ABB IRB 6640 User manual

Product manual
Articulated robot
IRB 6640 - 180/2.55
IRB 6640 - 235/2.55
IRB 6640 - 205/2.75
IRB 6640 - 185/2.8
IRB 6640 - 130/3.2
IRB 6640ID - 200/2.55
IRB 6640ID - 170/2.75
M2004

© Copyright 2007-2010 ABB. All rights reserved.
Product manual
IRB 6640 - 180/2.55
IRB 6640 - 235/2.55
IRB 6640 - 205/2.75
IRB 6640 - 185/2.8
IRB 6640 - 130/3.2
IRB 6640ID - 200/2.55
IRB 6640ID - 170/2.75
M2004
Document ID: 3HAC026876-001
Revision: F

© Copyright 2007-2010 ABB. All rights reserved.
The information in this manual is subject to change without notice and should not be
construed as a commitment by ABB. ABB assumes no responsibility for any errors that
may appear in this manual.
Except as may be expressly stated anywhere in this manual, nothing herein shall be
construedasany kindof guaranteeor warranty by ABBfor losses,damagesto persons
or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's written
permission, and contents thereof must not be imparted to a third party nor be used for
any unauthorized purpose. Contravention will be prosecuted.
Additional copies of this manual may be obtained from ABB at its then current charge.
© Copyright 2007-2010 ABB All rights reserved.
ABB AB
Robotics Products
SE-721 68 Västerås
Sweden

Table of Contents
33HAC026876-001 Revision: F
© Copyright 2007-2010 ABB. All rights reserved.
Overview of this manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Product documentation, M2004 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
How to read the product manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1 Safety 15
1.1 Introduction to safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1.2 General safety information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.1 Safety in the manipulator system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
1.2.2 Safety risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
1.2.2.1 Safety risks during installation and service work on manipulators. . . . . . . . . . . . . . . . . . 17
1.2.2.2 CAUTION - Hot parts may cause burns! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
1.2.2.3 Safety risks related to tools/workpieces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
1.2.2.4 Safety risks related to pneumatic/hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
1.2.2.5 Safety risks during operational disturbances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
1.2.2.6 Risks associated with live electric parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
1.2.3 Safety actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.1 Safety fence dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
1.2.3.2 Fire extinguishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
1.2.3.3 Emergency release of the manipulator’s arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
1.2.3.4 Brake testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
1.2.3.5 Risk of disabling function "Reduced speed 250 mm/s" . . . . . . . . . . . . . . . . . . . . . . . . . . 28
1.2.3.6 Safe use of the FlexPendant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
1.2.3.7 Work inside the manipulator's working range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1.2.3.8 Signal lamp (optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
1.2.4 Safety stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
1.2.4.1 What is an emergency stop? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
1.3 Safety related instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3.1 Safety signals in the manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
1.3.2 Safety symbols on the manipulator labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
1.3.3 DANGER - Moving manipulators are potentially lethal! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
1.3.4 DANGER - First test run may cause injury or damage! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
1.3.5 WARNING - The brake release buttons may be jammed after service work . . . . . . . . . . . . . . . . 42
1.3.6 WARNING - The unit is sensitive to ESD! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
1.3.7 WARNING - Safety risks during work with gearbox lubricants (oil or grease) . . . . . . . . . . . . . . 44
2 Installation and commissioning 47
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
2.2 Design 1 and Design 2 of IRB 6640. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2.3 Robot transportation precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.4 Securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
2.5 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.5.1 Pre-installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
2.5.2 Working range and type of motion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
2.5.3 Risk of tipping/stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
2.6 On-site installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.6.1 Lifting the robot with fork lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
2.6.2 Lifting robot with roundslings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
2.6.3 Manually releasing the brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
2.6.4 Lifting the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
2.6.5 Securing the base plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
2.6.6 Orienting and securing the robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
2.6.7 Fitting equipment on robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
2.6.8 Installation of cooling fan for motors, axes 1 and 2 (option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
2.6.9 Installation of Foundry Plus Cable guard (option no. 908-1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

Table of Contents
43HAC026876-001 Revision: F
© Copyright 2007-2010 ABB. All rights reserved.
2.6.10 Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
2.7 Restricting the working range. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
2.7.2 Mechanically restricting the working range of axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
2.7.3 Mechanically restricting the working range of axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
2.7.4 Mechanically restricting the working range of axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
2.8 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.8.1 Robot cabling and connection points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
2.9 Making robot ready for operation (Foundry Prime). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.9.1 Additional installation procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
2.9.2 Commissioning (Foundry Prime). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
2.10 Making robotready for operation, (Cleanroom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
2.10.1 Additional installation procedure, Clean room . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
3 Maintenance 113
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
3.2 Maintenance schedule and expected component life. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.2.1 Specification of maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
3.2.2 Maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
3.2.3 Expected component life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
3.3 Inspection activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.3.1 Inspection, oil level gearbox axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
3.3.2 Inspection, oil level gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
3.3.3 Inspection, oil level gearbox axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
3.3.4 Inspection, oil level gearbox axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
3.3.5 Inspection, oil level, gearbox axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
3.3.6 Inspection, oil level gearbox axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
3.3.7 Inspection, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
3.3.8 Inspection, cable harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
3.3.9 Inspection of air hoses (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
3.3.10 Inspection of surface treatment (Foundry Prime) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
3.3.11 Inspection, information labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
3.3.12 Inspection, mechanical stop pin, axis 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
3.3.13 Inspection, additional mechanical stops. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
3.3.14 Inspection, damper axes 2-5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
3.3.15 Inspection, signal lamp (option). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
3.4 Replacement / Changing activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.4.1 Type of oil in gearboxes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
3.4.2 Oil change, gearbox axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
3.4.3 Oil change, gearbox axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
3.4.4 Oil change, gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
3.4.5 Oil change, gearbox, axis 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
3.4.6 Oil change, gearbox, axis 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
3.4.7 Oil change, gearbox axis 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
3.4.8 Replacement of SMB battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
3.5 Lubrication activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3.5.1 Lubrication of spherical roller bearing, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
3.5.2 Rust preventive measures, sealing axis 4 (Foundry Prime). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
3.5.3 Rust preventive measures, support bearing in wrist (Foundry Prime). . . . . . . . . . . . . . . . . . . . . 191
3.6 Cleaning activities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
3.6.1 Cleaning, robot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Table of Contents
53HAC026876-001 Revision: F
© Copyright 2007-2010 ABB. All rights reserved.
4 Repair 195
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
4.2 General procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.2.1 Performing a leak-down test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
4.2.2 Mounting instructions for bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
4.2.3 Mounting instructions for seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
4.2.4 Exchange of parts on Clean room robots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
4.3 Complete robot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4.3.1 Replacement of cable harness, axes 1-6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
4.3.2 Replacement of cabling, axis 5 motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
4.3.3 Fitting cable package attachments (Cleanroom) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
4.3.4 Replacement of cable harness, Cleanroom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224
4.3.5 Replacement of cable harness, axes 1-4 IRB 6640ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237
4.3.6 Replacement of cable harness, axes 5-6 - IRB 6640ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 245
4.3.7 Replacement of complete arm system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
4.4 Upper and lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
4.4.1 Replacement of turning disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 260
4.4.2 Replacement of complete wrist unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
4.4.3 Replacement of complete wrist unit, IRB 6640ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
4.4.4 Replacement of upper arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
4.4.5 Replacement of complete lower arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
4.5 Frame and base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.5.1 Replacement of SMB unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
4.5.2 Replacement of brake release unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
4.5.3 Replacement of spherical roller bearing, balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
4.5.4 Replacement of balancing device (design 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297
4.5.5 Replacement of balancing device (design 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306
4.5.6 Unloading the balancing device using distance tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
4.5.7 Restoring the balancing device using distance tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
4.5.8 Unloading the balancing device using hydraulic press tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
4.5.9 Restoring the balancing device using a hydraulic press tool.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 325
4.6 Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
4.6.1 Replacement of motor, axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
4.6.2 Replacement of motor axis 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 332
4.6.3 Replacement of motor, axis 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
4.6.4 Replacement of motor, axis 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
4.6.5 Replacement of motor, axis 5 IRB 6640 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .346
4.6.6 Replacement of motor, axis 5, IRB 6640ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 351
4.6.7 Replacement of motor, axis 6, IRB 6640 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .354
4.6.8 Replacement of motor, axis 6, IRB 6640ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
4.7 Gearboxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
4.7.1 Replacement gearbox axis 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
4.7.2 Replacement gearbox axis 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
4.7.3 Replacement of gearbox, axis 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 376
4.7.4 Replacement of gearbox, axis 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
5 Calibration information 387
5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 387
5.2 Calibration methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 388
5.3 Calibration scale and correct axis position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390
5.4 Calibration movement directions for all axes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
5.5 Updating revolution counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 392
5.6 Checking the calibration position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

Table of Contents
63HAC026876-001 Revision: F
© Copyright 2007-2010 ABB. All rights reserved.
6 Decommissioning 397
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 397
6.2 Environmental information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398
6.3 Decommissioning of balancing device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
7 Reference information 401
7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
7.2 Applicable safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402
7.3 Unit conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404
7.4 Screw joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
7.5 Weight specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408
7.6 Standard toolkit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
7.7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
7.8 Dismounting and mounting tool 3HAC028920-001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413
7.9 Lifting equipment and lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428
8 Spare parts 429
8.1 Spare parts and exploded views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 429
9 Circuit diagrams 431
9.1 About circuit diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 431
Index 433

Overview of this manual
73HAC026876-001 Revision: F
© Copyright 2007-2010 ABB. All rights reserved.
Overview of this manual
About this manual This manual contains instructions for:
•mechanical and electrical installation of the robot
•maintenance of the robot
•mechanical and electrical repair of the robot.
Usage This manual should be used during:
•installation, from lifting the robot to its work site and securing it to the foundation, to
making it ready for operation
•maintenance work
•repair work and calibration.
Who should read this manual?
This manual is intended for:
•installation personnel
•maintenance personnel
•repair personnel.
Prerequisites A maintenance/repair/installation craftsman working with an ABB Robot must:
•be trained by ABB and have the required knowledge of mechanical and electrical
installation/repair/maintenance work.
Organization of chapters
The manual is organized in the following chapters:
Chapter Contents
Safety 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.
Installation and commis-
sioning Required information about lifting and installation of the robot.
Maintenance Step-by-step procedures that describe how to perform
maintenanceoftherobot.Basedonamaintenanceschedule that
may be used to plan periodical maintenance.
Repair Step-by-step procedures that describe how to perform repair
activities 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

Overview of this manual
3HAC026876-001 Revision: F8
© Copyright 2007-2010 ABB. All rights reserved.
References
Other references The following documents are referenced in some descriptions regarding robots with the
option Foundry Prime.
Reference information Useful information when performing installation, maintenance or
repair work. Includes lists of necessary tools, additional
documents, safety standards etc.
Spare part / part list Complete spare part list and complete list of robot components,
shown in exploded views.
Exploded views Detailed illustrations of the robot with reference numbers to the
part list.
Circuit diagram Reference to the circuit diagram for the robot..
Chapter Contents
Reference Document ID
Product specification - IRB 6640 3HAC028284-001
Circuit diagram IRB 6640 3HAC025744-001
Product manual - DressPack/SpotPack IRB 6640 3HAC028638-001
Product manual - IRC5 3HAC021313-001
Operating manual - IRC5 with FlexPendant 3HAC16590-1
Operating manual - Calibration Pendulum 3HAC16578-1
Operating manual - Service Information System 3HAC025709-001
Application manual - Additional axes and stand alone controller 3HAC021395-001
Technical reference manual - System parameters 3HAC17076-1
Application manual - Electronic Position Switches 3HAC027709-001
Application manual - CalibWare Field 5.0 3HAC030421-001
Reference Document ID
Replacement gearbox axis 1 on IRB 6640 - Option Foundry
Prime 3HAC037959-001
Replacement gearbox axis 2 on IRB 6640 - Option Foundry
Prime 3HAC037959-002
Replacement gearbox axis 3 on IRB 6640 - Option Foundry
Prime 3HAC037959-003
Replacement gearbox axis 6 on IRB 6640 - Option Foundry
Prime 3HAC037959-004
Replacement of cable harness, axis 1-6 - Option Foundry
Prime 3HAC037959-005
Replacement of balancing device (design 1) - Option Foundry
Prime 3HAC037959-006
Replacement of balancing device (design 2) - Option Foundry
Prime 3HAC037959-007
Replacement of motor, axis 1 - Option Foundry Prime 3HAC037959-008
Replacement of motor, axis 2 - Option Foundry Prime 3HAC037959-009
Replacement of motor, axis 3 - Option Foundry Prime 3HAC037959-010
Continued
Continues on next page

Overview of this manual
93HAC026876-001 Revision: F
© Copyright 2007-2010 ABB. All rights reserved.
Revisions
Replacement of motor, axis 4 - Option Foundry Prime 3HAC037959-011
Replacement of motor, axis 5 - Option Foundry Prime 3HAC037959-012
Replacement of motor, axis 6 - Option Foundry Prime 3HAC037959-013
Replacement of SMB unit - Option Foundry Prime 3HAC037959-014
Reference Document ID
Revision Description
-First edition
AProduct name Sikaflex 252FC is changed to Sikaflex 521FC. New article
number is 3HAC026759-001.
Cleanroom variant added throughout the manual.
Changes made in:
• Prerequisites in section Overview
• Oil change in section Maintenance
BContent updated in section:
• 2.9 Making robot ready for operation, Cleanroom / 2.9.1 Additional
installation procedure
CChanges made in:
• Section Maintenance, Repair and Spare part list regarding new lower
arm and new balancing device called (design 2).
DChanges made in:
• New Spare part list
• Section Repair regarding balancing device
• New section regarding tool 3HAC028920-001
• Section Maintenance schedule in chapter Maintenance: Intervals for
inspection activities and oilchanges has been revised.
• Section Maintenance schedule in chapter Maintenance: Overhaul of
robot is new.
• Section Maintenance schedule in chapter Maintenance: The
information about Service Information System (SIS) has been updated.
• Section Maintenance schedule in chapter Maintenance: Interval for
replacement of battery pack changed.
• Section Expected component life in chapter Maintenance: The lifetime
of certain parts have been revised.
• Section Cleaning of robot updated
• Section What is an emergency stop? added to chapter Safety.
EThis revision includes the following additions:
•NewWARNING! added in Safety chapter section Work inside the
robot´s working range.
•NewWARNING! added in Safety chapter section WARNING! - Safety
risks during work with gearbox oil.
• The text in the introductions to chapters Installation, Maintenance and
Repair has been updated concerning the robot being connected to
earth when power connected.
• Section Expected component life in chapter Maintenance: The lifetime
of certain parts has been updated.
• Section Type of oil in chapter Maintenance has been updated.
• Section Foundry Plus,Cable guard added to chapter Installation.
Continued
Continues on next page

Overview of this manual
3HAC026876-001 Revision: F10
© Copyright 2007-2010 ABB. All rights reserved.
FThis revision includes the following additions:
• Instructions about Foundry Prime has been updated throughout the
manual. The updates in the Repair chapter is presented as separate
documents on the documentation DVD and ABB Library. Article
numbers can be found in the beginning of the sections in question.
•Sealing compound updated in Exchange of parts on Clean room robots
on page 201.
•Lifting tools not applicable to IRB 6640, removed from the manual.
•Weight updated for version IRB 6640ID-200/2.55 in section Pre-instal-
lation procedure on page 58.
•Working area updated for variants IRB 6640-2.55 and 6640ID-2.55 in
section Working range and type of motion on page 60.
•Lifting equipment and tools for the robot throughout the manual,
updated.
•SectionFitting cable package attachments (Cleanroom) moved from
Installation chapter to Repair chapter.
•Wrist type 1 added throughout the manual where it has been missing.
Updates in section Maintenance schedule on page 115:
•Interval updated for inspection of balancing device (Foundry Prime).
•Interval updated for lubrication of balancing device bearing (Foundry
Prime).
• Rust preveting activity for axis 1 sealing (Foundry Prime) removed.
•Inspection of surface treatment added (Foundry Prime).
Updates in the chapter Safety:
• Updated safety signal graphics for the levels Danger and Warning, see
Safety signals in the manual on page 34.
• New safety labels on the manipulators, see Safety symbols on the
manipulator labels on page 36.
• Revised terminology: robot replaced with manipulator.
Revision Description
Continued

Product documentation, M2004
113HAC026876-001 Revision: F
© Copyright 2007-2010 ABB. All rights reserved.
Product documentation, M2004
Categories for manipulator documentation
The manipulator documentation is divided into a number of categories. This listing is based
on the type of information in the documents, regardless of whether the products are standard
or optional.
All documents listed can be ordered from ABB on a DVD. The documents listed are valid for
M2004 manipulator systems.
Product manuals All hardware, manipulators and controllers will be delivered with a Product manual that
contains:
•Safety information.
•Installation and commissioning (descriptions of mechanical installation, electrical
connections).
•Maintenance (descriptions of all required preventive maintenance procedures
including intervals).
•Repair (descriptions of all recommended repair procedures including spare parts).
•Additional procedures, if any (calibration, decommissioning).
•Reference information (article numbers for documentation referred to in Product
manual, procedures, lists of tools, safety standards).
•Parts list.
•Foldouts or exploded views.
•Circuit diagrams (or references to circuit diagrams).
Technical reference manuals
The technical reference manuals describe the manipulator software in general and contain
relevant reference information.
•RAPID Overview: An overview of the RAPID programming language.
•RAPID Instructions, Functions and Data types: Description and syntax for all
RAPID instructions, functions, and data types.
•RAPID Kernel: A formal description of the RAPID programming language.
•System parameters: Description of system parameters and configuration workflows.
Application manualsSpecific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several applications.
An application manual generally contains information about:
•The purpose of the application (what it does and when it is useful).
•What is included (for example cables, I/O boards, RAPID instructions, system
parameters, CD with PC software).
•How to use the application.
•Examples of how to use the application.
Continues on next page

Product documentation, M2004
3HAC026876-001 Revision: F12
© Copyright 2007-2010 ABB. All rights reserved.
Operating manuals The operating manuals describe hands-on handling of the products. The manuals are aimed
at those having first-hand operational contact with the product, that is production cell
operators, programmers, and trouble shooters.
The group of manuals includes:
•Emergency safety information
•General safety information
•Getting started, IRC5 and RobotStudio
•IRC5 with FlexPendant
•RobotStudio
•Introduction to RAPID
•Trouble shooting, for the controller and manipulator.
Continued

How to read the product manual
133HAC026876-001 Revision: F
© Copyright 2007-2010 ABB. All rights reserved.
How to read the product manual
Reading the procedures
The procedures contain references to figures, tools, material, etc. The references are read as
described below.
References to figures The procedures often include references to components or attachment points located on the
manipulator/controller. The components or attachment points are marked with italic text in
the procedures and completed with a reference to the figure where the current component or
attachment point is shown.
The denomination in the procedure for the component or attachment point corresponds to the
denomination in the referenced figure.
The table below shows an example of a reference to a figure from a step in a procedure.
References to required equipment
The procedures often include references to equipment (spare parts, tools, etc.) required for the
different actions in the procedure. The equipment is marked with italic text in the procedures
and completed with a reference to the section where the equipment is listed with further
information, that is article number and dimensions.
The designation in the procedure for the component or attachment point corresponds to the
designation in the referenced list.
The table below shows an example of a reference to a list of required equipment from a step
in a procedure.
Safety information The manual includes a separate safety chapter that must be read through before proceeding
with any service or installation procedures. All procedures also include specific safety
information when dangerous steps are to be performed.
Read more in the chapter Safety on page 15.
Action Note/Illustration
8. Remove the rear attachment screws, gearbox. Shown in the figure Location of
gearbox on page xx.
Action Note/Illustration
3. Fit a new sealing, axis 2 to the gearbox. Art. no. is specified in Required
equipment on page xx.

How to read the product manual
3HAC026876-001 Revision: F14
© Copyright 2007-2010 ABB. All rights reserved.

1 Safety
1.1. Introduction to safety information
153HAC026876-001 Revision: F
© Copyright 2007-2010 ABB. All rights reserved.
1 Safety
1.1. Introduction to safety information
Overview The safety information in this manual is divided in two categories:
•General safety aspects, important to attend to before performing any service work on
the robot. These are applicable for all service work and are found in General safety
information on page 16.
•Specific safety information, pointed out in the procedures. How to avoid and eliminate
the danger is either described directly in the procedure, or in specific instructions in
the section Safety related instructions on page 34.

1 Safety
1.2.1. Safety in the manipulator system
3HAC026876-001 Revision: F16
© Copyright 2007-2010 ABB. All rights reserved.
1.2 General safety information
1.2.1. Safety in the manipulator system
Validity and responsibility
The information does not cover how to design, install and operate a complete system, nor
does it cover all peripheral equipment that can influence the safety of the total system. To
protect personnel, the complete system must be designed and installed in accordance with the
safety requirements set forth in the standards and regulations of the country where the
manipulator is installed.
The users of ABB industrial manipulators are responsible for ensuring that the applicable
safety laws and regulations in the country concerned are observed and that the safety devices
necessary to protect people working with the manipulator system are designed and installed
correctly. Personnel working with manipulators must be familiar with the operation and
handling of the industrial manipulator as described in the applicable documents, for example:
•Operating manual - IRC5 with FlexPendant
•Product manual
Connection of external safety devices
Apart from the built-in safety functions, the manipulator is also supplied with an interface for
the connection of external safety devices. Via this interface, an external safety function can
interact with other machines and peripheral equipment. This means that control signals can
act on safety signals received from the peripheral equipment as well as from the manipulator.
Limitation of liability Any information given in this manual regarding safety must not be construed as a warranty
by ABB that the industrial manipulator will not cause injury or damage even if all safety
instructions are complied with.
Related information
Type of information Detailed in document Section
Installation of safety
devices Product manual for the manipulator Installation and commissioning
Changing operating
modes Operating manual - IRC5 with FlexPendant Operating modes
Restricting the working
space Product manual for the manipulator Installation and commissioning

1 Safety
1.2.2.1. Safety risks during installation and service work on manipulators
173HAC026876-001 Revision: F
© Copyright 2007-2010 ABB. All rights reserved.
1.2.2. Safety risks
1.2.2.1. Safety risks during installation and service work on manipulators
Overview This section includes information on general safety risks to be considered when performing
installation and service work on the manipulator.
General risks during installation and service
•The instructions in the Product manual in the chapter Installation and commissioning
must always be followed.
•Emergency stop buttons must be positioned in easily accessible places so that the
manipulator can be stopped quickly.
•Those in charge of operations must make sure that safety instructions are available for
the installation in question.
•Those who install the manipulator must have the appropriate training for the
equipment in question and in any safety matters associated with it.
Nation/region specific regulations
To prevent injuries and damage during the installation of the manipulator, the regulations
applicable in the country concerned and the instructions of ABB Robotics must be complied
with.
Non-voltage related risks
•Safety zones, which must be crossed before admittance, must be set up in front of the
manipulator's working space. Light beams or sensitive mats are suitable devices.
•Turntables or the like should be used to keep the operator out of the manipulator's
working space.
•The axes are affected by the force of gravity when the brakes are released. In addition
to the risk of being hit by moving manipulator parts, there is a risk of being crushed
by the parallel arm (if there is one).
•Energy stored in the manipulator for the purpose of counterbalancing certain axes may
be released if the manipulator, or parts thereof, are dismantled.
•When dismantling/assembling mechanical units, watch out for falling objects.
•Be aware of stored heat energy in the controller.
•Never use the manipulator as a ladder, that is, do not climb on the manipulator motors
or other parts during service work. There is a serious risk of slipping because of the
high temperature of the motors or oil spills that can occur on the manipulator.
To be observed by the supplier of the complete system
•The supplier of the complete system must ensure that all circuits used in the safety
function are interlocked in accordance with the applicable standards for that function.
•The supplier of the complete system must ensure that all circuits used in the
emergency stop function are interlocked in a safe manner, in accordance with the
applicable standards for the emergency stop function. Continues on next page

1 Safety
1.2.2.1. Safety risks during installation and service work on manipulators
3HAC026876-001 Revision: F18
© Copyright 2007-2010 ABB. All rights reserved.
Complete manipulator
Cabling
Gearboxes and motors
Balancing device
Safety risk Description
Hot components!
CAUTION!
Motors and gears are HOT after running the manipulator!
Touching motors and gears may result in burns!
Withahigherenvironmenttemperature,moresurfaceson
the manipulator will get HOT and may also result in burns.
Removed parts may result in
collapse of manipulator!
WARNING!
Take any necessary measures to ensure that the
manipulator does not collapse as parts are removed, e.g.
secure the lower arm with fixtures if removing motor, axis
2.
Safety risk Description
Cable packs are sensitive to
mechanical damage!
CAUTION!
The cable packs are sensitive to mechanical damage!
They must be handled with care, especially the
connectors, in order to avoid damaging them!
Safety risk Description
Gears may be damaged if
excessive force is used!
CAUTION!
Whenever parting/mating motor and gearbox, the gears
may be damaged if excessive force is used!
Safety risk Description
Dangerous balancing device!
WARNING!
Do not under any circumstances, deal with the balancing
device in any other way than that detailed in the product
documentation! For example, attempting to open the
balancing device is potentially lethal!
Continued