Contents - Table Of Contents
- Table Of Contents
- Table Of Contents
- Table Of Contents
- Overview
- Product documentation, M2004
- How to read the product manual
- Safety
- General safety information
- Safety risks
- Safety risks related to tools/workpieces
- Safety risks related to pneumatic/hydraulic systems
- Safety risks during operational disturbances
- Risks associated with live electric parts
- Safety actions
- Fire extinguishing
- Emergency release of the robot's arm
- Brake testing
- Risk of disabling function "Reduced speed 250 mm/s
- Safe use of the FlexPendant
- Work inside the robot's working range
- Signal lamp (optional)
- Translate the information on safety and information labels
- Safety related instructions
- DANGER - Moving robots are potentially lethal
- DANGER - First test run may cause injury or damage
- WARNING - The brake release buttons may be jammed after service work
- WARNING - The unit is sensitive to ESD
- WARNING - Safety risks during work with gearbox oil
- Installation and commissioning
- Robot transportation precautions
- Securing the robot
- Unpacking
- Working range and type of motion
- Risk of tipping / stability
- On-site installation
- Lifting robot with roundslings
- Manually releasing the brakes
- Lifting the base plate
- Securing the base plate
- Orienting and securing the robot
- Fitting cable package attachments (Cleanroom)
- Fitting equipment on robot
- Installation of cooling fan for motors, axes 1 and 2 (option)
- Loads
- Restricting the working range
- Mechanically restricting the working range of axis 1
- Mechanically restricting the working range of axis 2
- Mechanically restricting the working range of axis 3
- Electrical connections
- Making robot ready for operation (Foundry Prime)
- Commissioning (Foundry Prime)
- Making robotready for operation, (Cleanroom)
- Maintenance
- Maintenance schedule and expected component life
- Maintenance schedule
- Expected component life
- Inspection activities
- Inspection, oil level gearbox axis 2
- Inspection, oil level gearbox axis 3
- Inspection, oil level gearbox axis 4
- Inspection, oil level, gearbox axis 5
- Inspection, oil level gearbox axis 6
- Inspection, balancing device
- Inspection, cable harness
- Inspection of air hoses (Foundry Prime)
- Inspection, information labels
- Inspection, mechanical stop, axis 1
- Inspection, additional mechanical stops
- Inspection, damper axes 2-5
- Inspection, signal lamp (option)
- Replacement / Changing activities
- Oil change, gearbox axis 1
- Oil change, gearbox axis 2
- Oil change, gearbox, axis 3
- Oil change, gearbox, axis 4
- Oil change, gearbox, axis 5
- Oil change, gearbox axis 6
- Replacement of SMB battery
- Lubrication activities
- Rust preventive measures, bearing axis 1 (Foundry Prime)
- Rust preventive measures, bearing axis 4 (Foundry Prime)
- Rust preventive measures, support bearing in wrist (Foundry Prime)
- Cleaning activities
- Repair
- General procedures
- Mounting instructions for bearings
- Mounting instructions for seals
- Complete robot
- Replacement of cabling, axis 5 motorIRB 6640
- Replacement of cable harness, Cleanroom
- Replacement of cable harness, axes 1-4- IRB 6640ID
- Replacement of cable harness, axes 5-6 - IRB 6640ID
- Replacement of complete arm system
- Replacement of air nipple and hose (Foundry Prime)
- Upper and lower arm
- Replacement of complete wrist unit
- Replacement of complete wrist unit, IRB 6640ID
- Replacement of upper arm
- Replacement of complete lower arm
- Frame and base
- Replacement of brake release unit
- Replacement of spherical roller bearing, balancing device (old and new)
- Replacement of balancing device (old and new)
- Unloading the balancing device (old and new)
- Restoring the balancing device
- Motors
- Replacement of motor axis 2
- Replacement of motor, axis 3
- Replacement of motor, axis 4
- Replacement of motor, axis 5. IRB 6640
- Replacement of motor, axis 5, IRB 6640ID
- Replacement of motor, axis 6, IRB 6640, IRB 6620/Foundry Plus
- Replacement of motor, axis 6, IRB 6640ID
- Gearboxes
- Replacement gearbox axis 2
- Replacement of gearbox, axis 3
- Replacement of gearbox, axis 6
- Calibration information
- Calibration methods
- Calibration scales and correct axis position
- Calibration movement directions for all axes
- Updating revolution counters
- Checking the calibration position
- Decommissioning
- Environmental information
- Decommissioning of balancing device
- Reference information
- Applicable Safety Standards
- Unit conversion
- Screw joints
- Weight specifications
- Standard toolkit
- Special tools
- Lifting equipment and lifting instructions
- Spare Part List IRB 6640
- Spare parts - Balancing device
- Frame to lower arm
- Lower arm to upper arm
- Upper arm including wrist unit, motors ax. 3- 6 (IRB 6640 and IRB 6640ID)
- Cable harness and SMB unit
- Circuitdiagrams
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Overview73HAC026876-001 Revision: C© Copyright 2006-2008 ABB. All rights reserved.OverviewAbout This ManualThis manual contains instructions for:• mechanical and electrical installation of the robot• maintenance of the robot• mechanical and electrical repair of the robot.UsageThis manual should be used during:• installation, from lifting the robot to its work site and securing it to the foundation, tomaking it ready for operation• maintenance work• repair work and calibration.Who Should Read This Manual?This manual is intended for:• installation personnel• maintenance personnel• repair personnel.PrerequisitesA maintenance/repair/ installation craftsman working with an ABB Robot must:• be trained by ABB and have the required knowledge of mechanical and electricalinstallation/repair/maintenance work.Organization of chaptersThe manual is organized in the following chapters:Chapter ContentsSafety Safety information that must be read through before performingany installation or service work on the robot. Contains generalsafety aspects as well as more specific information on how toavoid personal injuries and damage to the product.Installation and commis-sioningRequired information about lifting and installation of the robot.Maintenance Step-by-step procedures that describe how to performmaintenance of the robot. Based on a maintenance schedule thatmay be used to plan periodical maintenance.Repair Step-by-step procedures that describe how to perform repairactivities of the robot. Based on available spare parts.Calibration information Procedures that do not require specific calibration equipment.General information about calibration.Decommissioning Environmental information about the robot and its components.Continues on next page
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