Irb 6640 Spare Parts PDF

ABB Robotics
Product manual, spare parts

IRB 6640
Trace back information:

Workspace RW 5-15-01 version a2
Checked in 2013-03-15
Skribenta version 1184
Product manual, spare parts

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: 3HAC038330-001
Revision: C
Copyright 2010-2013 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
construed as any kind of guarantee or warranty by ABB for losses, damages to
persons or property, fitness for a specific purpose or the like.
In no event shall ABB be liable for incidental or consequential damages arising from
use of this manual and products described herein.
This manual and parts thereof must not be reproduced or copied without ABB's
written permission.
Additional copies of this manual may be obtained from ABB.
The original language for this publication is English. Any other languages that are
supplied have been translated from English.

ABB AB
Robotics Products
SE-721 68 Vsters
Sweden
Table of contents
Table of contents
Overview of this manual ...................................................................................................................
Product documentation, M2004 .......................................................................................................
1
Rebuilding robot
1.1
7
9
11
Rebuilding parts ................................................................................................ 11
Spare parts and exploded views
15
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
15
19
21
26
30
31
33
38
40
41
42
44
46
49
Spare parts - balancing device .............................................................................

Spare parts - lower arm ......................................................................................
Spare parts - motors ..........................................................................................
Spare parts - wrist unit .......................................................................................
Spare parts - axis 6 complete ..............................................................................
Spare parts - turning disk ....................................................................................
Spare parts - gearboxes .....................................................................................
Spare parts - armhouse ......................................................................................
Spare parts - axis 3-4 .........................................................................................
Spare parts - upper arm ......................................................................................
Spare parts - upper arm extenders .......................................................................
Spare parts - SMB .............................................................................................
Spare parts - manipulator harness ........................................................................
Spare parts - other parts .....................................................................................
3HAC038330-001 Revision: C
5
This page is intentionally left blank
Overview of this manual

About this manual
This manual contains spare parts for:
IRB 6640 and all its variants.
Usage
This manual shall be used as a complement to the product manual for IRB 6640
during:
maintenance work
repair work.
Who should read this manual?

This manual is intended for:
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.
References
Reference
Document Id
Product manual - IRB 6640 Foundry Prime
3HAC040586-001
Product manual - IRB 6640
3HAC026876-001
Circuit diagram - IRB 6640
3HAC025744-001
Revisions
Revision
Description
First edition
This revision includes following additions and/or changes:

Section Rebuilding parts on page 11 added.
Section Manipulator harness - other parts on page 46 position 532
changed.
Continues on next page

7

Continued
Revision
Description
This revision includes following corrected, added or deleted spare part

numbers:
axis-5 motor, complete axis 6, see Rebuilding parts on page 11.
axis-3 motor and axis-5 motors, see Spare parts - motors on page 21.
balancing device, design 2 and VK covers, see Balancing device design 2 on page 17.
cover, sealing and gasket for armhouse, see Spare parts - armhouse
on page 38.
axis 3-4, see Spare parts - axis 3-4 on page 40.
support shaft including bearing, see Spare parts - wrist unit on page 26.
cradle for the balancing device, see Spare parts - balancing device
on page 15.
turning disk, see Spare parts - turning disk on page 31.
attachment screw, see Spare parts - gearboxes on page 33.
arm extenders, see Spare parts - upper arm extenders on page 42.
covers, see Spare parts - SMB on page 44.
gaskets for Foundry Plus and Foundry Prime, see Spare parts - upper
arm extenders on page 42, Spare parts - wrist unit on page 26 and
Spare parts - upper arm on page 41.
motor gasket for Clean Room, see Spare parts - motors on page 21.
This revision includes following corrected, added or deleted spare part

numbers:
Deleted 3HAC029980-001 and 3HAC030432-001 in section Spare parts
- manipulator harness on page 46.
A new SMB unit and battery is introduced, with longer battery lifetime.
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
Manipulators, controllers, DressPack/SpotPack, and most other hardware will be
delivered with a Product manual that generally contains:
Safety information.
Installation and commissioning (descriptions of mechanical installation or

electrical connections).
Maintenance (descriptions of all required preventive maintenance procedures

including intervals and expected life time of parts).
Repair (descriptions of all recommended repair procedures including spare

parts).
Calibration.
Decommissioning.
Reference information (safety standards, unit conversions, screw joints, lists

of tools ).
Spare parts list with exploded views (or references to separate spare parts
lists).
Circuit diagrams (or references to circuit diagrams).
Technical reference manuals

The technical reference manuals describe reference information for robotics
products.
Technical reference manual - Lubrication in gearboxes: Description of types

and volumes of lubrication for the manipulator gearboxes.
Technical reference manual - RAPID overview: An overview of the RAPID

programming language.
Technical reference manual - RAPID Instructions, Functions and Data types:

Description and syntax for all RAPID instructions, functions, and data types.
Technical reference manual - RAPID kernel: A formal description of the

RAPID programming language.
Technical reference manual - System parameters: Description of system

parameters and configuration workflows.
Application manuals
Specific applications (for example software or hardware options) are described in
Application manuals. An application manual can describe one or several
applications.
9

Continued
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, DVD with PC software).
How to install included or required hardware.
How to use the application.
Examples of how to use the application.
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 (among others):
Operating manual - Emergency safety information
Operating manual - General safety information
Operating manual - Getting started, IRC5 and RobotStudio
Operating manual - Introduction to RAPID
Operating manual - IRC5 with FlexPendant
Operating manual - RobotStudio
Operating manual - Trouble shooting IRC5, for the controller and manipulator.
10
1 Rebuilding robot
1.1 Rebuilding parts
1 Rebuilding robot
Introduction
The robot has some rebuilding parts, depending on robot version. This section is
an overview of which part is used on which version. The tables are divided according
to the protection of the robot.
More detailed information about the components needed for actual rebuild from a
certain robot version into an other is found on ABB Library or is attained from ABB.
Also, further details of the parts listed are specified in Spare parts and exploded
views on page 15.
Rebuilding parts - Standard and Foundry Plus
Spare part number Description
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
3HAC028470-001
Balancing device - design 1
3HAC032124-003
3HAC034056-001
Lower arm, design 2
3HAC034056-002
Lower arm - long, design 2
3HAC033182-001
Motor, axis 1, incl. pinion
3HAC033163-001
3HAC033203-001
3HAC033209-001
3HAC033207-001
3HAC038443-001
Motor, axis 5, excl. pinion
3HAC17484-10
3HAC033236-001
3HAC033224-001
3HAC033234-001
3HAC033225-001
3HAC16627-3
Wrist, type 1
3HAC17372-2
Wrist, type 1 - Insulated
3HAC16626-2
Wrist, type 2
3HAC16626-3
Wrist, type 2 - Insulated
3HAC024793-001
Wrist - Process
3HAC16032-3
Axis 6 complete (wrist type 1)
3HAC17372-2
Axis 6 complete (wrist type 1 - insulated) X
3HAC037210-002
3HAC17371-3
Axis 6 complete (wrist type 2 - insulated)
X
X
X
X
X
X

11
1 Rebuilding robot
Continued
Spare part number Description
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
3HAC026114-005
Gearbox, axis 1
3HAC024316-005
Gearbox, axis 2
3HAC021127-004
Gearbox, axis 3
3HAC037835-001
Gearbox, axis 6 (wrist type 1)
3HAC037635-002
3HAC12311-40
Arm extension set, 250 mm
3HAC12311-50
3HAC031851-001
Serial measurement unit
3HAC024385-001
Manipulator harness, axes 1-6
3HAC024386-001
3HAC039428-001
3HAC039429-001
3HAC14139-1
Manipulator harness, axis 5
3HAC023717-001
X
X
X
X
X
X
X
X
X
X
Rebuilding parts - Foundry Prime

Spare part number
Description
3HAC12311-40
235/2.55
185/2.8
X
Rebuilding parts - Clean Room

Spare part number
Description
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
3HAC030868-001
3HAC033372-001
3HAC034056-004
Lower arm, design 2
3HAC034056-005
Lower arm - long, design 2
3HAC030794-001
3HAC030800-001
3HAC030825-001
3HAC032501-001
3HAC030826-001
3HAC17484-7
3HAC17484-10
3HAC030828-001
3HAC030829-001
3HAC033868-001
Wrist, type 1
3HAC030281-003
Wrist, type 2
X
X

12
1 Rebuilding robot
Continued
Spare part number
Description
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
3HAC033868-001
3HAC030281-003
3HAC026114-006
Gearbox, axis 1
3HAC024316-006
Gearbox, axis 2
3HAC021127-005
Gearbox, axis 3
3HAC037835-002
3HAC037635-003
3HAC031851-001
Serial measurement unit
3HAC029840-003
Manipulator harness, axes 1-6 / axis 1-3 cable
13
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2 Spare parts and exploded views

2.1 Spare parts - balancing device

Pos
Spare part number Part number

(WebConfig)
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
3HAC028470-001
Standard
Foundry Plus
3HAC026268-001
3HAC033363-001
Foundry Prime
3HAC027987-001
3HAC030868-001
Clean Room
3HAC026268-001
X
X
X
X
Maintenance sets, balancing device- design 1

Pos
Part number
Description
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
G.1
3HAC029288-001
Maintenance set,
Cradle
G.2
3HAC029054-001
Maintenance set,
Shaft
G.3
3HAC17188-1
Gasket,
End cover
G.4 i
3HAC026582-006
Cradle
Standard
Foundry Plus
3HAC026582-005
Cradle
Foundry Prime
3HAC026582-007
Cradle
Clean Room
3HAC4836-21
VK cover
G.5
The cradle is the same for both design 1 and design 2 of the balancing device. Location of the
cradle is shown in figure Illustration - design 2 on page 18.

15

Continued
Illustration - design 1
G.5
G.2
G.1
G.3
xx0700000341

16

Continued
Pos

(WebConfig)
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
3HAC032124-003
Standard
Foundry Plus
3HAC032124-001
3HAC034865-003
Foundry Prime
3HAC034865-001
3HAC033372-001
Clean Room
3HAC032124-001
Maintenance sets, balancing device - design 2

Pos
Part number
Description
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
G.1
3HAC033413-001
Maintenance set,
Cradle
G.2
3HAC033411-001
Maintenance set,
Shaft
G.3
3HAC17188-1
Gasket,
End cover
G.4
3HAC026582-006
Cradle
Standard
Foundry Plus
3HAC026582-005
Cradle
Foundry Prime
3HAC026582-007
Cradle
Clean Room
3HAA2166-12
VK cover
G.5

17

Continued
Illustration - design 2
2x
G
G.2
G.1
G.5
G.3
G.4
xx0800000253
18

2.2 Spare parts - lower arm

Spare part list - design 1
Pos
Spare part number
Part number
(WebConfig)
180/
2.55
235/
2.55
210/
2.55
205/
2.75
J.1
3HAC033733-001
Standard
Foundry Plus
3HAC023627-005
J.1
3HAC033733-005
Foundry Prime
3HAC027883-003
J.1
3HAC033733-002
Clean Room
3HAC023627-005
J.1
3HAC033733-003
(long lower arm)
Standard
Foundry Plus
3HAC027033-005
J.1
3HAC033733-004
(long lower arm)
Clean Room
3HAC027033-005
130/
3.2
X
X
185/
2.8
200/
2.55
(ID)
170/
2.75
(ID)
X
X
X
X
Spare part list - design 2

Pos
Spare part number
Part number
(WebConfig)
180/
2.55
235/
2.55
210/
2.55
205/
2.75
J.2
3HAC034056-001
Standard
Foundry Plus
3HAC031985-001
J.2
3HAC033733-006
Foundry Prime
3HAC034868-001
J.2
3HAC034056-004
Clean Room
3HAC031985-001
J.2
3HAC034056-002
(long lower arm)
Standard
Foundry Plus
3HAC032177-001
J.2
3HAC034056-005
(long lower arm)
Clean Room
3HAC032177-001
130/
3.2
X
X
185/
2.8
200/
2.55
(ID)
170/
2.75
(ID)
X
X
X
X
Lower arm - other parts

Pos
Part number
Description
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
J.3
3HAC12991-1
Damper, axis 2

19

Continued
Pos
Part number
Description
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
J.4
3HAC14300-1
Cable protector
Illustration - spare part lower arm design 1 (J1) and design 2 (J2)
xx0800000429
20

2.3 Spare parts - motors

Motors axis 1 (including pinion)
Pos

(WebConfig)
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
3HAC033182-001
Type A2
Standard
Foundry Plus
3HAC024519-001
3HAC034783-003
Type A2NB
Foundry Prime
3HAC027514-004
3HAC030794-001
Type A2
Clean Room
3HAC024519-001

Pos

(WebConfig)
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
3HAC033163-001
Type M13
Standard
Foundry Plus
3HAC025724-001
3HAC034782-003
Type M13NB
Foundry Prime
3HAC031145-001
3HAC030800-001
Type M13
Clean Room
3HAC025724-001
Pos
Part no.
Description
3HAC026770-001
Pinion RV550E

Pos
Spare part number
Part number
(WebConfig)
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
2.75
3HAC033203-001
Type M9
Standard
Foundry Plus
3HAC17484-9
3HAC034832-003
Type M9NB
Foundry Prime
3HAC027514-009

21

Continued
Pos
Spare part number
Part number
(WebConfig)
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
3HAC030825-001
Type M9
Clean Room
3HAC17484-9
Pos
Part no.
Description
3HAC10122-15
Pinion RV410F
200/
2.55
(ID)
170/
2.75
2.75

Pos

(WebConfig)
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
2.75
3HAC033209-001
Type M7
Standard
Foundry Plus
3HAC17484-7
3HAC032501-001
Type M7
Clean Room
3HAC17484-7
3HAC033207-001
Type M10
Standard
Foundry Plus
3HAC17484-10
3HAC035065-003
Type M10NB
Foundry Prime
3HAC027514-010
3HAC030826-001
Type M10
Clean Room
3HAC17484-10
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
Motors axis 5 IRB6640 (excluding pinion)

Pos

(WebConfig)
180/
2.55
3HAC038443-001
Type M7
Standard
Foundry Plus
3HAC17484-7
3HAC17484-7
Type M7
Clean Room
3HAC17484-7
235/
2.55
210/
2.55
170/
2.75
(ID)

22

Continued
Pos

(WebConfig)
3HAC17484-10
Type M10
Standard
Foundry Plus
Clean Room
3HAC033223-001
Type M10NB
Foundry Prime
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
3HAC17484-10
3HAC027514-010
200/
2.55
(ID)
170/
2.75
(ID)
200/
2.55
(ID)
170/
2.75
(ID)
200/
2.55
(ID)
170/
2.75
(ID)
Motors axis 5 IRB 6640ID (including pinion)

Pos

(WebConfig)
3HAC033236-001
Type PM2
Standard
Foundry Plus
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
3HAC12638-1

Pos

(WebConfig)
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
3HAC033224-001
Type M8
Standard
Foundry Plus
3HAC17484-8
3HAC030828-001
Type M8
Clean Room
3HAC17484-8
3HAC033234-001
Type M8
Standard
Foundry Plus
3HAC17484-8
3HAC034862-003
Type M8NB
Foundry Prime
3HAC027514-008
3HAC030829-001
Type M8
Clean Room
3HAC17484-8
3HAC033225-001
Type PM1
Standard
Foundry Plus
3HAC12638-3

23

Continued
Pos

(WebConfig)
180/
2.55
3HAC10122-24
Pinion RV40E
3HAC11173-3
Pinion RV70F
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
Motors - other parts

Pos
Part number
Description
180/
2.55
235/
2.55
210/ 205/
2.55 2.75
185/
2.8
130/
3.2
3HAC030161-001
Protection plugs
3HAC026511-001
Elbow fittings
21522012-430
O-ring
(89.5x3)
3HAB3772-22
O-ring
(67.5x3.0)
3HAC3438-1
Motorplate
Motor, axes 1-5
3HAC033206-001
Gasket
Motor axis 6
3HAC033489-001
Gasket, cover
Motor axis 6
3HAC7941-28
Set of shims
Motor axis 5
3HAC033489-001
Gasket for axis-6 motor

cover
Clean Room
200/
2.55
(ID)
170/
2.75
(ID)

24

Continued
Illustration
xx0700000383
25

2.4 Spare parts - wrist unit

Spare parts - wrist, type 1
Pos
Spare part number
Part number
(WebConfig)
180/
2.55
3HAC16627-3
Standard
Foundry Plus
3HAC8114-1 or
3HAC8114-6
3HAC17372-2
Insulated
3HAC8114-7
3HAC033868-001
Clean Room
3HAC030279-001
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
Spare parts - wrist, type 2

Pos
Spare part number
Part number
(WebConfig)
180/2.55 235/2.55 210/2.55 205/2.75 185/2.8 130/3.2 200/2.55(ID) 170/2.75

(ID)
3HAC16626-2
Standard
Foundry Plus
3HAC8114-3 or
3HAC8114-5
3HAC16626-3
Insulated
3HAC8114-8
3HAC026879-002
Foundry Prime
3HAC034863-001
3HAC030281-003
Clean Room
3HAC030281-001
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
Spare part - wrist, process

Pos
Spare part number
Part number
(WebConfig)
3HAC024793-001
Standard
Foundry Plus
3HAC023639-001
180/
2.55
200/
2.55
(ID)
170/
2.75
(ID)
200/
2.55
(ID)
170/
2.75
(ID)
Spare part - other parts

Pos
Spare part number
Part number
(WebConfig)
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
H.4
3HAC8081-10
Gear cover
(Gasket included)
Standard
Foundry Plus
3HAC8081-8

26

Continued
Pos
Spare part number
Part number
(WebConfig)
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
H.4
3HAC8081-11
Gear cover
(Gasket included)
Clean Room
3HAC8081-8
H.4
3HAC037426-003
Gear cover
(Gasket included)
Foundry Prime
3HAC037426-001
H.4
3HAC024810-001
Gear cover
(Gasket included)
3HAC024810-001
H.5
3HAC022172-003
Cable cover
Standard
Foundry Plus
3HAC022172-001
H.5
3HAC022172-004
Cable cover
Cleanroom
3HAC022172-001
H.5
3HAC034932-002
Cable cover
Foundry Prime
3HAC034932-001
H.6
3HAC035975-001
3HAC027205-001
Support shaft including
bearing
Standard
Foundry Plus
Foundry Prime
H.6
3HAC026318-001
3HAC7941-32
Support shaft including
bearing
Clean Room
H.7
Damper axis 5
3HAB4337-2
H.8
Sync. plate
(Wrist, type 1)
3HAC025565-001
H.8
Sync. plate
(Wrist, type 2)
3HAC025581-001
H.9
Magnetic plug
G1/2"
3HAC16721-1

27

Continued
Pos
Spare part number
Part number
(WebConfig)
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
H.10
Magnetic plug
G1/4"
3HAC037925-001
H.10
Sealing for magnetic

plug G1/4"
3HAC029646-001
H.11
Protection cover
(Cal. axis 6)
3HAC14263-1
Gasket for wrist house 3HAC043225-001

cover
Foundry Plus
Foundry Prime
200/
2.55
(ID)
170/
2.75
(ID)

28

Continued
Illustration wrist
H.2
H.3
D
H.11
H.10
H.1
H.8
D
D-D
H.4
H.7
H.9
H.6
H.5
xx0800000397
29

2.5 Spare parts - axis 6 complete
2.5 Spare parts - axis 6 complete

Axis 6 complete, wrist type 1
Pos
Spare part number
Part number
(WebConfig)
180/
2.55
H.1
3HAC16032-3
Standard
Foundry Plus
3HAC030147-001
or
3HAC16032-1
H.1
3HAC17372-2
Insulated
3HAC021156-001
H.1
3HAC033868-001
Clean Room
3HAC030278-001
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
Axis 6 complete, wrist type 2

Pos

(WebConfig)
180/
2.55
H.1
3HAC037210-002
Standard
Foundry Plus
3HAC030141-001
H.1
3HAC17371-3
Insulated
3HAC025177-001
H.1
3HAC026879-002
Foundry Prime
3HAC034865-001
H.1
3HAC030281-003
Clean Room
3HAC030280-001
X
X
30

2.6 Spare parts - turning disk

Turning disk, type 1
Pos
Spare part number
Part number
(WebConfig)
180/
2.55
H.2
3HAC030264-001
Foundry Plus
Clean Room
3HAC030264-001
3HAC030223-001
Standard
Foundry Prime
3HAC030223-001
3HAC035285-004
Process wrist
Standard
Foundry Plus
3HAC035285-004
21212518-577
M14x25, 12.9
(6 pcs)
21212518-577
21520431-20
O-ring 15.5x1.5
(6 pcs)
21520431-20
3HAB3772-65
O-ring 131x2
3HAB3772-65
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
200/
2.55
(ID)
170/
2.75
(ID)
Turning disk, type 2

Pos
Spare part number
Part number
(WebConfig)
H.3
3HAC030224-001
Standard
Foundry Plus
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
3HAC030224-001
3HAC037848-001
Foundry Prime
Clean Room
3HAC037848-001
3HAC035285-005
Process wrist
Standard
Foundry Plus
3HAC035285-005
3HAB3409-65
M12x30, 12.9
(12 pcs)
3HAB3409-65
3HAB3772-61
O-ring 13.1x1.6
(12 pcs)
3HAB3772-61

31

Continued
Pos
Spare part number
Part number
(WebConfig)
3HAB3772-64
O-ring 150x2
3HAB3772-64
180/
2.55
235/
2.55
210/
2.55
205/
2.75
32
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)

2.7 Spare parts - gearboxes

Gearboxes axis 1
Pos
Spare part number
Part number
(WebConfig)
180/
2.55
235/
2.55
210/
2.55
210/ 185/
2.75 2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
K.1
3HAC026114-005
RV320C-191.35
Standard
Foundry Plus
3HAC026114-001
K.1
3HAC026114-004
RV320C-191.35
Foundry Prime
3HAC026114-001
K.1
3HAC026114-006
RV320C-191.35
Clean Room
3HAC026114-001
Gearbox axis 1 - other parts

Pos
Part number
Description
Note
3HAC024286-001
Cable guide
3HAC11581-4
Sealing, RV320C pipe
3HAC026892-001
Protection pipe
3HAB3772-97
O-ring (23x3.6)
3 pcs
3HAB3772-93
O-ring (380.6x3.53)
Included in RV320C
3HAB3409-86
M16x60, Gleitmo 12.9
12 pcs
3HAA1001-186
Washer, (17x25x3)
12 pcs
3HAB3409-74
16 pcs
3HAC026169-001
Serrated washer, (12.6x18x1.8)
16 pcs
Gearboxes axis 2
Pos
Spare part number
Part number
(WebConfig)
180/
2.55
235/
2.55
210/
2.55
210/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
K.2
3HAC024316-005
RV550E-242.73
Standard
Foundry Plus
3HAC024316-001
K.2
3HAC024316-004
RV550E-242.73
Foundry Prime
3HAC024316-001
K.2
3HAC024316-006
RV550E-242.73
Clean Room
3HAC024316-001

33

Continued
Gearbox axis 2- other parts
Pos
Part number
Description
Note
3HAB3772-91
O-ring (339.3x5.7)
Included in RV550E
3HAB3409-84
20 pcs
3HAA1001-186
Washer, 17x25x3
20 pcs
3HAB3409-71
32 pcs
3HAA1001-134
Washer, 13x19x1.5
32 pcs
Gearboxes axis 3
Pos
Spare part number
Part number
(WebConfig)
180/
2.55
235/
2.55
210/
2.55
210/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
K.3
3HAC021127-004
RV410F-270.176
Standard
Foundry Plus
3HAC021127-001
K.3
3HAC021127-003
RV410F-270.176
Foundry Prime
3HAC021127-001
K.3
3HAC021127-005
RV410F-270.176
Clean Room
3HAC021127-001
Gearbox axis 3 - Other parts

Pos
Part number
Description
Note
3HAC17212-1
Sealing axis 2/3
3HAB3772-68
O-ring (276x3.53)
Included in RV410F
3HAB3409-71
M12x60 Gleitmo 12.9
24 pcs
3HAA1001-134
Washer, 13x19x1.5
24 pcs
3HAB7700-69
M12x50 Gleitmo 12.9
33 pcs
3HAC038648-001
Foundry Plus (grey)
Washer axis 3
3 pcs
3HAC038648-002
Washer axis 3
Standard
Foundry Plus (orange)
3 pcs

34

Continued
Gearboxes axis 6 - Wrist, type 1
Pos
Spare part number
Part number
(WebConfig)
180/
2.55
K.6
3HAC037835-001
RV40E-81
Standard
Foundry Plus
3HAC10828-10
K.6
3HAC037835-002
RV40E-81
Clean Room
3HAC10828-10
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
130/ 200/
3.2
2.55
(ID)
170/
2.75
(ID)
Gearboxes axis 6 - Wrist, type 2

Pos
Spare part number
Part number
(WebConfig)
180/
2.55
K.6
3HAC037635-002
RV70F-125.8
Standard
Foundry Plus
3HAC10828-13
K.6
3HAC037635-001
RV70F-125.8
Foundry Prime
3HAC10828-13
K.6
3HAC037635-003
RV70F-125.8
Clean Room
3HAC10828-13
Gearbox axis 6 - Other parts

Pos
Part number
Description
180/
2.55
3HAB3772-58
O-ring, 152.0x3.53
Included in RV40E
Wrist type 1
3HAB7700-55
M8x40, Gleitmo 12.9

Wrist type 1
(8 pcs)
3HAA1001-172
Washer, 8.4x13x1.5
Wrist type 1
(8 pcs)
3HAB3772-65
O-ring, 131.0x2.0
Wrist type 1
21520431-20
O-ring, 15.5x1.5
Wrist type 1
(6 pcs)
235/
2.55
210/
2.55
205/
2.75
185/
2.8

35

Continued
Pos
Part number
Description
3HAB3772-57
O-ring, 164.7x3.53
Included in RV70F
Wrist type 2
3HAB7700-55
M8x40, Gleitmo 12.9

Wrist type 2
(18 pcs)
3HAA1001-172
Washer, 8.4x13x1.5
Wrist type 2
(18 pcs)
3HAB3772-64
3HAB3772-61
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/ 200/
3.2
2.55
(ID)
O-ring, 150.0x2.0
Wrist type 2
O-ring, 13.1x1.6
Wrist type 2
(12 pcs)
170/
2.75
(ID)

36

Continued
Illustration gearboxes
xx0800000442
37

2.8 Spare parts - armhouse

Pos Spare part no.
Description
Axis-4 cover
For robots with protection
Standard and Foundry
Plus.
3HAC036148-001
3HAC036148-002
3HAC036148-003
Note
Includes sealing 3HAA1001-628.

Fits robots that has a sleeve installed on the tube shaft.
The figure Sleeve on tube shaft on
page 39 shows where the sleeve is
Axis-4 cover
located.
If the robot is manufactured prior to
Foundry Prime.
November 2009, it is recommended
that a sleeve should be installed,
Axis-4 cover
For robots with protection according to the repair kit for axis 4
(see further down in the table), if not
Clean Room.
already installed. The recommendation is valid for all protection types.
3HAC12149-4
Axis-4 cover
Includes sealing 3HAA1001-628.
For robots with protection Fits robots that has not a sleeve inStandard.
stalled on the tube shaft. Robots with
protection type Standard, manufactured after November 2009, do not
need the sleeve.
The figure Sleeve on tube shaft on
page 39 shows where the sleeve is
located.
3HAC12149-2
Gasket, axis-4 cover
3HAA1001-628
Sealing
3HAC036161-001
Repair kit for axis 4

Standard and Foundry
Plus.
3HAC036161-002
3HAC036161-003
It is recommended that a sleeve

should be installed on the tube shaft
on robots (all protection types)
manufactured prior to November
2009. Foundry Prime and Clean
Room robots manufactured after
For robots with protection November 2009 are delivered with
the sleeve installed.
Foundry Prime.
The repair kit contains the sleeve,
the axis-4 cover and instructions for
For robots with protection how to fit the sleeve to the tube
Clean Room.
shaft.
Note
Fitting the sleeve requires an installation tool, 3HAC035563-001, not included in the repair kit.
3HAC037677-001
Axis-4 wheel unit

38

Continued
Illustration armhouse
xx1200000203
Sleeve on tube shaft

The figure shows where the sleeve is visible on the upper arm house.
39

2.9 Spare parts - axis 3-4
2.9 Spare parts - axis 3-4

Pos
Spare part number
180/
2.55
3HAC10746-7
Standard
3HAC10746-6
Standard
-
3HAC034834-002
Foundry Prime
3HAC034221-001
Clean Room
3HAC036134-001
Clean Room
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
40

2.10 Spare parts - upper arm
2.10 Spare parts - upper arm

Pos
Description
Spare part number
180/
2.55
Gasket for cable cover

on upper arm tube
3HAC043224-001
Foundry Plus
Foundry Prime
Gasket for small cover

on upper arm tube
3HAC043303-001
Foundry Plus
Foundry Prime
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
41

2.11 Spare parts - upper arm extenders

Spare part list - upper arm extenders
Pos

(WebConfig)
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
3HAC15859-2
Arm extender
250 mm
Standard
Clean Room
3HAC9760-3
3HAC038665-003
Arm extender
250 mm
Foundry Plus
3HAC15859-2
3HAC15859-4
Arm extender
450 mm
Foundry Plus
3HAC9760-7
Cable cover,
250 mm
3HAC9760-9
Cable cover,
450 mm
3HAC9760-10
Gasket for cable

cover on arm extender 250 mm
Foundry Plus
Foundry Prime
3HAC043302-001
Gasket for cable

cover on arm extender 450 mm
Foundry Plus
Foundry Prime
3HAC043398-001
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
200/
2.55
(ID)
170/
2.75
(ID)
X
X
X
Arm extenders - other parts

Pos
Part number
Description
3HAB7700-69
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
Hex socket head cap screw

M12x50, 12.9 Gleitmo
(12 pcs)
3HAA1001-134
Washer
13x19x1.5
9ABA107-56
Parallel pin
9ADA618-56
Torx pan head screw

M6x16, 8.8-A2F
(6 pcs)

42

Continued
Illustration - arm extenders
xx1000000259
43

2.12 Spare parts - SMB

Spare part list - SMB
Pos
Part number
(WebConfig)
Description
506
3HAC044168-001
507
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
SMB unit, RMU101 or RMU102 X
3HAC044075-001
Battery pack
X
Can only be used with SMB unit
3HAC044168-001
506
3HAC031851-001
SMB unit, DSQC633A
507
3HAC16831-1
Battery pack
X
Can only be used with SMB unit
3HAC031851-001
508
3HAC13151-1
Cable battery/SMB
518
3HAC16035-1
Brake release unit with buttons X

DSQC 563
519
3HAC6499-1
Push button guard
530
3HAC14791-4
Cover battery box

Standard
Foundry Plus
Clean Room
530
3HAC026190-001
Cover battery box

Foundry Prime
514
3HAC15619-1
Cable
FB7-SMB 1.7
521
3HAC026331-001
2BU Button Guard Plate
526
3HAC020105-001
Battery holder

44

Continued
Illustration Spare part - SMB
514
518
521 519
506
530
507
526
508
xx0800000443
45

2.13 Spare parts - manipulator harness

Spare part list - manipulator harness
Pos Spare part number
Part number
(WebConfig)
180/
2.55
235/
2.55
210/
2.55
Manipulator harness
Axes 1-6
Standard
Foundry Plus
Foundry Prime
3HAC024385-001
Manipulator harness
Axes 1-6
Standard
Foundry Plus
Foundry Prime
3HAC024386-001
Manipulator harness
Axes 1-6/MH axis 1-3 cable
Clean Room
3HAC029840-003
Cable harness, manipulator

Axes 1-4
Standard
Foundry Plus
3HAC039428-001
Cable harness, manipulator

Axes 1-4
Standard
Foundry Plus
3HAC039429-001
Manipulator harness,
Axis 5
3HAC14139-1
Manipulator harness,
Axes 5-6
Standard
Foundry Plus
3HAC023717-001
205/
2.75
185/
2.8
200/
2.55
(ID)
170/
2.75
(ID)
130/
3.2
X
X
Manipulator harness - other parts

Pos
Part number
(WebConfig)
Description
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
502
3HAC11774-3
Adapter, complete
Standard
Foundry Plus
Foundry Prime
25
3HAC11774-3
Adapter, complete
Clean Room
533
3HAC025079-001
Connection plate
Standard

46

Continued
Pos
Part number
(WebConfig)
Description
180/
2.55
235/
2.55
210/
2.55
205/
2.75
185/
2.8
130/
3.2
200/
2.55
(ID)
170/
2.75
(ID)
533
3HAC034080-001
Connection plate FP
Foundry Plus
Foundry Prime
534
3HAC025080-001
Frame bracket
Standard
Clean Room
534
3HAC033314-001
Frame bracket FP
Foundry Plus
Foundry Prime
23
3HAC030090-001
Attachment plate
Clean Room
24
3HAC13416-1
Protection cover
Clean Room
532
3HAC025081-001
Base cover
Standard
Clean Room
532
3HAC033315-001
Base cover FP
Foundry Plus
Foundry Prime
22
3HAC13960-1
Connection plate
Axis 3
Clean Room

47

Continued
Illustration spare part manipulator harness
7
L
24
25
532
22
24
534
25
502
23
533
xx0800000444
48

2.14 Spare parts - other parts
2.14 Spare parts - other parts

Surface treatment
Part no.
Description
3HAC035355-001
Touch up paint Foundry Prime 2, grey
3HAC037052-001
Touch up paint Foundry Prime, orange
3HAC036639-001
Touch up paint Clean Room, Wite
Part no.
Description
3HAC038642-001
Label and plate set
3HAC021505-002
Label set, oil labels (IRB6640)
3HAC025700-001
Label set, oil labels (IRB6640ID)
Spare part number
Description
3HAC12937-9
Base plate
3HAC028196-001
UL signal lamp
3HAC037677-001
Axis-4 wheel unit
Labels and plates
Options
49
ABB AB
Discrete Automation and Motion
Robotics
S-721 68 VSTERS, Sweden
Telephone +46 (0) 21 344 400
ABB AS, Robotics
Box 265
N-4349 BRYNE, Norway
Telephone: +47 51489000
ABB Engineering (Shanghai) Ltd.
5 Lane 369, ChuangYe Road
KangQiao Town, PuDong District
SHANGHAI 201319, China
Telephone: +86 21 6105 6666
ABB Inc.
Robotics
1250 Brown Road
Auburn Hills, MI 48326
USA
Telephone: +1 248 391 9000
www.abb.com/robotics
3HAC038330-001, Rev C, en
Contact us

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ABB Robotics

Product manual, spare parts

Trace back information:

Product manual, spare parts

Copyright 2010-2013 ABB. All rights reserved.

Copyright 2010-2013 ABB. All rights reserved.

Rebuilding parts ................................................................................................ 11

Spare parts and exploded views

Spare parts - balancing device .............................................................................

This page is intentionally left blank

Overview of this manual

Overview of this manual

IRB 6640 and all its variants.

Who should read this manual?

be trained by ABB and have the required knowledge of mechanical and

Product manual - IRB 6640 Foundry Prime

Product manual - IRB 6640

Circuit diagram - IRB 6640

This revision includes following additions and/or changes:

Continues on next page

Overview of this manual

This revision includes following corrected, added or deleted spare part

This revision includes following corrected, added or deleted spare part

Product documentation, M2004

Product documentation, M2004

Installation and commissioning (descriptions of mechanical installation or

Maintenance (descriptions of all required preventive maintenance procedures

Repair (descriptions of all recommended repair procedures including spare

Reference information (safety standards, unit conversions, screw joints, lists

Circuit diagrams (or references to circuit diagrams).

Technical reference manuals

Technical reference manual - Lubrication in gearboxes: Description of types

Technical reference manual - RAPID overview: An overview of the RAPID

Technical reference manual - RAPID Instructions, Functions and Data types:

Technical reference manual - RAPID kernel: A formal description of the

Technical reference manual - System parameters: Description of system

Product documentation, M2004

An application manual generally contains information about:

The purpose of the application (what it does and when it is useful).

How to install included or required hardware.

How to use the application.

Examples of how to use the application.

Operating manual - Emergency safety information

Operating manual - General safety information

Operating manual - Getting started, IRC5 and RobotStudio

Operating manual - Introduction to RAPID

Operating manual - IRC5 with FlexPendant

Operating manual - RobotStudio

Balancing device - design 1

Balancing device - design 2

Lower arm, design 2

Lower arm - long, design 2

Motor, axis 1, incl. pinion

Motor, axis 2, incl. pinion

Motor, axis 3, incl. pinion

Motor, axis 4, incl. pinion

Motor, axis 4, incl. pinion

Motor, axis 5, excl. pinion

Motor, axis 5, excl. pinion

Motor, axis 5, incl. pinion

Motor, axis 6, incl. pinion

Motor, axis 6, incl. pinion