the refitting on page 426 Refitting gearbox axis 3 on the upper arm on page 427 Refitting the upper arm on page 428 Concluding refitting procedure on page 429 Continues on next page Product manual IRB 6640 Foundry Prime 419 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights r...

Page 420: ...mo 24 pcs D Attachment screws M12x50 quality 12 9 Gleitmo 33 pcs E Washer 3 pcs F Required equipment Note Art no Spare part no Equipment Includes Gearbox O ring 3HAB3772 68 See Spare parts chapter Gearbox Continues on next page 420 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 3 Replacing gearbox axis 3 Continued ...

Page 421: ...e pins For guiding gearbox Always use guide pins in pairs M12x250 3HAC13056 4 Guide pins For guiding gearbox Always use guide pins in pairs 80 mm 3HAC14628 1 Guide pins For guiding sealing ax 2 3 Always use guide pins in pairs 100 mm 3HAC14628 2 Guide pins For guiding sealing ax 2 3 Always use guide pins in pairs Content is defined in section Standard tools on page 465 Standard toolkit Complete ki...

Page 422: ...lic pressure supply to the robot before entering the robot working area 4 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 219 5 See section Changing oil axis 3 gearbox on page 176 Drain the axis 3 gearbox 6 How to lift and remove the upper arm is decribed in section Removal upper ar...

Page 423: ...r the attachment screws of the gearbox 13 For art no see Required equipment on page 420 xx0200000201 If required use two M12 screws in the the holes shown in the figure in order to press the gearbox free 14 A M12 holes for pressing the gearbox out B Holes for attachment screws between gearbox and upper arm C Holes for attachment screws between gearbox and lower arm CAUTION The gearbox weighs 60 kg...

Page 424: ...edges for the gearbox in the lower arm joint surface 2 Parts A Joint surface 3x B Guidance edge 3x C Lower arm xx1000000433 Apply Mercasol on the guidance edges as well as between these 3 Parts A Mercasol on guidance edge B Lower arm C Joint surface 3x Note Make sure that there is no Mercasol on the joint surfaces Continues on next page 424 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revi...

Page 425: ... necessary preparations of the upper arm before refitting gearbox axis 3 Note Action xx1000000435 Clean the machined joint surface on the uipper arm housing Remove contaminations such as paint oil corrosion coating etc from the surface 1 Parts A Joint surface Surface for o ring See figure above Clean the surface for the o ring in the upper arm housing 2 Continues on next page Product manual IRB 66...

Page 426: ... Unpainted surfaces B Painted surfaces Dimension 276x3 53 xx0200000173 Make sure that the o ring is fitted on the new gearbox unit Tip Apply some grease on the o ring in order to make it stay in the groove during assembly 2 Part A O ring gearbox axis 3 Continues on next page 426 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7...

Page 427: ... A Loctite 574 Refitting gearbox axis 3 on the upper arm Use this procedure to refit gearbox axis 3 on the upper arm Note Action DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 1 Continues on next page Product manual IRB 6640 Foundry Prime 427 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 3...

Page 428: ...r arm 6 Place the gearbox on the guide pins and slide it carefully into position 7 Make sure that the o rings are seated correctly the gearbox is correctly oriented 8 Remove the lifting tool 9 M12x60 Secure the gearbox with 22 of the 24 attach ment screws 10 Tightening torque 115 Nm Note Use new attachment screws and washers Refitting the upper arm Use this procedure to refit the upper arm Note Ac...

Page 429: ...ling axis 2 3 4 Concluding refitting procedure Use this procedure for the concluding procedure of refitting gearbox axis 3 Note Action See section Changing oil axis 3 gearbox on page 176 Refill gearbox axis 3 with oil 1 See section Replacing motor axis 3 on page354 Refit motor axis 3 2 Calibration is detailed in a separate calib ration manual enclosed with the calibra tion tools Recalibrate the ro...

Page 430: ... the first test run These are further detailed in the section First test run may cause injury or damage on page29 4 430 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 3 Replacing gearbox axis 3 Continued ...

Page 431: ...e on page 436 Location of gearbox axis 6 The gearbox axis 6 is located in the center of the wrist unit as shown in the figure xx0200000219 Gearbox axis 6 A Attachment screws M8x40 with washers 18 pcs B Oil plug draining C Oil plug filling D O ring not shown in the figure Continues on next page Product manual IRB 6640 Foundry Prime 431 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights re...

Page 432: ...0 3HAB3772 64 O ring type 2 Must be replaced when reas sembling the gearbox 13 1x1 6 3HAB3772 61 O ring type 2 Must be replaced when reas sembling the gearbox 12 pcs For lubricating o ring 3HAB3537 1 Grease Content is defined in section Standard tools on page 465 Standard toolkit Complete kit which also includes Operating manual 3HAC15716 1 Calibration Pendu lum toolkit These procedures include re...

Page 433: ...area 1 CAUTION Always cut the paint with a knife and grind the paint edge when disassembling parts See Cut the paint or surface on the robot before replacing parts on page 219 2 See section Changing oil axis 6 gearbox on page 185 Drain the oil from gearbox axis 6 3 See section Replacing the turning disk on page 259 Remove the turning disk 4 See section Location of gearbox axis 6 on page 431 Remove...

Page 434: ...ully 7 Refitting gearbox axis 6 Use this procedure to refit gearbox axis 6 Note Action DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 1 Make sure the o ring is fitted to the rear of the gearbox 2 Lubricate the o ring with grease Continues on next page 434 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyrig...

Page 435: ...e Spare parts See the figure in Location of gearbox axis 6 on page 431 Place gearbox axis 6 in the wrist unit Note Make sure the gears of the gearbox mate with the gears of the motor 6 See the figure in Location of gearbox axis 6 on page 431 M8x40 quality 12 9 Gleitmo 18 pcs Secure the gearbox with its attachment screws and washers Tightening torque 30 Nm Note Use new attachment screws and washers...

Page 436: ...es shown in the figure 2 xx1000000448 Apply Loctite 574 on surfaces of the gear box as shown in the figure 3 Part A Loctite 574 See section Replacing the turning disk on page 259 Refit the turning disk 4 See section Performing a leak down test on page 214 Perform a leak down test 5 See section Changing oil axis 6 gearbox on page 185 Refill gearbox axis 6 with oil 6 Continues on next page 436 Produ...

Page 437: ...ion Calibration information on page 439 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section First test run may cause injury or damage on page 29 8 Product manual IRB 6640 Foundry Prime 437 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 4 Repair 4 7 4 Replacing gearbox axis 6 Continued ...

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Page 439: ...unter memory is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 444 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 co...

Page 440: ...n focuses on pos itioning accuracy in the Cartesian coordinate system for the robot Absolute accuracy calibration option al 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 fi...

Page 441: ... Field 5 0 If a service operation is done to a robot with the option 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 ...

Page 442: ... calibration marks on the robot xx0700000340 Calibration mark axis 1 A Calibration mark axis 2 B Calibration mark axis 3 C Calibration mark axis 4 D Calibration mark axis 5 E Calibration mark axis 6 F Calibration mark axis 5 IRB 6640ID G Calibration mark axis 6 IRB 6640ID H 442 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 5 Calibration...

Page 443: ...le the calibration movements automatically and these might be different from the positive directions shown below Manual 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 Product manual IRB 6640 Foundry Prime 443 3HAC040586 001 Re...

Page 444: ...rrect manipulator calibration Make sure the axes are positioned according to the correct calibration values not only according to the synchronization marks The correct values are found on a label located either on the lower arm underneath the flange plate on the base or on the frame At delivery the manipulator is in the correct position do NOT rotate axis 4 or 6 at power up before the revolution c...

Page 445: ...Calibration xx1500000942 1 All mechanical units connected to the system are shown with their calibration status 2 Tap the mechanical unit in question xx1500000943 Continues on next page Product manual IRB 6640 Foundry Prime 445 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 5 Calibration information 5 5 Updating revolution counters Continued ...

Page 446: ...arning 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 selected revolution counters and removes the tick from the list of axes 6 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn may cause damag...

Page 447: ... Updating revolution counters on page 444 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis 1 2 or 3 3 M...

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Page 449: ...untry 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 which 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 c...

Page 450: ...wer arm upper arm Cast iron nodular iron Gears screws base frame and so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearboxes Oil grease Covers synchronization brackets Aluminium Turning disc foundry Nickel Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with local regul...

Page 451: ...isms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination Product manual IRB 6640 Foundry Prime 451 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 6 Decommissioning 6 2 Environmental information Continued ...

Page 452: ...is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire When motors are removed from the robot the robot will collapse if it is not properly supported before the motor is removed 452 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 AB...

Page 453: ... step by step in structions below 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 Note Action Deta...

Page 454: ...ted away from personnel 1 Clamp the device at the working location Place the device at ground level so that the hole and spring coils are cut from a more safe distance 2 DANGER The hole must be cut as specified in the figure Pieces can be ejected from the cyl inder at high speed if the hole is cut larger than specified 3 Use a cutting torch with a long shaft Cut a hole in the housing as shown in t...

Page 455: ... away from personnel 5 Use a cutting torch with a long shaft Cut the coils of the 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 6 Double check the number of coils cut and make sure all the tension in the springs are removed 7 Product manual IRB 6640 Foundry Prime 455 3HAC040586 001 Revis...

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Page 457: ...cludes general information complementing the more specific information in the different procedures in the manual Product manual IRB 6640 Foundry Prime 457 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 1 Introduction ...

Page 458: ...gonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 IEC 61000 6 2 2005 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1 2012ii Arc welding equipment Part 10 EMC requirements EN IEC 60974 10 2014ii Safety of machinery Electrical equipment of machi...

Page 459: ...Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 Product manual IRB 6640 Foundry Prime 459 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 2 Applicable standards Continued ...

Page 460: ...n 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume 460 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 3 Unit conversion ...

Page 461: ...uld 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...

Page 462: ...intenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The follow...

Page 463: ...rque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 Product manual IRB 6640 Foundry Prime 463 3HAC040586 ...

Page 464: ...mponents with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The robot weighs 1 340 kg IRB6640 1 405 kg IRB6640ID All lifting accessories used must be sized accord ingly 464 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Co...

Page 465: ...ents standard toolkit Rem Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 5 17 mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 10 100 Nm 1 Torque wrench 75 400 Nm 1 Ratchet head for torque wrench 1 2 1 Hexagon headed screw M10x100 2 Hex bit socket head cap no 14 socket 40 mm L 100 mm 1 To be shortened to 12 mm Hex bit socket head cap no 14 socket 40 mm L 20 mm 1 Hex bit socket...

Page 466: ...01 1 Lifting tool motor ax 2 3 4 3HAC14972 1 2 Removal tool motor M10x Fits motors axes 4 5 and 6 3HAC14973 1 2 Removal tool motor M12x Fits motors axes 1 2 and 3 3HAC17105 1 1 Rotation tool 3HAC12708 1 2 Mechanical stop axis 3 3HAB3409 86 2 Bolts M16 x 60 for mechanical stop axis 3 3HAA1001 186 2 Washers for mechanical stop axis 3 3HAC15571 1 1 Standard toolkit content described in section Standa...

Page 467: ...3HAC021590 001 1 Oil injector max 500 MPa 3HAC026594 001 1 Press gear axis 1 3HAC020902 001 1 Press tool balancing device 3HAC020997 001 1 Shackle balancing device 3HAC15535 1 1 Support base 3HAC028920 001 1 Tool set balancing device Calibration equipment Levelmeter alternative method The following table specifies the calibration equipment required when calibrating the robot with the alternative m...

Page 468: ...Oil exchange equipment The following table specifies the recommended equipment for oil exchange Note Art no Description Includes Vacuum pump with regulator hose and coupling Couplings and adapters Pump manual with hose and coupling Graduated measuring glass Oil gun User instructions 3HAC021745 001 Oil exchange equipment 468 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright ...

Page 469: ...l front shaft design 1 and 2 on page 471 Removal front bearing Design 1 on page 475 Refitting front bearing and sealing Design 1 on page 477 Removal front bearing Design 2 on page 478 Refitting front bearing with sealing Design 2 on page 480 Removal rear shafts Design 1 and 2 on page 481 Refitting rear shafts Design 1 on page 482 Refitting rear shafts Design 2 on page 484 Continues on next page Pr...

Page 470: ... in tool 3HAC028920 001 ordered separ ately 1 Press tool D 103 A 2 Continues on next page 470 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 8 Dismounting and mounting tool 3HAC028920 001 Continued ...

Page 471: ...ress tool D 62 H 13 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 xx0900000026 Configuration 8 C 4 B Continues on next page Product manual IRB 6640 Foundry Prime 471 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 8 Dismounting and mounting too...

Page 472: ...er Distance on to the threaded bar M16 4 Assemble the nut M16 xx0900000028 Alternative con figuration 4 F 1 A B Continues on next page 472 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 8 Dismounting and mounting tool 3HAC028920 001 Continued ...

Page 473: ...semble the knurled nut D 80 Refitting front shaft design 1 and 2 The following configuration is used for refitting of the front shaft Design 1 and 2 xx0900000063 Configuration 8 C 4 Continues on next page Product manual IRB 6640 Foundry Prime 473 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 8 Dismounting and mounting tool 3HAC028920 001 Continued ...

Page 474: ...0065 Continues on next page 474 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 8 Dismounting and mounting tool 3HAC028920 001 Continued ...

Page 475: ...t bearing Design 1 The following configuration is used for removal of the front bearing Design 1 xx0900000031 Configuration D A C 8 4 Continues on next page Product manual IRB 6640 Foundry Prime 475 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 8 Dismounting and mounting tool 3HAC028920 001 Continued ...

Page 476: ...ress tool D 103 on to the threaded bar M16 4 Assemble the Slide hammer Distance 5 Assemble the nut M16 xx0900000033 Alternative con figuration D A 1 F 4 Continues on next page 476 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 8 Dismounting and mounting tool 3HAC028920 001 Continued ...

Page 477: ...lic press 1 5 Assemble the Knurled nut D 80 F Refitting front bearing and sealing Design 1 The following configuration is used for refitting of the front bearing and sealing Design 1 xx0900000036 Configuration 4 F E C 8 Continues on next page Product manual IRB 6640 Foundry Prime 477 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 8 Dismounting and m...

Page 478: ...e C 5 Assemble the Nut M16 8 Removal front bearing Design 2 The following configuration is used for removal of the front bearing Design 2 xx0900000038 Configuration H A C 8 4 Continues on next page 478 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 8 Dismounting and mounting tool 3HAC028920 001 Continued ...

Page 479: ...s tool D 103 A on to the threaded bar M16 4 Assemble the Slide hammer Distance C 5 Assemble the nut M16 8 xx0900000040 Alternative config uration H A 1 F 4 Continues on next page Product manual IRB 6640 Foundry Prime 479 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 8 Dismounting and mounting tool 3HAC028920 001 Continued ...

Page 480: ...ic press 1 5 Assemble the Knurled nut D 80 F Refitting front bearing with sealing Design 2 The following configuration is used for refitting of the front bearing with sealing Design 2 xx0900000042 Configuration 4 F J 7 8 Continues on next page 480 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 8 Dismounting and ...

Page 481: ... Assemble the Nut M16 8 Removal rear shafts Design 1 and 2 The following configuration is used for removal of the rear shafts Design 1 and 2 xx0900000044 Configuration B A J C 8 4 Continues on next page Product manual IRB 6640 Foundry Prime 481 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 8 Dismounting and mounting tool 3HAC028920 001 Continued ...

Page 482: ...ance C 5 Assemble the nut M16 8 Refitting rear shafts Design 1 The following configuration is used for refitting of the rear shafts Design 1 xx0900000047 Configuration 4 F G C 8 Continues on next page 482 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 8 Dismounting and mounting tool 3HAC028920 001 Continued ...

Page 483: ... Press tool D 110 G 4 Assemble the Slide hammer Distance C 5 Assemble the Nut M16 8 xx0900000048 Continues on next page Product manual IRB 6640 Foundry Prime 483 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 8 Dismounting and mounting tool 3HAC028920 001 Continued ...

Page 484: ...readed 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 xx0900000050 484 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 8 Dismounting and mounting tool 3HAC028920 001 Continued ...

Page 485: ...cessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference Product manual IRB 6640 Foundry Prime 485 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 7 Reference information 7 9 Lifting accessories and l...

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Page 487: ... not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRB 6640 Foundry Prime 487 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 8 Spare parts 8 1 Spare part lists and illustrations ...

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Page 489: ...ype C 3HAC025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB 2400 3H...

Page 490: ...650S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram IRB 14000 3HAC056159 002 Circuit diagram IRB 910SC 490 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved 9 Circuit diagrams 9 1 Circuit diagrams...

Page 491: ...isposal 450 changing oil axis 1 170 cleaners approved 212 requirements 212 cleaning 210 climbing on robot 26 Cold environments 117 complete arm system replacement 240 connecting the robot and controller cabling 115 connection external safety devices 27 copper disposal 450 D damage to additional mechanical stop 161 damage to mechanical stop 159 danger levels 41 detergents approved 212 requirements ...

Page 492: ... motion of axes 67 MoveAbsJ instruction 447 N nation specific regulations 19 negative directions axes 443 neodymium disposal 450 NiCad disposal 450 nodular iron disposal 450 O oil amount in gearboxes 168 disposal 450 type of oil 168 oil change axis 1 170 safety risks 39 oil level gearbox axis 6 139 gearbox axis 5 136 gearbox axis 4 134 gearbox axis 3 131 gearbox axis 2 129 gearbox axis 1 127 opera...

Page 493: ...pecial tools 466 speed adjusting 117 stability 69 standards 458 ANSI 459 CAN 459 EN 458 EN IEC 458 EN ISO 458 start of robot in cold environments 117 steel disposal 450 storage conditions 64 symbols safety 41 synchronization position 444 sync marks 442 system integrator requirements 19 T temperatures operation 65 storage 64 testing brakes 37 three position enabling device 31 tightening torque mech...

Page 494: ...Z zero position checking 447 494 Product manual IRB 6640 Foundry Prime 3HAC040586 001 Revision N Copyright 2011 2018 ABB All rights reserved Index ...

Page 495: ......

Page 496: ...265 N 4349 BRYNE Norway Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC040586 001 Rev N en Copyright 2011 2018 ABB All rights reserved ...

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