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IRB6400
ABB IRB6400 Assembly Guidelines
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Effective Date: June 1, 1996
Flexible Automation Inc.
1250 Brown Road
Auburn Hills, Mich. 48326
1-800-451-6268
FOR
IRB6400
INDUSTRIAL ROBOT
MECHANICAL
DISASSEMBLY/ASSEMBLY
GUIDELINES
Manual Part #7000695-001
2
Table of Contents
Introduction
6
What You Must Know to Use the Robot
11
Robot Components
12
Robot Identification
13
Symbols Used in this Manual
14
Safety
16
Table of Contents
16
General Safety
18
Safety Features
19
Safety Guidelines
20
Safety During Maintenance
21
Safety During Programming
22
Safety Control Chain of Operation
23
Risks Associated with Live Parts
24
Robot Lifting
28
Releasing Axes Brakes Manually
32
Restricting Axes Movement Mechanicall y
33
Axis
35
General Maintenance
36
Axis
37
Maintenance Schedule
37
General Instructions
38
Maintenance Instructions
38
Axis
39
Lubricating Axis 1 Gear Reduction Unit (S59)
40
Disassembly/Assembly
40
Lubricating Axes 2 & 3 Gear Units (S35)
41
Disassembly/Assembly
41
Oil Change Gearbox, Axis 4 (U61)
42
Guidelines IRB
42
Oil Change for Axis 5 Gearbox (W8)
44
Lubricating Axis 6 Gearbox (F17)
46
Checking Axis 1 Mechanical Stop
47
Changing Measuring System Battery
48
Changing Axis 1 Cooling Filter
49
Changing Control Air Conditioner Filter
50
Changing Control Memory Battery Backup
51
Adjusting Axis 4 Gear Play
52
Adjusting Play between Intermediate Gear (U74)
52
Final Gear (U41)
52
Adjusting Play between Axis 4 Motor Pinion
53
Checking Axis 5 Gear Play
53
Adjusting Axis 5 Gear Play
54
Adjusting Axis 5 Bearings Pre-Tension
55
Checking Axis 6 Gear Reduction Unit Play
56
Tool List
59
Disassembly/Assembly
61
Lubricating Axis 1 Large Bearing (S46)
39
Axis 1
62
Motor (S16) Removal
63
Motor (S16) Installation
65
Gear Reduction Unit (S59) Removal
67
GEAR REDUCTION UNIT (S59) Installation
70
Bearing (B47) Removal
73
Bearing (B47) Installation
76
Disassembly/Assembly
81
Axes 2 & 3
82
Motor (S71) Removal
83
Motor (S71) Installation
85
Gear Reduction Unit (S35) Removal
87
GEAR REDUCTION UNIT (S35) Installation
88
Parallel Bar (L42) Removal
92
Parallel Bar (L42) Installation
95
Bearings (L40) & (L56) Removal
96
Upper Arm Assembly Removal
101
Upper Arm Assembly Installation
103
Axis 4
108
Motor (U83) Removal
109
Motor (U83) Installation
112
INTERMEDIATE GEAR UNIT (U75) Removal
115
INTERMEDIATE GEAR UNIT (U75) Installation
118
Final Gear (U41) Removal
120
Final Gear (U41) Installation
123
Tube Shaft (U19) Removal
125
Tube Shaft (U19) Installation
126
Robot Calibration
170
Calibration Procedures
172
Overview
172
Rough" Resolver Calibration Procedure
173
Manually Entering Calibration Values
179
Precision Resolver Calibration Procedure
183
Calibrating Axis 1
184
Calibrating Axis 2-6
185
Counter Updating Procedure
192
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ABB IRB6400 Specifications
General
Manufacturer
ABB
Model
IRB6400
Type
Industrial Robot
Payload Capacity
150 kg
Degrees of Freedom
6
Number of axes
6
Protection
IP54
Mounting
Wall
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