S4CPlus-Product Manual IRB 640 3HAC 7579-1 M2000

8/9/2019 S4CPlus-Product Manual IRB 640 3HAC 7579-1 M2000

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Product Manual

3HAC 7579-1

IRB 640

M2000


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Installation and Commissioning

CONTENTSPage

1 Transporting and Unpacking ......................................................................................... 3

1.1 Stability / risk of tipping......................................................................................... 4

1.2 System diskettes ..................................................................................................... 4

2 On-Site Installation ......................................................................................................... 5

2.1 Lifting the manipulator........................................................................................... 5

2.2 Assembling the robot.............................................................................................. 9

2.2.1 Manipulator.................................................................................................. 9

2.3 Stress forces............................................................................................................ 10

2.3.1 Stiffness........................................................................................................ 10

2.3.2 All versions .................................................................................................. 10

2.4 Amount of space required....................................................................................... 11

2.4.1 Manipulator.................................................................................................. 11

2.5 Manually engaging the brakes................................................................................ 12

2.6 Restricting the working space................................................................................. 13

2.6.1 Axis 1 ........................................................................................................... 13

2.6.2 Axes 2 and 3................................................................................................. 14

2.7 Mounting holes for equipment on the manipulator ................................................ 15

2.7.1 Quality of screws for fitting extra equipment.............................................. 15

2.8 Loads ...................................................................................................................... 16

3 Customer connections on manipulator ......................................................................... 19

3.1 Connection of extra equipment to the manipulator ................................................ 23

3.1.1 Connections on upper arm. .......................................................................... 23

3.1.2 Connections on upper arm with CanBus...................................................... 243.1.3 Connection of signal lamp on upper arm (option) ....................................... 25


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Installation and Commissioning

Page


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Transporting and Unpacking Installation and Commissioning

1.1 Stability / risk of tipping

When the manipulator is not fastened to the floor and standing still, the manipulatoris not stable in the whole working area. When the arms are moved, care must betaken so that the centre of gravity is not displaced, as this could cause the manipula-tor to tip over.

The following table shows the positions where there is a risk of tipping and refers to fig-ures in chapter 3.8 in Product Specification IRB 640, for definition of position 0 and 5.

no = stableyes = risk of tipping

1.2 System diskettes

The diskettes in the box, fixed to the shelf for the teach pendant, should be copied

(in a PC) before they are used. Never work with the original diskettes. When you havemade copies, store the originals in a safe place.

Do not store diskettes inside the controller due to the high temperatures there.

Working area, position 0

load = 0 kg load = max

Working area, position 5load = 0 kg load = max

no no no yes


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Installation and Commissioning On-Site Installation

2 On-Site Installation

2.1 Lifting the manipulator

The following lifting instructions are valid for a nakedrobot. Wheneveradditional equipment is put on the robot, the centre of gravity can change andmake lifting dangerous.

Never walk under a suspended load.

If the integrated lifting ears on the front cannot be reached, the manipulator must bereoriented to the sync position.

The best way to lift the manipulator is to use lifting straps and a traverse crane.

Attach the straps to the integrated lifting eyes on both sides of the frame (seeFigure 2). The lifting strap dimensions must comply with the applicable standardsfor lifting. It is also possible to use two lifting devices (option) for use with a forklift truck (see Figure 4).

NB!The right lifting device, the robot seen from behind, must be removed beforestart-up, see Figure 1.

Lifting device


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On-Site Installation Installation and Commissioning

Figure 2 Lifting the manipulator using a traverse crane.

Length=1150 Length=950

Crane lift

240

700


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Figure 3 Lifting the manipulator with the arm system in the calibration position.

Crane lift, in calibration position

Length=1150 Length=950


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2.2 Assembling the robot

2.2.1 Manipulator

The three support points of the manipulator foot shall be mounted on three flat surfaceswith a flatness within the specification. Use shims if necessary. The rest of the surfacemust be flat within 2 mm. Footprint diagram, see Figure 5. Floor mounted models

can be tilted max. 5

o

.The levelness requirement for the surface is as follows:

0.5

D=64 H9 (3x)

Support surface D=85 (3x)

A

0.2 720

4800.1

A

415.7

D=32(3x)D=48(3x)

A - A

X

Y

Z 100 0,5

15+2

0

Guide sleeve


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On-Site Installation Installation and Commissioning

2.3 Stress forces

2.3.1 Stiffness

The stiffness of the foundation must be designed to minimize the influence on thedynamic behaviour of the robot. For optimal performance the frequency of the founda-tion with the robot weight must be higher than 22 Hz.

TuneServo can be used for adapting the robot tuning to a non-optimal foundation.

2.3.2 All versions

Endurance load Max. load(In operation) (Emergency stop)

Force xy 12 000 N 18 000 N

Force z 21 000 5 500 N 21 000 10000 N

Torque xy 32 000 Nm 39 000 Nm

Torque z 6 000 Nm 13 000 Nm

Force xy and torque xy are vectors that can have any direction in the xy plane.

YX


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2.4 Amount of space required

The amount of working space required to operate the manipulator and controller isillustrated in Figure 7.

The working range for axis 1 is +/- 180.

NB: There are no software or mechanical limits for the working space under thebase of the manipulator.

2.4.1 Manipulator

IRB 640

+1-1

1220

+2-2

+3

-3

2/3

+6-6

TCP 0

2310

599


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2.7 Mounting holes for equipment on the manipulator

NB: Never drill a hole in the manipulator without first consulting maintenancestaff or the design department at ABB Flexible Automation.

Figure 11 Holes for mounting extra equipment (dimensions in mm).

M10 (2x)

200

6069

220

411

486

80

depth 25

99

126

Limit for M10 surfaces

Limit for M10 surfaces

45

M10 (2x) through M10 (4x) through260

130

2301

00

35

30o

60o

D=10 H7depth 10

M10 (6x) depth 18

D

=160h7

D=80H7

D=125

8

8F - F


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Customer connections on manipulatorInstallation and Commissioning

Figure 14 Customer connector

Name ABB part no. Type Comments

Pin 5217 649-72

5217 649-25

5217 649-70

5217 649-3

5217 649-68

5217 649-105217 649-31

24/26

24/26

20/22

20/22

16/20

24/2616/20

Burndy Machine tooling

Burndy Hand tooling


Burndy Hand tooling


Burndy GroundBurndy Ground

Socket 5217 649-73

5217 649-26

5217 649-71

5217 649-69

5217 1021-4

5217 1021-5

24/26

24/26

20/22

16/18

DIN 43 652

DIN 43 652


Burndy Hand tooling



Tin bronze (CuSu)

0.14 - 0.5mm2

AWG 20-26Tin bronze (CuSu)

0.5 - 1.5mm2AWG 16-20

14 5

2

3

6


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Maintenance


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2.3 Lubricating the large diameter bearing, axis 1

Remove the two plugs.

Fit the grease nipples (R1/8 art. No. 2545 2021-26).

Grease through (1) the two nipples. Turn the axis 1 +90owhile greasing is in progress.

Continue greasing until new grease exudes from the rubber seal (2).

Figure 5 Lubricating the large diameter bearing.

Remove excess grease with a cloth.

Type of grease:

- ABB art. no. 1171 4013-301, quality 7 1401-301

- ESSO Beacon EP 2

- Shell Alvanina EP Grease

- SKF Grease LGEP 2

- BP Energrease LS-EP 2.

Tools:

- See Tool List.

A-A1 2

A-A

A-A


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Maintenance


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2.5 Inspect and lubricate the bearings, balancing units axis 2

The bearings should be inspected and lubricated every 12 000 hours.

1. Move axis 2 to the sync position.

Make sure the shaft between the upper and lower arms does not rotate whenunscrewing the KM nut.

2. Remove the KM- nuts (KM-8), the outer support washers and sealing rings.

Inspect

3. Fit the auxiliary shafts on the upper and lower axes (upper: aux. shaft3HAB 6558-1, lower: aux. shaft 3HAB 6567-1). The shafts should be tightened totheir bottom position.

4. Off-load the bearings using an M10x50 screw at the cylinder top.

5. Put out the cylinder so that the inner rings are fully exposed. Wipe the inner ringsclean and check that there are no pressure marks or other similar deformations.It is quite normal for the bearing races to have a darker colour than the surroundingmaterial.

6. Inspect the support washers and sealing rings.

7. Push in the cylinder, make sure the inner support washers and sealing rings gets incorrect position.

8. Remove the auxiliary shafts.

Lubrication

8. Fit the lubricating tool 3HAC 4701-1. The tool should be tightened to the bottomposition only by hand power.

9. Grease through the nipple. Continue greasing until the grease excudes behind theinner sealing ring. Repeat procedure for the other bearings.

10. Remove the lubricating tool and clean the threads on the shaft ends free fromgrease.

11 Remount the outer sealing rings apply some grease on the support washers apply


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Repairs


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CONTENTSPage

6 Pushbutton unit for releasing brakes ............................................................................ 37

6.1 Replacing pushbutton unit...................................................................................... 37

7 Axis 6 ................................................................................................................................ 39

7.1 Dismounting the tilt housing .................................................................................. 39

7.2 Replacing motor/gear axis 6................................................................................... 40

7.3 Checking play in axis 6 .......................................................................................... 41

8 Motor units ...................................................................................................................... 43

8.1 General ................................................................................................................... 43

8.2 Checking brake performance.................................................................................. 44

9 Calibration....................................................................................................................... 45

9.1 General ................................................................................................................... 45

9.2 Calibration procedure ............................................................................................. 459.3 Aligning the tilt housing ................................................................................. 51

9.4 Setting the calibration marks on the manipulator................................................... 52

9.5 Checking the calibration position........................................................................... 55

9.6 Alternative calibration positions ............................................................................ 55

9.7 Calibration equipment ............................................................................................ 57

10 Special Tools List........................................................................................................... 59
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Repairs General Description


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1.1 Document Guidance

The subsequent chapters describe the type of service work that can be carried out by

the Customers own service staff on site. Certain types of work, requiring special expe-

rience or special aids, are not dealt with in this manual. In such cases, the defective

module or component should be replaced on site. The faulty item should be sent to

ABB Flexible Automation for service.

Calibration.Recalibration of the robot may have to be carried out after replacing

mechanical unit parts or when the motor and feedback unit have been separated; or

when a resolver error has occurred or the power supply between a measurement board

and resolver has been interrupted. The procedure is described in detail in Chapter 9,

Calibration.

IMPORTANT! When work is done on the robot signal cabling, this may result inthe robot moving to incorrect positions.

After doing such work, it is important that the robot calibration position ischecked as described in Chapter 9.5, Checking the calibration position. If a cali-bration fault is discovered, the robot must be recalibrated as described in Chapter9, Calibration.

Tools. Two types of tools are required for various service jobs involving dismantling;

on the one hand, conventional tools like socket and ratchet spanners, etc.; on the other

hand, special tools may be necessary, depending on what type of service is being car-ried out. The conventional tools are not dealt with in this manual, based on the assump-

tion that the service personnel have sufficient technical basic competence. However,

service work requiring the use of special tools is described in this manual.

Foldouts. In the Spare Parts chapter of this manual, there are a number of foldouts

illustrating the robot parts, intended to facilitate quick identification of both the type of

service required and the composition of the various components. The parts are itemnumbered on the foldouts. The foldouts are referred to in the Manual text within

arrow heads (< >) as exploded view numbers. Where reference is made to foldouts,

other than those specified in the paragraph title, the foldout number is included in the

item number reference for example or the digit(s) before the stroke
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General Description Repairs


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Flange Seals and Static Seals

11. Check the flange surfaces. They must be even and free from pores. It is easy tocheck flatness using a gauge on the fastened joint (without sealing compound).

12. Differences in surface level or the presence of burrs due to incorrect machining

are not permissible. If flange surfaces are defective, the parts must not to be used,

because leakage could result.

13. The surfaces must be properly cleaned in accordance with ABB ROBOTICS

PRODUCTS recommendations.

14. Distribute the sealing compound evenly over the surface, preferably with a brush.

15. Tighten the screws evenly when fastening the flange joint.

O-rings

16. Check the O-ring grooves. The grooves must be geometrically correct and free

from pores and contamination.

17. Check the O-ring with regard to surface defects, burrs, shape accuracy, etc.

18. Ensure that the correct O-ring size is used.

19. Tighten the screws evenly when assembling.

20. Defective O-rings and O-ring grooves must not be used.

21. Fitting defective parts will result in leakage. Grease the O-ring with lubricant

before mounting.

Repairs General Description


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1.4 Instructions for Tightening Screw Joints

General

It is of the utmost importance that all screw joints be tightened with the correct torque.

Application

The following tightening torques are to be used for all screw joints in metallic materials

unless otherwise specified in the text.

These instructions do not apply to screw joints comprising soft or brittle materials.

For screws with a higher property class than 8.8, the data for 8.8 must be used unless

otherwise specified.

Screws treated with Gleitmo (lubricated)

When handling screws treated with Gleitmo, protective gloves of nitrile rubbertype should be used.

Screws treated with Gleitmo can be unscrewed and screwed in again 3-4 times before

the slip coating disappears. Screws can also be treated with Molycote 1000.

When screwing in new screws that are not Gleitmo treated, these should first be lubri-

cated with Molycote 1000 and tightened to the specified torque.

Assembly

Lubrication with molybdenum disulphide grease (Molycote 1000) should only be usedwhen specified in the text.

Screws lubricated with Molycote 1000 and then torque tightened, should also to be

lubricated between the washer and the head of the screw.


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Repairs Axis 1


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2 Axis 1

2.1 Replacement of motor

Refer to foldout no. 2.

Dismounting:

Be careful not to tap or hit the shaft axially, nor displace the shaft axially in anyway, as this could give rise to an incorrect air gap in the brake.

1. Remove the cover in the frame between axes 2 and 3.

2. Unscrew the 3 screws on the top of motor 1. Remove the cover.

3. Unscrew the 4 cable inlet cover screws.

4. Disconnect connectors R2.MP1 and R3.FB1 in the motor.

5. Unscrew the motor flange, 4 screws . Use two screws in the threaded holes(M8) on the motor flange, to push out the motor from its attachment.

6. Loosen screw , fit a 150 mm screw, and pull off the pinion with the help of a

puller.

Mounting:

7. Mount a threaded pin in the motor shaft and press the gear on to the shaft with anut and washer. Mount screw through the gear, torque 70 Nm, Loctite 243.

Axial force through the bearings in the motor is prohibited.

8. Ensure that assembly surfaces are clean and unscratched.

9. Apply sealing liquid Permatex 3 under the motor flange.


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Axis 1 Repairs


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2.3 Replacing the gearbox

Refer to foldouts no. 2 and 4.

Dismounting:

1. Dismount motor and the cabling, as described in Chapter 2.1, Replacement ofmotorand Chapter 2.2, Cabling axis 1.

2. Disconnect the cables and the air hose that comes through the lower arm, and is

connected to the frame.

3. Attach a hoist in existing lifting eye bolts.

For instructions about lifting, see Chapter 7, Installation and Commissioning.

To facilitate dismounting, it is essential that the arm system is evenly balanced.Move the lower arm slightly backwards and allow the upper arm to move down

as far as possible, in order to concentrate the centre of gravity as close as possible.If there is any load on the wrist, or any other equipment, the positioning may beaffected.

4. Unscrew screws for the gear. Accessible through holes in the frame.

5. Remove screws holding the joint bearing.

6. Lift the arm system straight up.

7. Place the arm system on some kind of support.

Make sure that the arm system is properly supported, so that the gearbox can besafely removed.

8. Loosen screws for the gearbox.

Mounting:

9. Mount two guide pins, M12x200 under the frame, to facilitate mounting of thefriction ring and gear.
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Axis 1 Repairs


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2.5 Dismounting cooling axis 1

Refer to foldout 10.

Dismounting:

1. Dismount cover in the frame between axes 2 and 3.

2. Disconnect fan cabling , R3.FAN.

3. Loosen nuts .

4. Remove the fan .

Mounting:

5. Mount in reverse order.


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Axis 2 Repairs

Tightening torque:


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Tightening torque:

Screws for motor, item 1.31: 50 Nm

Screw for gear, item 1.30: 70 Nm

3.2 Replacing the gearbox

Refer to foldout 5.

Dismounting:

1. Remove motor as in Chapter 3.1, Replacing motor.

2. Unscrew screws and remove the motor socket .

3. Mount 2 guide pins, M12, through the gearbox.

4. Loosen the screws and .

5. Pull the gearbox out, suspended on the guide pins.

Mounting:

6. Clean the surfaces in the frame, lower arm and gearbox.

7. Mount 2 guide pins, M12.

8. Mount friction rings and O-ring .

9. Put the gearbox on the 2 guide pins and place the friction ring on tothe gearbox.

10. Mount screws and , lubricate with Molycote 1000 and tighten screw

with 300 Nm and screw with 120 Nm.

11. Mount O-ring .

12. Suspend the motor socket on the 2 guide pins.
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Axis 2 Repairs

16. Then mount the motor and gearbox for axis 3 as in Chapter 4.2, Replacing gearbox.


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16. Then mount the motor and gearbox for axis 3 as in Chapter 4.2, Replacing gearbox.

17. Secure the lower arm with the locking screws.

18. Mount the upper arm as in Chapter 4.5, Dismounting upper arm, complete.

19. Mount the parallel bar as in Chapter 4.4, Replacing parallel bar with bearings.

20. Mount the linkage according to Chapter 5, Link system.

21. Mount the cables as in Chapter 3.8, Dismounting cables, lower arm/upper arm.

22. Mount the balancing weight for axis 3, lubricate screws with Molycote1000 and tighten with 300 Nm.

23. Mount the balancing unit for axis 2 as described in Chapter 3.5, Dismounting bal-ancing unitor Chapter 3.6, Replacing guiding ring, balancing unit.

Do not forget to remove the locking screws!

24. Calibrate the robot as described in Chapter 9, Calibration.

Tightening torque:

Screw joint balancing weight/parallel arm, item 1/3.142: 300 Nm.

3.4 Replacing bearing in lower arm

Refer to foldout no. 6:1.

Dismounting:

1. Remove the lower arm as in Chapter 3.3, Replacing lower arm.

2. Place the lower arm on a workbench or similar.

3. Dismount the parallel arm as in Chapter 4.3, Dismounting parallel arm.

4. Remove the bearings with a puller.
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Axis 2 Repairs

3 7 Replacing bearings balancing unit


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3.7 Replacing bearings, balancing unit

Use recondition kit 3HAC 2840-1.

1. Dismantle the balancing unit according to Chapter 3.5, Dismounting balancingunit.

2. Push out the old bearing, using tool 3HAC 1981-1. See Figure 4.

Figure 4 Dismounting of bearing.

3. Turn the tool upside down. Place the new bearing on the tool with the bearingnumber upwards (facing the tool). Push the new bearing down according toFigure 5.

Press

Old bearing

Tool 3HAC 1981-1

Support

Press

New bearing
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Axis 2 Repairs


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Repairs Axis 3

4 Axis 3


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4 Axis 3

4.1 Replacing motor

Refer to foldout 5.

Dismounting:

Be careful not to tap or hit the shaft axially, nor displace the shaft axially in anyway, as this could give rise to an incorrect air gap in the brake.

1. Lower the balancing weight to its lowest position and secure axis 3 with ahoist, or mount two extra mechanical stops on each side of the moving stopon axis 3, to lock the movement of axis 3.

Danger! Be careful! Make sure that the balancing weight or the upper arm are

locked in their positions and that they cannot move when the motor with brake isdismounted.

2. Unscrew the 3 screws on the top of motor 3. Remove the cover.

3. Unscrew the 4 cable inlet cover screws.

4. Disconnect connectors R3.MP3 and R3.FB3.

5. Attach a hoist to the motor. The weight of the motor is 17 kg.

6. Unscrew the screws for the motor.

7. Pull out the motor.

8. Loosen screw and mount a screw with a length of 150 mm and pull off

the gear with a puller.

Mounting:

9. Mount a fully threaded pin in the motor shaft and press the gear on to the shaftith t d h M t 1 30 th h th t 70 N

Axis 3 Repairs

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Tightening torque:

Screws for motor, item 1.31: 50 Nm

Screw for gear, item 1.30: 70 Nm

4.2 Replacing gearbox

Refer to foldout nos. 5.

Dismounting:

1. Dismount motor as described in Chapter 4.1, Replacing motor.

2. Unscrew screws and dismount the motor socket .

3. Mount 2 guide pins, M12 through the gearbox.

4. Loosen screws and .

5. Pull out the gear box , hanging on the guide pins.

Mounting:

6. Clean the surfaces in the frame, lower arm and gearbox.

7. Mount 2 guide pins, M12.

8. Mount friction rings and O-ring .

9. Put the gear box on the 2 guide pins and place the friction ring on to thegearbox.

10. Mount screws and , lubricate with Molycote 1000 and tightenscrew with 300 Nm and screw with 120 Nm.

11. Mount O-ring .

Repairs Axis 3

Tightening torque:
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Screw joint gearbox/parallel arm, item 1. 7: 300 Nm

Screw joint gearbox/parallel arm, item 1.5: 120 NmScrew joint motor socket/frame, item 1.38.2: 120 Nm

4.3 Dismounting parallel arm

Refer to foldout no. 6 and 6:1.

Dismounting:

1. Remove the lower arm as in Chapter 3.3, Replacing lower arm.

2. Place the arm on a workbench.

3. Attach a hoist to the parallel arm.

4. Force the parallel arm to the right, seen from the rear.

5. Lift the parallel arm away.

Mounting:

6. Place the parallel arm in position.

7. Press the parallel arm into the lower arm.

8. Mount the lower arm as described in Chapter 3.3, Replacing lower arm.

4.4 Replacing parallel bar with bearings

Refer to foldout no. 1.

Dismounting:

IMPORTANT! Secure axis 3 with two extra mechanical stops, so that the

Axis 3 Repairs

Mounting:


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4. Lift the parallel bar in position.

5. Lubricate screws with Molycote 1000 and tighten to a torque of 300 Nm.

6. Make sure that the clamps are tightened symmetrically.

Do not forget to remove the 2 extra mechanical stops!

Tightening torque:

Screws, clamps, item 3.142: 300 Nm.

4.5 Dismounting upper arm, complete

Refer to foldout nos. 1 and 1:1.

Dismounting:

IMPORTANT! Secure axis 3 with two extra mechanical stops, so that the balanc-ing weight for axis 3 cannot fall down.

1. Dismount balancing unit as described in Chapter 3.5, Dismounting balancingunitor Chapter 3.6, Replacing guiding ring, balancing unit.

2. Remove the cables and air hose inside the lower arm as in Chapter 3.8, Dis-

mounting cables, lower arm/upper arm3. Attach a hoist to the upper arm. See Figure 6.

Repairs Axis 3

6. Remove the stop screws in the lower arm.
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7. Unscrew the shafts . The bearing is pressed out with the shaft.

Note! Be careful with the threads on the shafts.

8. Lift the upper arm away.

Mounting:

9. Place the upper arm in position.

NOTE! Mount the left side first, complete, robot seen from behind!

10. Mount sealing ring , turn the largest diameter inwards.

11. Mount the outer ring of the bearing in the upper arm.

12. Mount the V-ring on the shaft.

13. Mount the shaft . Lubricate the threads with Molycote 1000 andtighten to a torque of 300 Nm.

14. Apply Loctite 243 on stop screw and tighten to torque 34 Nm.

15. Insert the distance ring on the shaft (only on the left side).

16. Mount the bearing .

17. Insert the NILOS-ring and distance ring .

18. Mount the KM nut. Apply Loctite 243 and tighten the nut, then loosen the nutagain and tighten to a torque of 90 Nm.

19. Then mount the right side, paragraphs 12-18 (similar to the left side, except forthe distance ring


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Shafts, item 1:1/203: 300 Nm

KM nut, item 1:1/136: 90 Nm

Screws, clamps, item 1/3.142, 1/3.160: 300 Nm


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Link system Repairs

Mounting:

Lower rod


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Lower rod

The bearings can take a skew setting. But be careful.

14. Apply Loctite on the shaft before mounting the ring , see foldout 1:4view D-D and E-E. Mount ring on both the upper and lower shaft.

15. Mount the lower rod with bearings .

16. Refill the bearing with grease.

17. Mount KM-nut at the upper shaft. Tighten to 50 Nm.

18. Mount friction washer , support washer and screw use Loctite 243.

19. Mount a new cover .

Upper rod

Note! When changing bearing, pushing a bearing is only allowed on its textside. The other side is not hard enough.

20. Place ring , support ring , sealing ring and the innerraces of the bearings on the front and rear shaft. Grease the bearing.

21. Mount the upper rod .

22. Mount sealing ring , support washer and KM-nuts ,use Loctite 243. Tighten to a torque of 50 Nm.


Tightening torque:

KM-nut, item 205.6: 50 Nm
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Link system Repairs


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Pushbutton unit for releasing brakes Repairs


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Repairs Axis 6

7 Axis 6


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7.1 Dismounting the tilt housing

Refer to foldout no. 7

Dismounting:

1. Remove the drive unit axis 6 as described in Chapter 7.2, Replacing motor/gear axis 6

2. Attach a hoist to the tilt housing.

3. Dismount the upper rod in the front as described in Chapter 5.1, Replacing upper and

lower rod.

4. Remove covers and on both sides by deformation or push the covers from

inside with thickest possible 16 mm tool. If the covers are not deformed they can bereused.

5. Unscrew KM-nuts .

6. Mount tool 3HAC 2486-1 and pull out the shaft on both sides.

7. Lift the tilt housing away.

Mounting:

9. Mount the sealings in the tilt housing. Use tool 3HAC 0905-1.

10. Mount the bearings in the tilt housing. Use tool 3HAC 3437-1.

11. Apply a little grease in the hole for the shafts. Apply grease also to both the shafts.

12. Insert shaft on the same side as the balancing unit (left side of robot as seen from

behind).

Axis 6 Repairs

16. Remove the wedges and check that there is a gap and that the tilt housing can

move about 1 mm. Use Loctite on the KM nuts and tighten them until the

movement is removed.


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movement is removed.

N.B. Stop as close to clearance-free as possible. The KM nuts should be tightened

with a spanner 210 degrees to achieve the correct preloading.

17. Mount covers and .

18. Refill the bearing house with grease.


Tightening torque:

KM-nut, : 90 Nm

7.2 Replacing motor/gear axis 6

Refer to foldout nos. 7 and 9.

It is not necessary to remove the tilt housing from the upper arm.

Dismounting:

1. Dismount cabling for axis 6.

2. Drain the grease. Open both magnetic plugs.

3. Unscrew screws . Dismount shaft with the help of pinscrews M8x65.

4. Loosen screws .

5. Free the drive unit and lift it out.

6. Loosen screws . Dismount the gear with the help of 2 screws (M8 holes in

h fl )

Repairs Axis 6

9. Mount the gear on the motor . Use a new O-ring . Turn the gear so

that the screw hole and magnetic oil plug come in the right position. Torque 35

Nm.
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N .

10. Move the sync plates and connector holder on the resolver side over to the new

motor. When replacing the gear, the sync plate on the gear is glued.

Clean the surface careful before mounting (a new sync plate must be fitted).

11. Mount the drive unit in the tilt housing .

12. Mount screws and washers . Tightening torque 70 Nm.

13. Mount shaft , screws , tightening torque 24 Nm.

14. Pour grease into axis 6 as described in the Maintenance Manual IRB 640.


Tightening torque:

Screw joint motor/gear, 9/4: 35 Nm

Screw joint, drive unit/shaft, 7/13: 24 Nm

Screw joint tilt housing/drive unit, 7/6: 70 Nm

7.3 Checking play in axis 6

Axis 6

1. Check the play in axis 6 with tool 6896 134-CF.

2. Measure with a PEK dial indicator against the tool. See Figure 7.

3. Max. play 0.06 mm at a distance of 190 mm from the centre of axis 6.

Comment: The play in the gear unit cannot be adjusted. If necessary, the gear

unit must be replaced, see Chapter 7.2, Replacing motor/gear axis 6.

Axis 6 Repairs


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Repairs Motor units

8 Motor units


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8.1 General

Each manipulator axis is provided with a motor unit consisting of:

- A synchronous AC motor

- A brake unit

- A feedback unit.

A gear on the output shaft of the motor forms together with the gear on each axis, thecomplete gear unit. Dismounting/mounting of the gear unit is described in an earlierchapter of this manual.The electro-magnetic brake is built into the motor unit. The brake is released by a24 V DC supply. For brake release see Section 7, Installation and Commissioning.The feedback unit consists of a resolver mounted on the motor shaft and is built into

the motor unit in a similar way as the brake.Power and signal connections to the motor units are via separate cables betweenconnections points inside the manipulator and each motor. The cables are connectedto the motor units with connectors.

- The feedback unit is fitted by the motor manufacturer and must never be sep-arated from the motor.

- The communication angle is + 90 (COMOFF=2048).

The motors never need commutating.- The motor, resolver and brake is to be regarded as an replacement motor unit.

Faulty motor units are repaired by the motor manufacturer at the request ofthe ABB Robotics service organisation.

- The cable routing is shown in Figure 8. Note that the signal connection cableand the power connection cable must not be entwined.

Motor units Repairs

8.2 Checking brake performance

A i M t St ti b k G d ti


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Axis Motor Static brake Gear reductiontorque (Nm) ratioMin.

1/2/3 3HAB 8278-1 22 185

6 3HAB 5762-1 6 81

A check on the static brake torque for each motor unit can be done by applying a loadon the moving arm or on the turning disc in some suitable way. When calculating thebrake torque, the arm and gear reduction ratio must be taken into consideration. Thecoefficient of efficiency for the gear is assumed to be 1.0.

Repairs Calibration

9 Calibration


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9.1 General

The robot measurement system consists of one feedback unit for each axis and a meas-urement board that continuously keeps track of the current robot position.The measurement board memory has a battery backup.

Note! The accumulator unit will be fully recharged when the mains supply hasbeen on for 36 hrs. without any power interruptions.

If any of the resolver values are changed, the measurement system must be carefullycalibrated (as described in Chapter 9.2, Calibration procedure). This happens when:

- parts affecting the calibration position have been replaced on the robot.

If the contents of the revolution counter memory are lost, the system needs to beroughly calibrated (as described in Chapter 9.4, Setting the calibration marks on themanipulator). This may happen when:

- the battery is discharged.

- a resolver error occurs.

- the signal between a resolver and measurement board is interrupted.

- a robot axis has been moved with the control system disconnected.

9.2 Calibration procedure

The axes must be adjusted in increasing sequence, i.e., 1 - 2 - 3 - 5 - 6.

1. Position the manipulator approximately in calibration position 0 as shown Figure11.

2. Select the MOTORS OFF mode.

Calibration Repairs

6. Align the pin and tool with a sliding calliper. See Figure 9.
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Figure 9 Aligning the pin and tool with a sliding calliper for axis 1.

Before calibrating axes 2, 3 and 6, calibrate the sensors against each other, using a reference

plane surface, in the same direction. See Figure 10.

Figure 10 Calibrating the sensors.

Axes 2, 3 and 67. Release the enabling device.

8. Mount sensor fixture 6808 0011-GM on the bases reference plane, see Figure 11.

MANIPULATOR

6896 0011-YM

Sliding calliper

0000

Reference plane

Sensor

Repairs Calibration

Axis 3Tilt housing


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Axis 6

Reference

Axis 2

Sync fixture axis 6,see Figure 12.

Aligning the turning disc

View fromabove

Axis 3

Inclination instrument6807 081-D
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Repairs Calibration

14. Move the sensor and continue the calibration procedure for the other axes.

15. When all the axes have been adjusted, the resolver values are stored by executing

the following commands on the teach pendant.


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the following commands on the teach pendant.

16. Press the Misc.window key (see Figure 13).

Figure 13 The Misc. window key from which the Service window can be selected

17. Select Servicein the dialog box shown on the display.

18. Press Enter .

19. Select View: Calibration. The window in Figure 14appears.

21

2 3

0

1

4 5 6

7 8 9

P3

P1 P2

File Edit View Calib

1(1)

Service Calibration

Unit Status

Robot Not Calibrated

Calibration Repairs

- Not calibratedOne (or more) of the axes is NOT fine-calibrated. This or these axes, musttherefore be fine-calibrated as described in Chapter 9.2, Calibration proce-

dure.
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20. If there is more than one unit, select the desired unit in the window in Figure 14.Choose Calib: Calibrateand the window shown in Figure 15will appear.

Figure 15 The dialog box used to calibrate the manipulator.

21. Press the function keyAllto select all axes, if all axes are to be commutated.Otherwise, select the desired axis and press the function keyIncl(the selected axisis marked with an x).

22. Confirm by pressing OK. The window in Figure 16appears.

Incl All Cancel OK

1(6)

Calibration!

Robot

To calibrate, include axes and press OK.

Axis Status

X 1 Not Fine Calibrated


3 Fine Calibrated

4

X 5


Calibration!

Robot

- - - - - WARNING - - - - -

The calibration for all marked axes

will be changed.

It cannot be undone.

OK to continue?
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Calibration Repairs

9.4 Setting the calibration marks on the manipulator

When starting up a new robot, you may receive a message telling you that the manipu-lator is not synchronised The message appears in the form of an error code on the teach


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lator is not synchronised. The message appears in the form of an error code on the teachpendant. If you receive such a message, the revolution counter of the manipulator mustbe updated using the calibration marks on the manipulator. See Figure 17.

Examples of when the revolution counter must be updated:

- when the battery unit is discharged

- when there has been a resolver error

- when the signal between the resolver and the measuring system board hasbeen interrupted

- when one of the manipulator axes has been manually moved without the con-troller being connected.

It takes 36 hours operation to recharge the battery unit without any power interrup-

tions.

If the resolver values must be calibrated, this should be done as described in the chapteron Repairs in the IRB 640 Product Manual.

WARNINGWorking in the robot work cell is dangerous.

Press the enabling device on the teach pendant and, using the joystick, move the robotmanually so that the calibration marks lie within the tolerance zone (see Figure 22).

Note that axis 6 does not have any mechanical stop and can thus be calibrated at thewrong faceplate revolution.

When all axes have been positioned as above, the values of the revolution counter canbe stored by entering the following commands on the teach pendant:

1. Press the Misc.window key (see Figure 18).

4 5 6

7 8 9


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Calibration Repairs

7. Confirm by pressing OK. A window like the one in Figure 21appears.

Rev. Counter Updating!Robot
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Figure 21 The dialog box used to start updating the revolution counter.

8. Start the update by pressing OK.

If a revolution counter is incorrectly updated, it will cause incorrect positioning.Thus, check the calibration very carefully after each update. Incorrect updating candamage the robot system or injure someone.

9. Check the calibration as in Chapter 9.5, Checking the calibration position.

Figure 22 Calibration marks on the manipulator.

10. Save the system parameters on a floppy disk.

Cancel OK

Robot

The Rev. Counter for all marked axes

will be changed.

It cannot be undone.

OK to continue?

+

-

*)

*) axis number

Repairs Calibration

9.5 Checking the calibration position

There are two ways to check the calibration position; both are described below.
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Using the diskette, Controller Parameters:

Run the program \ SERVICE \ CALIBRAT \ CAL 640 on the diskette and follow the instruc-tions displayed on the teach pendant. When the robot stops, switch to MOTORS OFF. Checkthat the calibration marks for each axis are at the same level, see Figure 17. If they are not,the setting of the revolution counters must be repeated.

Using the Jogging window on the teach pendant:

Open the Jogging window and choose running axis-by-axis. Using the joystick, movethe robot so that the read-out of the positions is equal to zero. Check that the calibrationmarks for each axis are at the same level, see Figure 17. If they are not, the setting of therevolution counters must be repeated.

9.6 Alternative calibration positions

Before it can be calibrated in one of the two alternative positions, the robot must have beencalibrated with calibration equipment at calibration position 0 for all axes (the robot is deliv-ered with calibration position 0). See Figure 23.

Cal.pos. 0

Cal.pos. 2 +90o

Y

X

Left (1.570796)

Calibration Repairs

1. Run the calibration program CAL64 on system disk IRB 2 (SERVICE.DIR\ CALI-BRATE.DIR). Select Normal position, check the calibration marks for each axes.

2. Run the calibration program again and select the desired calibration position (Left orRight), see Figure 23.


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g g

3. Change to the new calibration offset for axis 1, as follows:

Select the window SERVICE;

View: Calibration;

Calib: Calibrate;

Select axis 1 (no other axes)

Then confirm by pressing OKtwo times.

4. Change to the new calibration offset on the label, located on the frame to the left ofmotor axis 1 (remove the cover between axes 2 and 3). The new calibration offset valuescan be found as follows:

Select the window SYSTEM PARAMETERS;

Types: Motor;

Select axis 1;

Press Enter

Note the Cal offset value.

5. Change to the new calibration position on axis 1, as follows:

Select the window SYSTEM PARAMETERS;

Topics: Manipulator;

Types: Arm;

Select axis 1;

Change Cal pos to 1.570796 or -1.570796 depending on selected calibration posi-tion. The angle is in radians, see Figure 23.

6. Restart the robot by selecting File: Restart.

Repairs Calibration

9.7 Calibration equipment

1. Inclination instrument 6807 081-D

2 C lib i i 6808 011 GM S fi


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2. Calibration equipment 6808 011-GM Sensor fixture6896 011-YM Sync fixture axis 16896 0011-YN Measuring rod6808 0011-LP Angle bracket3HAC 1904-1 Sync fixture, axis 6

Calibration tools for TCP check

Tool for TCP adjustment 3HAA 0001-UA X= -15 mm, Z= -150 mmCalibration set for Opti Master 3HAA 0001-XR

Calibration Repairs


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Repairs Special Tools List

10 Special Tools List

Tools marked with an * are used for service at more than one place.


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p

The need for special tools has been reduced to a minimum. When tools are needed fordismounting/mounting work, a description is given in the Product Manual, ChapterRepairs.During the ordinary service training courses arranged by ABB Flexible Automation,detailed descriptions of the tools are given together with their use.

Axis 1

Guide pins, 2 M12x200

Guide pins M12x300

Rotating gear, axes 1, 2 and 3 3HAC 0266-1

Lifting device for bearing axis 1 6896 134-XD

Lifting tool, motor axis 1 3HAB 7396-1

Axis 2

Auxiliary shaft 3HAB 6558-1

Auxiliary shaft 3HAB 6567-1

Screw for locking axis 2 M16x150

Tubular KM socket 4-KM 8

Pressing tool bearing, lower arm 6896 134-FJ

Lifting gear axes 2 and 3, chain hoist 6896 0011-YL

Tool for guiding ring assembly 3HAC 0879-1

Axis 3

Hydraulic cylinder NIKE CLF 50-10

Special Tools List Repairs

Tool for dismounting shafts 3HAC 2486-1

Pressing tool for shafts 3HAC 0902-1

Play measurement tool, wrist 6896 134-CF


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Tightening tool 3HAB 1022-1

Miscellaneous

Pressing tool, support bearing/seal 6896 134-FR/-FP

Pull rod 6896 134-FH

Dismounting bearing and sealing, p-rod 3HAB 7806-1

Grease nipples (R 1/8) 2545 2021-26

Calibration tool for TCP check

Tools for grease replacement, axes 1-3

Axis 1

Socket 3HAB 1561-1

Nipple 3HAA 7601-090

Hose D=18/12 mm, L=1000 mm

Hose clip D=15-20 mm

Socket Square 1/2 / hexagon 10 mm

Extender 1/2 / L=250 mm

Ratchet wrench

Axis 2-3, 6

Nipple 3HAA 7601-091

Hose D=18/12 mm, L=1000 mm

Allen key 6 mm

Repairs Special Tools List

Tilt house

Mounting of sealing 3HAC 0905-1


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Lifting the tilt house with motor 3HAC 1060-1

Upper rod

Pressing tool for needle bearing 3HAC 1388-1

Lower rod/LinkMounting of bearing 3HAC 2241-1

Pressing tool for bearing 3HAC 0906-1

Pressing tool for sealing 3HAC 2226-1


Pressing tool for bearing 3HAC 4315-1



Tilthouse/Upper arm

Distance when mounting bearing 3HAC 2984-1

Wedge for adjustment of tilt house/upper

arm

3HAC 2347-1

Pressing tool for shaft 3HAC 3409-1

Ratchet wrench, socket 4 - KM8, graduated

arc

Tool for dismounting bearing in tilt houseInner expanded socket

Standard pullet

Special Tools List Repairs


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Spare Parts

CONTENTSPage

1 Manipulator ............................................................................................................. 2

1.1 IRB 640...........................................................................................................2

1 2 A i 1 l t 5


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1.2 Axis 1, complete .............................................................................................5

1.3 Base.................................................................................................................7

1.4 Frame, complete..............................................................................................8

1.5 Axes 2 and 3....................................................................................................9

1.6 Lower arm.......................................................................................................111.7 Upper arm .......................................................................................................12

1.8 Parallel rod ......................................................................................................13

1.9 Drive unit axis 6..............................................................................................14

1.10 Cooling device axis 1....................................................................................15

1.11 Cabling ..........................................................................................................15

1.12 Position switches, axes 1 and 2.....................................................................151.13 Signal lamp ...................................................................................................16

1.14 Customer vacum set ......................................................................................16

Spare Parts

Spare Parts

1 Manipulator
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Item numbers refer to item numbers on the foldouts.

1.1 IRB 640

Itm Qty Name Art. no. Rem

1 Mtrl set axis 1 3HAC 4325-1 CP/CSMtrl set axis 1 3HAC 4326-1 CP/CS, CAN

2 Mtrl set axes 2 and 3 3HAC 4324-1

3 Manipulator, mtrl set complete 3HAC 1215-1

50 Mtrl set 3HAB 4217-1

50.1 1 Balancing unit 3HAB 5971-1 Type B

50.1.1 1 Circlip 3HAB 6178-1 Not shown

50.1.2 1 Guiding ring 3HAB 6176-1 Not shown

50.1.3 2 Adjust. needle bearing 3HAB 6432-1 Not shown50.2 4 Sealing ring 3HAB 6254-1

50.3 2 Ring 3HAB 6275-150.4 4 Support washer 3HAB 6279-1

50.5 2 Lock nut 3HAB 6271-1

60 Lift device for fork lift 3HAA 0001-SY

8 Screw 3HAB 3409-93 M16x60 12.98 Washer 3HAA 1001-186 17x30x32 Lifting device 3HAB 4229-1

2 Lifting device 3HAB 4230-14 Instruction plate 3HAB 4232-1

70 Fan 3HAC 2306-1 See 1.10

109 10 Cli l k 5217 520 11

Spare Parts

136 2 Lock nut 2126 2851-112 M60x2

137 2 Set screw, cup point 9ADA 205-75 M10x20

138 1 Spacer 3HAA 1001-125

139 2 Spacer 3HAA 1001-126

140 2 Sealing ring 3HAA 1001-173


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145.x 1 Lables IRB 640 3HAC 2103-1

146 1 Battery unit 4944 026-4

149 1 Cable straps, outdoors 2166 2055-4 4.8x290

154 2 Protective plate 3HAA 1001-164

155 2 Torx counters roll. screw 9ADA 633-55 M6x12

159 Locking liquid 1269 0014-410 Loctite 243 1 ml

163 1 Grease tube 3HAA 1001-716

166 Sealant 1269 1907-1 Loctite 577 1 ml

167 2 Torx pan head roll. screw 9ADA 629-59 M6x30

169 6 Lubricating grease 1171 4013-301 EP-grease

170 Locking liquid 1269 0014-409 Loctite 290 1 ml171 Grease 3HAC 2331-1 Molywhite 1300 ml



177 2 Washer 2151 2082-150 6.1x20x2

178 1 Guide for cabling 3HAA 1001-721

182 1 Cover 3HAA 1001-161183 6 Torx pan head rol. screw 9ADA 629-55 M6x12

202 1 Shaft 3HAA 1001-127

203 1 Shaft lower arm 3HAC 1208-1

620 1 Limited working range 3HAB 4224-1 option 621

1 Stop arm 3HAB 4533-14 Hexagon head screw 9ADA 120-77 M16x50 8.84 Plain washer 9ADA 313-5 17x30x31 Erection provision 3HAB 4223-1

620 Limited working range 3HAB 4225-1 option 621, 622 and623

Spare Parts

2.181 1 Hex socket head cap screw 3HAB 7700-69 M12x50 12.9UnbrakoGleitmo 610

3.107 1 Parallel rod, complete 3HAA 0001-ER3.120 37 Torx pan head roll. screw 9ADA 629-56 M6x16


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3.142 4 Hex socket head cap screw 3HAB 3409-86 M16x60Gleitmo 610

3.143 12 Washer 3HAA 1001-186

3.160 8 Hex socketnhead cap screw 3HAB 3409-88 M16x70Gleitmo 610

3.201 1 Upper arm, complete 3HAC 1217-1

3.204 1 Balancing weight 3HAC 1738-1 413 kg

205 1 Linkage, complete 3HAC 1219-1

205.1 1 Upper rod 3HAC 1051-1

205.2 2 Adjust. needle bearing 3HAB 6432-1

205.3 4 Sealing ring 3HAB 6254-1

205.4 2 Ring 3HAB 6275-1

205.5 4 Support washer 3HAB 6279-1

205.6 4 Lock nut 3HAB 6271-1

205.7 Locking liquid 1269 0014-410 Loctite 243 1 ml

205.8 Lubricating grease 1171 4012-201 1 g

205.20 1 Lower rod 3HAC 1050-1

205.21 2 Spherical roller bearing 3HAA 2167-11

205.22 2 Sealing, without dust lip 3HAB 3702-14

205.24 1 VK-cover 3HAA 2166-11 D=80 B=10

205.26 Lubricating grease 1171 4012-201

205.27 1 Sealing ring without dust lip 3HAB 3702-18 D=52/68 B=8

205.28 1 Support washer 3HAC 2627-1205.29 1 Hex socket head cap screw 9ADA 183-65 M13x30 8.8

205.30 2 Retaining ring, bore 9ABA 137-31 80


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Spare Parts

41 7 Straps 2166 2055-3 L=208

42 1 Holder 3HAA 1001-668

43 3 Screw 3HAB 7700-94 M16x140 12.9

Unbrako

44 3 Spring washer 3HAA 1001-181


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45 3 Screw 3HAB 7700-84 M12x140 12.9Unbrako

46 3 Support washer 3HAA 1001-200 12.5x24x5.9

47 1 Axis 2 cabling 3HAC 0703-1

48 1 Axis 3 cabling 3HAB 8737-149 18 Screw 9ADA 618-55 M6x12 8.8

Spare Parts

1.3 Base


Base, complete 3HAC 3806-1


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1 1 Base 3HAC 0517-2

2 1 Bottom plate 3HAA 1001-695

3 1 Cable guide rail 3HAA 1001-691

5 1 Stop shaft 3HAB 4082-1

6 8 Screw 9ADA 618-56 M6x16 8.8

8 2 Angle 3HAA 1001-154


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Spare Parts

1.5 Axes 2 and 3


1 Material set, axes 2 and 3 3HAC 4324-1


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2 Manipulator material set, complete 3HAC 1215-1

1.3 2 Reduction gear 3HAB 4226-1 RV-250AII

1.4 2 O-ring 2152 0431-17 234.54x3.53

1.5 6 Screw 3HAB 7700-80 M12x140 12.9

Gleitmo 610

1.6 6 Support washer 3HAA 1001-200 12.5x24x5.9

1.7 6 Screw 3HAB 7700-94 M16x140 12.9Gleitmo 610

1.9 6 Spring washer 3HAA 1001-181

1.14 2 O-ring 2152 2012-550 269.3x5.7

1.16 2 Friction ring 3HAA 1001-6161.28 2 O-ring 2152 2012-437 124.5x3

1.29 2 Motor, axis 2,3 3HAB 8278-1

1.30 2 Screw 3HAB 3409-62 M10x100 12.9Gleitmo 610

1.31 8 Screw 9ADA 183-50 M10x25 8.8

1.32 8 Plain washer 9ADA 312-8 10.5x20x2

1.33 4 Magnetic plug 2522 122-1 1/4

1.34 Grease 3HAC 2331-1 Molywhite

1.35 4 Washer 2152 0441-1 13.5x18x1.5

1.37 2 Friction ring 3HAA 1001-613

1.38 Motor socket, mtrl kit 3HAB 4193-1

1.38.1 2 Motor socket 3HAB 4056-1

1.38.2 16 Screw 3HAB 3409-74 M12x80 12.9

1.38.3 16 Washer 3HAA 1001-632 13x21x2

1.39 1 Sync. plates 3HAA 0001-SU

Spare Parts

2.117 3 Nut 9ADA 267-3 M3 8

2.119 1 Measuring card unit 3HAB 4259-1

2.119.1 1 Serial measurement board 3HAB 2213-1 DSQC 313

2.120 29 Screw 9ADA 629-56 M6x16 8.8

2.121 1 Cover 3HAA 0001-SZ

2 146 1 k 4944 026 4


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2.146 1 Battery pack 4944 026-4

2.163 1 Grease tube 3HAA 1001-716

2.167 2 Screw 9ADA 629-59 M6x30

2.172 3 Screw 9ADA 629-57 M6x20

2.178 1 Guide for cabling 3HAA 1001-721

Spare Parts

1.6 Lower arm


Lower arm system 3HAB 4167-1


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1 1 Lower arm 3HAB 4168-1

2 1 Parallel arm 3HAC 1110-1

3 2 Spherical roller bearing 3HAB 4169-1

4 2 Spacing sleeve 3HAB 4387-1

5 2 Set screw 2122 2765-99 M20x20

6 2 Damper 3HAA 1001-81

7 2 Damper 3HAA 1001-123

8 4 Screw 9ADA 183-37 M8x25

9 4 Washer 9ADA 312-7 8.4x16x1.6

10 1 Damper 3HAA 1001-90

11 1 Support plate 3HAA 1001-282

12 2 Screw 2121 2763-364 M6x10

13 2 Damper 3HAA 1001-622

14 4 Screw 9ADA 618-56 M6x16

15 4 Plain washer 9ADA 312-6 6.4x12x1.6

16 Sealant 1269 1907-1 Loctite 577, 1 ml

17 Locking fluid 1269 0014-410 Loctite 243, 1 ml

Spare Parts

1.7 Upper arm


Upper arm complete 3HAC 1217-1


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1 1 Upper arm, machining 3HAC 2888-1

2 4 Plug 2529 1920-2 R1/8

3 1 Tilt house, machining 3HAC 3010-1

4 1 Drive unit axis 6 3HAB 6828-1

5 1 Shaft tilt house 3HAC 1210-1

6 12 Hex socket head cap screw 3HAB 3409-50 M10x40 12.9Gleitmo 610

7 12 Plain washer 3HAC 1315-1

8 6 Hex socket head cap screw 3HAB 3402-37 M8x25 8.8Gleitmo 610

9 2 Shaft upper arm 3HAC 2887-110 2 Sealing ring without dust lip 3HAB 3701-23 D=48/62 B=8

11 2 Taper roller bearing 3HAB 3729-14 D=40/90 B=23

12 Lubricating grease 1171 4012-201 5 g

13 Locking liquid 1269 0014-410 Loctite 243 5 ml

14 2 Lock nut 2126 2851-108 M40x1.5

15 2 VK-cover 3HAA 2166-17 D=19 B=616 2 VK-cover 3HAA 2166-20 D=90 B=8

17 1 Cabling upper front c.-conn. 3HAC 0710-1

18 1 Bracket motor 6 3HAC 1087-1

19 12 Toex pan head roll. screw 9ADA 629-54 M6x10

20 1 Plastic cover 3HAC 1854-1



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Spare Parts

1.9 Drive unit axis 6


Drive unit axis 6 3HAB 6828-11 1 Motor 3HAB 5762 1


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1 1 Motor 3HAB 5762-1

2 1 O-ring 2152 0431-12 151.99x3.53

3* 1 Reduction gear 3HAB 5593-1 ERV-30A-81

3.3 1 Pinion 3HAA 1001-522 RV-30E-81

4 8 Hexagon cap screw 3HAB 3409-40 M8x40 12.9

5 1 Hexagon cap screw 9ADA 183-21 M5x50 8.8

6 8 Washer 3HAA 1001-172 8.4x13x1.5

7 1 Magnetic plug 2522 122-1 R 1/4

8 1 Washer 2152 0441-1 13.5x18x1.5

9 1 Sync. plate axis 5 3HAA 1001-77

10 1 Sync. plate axis 6 3HAA 1001-78

11 1 Sync. plate with nonie 3HAA 1001-174

12 4 Six point socket screw 9ADA 629-32 M4x8

13 4 Plain washer 9ADA 312-4 4.3x9x0.8

14 Grease 3HAC 2331-1 Molywhite 300 ml

15 Locking fluid 1290 014-410 Loctite 243 1 ml

* when exchanging the reduction gear a new item 11 must be fitted

Spare Parts

1.10 Cooling device axis 1


1 Cooling axis 1 3HAC 2306-1

1 1 R di l f 3HAA 0001 UL


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1 1 Radial fan 3HAA 0001-UL

2 4 Screw 9ADA 618-56 M6x16 8.8

3 1 Gasket 3HAA 1001-607

4 1 Bracket 3HAB 5882-1

5 2 Gasket 3HAB 6968-1

6 1 Flange 3HAA 1001-605

7 4 Nut 9ADA 267-6 M6 8

8 1 Cover 3HAC 2341-1

9 1 Screw 9ADA 618-61 M6x40 8.8

10 1 Holder 3HAC 2342-1

11 1 Cover 3HAA 0001-VH

12 1 Fan cabling 3HAA 0001-ACE

13 1 Cable gland 3HAB 6509-7 Pr 18.6

16 4 Air filter 3HAA 1001-612

17 1 Sealing plug 2522 253-2 Pr 18.6

1.11 Cabling

21 1 Base cabling 3HAC 3766-1 See section 1.2CP/CS

21 1 Base cabling 3HAC 3880-1 See section 1.2CP/CS, CAN

47 1 Axis 2 cabling 3HAC 0703-1 See section 1.248 1 Axis 3 cabling 3HAB 8737-1 See section 1.2

17 1 Cabling upper front 3HAC 3953-1 See section 1.7CP/CS

Spare Parts

1.13 Signal lamp


Signaler lamp 3HAC 3736-1 Foldout 11

1 1 Lamp 3HAC 2552 1


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1 1 Lamp 3HAC 2552-1

2 1 Lamp holder 3HAC 2987-1

3 1 O-ring 3HAB 3772-21

4 1 Bracket signal lamp 3HAC 3629-1

5 1 Cable gland (tabular dr.) 3HAB 6509-2

6 1 Torx pan head roll. screw 9ADA 629-54

1.14 Customer vacum set


Customer vacum, complete 3HAC 2127-1

1 1 Cover with gasket 3HAB 7748-1

1 1 Cover with gasket 3HAC 2128-1

2 1 Cust. power vaccuum, R1-R2 3HAC 2130-1

3 1 Sealing gasket 2152 0363-5

4 4 Torx pan head screw 9ADA 618-235 1 Dust cap 3HAA 1001-630

6 1 Contactholder 3HAB 4132-1

7 1 Cable straps, outdoors 2166 2055-3

8 1 Earth symbol 3HAB 5617-1

9 5 Torx pan head roll. screw 9ADA 629-42

10 3 Plain washer 9ADA 312-511 0.8 Single-core cable 9ADA 103-35

12 2 Cable lug 9ADA 219-11


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Circuit Diagram

CONTENTSPage

Circuit Diagram 3HAC 1352-1 Rev. 00

Contents......................................................................................................................... 3Connection Point Location ........................................................................................... 4

Legend .......................................................................................................................... 5

Brake Unit..................................................................................................................... 6

Axis 1............................................................................................................................ 7

Axis 2............................................................................................................................ 8


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Axis 2............................................................................................................................ 8

Axis 3............................................................................................................................ 9

Axis 6............................................................................................................................ 10

Customer Power Connection (Option) ......................................................................... 11Customer Signal Connection........................................................................................ 12


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Revision

00No. of sheetssheet

3 10

CircuitDiagram3HAC

1352-1Contents


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Revision


5 10

CircuitDiagram3HAC

1352-1Legend


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Revision


6 10

CircuitDiagram3HAC

1352-1Brake Unit


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Revision


7 10

CircuitDiagram3HAC

1352-1Axis 1


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Revision


8 10

CircuitDiagram3HAC

1352-1Axis 2


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Revision


9 10

CircuitDiagram3HAC

1352-1Axis 3


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Revision


10 10

CircuitDiag

ram3HAC

1352-1Axis 6


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Revision


11 10

CircuitDiag

ram3HAC

1352-1Customer Power Connection (Option)


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S4CPlus-Product Manual IRB 640 3HAC 7579-1 M2000

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