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ABB Robotics IRB 6790, Product Manual

The ABB IRB 6790 user manual can be easily accessed and downloaded for free from our website. This comprehensive manual provides step-by-step instructions and valuable insights on efficiently operating the IRB 6790 robot. Take advantage of this opportunity to enhance your understanding and maximize the potential of your ABB IRB 6790 robot.

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Note

Action

Attachment screws: M10x30 Stainless Steel
(3HAC060786-020) (4 pcs)

xx1300000554

Refit the cover plate.

7

Concluding procedure

Note

Action

Remove the lifting accessory.

1

Turn on the air pressure supply to the
overpressure system.

2

xx1700001593

Check the leak flow value on the flow
sensor and compare it to the initial value.
The value should be the same.
If the value is higher than the initial value,
fault trace according to

Inspecting the leak

flow (overpressure unit) in the system on
page 128

.

3

Axis Calibration is described in

Calibrating

with Axis Calibration method on page 623

.

Re-calibrate the robot.

4

General calibration information is included
in section

Calibration on page 613

.

DANGER

Make sure all safety requirements are met
when performing the first test run.

5

366

Product manual - IRB 6790

3HAC063331-001 Revision: B

© Copyright 2019 - 2020 ABB. All rights reserved.

4 Repair

4.5.4 Replacing the lower arm

Continued

Summary of Contents for IRB 6790

Page 1: ...ROBOTICS Product manual IRB 6790 ...

Page 2: ...Trace back information Workspace 20A version a8 Checked in 2020 03 09 Skribenta version 5 3 033 ...

Page 3: ...Product manual IRB 6790 235 2 65 IRB 6790 205 2 80 IRC5 Document ID 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ...ty 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 Keep for future reference Additional copies of this manual may be obtained ...

Page 5: ...site transportation 50 2 3 1 Robot transportation precautions 54 2 3 2 Securing the robot with a transport support 55 2 4 On site installation 55 2 4 1 Brief installation procedure 56 2 4 2 Lifting the base plate 57 2 4 3 Securing the base plate 60 2 4 4 Lifting the robot 60 2 4 4 1 Lifting the robot with fork lift 61 2 4 4 2 Lifting the robot with roundslings 65 2 4 5 Orienting and securing the r...

Page 6: ...xis 5 gearbox 154 3 5 7 Changing oil axis 6 gearbox 158 3 5 8 Replacing the SMB battery 161 3 6 Cleaning activities 161 3 6 1 Cleaning the IRB 6790 165 4 Repair 165 4 1 Introduction 166 4 2 General procedures 166 4 2 1 Performing a leak down test 167 4 2 2 Mounting instructions for bearings 169 4 2 3 Mounting instructions for sealings 172 4 2 4 Dismantle and mounting tool 3HAC028920 001 173 4 2 5 ...

Page 7: ...nt directions for all axes 619 5 3 Updating revolution counters 623 5 4 Calibrating with Axis Calibration method 623 5 4 1 Description of Axis Calibration 626 5 4 2 Calibration tools for Axis Calibration 628 5 4 3 Installation locations for the calibration tools 629 5 4 4 Axis Calibration Running the calibration procedure 634 5 4 5 Reference calibration 636 5 5 Verifying the calibration 637 5 6 Ch...

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Page 9: ...of the IRB 6790 Some variants and designs may have been removed from the business offer and are no longer available for purchase Organization of chapters The manual is organized in the following chapters Contents Chapter Safety information that must be read through before performing any installation or service work on robot Contains general safety aspects as well as more specific information on ho...

Page 10: ...168 001 Product specification IRB 6790 3HAC048484 002 Directions for use Fork lift accessory for IRB 6700 3HAC043446 005 Circuit diagram IRB 6700 IRB 6790 3HAC031045 001 Safety manual for robot Manipulator and IRC5 or OmniCore con troller i 3HAC047136 001 Product manual IRC5 IRC5 with main computer DSQC1000 3HAC021313 001 IRC5 with main computer DSQC 639 3HAC050941 001 Operating manual IRC5 with F...

Page 11: ...age 68 Added information about action if the system alerts for too high leakage Added information about working range restrictions Updated information about cable clamp attachment inside the upper arm tube Updated information about requirement of the cable protection on axis 1 Updated article numbers of motor cover o rings and connection box o rings Added information about screws at the balancing ...

Page 12: ...ioning Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists References to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Application ...

Page 13: ...s The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters Product manual IRB 6790 13 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved Product documentation Continued ...

Page 14: ... include specific safety information when dangerous steps are to be performed Read more in the chapter Safety on page 17 Illustrations The product is illustrated with general figures that does not take painting or protection type in consideration Likewise certain work methods or general information that is valid for several product models can be illustrated with illustrations that show a different...

Page 15: ...ed Pressurized components Motors balancing device and the serial measurement board cavity shall be pressurized on Foundry Prime robots during operation and shut down The overpressure can be dropped when atmospheric humidity has reached the same level as the surrounding environment For more information see Pressurized system on page 73 Cleaning Special procedures are needed when cleaning the Foundr...

Page 16: ...This page is intentionally left blank ...

Page 17: ...ration of the robot when the safety devices are defective not in their intended location or in any other way not working When instructions for operation and maintenance are not followed Non authorized design modifications of the robot Repairs on the robot and its spare parts carried out by in experienced or non qualified personnel Foreign objects Force majeure Spare parts and equipment ABB supplie...

Page 18: ...ence of alcohol drugs or any other intoxicating substances are not allowed to install maintain service repair or use the robot The plant liable must make sure that the personnel is trained on the robot and on responding to emergency or abnormal situations Personal protective equipment Use personal protective equipment as stated in the product manual 18 Product manual IRB 6790 3HAC063331 001 Revisi...

Page 19: ...on which if not avoided will result in ser ious injury DANGER Signal word used to indicate a potentially hazardous situation which if not avoided could result in serious injury WARNING Signal word used to indicate a potentially hazardous situation related to electrical hazards which if not avoided could result in serious injury ELECTRICAL SHOCK Signal word used to indicate a potentially hazardous ...

Page 20: ...d to indicate where to find additional information or how to do an operation in an easier way TIP 20 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 1 Safety 1 2 1 Safety signals in the manual Continued ...

Page 21: ...aphics See Symbols on safety labels on page 21 The information labels can contain information in text Symbols on safety labels Description Symbol Warning xx0900000812 Warns that an accident may occur if the instructions are not followed that can lead to serious injury possibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high vo...

Page 22: ...o not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page 22 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights rese...

Page 23: ... over if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 6790 23 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 24: ...1 06 xx1300001087 Moving robot 1 2 3 4 5 6 xx0900000819 The robot can move unexpectedly xx1000001141 1 2 3 4 xx1500002616 Continues on next page 24 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 25: ...01242 Lifting of robot xx0900000822 Oil xx0900000823 Can be used in combination with prohibition if oil is not allowed Mechanical stop xx0900000824 Continues on next page Product manual IRB 6790 25 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 26: ...t this part is pressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts 26 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Cont...

Page 27: ...rotective stops and emergency stops are described in the product manual for the controller For more information see Product manual IRC5 Product manual IRB 6790 27 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 1 Safety 1 3 Robot stopping functions ...

Page 28: ...r device fitted to the robot The maximum TCP speed and the maximum velocity of the robot axes are detailed in the section Robot motion in the product specification for the respective manipulator Consider exposure to hazards such as slipping tripping and falling Consider hazards from other equipment in the robot system for example that guards remain active until identified hazards are reduced to an...

Page 29: ...egrator of the robot system must ensure that emergency stop functions are interlocked in accordance with applicable standards The integrator of the robot system must ensure that safety functions are interlocked in accordance with applicable standards Other hazards WARNING Gravity and the release of braking devices can create additional hazards Never stay beneath a robot arm A robot may perform une...

Page 30: ...to drop Dump valves should be used in case of emergency Shot bolts should be used to prevent tools etc from falling due to gravity All pipes hoses and connections have to be inspected regularly for leaks and damage Damage must be repaired immediately Verify the safety functions Before the robot system is put into operation verify that the safety functions are working as intended and that any remai...

Page 31: ...ubricants oil or grease When handling oil grease or other chemical substances the safety information of the respective manufacturer must be observed Note Take special care when handling hot lubricants Elimination Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling h...

Page 32: ...w much has previously been drained from the gearbox Specified amount de pends on drained volume For lifetime reasons always drain as much oil as possible from the gearbox The magnetic oil plugs will gather residual metal chips Contaminated oil in gearboxes Hazards related to batteries Under rated conditions the electrode materials and liquid electrolyte in the batteries are sealed and not exposed ...

Page 33: ...ion See also the safety information related to installation and operation Product manual IRB 6790 33 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 1 Safety 1 5 1 Maintenance and repair Continued ...

Page 34: ...ing an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the manipulator does not result in additional hazards for example even more severe injuries on a trapped person DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Make sure no personnel is near or beneath the robot 34 Produ...

Page 35: ...s described below 1 Run each axis to a position where the combined weight of the manipulator and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the manipulator does not change position as the motors are switched off then the brake function is adequate Product manual IRB 6790 35 3HAC063331 001 Revision B Co...

Page 36: ...y time DANGER Troubleshooting on the controller while powered on must be performed by personnel trained by ABB or by ABB field engineers A risk assessment must be done to address both robot and robot system specific hazards Related information See also the safety information related to installation operation maintenance and repair 36 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019...

Page 37: ...1 7 Decommissioning General See section Decommissioning on page 639 Product manual IRB 6790 37 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 1 Safety 1 7 Decommissioning ...

Page 38: ...This page is intentionally left blank ...

Page 39: ...t that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page17 before performing any installation work Note If the IRB 6790 is connected to power always make sure that the robot is connected to protective earth...

Page 40: ...he weight of the robot as specified in Weight robot on page 40 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 42 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 43 7 Before taking the robot to its installation site make sure that the site ...

Page 41: ...e shows the various forces and torques working on the robot during different kinds of operation Note These forces and torques are extreme values that are rarely encountered during operation The values also never reach their maximum at the same time WARNING The robot installation is restricted to the mounting options given in following load table s Floor mounted Max load emergency stop Endurance lo...

Page 42: ...ted as the frequency of the robot mass inertia robot assumed stiff when a foundation translational torsional elasticity is added i e the stiffness of the pedestal where the robot is mounted The minimum resonance frequency should not be interpreted as the resonance frequency of the building floor etc For example if the equivalent mass of the floor is very high it will not affect robot movement even...

Page 43: ...nt between pH 6 to 7 if all parts of the robot are rinsed with tap water afterwards Organic acids e g acetic acid are not allowed to be used Washing and cleaning detergents with corrosion inhibitor is recommended Note If the pH value or the detergent concentration is varying from its original specification it can become very corrosive Protection classes robot The table shows the available protecti...

Page 44: ... revolutions The default working range for axis 6 can be extended by changing parameter values in the software Illustration working range IRB 6790 235 2 65 This illustration shows the unrestricted working range of the robot 1187 920 1908 2650 3114 320 Reach Handling capacity Robot type 2 65 m 235 kg IRB 6790 Continues on next page 44 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019...

Page 45: ...ing range of the robot 308 3259 1281 2039 958 2794 Reach Handling capacity Robot type 2 80 m 205 kg IRB 6790 Continues on next page Product manual IRB 6790 45 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 46: ...x1300001082 R1 mm Robot variant 2650 IRB 6790 235 2 65 2794 IRB 6790 205 2 80 46 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 47: ...rtation position This figure shows the robot in its shipping position and transportation position 45 2 0 6 5 70 890 50 570 55 xx1300000356 WARNING The robot will be mechanically unstable if not properly secured to the foundation Product manual IRB 6790 47 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Installation and commissioning 2 2 3 Risk of tipping stability ...

Page 48: ...iption Pos Radius ax1 front 532 mm B Radius ax1 back 633 mm C J H G F E D A Robot variant 186 209 1 182 5 1670 1135 2300 200 IRB 6790 235 2 65 209 186 1 182 5 1670 1280 2445 200 IRB 6790 205 2 80 48 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Installation and commissioning 2 2 4 Main dimensions ...

Page 49: ...ndling Note Action Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of static voltages and must be grounde...

Page 50: ... any compensation claim Method 1 recommended method Transportation according to method 1 is strongly recommended by ABB xx0800000030 Always follow these instructions when transporting an ABB robot according to method 1 Always remove the tool before transportation of the robot Always place the robot in the ABB recommended transport position described in section Risk of tipping stability on page 47 ...

Page 51: ...he ABB recommended transport position for robot with tool described in sub section Transport position with a transport support on page 52 Always use the recommended transport support described in sub section Recommended transport support on page 53 IRB 6790 A B D C xx0800000037 Transport Support A Hexagon socket head cap screw M16x140 B Threaded bar M10x200 C Nut M10 D Continues on next page Produ...

Page 52: ... robot with tool must follow these instructions IRB 6790 xx0800000040 Continues on next page 52 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Installation and commissioning 2 3 1 Robot transportation precautions Continued ...

Page 53: ... 200 30 65 130 10 R 3 M10 52 62 50 50 40 18 60 12 R 2 0 30 A 5 B xx1300001603 IRB 6790 205 2 80 IRB 6790 235 2 65 Variant 1280 1135 Lower arm L 1160 1000 A 21 21 B Product manual IRB 6790 53 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Installation and commissioning 2 3 1 Robot transportation precautions Continued ...

Page 54: ... a position as near above as possible to the recommended transport position for the specific robot as specified in section Transport position with a transport support on page 52 2 See attachment point for the specific ro bot in the section Transport position with a transport support on page 52 Use the brake release for axis 3 to reach the final resting position on the transport support see the sec...

Page 55: ...the robot on page 60 Lift and secure the manipulator to the plat form foundation 3 See Orienting and securing the ro bot on page 65 See Product manual IRC5 Connect the manipulator to the controller 4 See Product manual IRC5 Configure the safety settings 5 See Product manual IRC5 How to start and run the robot is described in the product manual for the controller 6 Install required equipment if any...

Page 56: ...g All lifting accessories used must be sized accordingly 1 Shown in figure Hole configur ation on page 56 Fit lifting eyes in specified holes 2 Fit lifting slings to the eyes and to the lifting accessory CAUTION Lift and move the base plate very slowly If the base plate starts to swing it is a risk for injuries or damage 3 56 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 AB...

Page 57: ...3x45º 0 3 Ø 45P7 A A Ø1 5 4x 6 3 4 8 2 1 6 3x45º B B 2 1 3 3x R1 3 x 4 3x 90º C C 4 5 K 7 0 5 0 47 0 25 c 2x R22 5 1 6 D 2 c 5 2 5 º Common Zone E F G H xx1000001053 Common tolerance zone accuracy all over the base plate from one contact surface to the other E F G H Continues on next page Product manual IRB 6790 57 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Installatio...

Page 58: ... 9ADA120 79 attachment screws and washers for securing the robot to the base plate Base plate Content is defined in section Standard toolkit on page 652 Standard toolkit These procedures include references to the tools required Other tools and procedures may be required See references to these procedures in the step by step instructions below Continues on next page 58 Product manual IRB 6790 3HAC0...

Page 59: ...he base plate and use the levelling bolts to level the base plate 6 If required fit strips of sheet metal underneath the base plate to fill any gaps 7 Secure the base plate to the foundation with screws and sleeves 8 Maximum allowed deviation all over the base plate from one contact surface to the other 0 3 mm Recheck the four contact surfaces on the base plate to make sure the base plate is level...

Page 60: ... number Equipment Contains fork lift pockets and all required hardware for installation User instructions are enclosed with the tool see Directions for use Fork lift accessory for IRB 6700 3HAC047054 003 Fork lift accessory set Required documents Document number Document 3HAC048484 002 Directions for use Fork lift accessory for IRB 6700 Lifting the robot Note Action Lift the robot according to the...

Page 61: ... 6790 205 2 80 Roundsling 2 5 m 4 pcs C Lifting eye M20 4 pcs D Required equipment See quantity of roundslings in figure Attaching the roundslings on page 61 Note Article number Equipment etc Overhead crane Working load limit 2 000 kg Lifting eye M20 Length 2 m Lifting capacity 2 000 kg Roundsling 2 m Length 2 5 m Lifting capacity 2 000 kg Roundsling 2 5 m Continues on next page Product manual IRB...

Page 62: ...icance Axis 5 70 Axis 6 no significance WARNING The robot is likely to be mechanically un stable if not secured to the foundation 1 Lifting the robot with roundslings Note Action xx1200001301 Fit lifting eyes to the outer holes on each corner of the base 1 xx1200001302 Continues on next page 62 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Installa...

Page 63: ...curing sling must not be strained at lifting It only secures for tipping 3 Length for the roundsling is given in the table Attaching the roundslings on page 61 xx1300001574 Attach a securing roundsling at the front according to figure Note The securing sling must not be strained at lifting It only secures for tipping 4 CAUTION The IRB 6790 robot weighs 1300 kg All lifting accessories used must be ...

Page 64: ...ont left corner is positioned on the correct side of the brake release unit plate when stretching the roundslings with the crane 7 64 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Installation and commissioning 2 4 4 2 Lifting the robot with roundslings Continued ...

Page 65: ...positioning and securing the robot D D 8x 30 8x 53 4x 45 H7 4 x 3 x 4 5 1 6 8 x 4 9 5 0 3 A 0 12 A 800 4x 90 5 2 5 4 x 1 5 D D E E 2x 25 H8 2 0 2 5 H 8 2 x 4 5 2 4 5 2 x 0 12 E E A A xx1300000243 Description Pos Holes for guide pins x2 A Continues on next page Product manual IRB 6790 65 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Installation and commissioning 2 4 5 Ori...

Page 66: ...sive environment the securing screws and washers must be of stainless steel M24 x 100 Suitable screws lightly lubricated 8 pcs Quantity 8 8 Quality 90 v 0 9 Screw tightening yield point utilization factor v according to VDI2230 4 mm flat washer Suitable washer 550 Nm screws lubricated with Molykote 1000 Tightening torque 600 725 Nm typical 650 Nm screws none or lightly lubricated Continues on next...

Page 67: ...age 61 Lift the robot 2 Move robot close to its installation location 3 Make sure the robot base is correctly fitted onto the guide sleeves Guide the robot gently using two M24 screws while lowering it into its mounting position 4 Specified in Attachment screws on page 66 Note Lightly lubricate screws before as sembly Fit the bolts and washers in the base attachment holes 5 Tighten bolts in a cros...

Page 68: ... shut down The overpressure can be dropped when the motors have the same temperature as the surrounding environment Precautionary measures Make sure that the Foundry Prime coating of the robot is not broken during testing installation or repair work Use the touch up kit available for Foundry Prime 3 article number 3HAC064578 001 to repair any damages in the coating Activity to lubricate gearboxes ...

Page 69: ... connectors from detergents The flow sensor at the connection point does not withstand fluids Protect the interface plate from direct or indirect spray with the harness interface cover Put the interface plate where it is not subject to direct or indirect spray xx1700001180 Continues on next page Product manual IRB 6790 69 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Inst...

Page 70: ...50 Note 1 0 5 0 5 0 5 5 15 5 6x M6 0 8 0 4 xx1900002083 Gasket required on the interface plate A gasket is required on the interface plate according to the figure B A 230 450 215 250 215 20 6x 7 C xx1700002199 Interface plate A Gasket attached with M6 6 pcs B Gasket width dimension C Continues on next page 70 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights rese...

Page 71: ...controller and interface plate A B C D E xx1800002565 Clean air inlet 0 2 0 3 bar 6 mm air hose type Festo A Overpressure unit B Flow sensor C Sealed control cable signal D Flow sensor cable E Continues on next page Product manual IRB 6790 71 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Installation and commissioning 2 4 6 Installation requirements for Foundry Prime robo...

Page 72: ...ess interface cover The harness interface cover is delivered separately with the robot It must be installed before the robot is taken into use It protects the connectors against direct water or chemicals Note Action Remove the nuts from the studs on the interface plate 1 xx1800000685 Pull the harness through the cover and fasten the cover with the nuts 2 Continues on next page 72 Product manual IR...

Page 73: ...et to Motors On and Auto Air leakage There is a constant normal leakage in the system The leakage value is individual for each system and is set by ABB when manufactured If the leakage exceeds a predefined value the system alerts with a signal to the I O system If the system alerts for too high leakage detect the leakage and seal it The I O system is alerted when the leakage value is described as ...

Page 74: ... bar Air pressure Setup the flow sensor Note Action Event log 37110 appears in cases where the signal is not set Configure the signal at setup via the I O system Set Leak Detection On to TRUE xx1700001401 1 If required setup an output signal warning lamp etc 2 Set the flow sensor The procedure is needed after replacement of for example cable harness All values are set in factory at delivery A B B ...

Page 75: ...ue is saved Adjust set point of the signal L Min SP is shown Set parameter with A or B X 1 0 L Min 9 Confirms value Tap Edit 10 The value is saved Adjust reset point Set the hysteresis parameter with A or B 0 5 L min 11 The screen shows the set values and exits the system Tap Edit three 3 times The device shows the flow display 12 Output A is set to 1 at X 1 0 l min and set to 0 at X 0 5 l min 13 ...

Page 76: ...If other alarm handling is desired it has to be programmed Information labels No adhesive labels are placed on the robot at delivery ABB recommends the user to place the labels outside the robot cell for example on the controller cabinet All warning labels are etched into the robot stainless steel plates Continues on next page 76 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 202...

Page 77: ... trapped into gearboxes or other cavities due to raised vacuum when cooling down Will give the robot a chance to dry as most rust preventive components in washing detergents have a decaying effect i e the rust preventive effect is reduced after a time Please refer to the Product Specification of the washing detergent in question for decaying effect Washing detergent or water without rust inhibitor...

Page 78: ...nit on page 78 The internal brake release unit is equipped with buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes If the robot is not connected to the controller power must be supplied to the connector R1 MP according to the section Supplying power to connector R1 MP on page 79 1 DANGER When releasing the holding brakes the robot axes may move ve...

Page 79: ... controller power must be supplied to connector R1 MP on the robot in order to enable the brake release buttons Note Action DANGER Incorrect connections such as supplying power to the wrong pin may cause all brakes to be released simultaneously 1 xx0600002937 Supply 0V on pin 12 and 24V on pin 11 2 Product manual IRB 6790 79 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 I...

Page 80: ... robot References Load diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must be defined in the software Operating manual IRC5 with FlexPendant Stopping time and braking distances The performance of the motor brake depends on if there are any loads attached to the robot For more information see product specification for the robot 80 P...

Page 81: ...cables used on the robot must be designed and fitted not to damage the robot and or its parts Frame hip load Extra load can be fitted on the frame Description JH 100 kgm2 Permitted extra load on frame JH JH0 M4 x R2 Recommended position see the fol lowing figure where JH0 is the moment of inertia of the equipment R is the radius m from the center of axis 1 M4 is the total mass kg of the equipment ...

Page 82: ... 50 kg with a distance a 500 mm from the center of gravity in the axis 3 extension a A M1 M1 xx1400002019 Mass center A Continues on next page 82 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Installation and commissioning 2 4 9 Fitting equipment to the robot Continued ...

Page 83: ...Center of gravity 50 kg A Continues on next page Product manual IRB 6790 83 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Installation and commissioning 2 4 9 Fitting equipment to the robot Continued ...

Page 84: ...1 3 4 x M 8 M12 20 52 5 H H 150 150 109 J K K A A J 2x M12 19 M12 19 C L Axis 4 B B A B E L H J M K C D F G 12 N B B xx1300000263 Allowed position for attachment holes M12 through Be careful not to touch the cables when drilling A Continues on next page 84 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Installation and commissioning 2 4 9 Fitting eq...

Page 85: ...0 104 102 33 147 349 437 365 652 5 500 270 R 216 IRB 6790 205 2 80 i Smallest circumscribed radius axis 4 Continues on next page Product manual IRB 6790 85 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Installation and commissioning 2 4 9 Fitting equipment to the robot Continued ...

Page 86: ...s 2 C L Axis 1 L xx1300000264 M L K J H G F E D C B Ai Variant 13 8 500 303 5 320 255 186 208 5 80 403 418 433 R 456 IRB 6790 235 2 65 13 8 500 303 5 320 255 186 208 5 80 408 423 438 R 456 IRB 6790 205 2 80 i Smallest circumscribed radius axis 3 Continues on next page 86 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Installation and commissioning 2...

Page 87: ...quality Use suitable screws and tightening torque for your application When the robot is used in a corrosive environment the securing screws and washers must be of stainless steel Product manual IRB 6790 87 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2 Installation and commissioning 2 4 9 Fitting equipment to the robot Continued ...

Page 88: ...s much as possible to reduce wear of for example the seals Use the air purge during storage This will keep the over pressure in the system and reduce risks of detergents coming into motors and gears The cell must be ventilated during shut down until the atmospheric humidity in the cell has reached the same level as the surrounding environment 88 Product manual IRB 6790 3HAC063331 001 Revision B Co...

Page 89: ... may be restricted Axis 1 hardware mechanical stop and software Axis 2 software Axis 3 software This section describes how to install hardware that restricts the working range Note Adjustments must also be made in the robot configuration software system parameters References to relevant manuals are included in the installation procedures Product manual IRB 6790 89 3HAC063331 001 Revision B Copyrig...

Page 90: ...nting position of the stop pin and one of the additional mechanical stops available for axis 1 A B C B xx1300001971 Attachment screws M12x70 quality 12 9 Gleitmo 603 2 pcs per additional mechanical stop A When the robot is used in a corrosive environment the securing screws and washers must be of stainless steel Movable mechanical stop B Mechanical stop pin axis 1 C Continues on next page 90 Produ...

Page 91: ...torque 60 Nm Fit the additional mechanical stop to the frame according to the figure Mechanical stops axis 1 on page 90 2 The system parameters that must be changed Upper joint bound and Lower joint bound are described in Technical reference manual System parameters Adjust the software working range limitations system parameter configuration to corres pond to the mechanical limitations 3 WARNING I...

Page 92: ...s communication See the product manual for the controller see document number in References on page 10 Robot cables These cables are included in the standard delivery They are completely pre manufactured and ready to plug in Connection point robot Connection point cabinet Description Cable sub category R1 MP XS1 Transfers drive power from the drive units in the controller to the robot motors Robot...

Page 93: ...on wall The grounding point is placed at the connector on the wall of the installation site The grounding bonding point is used for potential equalizing between control cabinet manipulator and any peripheral devices Flow sensor cable Connect the flow sensor cable to the controller and the flow sensor Product manual IRB 6790 93 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 2...

Page 94: ...regulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 100 mm s 20 20 3 ...

Page 95: ...ided according to the maintenance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 17 before performing any service work Note If the IRB 6790 is c...

Page 96: ...cified in months regardless of whether the system is running or not Operating time specified in operating hours More frequent running means more frequent maintenance activities Robots with the functionality Service Information System activated can show active counters in the device browser in RobotStudio or on the FlexPendant 96 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020...

Page 97: ...ies Cleaning the IRB 6790 on page 161 x Cleaning the robot Inspection activities Inspect the oil level in the actual gearbox if there is a suspected leakage after an oil change or a maintenance or repair activity where draining and filling oil is required Inspecting the oil level in gearboxes Inspecting the balancing device on page 114 x Inspecting the balancing device Inspecting the cable harness...

Page 98: ...xis 6 gearbox on page 154 x Changing the oil in axis 6 gearbox Replacing the SMB battery on page 158 x iii Replacing the SMB battery pack Analyzing activities NOTE Analyze the water content when changing oil x Analyzing the water content in gearbox oil Analyzing the water content in gearbox oil on page 130 Overhaul x Overhaul of complete robot i Operating hours counted by the DTC Duty time counter...

Page 99: ...ment iv The given life for the balancing device is based on a test cycle of 4 000 000 cycles that starts from the initial position and goes to maximum extension and back Deviations from this cycle will result in differences in expected life v The SIS for an IRC5 system is described in the Operating manual Service Information System Expected component life protection type Foundry Prime The demandin...

Page 100: ... on page 652 Standard toolkit Required consumables Note Article number Consumables Information about the oil is found in Technical reference manual Lubrica tion in gearboxes Lubricating oil Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page 100 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 20...

Page 101: ...involves several safety risks see Gearbox lubricants oil or grease on page 31 2 Make sure that the oil temperature is 25 C 10 C 3 xx1200000950 Open the oil plug 4 xx1300000692 Check the oil level Required oil level is 58 mm 5 mm below the sealing surface of the oil plug 5 Continues on next page Product manual IRB 6790 101 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 3 Main...

Page 102: ... or fill with oil is found in section Changing oil axis 1 gearbox on page 132 Tightening torque 24 Nm Refit the oil plug 7 DANGER Make sure all safety requirements are met when performing the first test run 8 102 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 3 Maintenance 3 3 1 Inspecting the oil level in axis 1 gearbox Continued ...

Page 103: ...652 Standard toolkit Required consumables Note Article number Consumables Information about the oil is found in Technical reference manual Lubrica tion in gearboxes Lubricating oil Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page Product manual IRB 6790 103 3HAC063331 001 Revision B Copyright 2019 2020 ABB Al...

Page 104: ...g 4 Check the oil level 5 Required oil level is 0 15 mm below the oil plug hole Type of oil and total amount is detailed in Technical reference manual Lubric ation in gearboxes Add or drain oil if required 6 Further information about how to drain or fill with oil is found in section Chan ging oil axis 2 gearbox on page 137 Tightening torque 24 Nm Refit the oil plug 7 DANGER Make sure all safety re...

Page 105: ...ormation about the oil is found in Technical reference manual Lubrica tion in gearboxes Lubricating oil Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Inspecting the oil level in axis 3 gearbox Use this procedure to inspect the oil level in the gearbox Note Action Run the robot to calibration position 1 Continues on next page Pro...

Page 106: ...20 mm below the oil plug hole Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Add or drain oil if required 7 Further information about how to drain or fill with oil is found in section Changing oil axis 3 gearbox on page 142 Tightening torque 24 Nm Refit the oil plug 8 DANGER Make sure all safety requirements are met when performing the first test ru...

Page 107: ...ormation about the oil is found in Technical reference manual Lubrica tion in gearboxes Lubricating oil Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Inspecting the oil level in axis 4 gearbox Use this procedure to inspect the oil level in the gearbox Note Action Run the robot to calibration position 1 Continues on next page Pro...

Page 108: ...10 mm below the oil plug hole Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Add or drain oil if required 7 Further information about how to drain or fill with oil is found in section Changing oil axis 4 gearbox on page 146 Tightening torque 24 Nm Refit the oil plug 8 DANGER Make sure all safety requirements are met when performing the first test ru...

Page 109: ... Lubrica tion in gearboxes Lubricating oil Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Inspecting the oil level in axis 5 gearbox Use this procedure to inspect the oil level in the gearbox Note Action Run the robot to calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before...

Page 110: ... detailed in Technical reference manual Lubrication in gearboxes Add or drain oil if required 7 Further information about how to drain or fill with oil is found in section Changing oil axis 5 gearbox on page 150 Tightening torque 24 Nm Refit the oil plug 8 DANGER Make sure all safety requirements are met when performing the first test run 9 110 Product manual IRB 6790 3HAC063331 001 Revision B Cop...

Page 111: ...it on page 652 Standard toolkit Required consumables Note Article number Consumable Information about the oil is found in Technical reference manual Lubrica tion in gearboxes Lubricating oil Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page Product manual IRB 6790 111 3HAC063331 001 Revision B Copyright 2019 2...

Page 112: ...pply to the robot before entering the robot working area 2 Make sure that the oil temperature is 25 C 10 C 3 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 31 4 xx1600002049 Open the oil plug 5 xx1300000693 Method 1 Check the oil level Required oil level is 50 mm 5 mm below the sealing surface of the oil plug 6 Continues on next page 112 Pro...

Page 113: ...8 Further information about how to drain or fill with oil is found in section Changing oil axis 6 gearbox on page 154 Tightening torque 20 Nm Refit the oil plug 9 DANGER Make sure all safety requirements are met when performing the first test run 10 Product manual IRB 6790 113 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 3 Maintenance 3 3 6 Inspecting the oil level in axis...

Page 114: ...device is located at the top rear of the frame as shown in the figure The figure also shows the inspection points further described in the instructions xx1300000413 Piston rod inside balancing device A Link ear B Rear attachments of the balancing device cradle bearing C Required tools Visual inspection no tools are required Continues on next page 114 Product manual IRB 6790 3HAC063331 001 Revision...

Page 115: ...the springs inside the cylinder 2 How to replace the device is detailed in section Repla cing the balancing device on page382 This section also specifies the spare part number If dissonance is detected perform maintenance accord ing to given instructions in Maintenance kit complete Check for dissonance from the piston rod squeaking may indicate worn plain bearings internal contamin ation or insuff...

Page 116: ...haft A Turcon Roto VL Seal B Spherical roller bearing C O ring 85x3 D End cover E End cover F Note Action Clean the area at the front ear from contamina tion 1 Run the robot for some minutes in order to move the balancing device piston 2 Continues on next page 116 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting the balanc...

Page 117: ...eaks are detected 5 Replacement of the complete bearing is described in section Replacing the balancing device on page 382 Check for contamination lack of free space Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot Before entering the robot working area 1 xx1300000423 Check that there are no obstacles inside the frame that could prevent the ...

Page 118: ...ecting the cable harness Use this procedure to inspect cable harness of axes 1 6 Note Action DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 1 Continues on next page 118 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the cable harness ...

Page 119: ...r cables visually for any damage 4 Check the connectors at the base visually for any damage 5 xx1300001094 Check the cabling going through the protec tion tube to detect possible cable chafing by using your hands inside the tube to feel the cables Ensure that the cables are un damaged Remove any objects that may cause pos sible cable chafing Replace damaged cabling if any 6 See Removing the cable ...

Page 120: ...ed Inspecting mechanical stop pin Use this procedure to inspect the axis 1 mechanical stop pin Note Action DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 1 Continues on next page 120 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 3 Maintenance 3 3 9 Inspecting the axis 1 mechanic...

Page 121: ...r damaged it must be replaced Note The expected life of gearboxes can be reduced after collision with the mechanical stop Product manual IRB 6790 121 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 3 Maintenance 3 3 9 Inspecting the axis 1 mechanical stop pin Continued ...

Page 122: ...Note Article number Equipment etc Limits the robot working range by 15 3HAC064612 001 Movable mechanical stop axis 1 Includes attachment screws and an as sembly drawing Mechanical stop Attachment screws stainless steel M12x70 and stainless steel wash ers Document for mechanical stop Content is defined in section Standard toolkit on page 652 Standard toolkit Continues on next page 122 Product manua...

Page 123: ...2 Make sure the stops are properly attached 3 Correct tightening torque additional mechanical stops Axis 1 60 Nm Article number is specified in Required equipment on page122 If any damage is detected the mechanical stops must be replaced Correct attachment screws Stainless steel M12x70 and stainless steel washers 2 pcs per additional mechanical stop 4 Product manual IRB 6790 123 3HAC063331 001 Rev...

Page 124: ...essory is fitted to the robot as shown in the figure A B Fork lift pocket 4 pcs A Hex socket head cap screw M20x60 quality steel 8 8 A3F 2 pcs per fork lift device B Required equipment Note Article number Equipment Fork lift accessory set Content is defined in section Standard toolkit on page 652 Standard toolkit Continues on next page 124 Product manual IRB 6790 3HAC063331 001 Revision B Copyrigh...

Page 125: ...of damage 3 Make sure fork lift device set is properly attached 4 Correct tightening torque fork lift devices 280 Nm Article number is specified in Required equipment on page122 If any damage is detected the fork lift device and attachment screws must be replaced Correct attachment screws M20x60 quality steel 8 8 A3F 2 pcs per addi tional mechanical stop 5 Product manual IRB 6790 125 3HAC063331 00...

Page 126: ... Inspecting dampers The procedure below details how to inspect the dampers Note A damaged damper must be replaced Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot Before entering the robot working area 1 Continues on next page 126 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 3 Maintenance 3 3 ...

Page 127: ...deformation 3 Spare part number is found in Product manual spare parts IRB 6700 IRB 6700Inv If any damage is detected the damper must be replaced with a new one Attachment screws M6x60 4 Locking liquid Loctite 243 Product manual IRB 6790 127 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 3 Maintenance 3 3 12 Inspecting the dampers Continued ...

Page 128: ...ure correct function Inspection points The following points on the robot must be inspected xx1700001382 Motor cover axis 1 A Battery cover B Motor cover axis 2 C Motor cover axis 3 D Motor cover axis 4 E Motor cover axis 6 F Connection to balancing device G Continues on next page 128 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 3 Maintenance 3 3 13 ...

Page 129: ...ow value is increas ing on the sensor 1 Axis 1 motor cover 2 Battery cover 3 Axis 2 motor cover 4 Axis 3 motor cover 5 Axis 4 motor cover 6 Axis 6 motor cover 3 xx1700001383 If the value doesn t increase when opening the covers there is a system leakage 1 Disconnect the air connection at Out 2 connection to create a leakage to ensure the correct settings and functions of the flow sensor 2 Reconnec...

Page 130: ...C xx0600003155 More than 3 water in oil With more than 3 water content there is a risk for corrosion in the gearbox and reduced viscosity in the oil 1 A Water content in gearbox oil B Months or hours in operation C Replacement of gearbox Normal replacement interval is required for the gearbox A B 3 6 12 18 24 30 3000 6000 9000 12000 15000 xx0600003156 Less than 3 water in oil 2 A Water content in ...

Page 131: ...as the amount in the specific gearbox can be found in Technical reference manual Lubrication in gearboxes available for registered users on myABB Business Portal www mypo rtal abb com Location of gearboxes The figure shows the location of the gearboxes Equipment Note Equipment Includes pump with outlet pipe Oil dispenser Use the suggested dispenser or a similar one Orion OriCan article number 2259...

Page 132: ...umables Note Material Information about the oil is found in Technical refer ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page131 Rust preventive Mercasol Required tools and equipment Note Article number Equipment etc The capacity of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser ...

Page 133: ...G Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 31 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let the excess pressure out 3 xx1200000948 Remove the protective cap from the nipple of the oil hole and connect the oil dis penser 4 Continues on next page Product manual IRB 6790 ...

Page 134: ...e639 for more in formation 7 Remove the oil dispenser 8 Apply Mercasol on the nipple Refit the protective cap on the nipple Tightening torque 24 Nm Refit the vent hole plug 9 Filling oil into the axis 1 gearbox Use this procedure to refill the gearbox with oil Note Action DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the safe guarded space 1 Conti...

Page 135: ...The vent hole is opened to let out air during the filling process 4 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil with the oil dis penser Note The amount of oil to be filled depends on the amount previously being drained 5 Continues on next page Product manual IRB 6790 135 3HAC063331 001 Revision B Copyright 2019 2020 AB...

Page 136: ... Nm Refit the vent hole plug 8 Note After all repair and maintenance work in volving oil always wipe the robot clean from all surplus oil The robot color can otherwise be discolored 9 DANGER Make sure all safety requirements are met when performing the first test run 10 136 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 3 Maintenance 3 5 2 Changing oi...

Page 137: ...city of the vessel must be sufficient to take the complete amount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 131 Oil dispenser Content is defined in section Standard toolkit on page 652 Standard toolkit Required consumable Note Material Information about the oil is found in Technical refer ence manual Lubrication in ge...

Page 138: ...NG Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 31 2 CAUTION The gearbox can contain an excess pres sure that can be hazardous Open the oil plug carefully in order to let the excess pressure out 3 xx1200000951 Remove the protective cap from the nipple of the oil hole and connect the oil dis penser 4 Continues on next page 138 Product manual IRB 67...

Page 139: ...ormation 7 Vent hole plug tightening torque 24 Nm Refill oil or 1 Remove the oil dispenser 2 Apply Mercasol on the nipple 3 Refit the protective cap on the nipple 4 Refit the vent hole plug 8 Filling oil into the axis 2 gearbox Use this procedure to refill the gearbox with oil Note Action DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the safe guar...

Page 140: ...t hole Note The vent hole is opened to let air out during the filling process 4 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil Note The amount of oil to be filled depends on the amount previously being drained 5 Continues on next page 140 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights...

Page 141: ...rbox on page 104 Remove the oil dispenser 7 Apply Mercasol on the nipple Refit the protective cap on the nipple Tightening torque 24 Nm Refit the level plug 8 DANGER Make sure all safety requirements are met when performing the first test run 9 Product manual IRB 6790 141 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 3 Maintenance 3 5 3 Changing oil axis 2 gearbox Continued...

Page 142: ...mount of oil Oil collecting vessel One example of oil dispenser can be found in section Type of lubrication in gearboxes on page 131 Oil dispenser Content is defined in section Standard toolkit on page 652 Standard toolkit Consumable Note Material Information about the oil is found in Technical refer ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on pa...

Page 143: ...e gearbox can contain an excess pres sure that can be hazardous Open the oil plug carefully in order to let the excess pressure out 4 xx1200000954 Remove the protective cap from the nipple of the oil hole and connect the oil dis penser 5 xx1200000955 Remove the plug from the vent hole WARNING Open the vent hole while using the dis penser to avoid damaging vital parts in the gear 6 Continues on nex...

Page 144: ...gearbox Use this procedure to refill the gearbox with oil Note Action Run the robot to calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the safe guarded space 2 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 31 3 xx1200000954 Remove the protective cap from the nipple of t...

Page 145: ...he oil level at the vent hole level plug 7 Required oil level is 0 20 mm below the oil plug hole More information is found in Inspecting the oil level in axis 3 gearbox on page 105 Remove the oil dispenser 8 Apply Mercasol on the nipple Refit the protective cap on the nipple Tightening torque 24 Nm Refit the level plug 9 DANGER Make sure all safety requirements are met when performing the first te...

Page 146: ...age 131 Oil dispenser Content is defined in section Standard toolkit on page 652 Standard toolkit Consumable Note Material Information about the oil is found in Technical refer ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page131 Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lubrication in gearbox...

Page 147: ...Open the oil plug carefully in order to let the excess pressure out 4 Place the oil collecting vessel underneath the oil drain plug 5 xx1200000956 Remove the oil plug from the drain hole and let the oil run into the vessel 6 xx1200000957 Remove the oil plug from the fill level hole Note The level hole is opened to speed up the drainage 7 Continues on next page Product manual IRB 6790 147 3HAC06333...

Page 148: ...sure supply to the robot before entering the safe guarded space 2 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 31 3 xx1200000957 Open the fill level plug 4 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil Note The amount of oil to be filled depends on the amount pre...

Page 149: ...ee Inspecting the oil level in axis 4 gear box on page 107 Tightening torque 24 Nm Refit the oil plug 7 DANGER Make sure all safety requirements are met when performing the first test run 8 Product manual IRB 6790 149 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 3 Maintenance 3 5 5 Changing oil axis 4 gearbox Continued ...

Page 150: ...age 131 Oil dispenser Content is defined in section Standard toolkit on page 652 Standard toolkit Consumable Note Material Information about the oil is found in Technical refer ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page131 Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lubrication in gearbox...

Page 151: ...lug from the drain hole and let the oil run into the vessel 5 Place the oil collecting vessel underneath the oil drain plug 6 xx1200000959 Remove the oil plug from the fill level hole Note The fill hole is opened to speed up the drainage 7 WARNING Used oil is hazardous material and must be disposed of in a safe way See section Decommissioning on page639 for more in formation 8 Tightening torque 24...

Page 152: ...otal amount is detailed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil Note The amount of oil to be filled depends on the amount previously being drained 5 xx1200000959 Inspect the oil level at the oil fill level hole level plug 6 Required oil level is 0 10 mm below the oil plug hole More information is found in Inspecting the oil level in axis 5 gearbox on page...

Page 153: ...re all safety requirements are met when performing the first test run 8 Product manual IRB 6790 153 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 3 Maintenance 3 5 6 Changing oil axis 5 gearbox Continued ...

Page 154: ...31 Oil dispenser Content is defined in section Standard toolkit on page 652 Standard toolkit Consumable Note Material Information about the oil is found in Technical refer ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page131 Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lubrication in gearboxes Dr...

Page 155: ...ous Open the oil plug carefully in order to let the excess pressure out 4 Place the oil collecting vessel underneath the oil drain plug 5 xx1200000962 Remove the oil plug from the drain hole and let the oil run into the vessel 6 xx1200000963 Remove the oil plug from the fill hole Note The fill hole is opened to speed up the drainage 7 Continues on next page Product manual IRB 6790 155 3HAC063331 0...

Page 156: ...pressure supply to the robot before entering the safe guarded space 2 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 31 3 xx1200000963 Open the fill plug 4 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil Note The amount of oil to be filled depends on the amount previ...

Page 157: ...he oil level in axis 6 gearbox on page 112 Method 2 Rotate axis 5 77 Required oil level is 0 10 mm below the oil plug hole Tightening torque 20 Nm Refit the oil plug 7 DANGER Make sure all safety requirements are met when performing the first test run 8 Product manual IRB 6790 157 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 3 Maintenance 3 5 7 Changing oil axis 6 gearbox ...

Page 158: ...the controller turned on until the battery is to be replaced WARNING See Hazards related to batteries on page 32 Location of SMB battery The SMB battery SMB serial measurement board is located on the frame as shown in the figure below xx1700001632 Continues on next page 158 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 3 Maintenance 3 5 8 Replacing t...

Page 159: ...e robot before entering the safeguarded space 2 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 49 3 xx1200001069 Remove the SMB battery cover by unscrewing the attachment screws CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which ca...

Page 160: ...on The unit is sensitive to ESD on page 49 2 xx1200001069 Connect the battery cable and install the battery pack into the SMB battery recess 3 Secure the SMB battery cover with its attachment screws 4 See Updating revolution counters on page 619 Update the revolution counters 5 DANGER Make sure all safety requirements are met when performing the first test run 6 160 Product manual IRB 6790 3HAC063...

Page 161: ...level again after for example 6 months 4 If the oil level is decreased then replace the gearbox Special cleaning considerations This section specifies some special considerations when cleaning the robot Always use cleaning equipment as specified Any other cleaning equipment may shorten the life of the robot Always check that all protective covers are fitted to the robot before cleaning Never point...

Page 162: ...rs Maximum flow 20 liters minI I Typical tap water pressure and flow Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus Wash or Foundry Prime can be cleaned using a steam cleaner or high pressure water cleaner 2 The following list defines the prerequisites Maximum water pressure at the nozzle 2500 kN m2 25 bar Fan jet nozzle should be used min 45 s...

Page 163: ...g environment robot on page 43 Washing and cleaning detergents with corrosion inhibitor is recommended Note If the pH value or the detergent concentration is varying from its original specification it can become very corrosive Temperature of cleaning bath Maximum temperature 60ºC Ambient temperature must not be higher than 50 C 122 F Cables Movable cables need to be able to move freely Remove wast...

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Page 165: ... unit and the replacement unit This is particularly important for safety equipment to maintain the safety integrity of the installation Safety information Make sure to read through the chapter Safety on page 17 before commencing any service work Note The robot should be secured with the transportation brackets during removing from refitting to the foundation Note If the IRB 6790 is connected to po...

Page 166: ...he pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that no...

Page 167: ...exposed to any stresses during the assembly work 3 Assembly of tapered bearings Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing gradually ...

Page 168: ...arted During operation the bearing should be filled to 70 80 of the available volume Ensure that grease is handled and stored properly to avoid contamination Grease the different types of bearings as following description Grooved ball bearings must be filled with grease from both sides Tapered roller bearings and axial needle bearings must be greased in the split condition 168 Product manual IRB 6...

Page 169: ...l before actual mounting The fitting of sealings and gears must be carried out on clean workbenches Use a protective sleeve for the main lip during mounting when sliding over threads keyways or other sharp edges Note Action Check the sealing to ensure that The sealing is of the correct type There is no damage on the main lip 1 Inspect the shaft surface before mounting If scratches or damage are fo...

Page 170: ... space between the dust lip and the main lip with grease If the sealing is without dust lip just lubricate the main lip with a thin layer of grease 3 A xx2000000072 A Gap Mount the sealing correctly with a mounting tool Never hammer directly on the sealing as this may result in leakage 4 Continues on next page 170 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights...

Page 171: ...n the screws evenly when fastening the flange joint 4 O rings The following procedure describes how to fit o rings Note Action Ensure that the correct o ring size is used 1 Defective o rings including damaged or deformed o rings may not be used Check the o ring for surface defects burrs shape accuracy or deformation 2 Check the o ring grooves 3 The grooves must be geometrically correct and should ...

Page 172: ... the tool parts are needed in each procedure The procedure specifies which tool part to be used The complete tool set 3HAC028920 001 as follows A xx1700000383 Part A hydraulic cylinder is ordered separately 3HAC11731 1 Hydraulic pump is ordered separately 3HAC13086 1 172 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 2 4 Dismantle and mount...

Page 173: ... Prime Foundry Prime 2 Foundry Prime 3 Grey Painting damaged nickel coated surfaces with touch up paint Note Action 3HAC035355 001 Use Touch up paint Foundry Prime grey to paint the damage Note Always read the instruction in the product data sheet in the paint repair kit for Foundry Prime 1 Product manual IRB 6790 173 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4...

Page 174: ...e to the robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action Make sure the power is turned off 1 Remove the push button guard if necessary 2 Verify that the push buttons of the brake release unit are working by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a button gets jam...

Page 175: ...the following parts of the robot upper arm wrist lower arm frame Attachment points of lifting accessory Required tools Note Article number Equipment etc M12 3HAC16131 1 Lifting eye Continues on next page Product manual IRB 6790 175 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 3 1 Attaching lifting accessories to complete arm system ...

Page 176: ...aching the lifting accessories Robot position Use this procedure to jog the robot into position Note Action xx1200001132 Jog the robot into position Axis 1 no significance as long as the robot is secured to the foundation Axis 2 40 Axis 3 65 approximately Axis 4 calibration position 0 Axis 5 90 Axis 6 calibration position 0 1 DANGER Turn off all electric power supply hydraulic pressure supply to t...

Page 177: ...33 Fit a lifting eye to the wrist Note Save the stop screw installed to refit after the lifting eye is removed 3 Lifting shackle SA 10 8 NA1 xx1200001234 Fit a lifting shackle in the wrist lifting eye 4 Roundsling 1 5 m Length 1 5 m Lifting capacity 2 000 kg xx1200001209 Run a roundsling through the hole in the frame Attach the roundsling choked See figure xx1400000730 5 Continues on next page Pro...

Page 178: ...002196 Fender washer 8 Fender washer Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm xx1200001134 Note Save the stop screw installed to refit after the lifting eye is removed Lifting accessory chain 3HAC15556 1 Attach the Lifting accessory chain to an over head crane or similar and then to the lifting eye in the arm house and to a roundsling run through the wrist 9 Ro...

Page 179: ...0 mm hole diameter 13 mm thickness 3 mm Fender washer SA 10 8 NA1 Lifting shackle Length 1 5 m Lifting capacity 2 000 kg Roundsling 1 5 m Length 1 m lifting capacity 1 000 kg Roundsling 1 m Lifting instruction 3HAC15880 2 en closed 3HAC15556 1 Lifting accessory chain Continues on next page Product manual IRB 6790 179 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 ...

Page 180: ...he founda tion Axis 2 45 Axis 3 65 approximately Axis 4 0 Axis 5 0 Axis 6 0 2 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 3 Attaching lifting accessories to the lower and upper arm Use this procedure to attach the lifting accessories Note Action CAUTION The lower and upper arms together weigh accord ing to variants 510 kg ...

Page 181: ... screw hole shown in the figure This is done to secure the roundsling from gliding when lifting Note Save the stop screw installed to refit after the lifting eye is removed 4 Roundsling 1 5 m Length 1 5 m Lifting capacity 2 000 kg xx1200001252 Run a roundsling around the lower arm beneath the securing screw 5 Continues on next page Product manual IRB 6790 181 3HAC063331 001 Revision B Copyright 20...

Page 182: ...wer arm 8 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 9 Lifting eye 3HAC16131 1 Fit a lifting eye in the arm house with a fender washer underneath xx1400002196 10 Fender washer Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm xx1200001134 Note Save the stop screw installed to refit after the li...

Page 183: ... xx1200001254 Raise the overhead crane to stretch the chains and roundslings 12 Verify that the roundsling between the wrist and the lower arm is stretched To release the brake connect the 24 VDC power supply 13 Connect to connector R2 MP2 axis 2 motor pin 2 pin 5 Product manual IRB 6790 183 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 3 2 Attaching lifting acce...

Page 184: ...diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm Fender washer Lifting instruction 3HAC15880 2 en closed 3HAC15556 1 Lifting accessory chain Content is defined in section Standard toolkit on page 652 Standard toolkit Continues on next page 184 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 3 3 Attaching lifting access...

Page 185: ...s to the upper arm Note Action CAUTION The weight of the complete upper arm in cluding the wrist is 360 kg All lifting accessories used must be sized accordingly 1 Lifting eye 3HAC16131 1 xx1200001133 Fit a lifting eye to the wrist Note Save the stop screw installed to refit after the lifting eye is removed 2 Continues on next page Product manual IRB 6790 185 3HAC063331 001 Revision B Copyright 20...

Page 186: ...15556 1 xx1200001308 Attach the upper arm lifting accessory chain to an overhead crane or similar and then to the lifting eye in the arm house and in the wrist 4 Raise the lifting accessories to take the weight of the upper arm 5 xx1400002197 In case of necessary adjustments use the shortening loops on the lifting accessory chain to find the level position 6 186 Product manual IRB 6790 3HAC063331 ...

Page 187: ...the figure xx1700001801 Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 652 Standard toolkit Continues on next page Product manual IRB 6790 187 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness ...

Page 188: ...ness in the carrier being un wound or placed in the wrong position Depending on what tool is used the other axes may need to be jogged to another position 1 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the safe guarded space 2 xx1700001593 Check the leak flow value on the flow sensor Note the value to be able to compare it when repair is complete...

Page 189: ...and axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 xx1300002247 Remove the wrist cover 2 xx1500001030 Remove the heat protection plates from the motor with the cabling still attached to the plate 3 Continues on next page Product manual IRB 6790 189 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved ...

Page 190: ... plate 4 Disconnecting the axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 xx1200001080 Unscrew the attachment screws and re move the motor cover 2 xx1300000488 Disconnect the motor cables 3 Continues on next page 190 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair...

Page 191: ...sealed with flange sealant Loctite 577 Remove the part carefully 5 xx1300001113 Pull out the carrier from its position 6 xx1300000666 Pull out the axis 6 motor cables by holding the cables with one hand at the motor and the other at the carrier 7 Continues on next page Product manual IRB 6790 191 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cabl...

Page 192: ... xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 192 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 193: ...re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Disconnecting the axis 3 and axis 4 motor cables Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover Note Axis 3 and 4 motors only Be careful not to damag...

Page 194: ...amaged Tip Make a note in which direction the cable gland hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Continues on next page 194 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 195: ...se caution not to damage the gasket not to loose the washers on the cover sealing or not to loose the inserts fitted on the cover 2 xx1700001803 If the cabling is to be replaced by a new cable harness remove the cover insert to use it on the new cabling 3 Continues on next page Product manual IRB 6790 195 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 1 Removing...

Page 196: ...00000557 Remove the side cover on the arm tube 5 xx1700001809 Unscrew the screws and remove the seal ing washers holding the metal clamp inside the arm tube 6 xx1700001567 Remove the four nuts at the cable plate between the wrist and the upper arm tube by reaching into the upper arm tube through the arm tube side hole 7 Continues on next page 196 Product manual IRB 6790 3HAC063331 001 Revision B C...

Page 197: ...trap at the cable fixing bracket 9 Cable fixing bracket xx1300000541 Remove the metal clamp on top of the arm house 10 Continues on next page Product manual IRB 6790 197 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 198: ...st xx1300000746 Person 1 working at side hole xx1300000745 Remove the cable harness out of the arm tube at the back of the upper arm Tip This step is best performed by two persons working together Person 1 Put one hand inside the side hole and take a hold of the cable harness Person 2 Take a hold on the cable harness at the back of the robot Together Move the cable harness out of the arm tube 12 P...

Page 199: ... base frame and lower arm Preparations before removing the cable harness in the base Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 CAUTION Turn off the air pressure supply 2 xx1700001580 Remove the base cover 3 Continues on next page Product manual IRB 6790 199 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repa...

Page 200: ...se 5 xx1700001581 Remove the cover that protects the R1 MP and R1 SMB connectors 6 xx1700001582 Disconnect connectors R1 MP R1 SMB Air hose to balancing device 7 Continues on next page 200 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 201: ...ulic pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover Note Axis 3 and 4 motors only Be careful not to damage the air hose or air nipple 2 xx1200001070 Make sure the o ring is present 3 Continues on next page Product manual IRB 6790 201 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable h...

Page 202: ...otor cables 6 Preparations before disconnecting the SMB unit Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 49 2 Continues on next page 202 Product manual IRB 6790 3HAC06...

Page 203: ...efore opening Metal residues can cause shortage on the boards which can result in hazardous failures 6 Disconnecting the brake release unit Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitiv...

Page 204: ...e release board 4 Removing the cable harness in the frame Note Action xx1700001583 Remove the air coupling from the R1 MP connector 1 xx1300000542 Unscrew the attachment screws that hold the metal clamp frame 2 Continues on next page 204 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 205: ...he SMB unit 4 xx1700002154 Unscrew the attachment screws that secure the brake release unit bracket Remove the bracket with the brake release unit fitted 5 Continues on next page Product manual IRB 6790 205 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 206: ...x1300000560 Use caution and pull out the cable harness from the SMB recess 7 xx1700002246 Disconnect the air hose from the balancing device 8 Continues on next page 206 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 207: ...emoving the cable harness in the lower arm Note Action xx1300000540 Loosen the axis 2 lower arm metal clamp and the axis 3 lower arm metal clamp loc ated on the inside of the lower arm by re moving the attachment screws Note The screws are reached from the outside of the lower arm 1 Continues on next page Product manual IRB 6790 207 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights rese...

Page 208: ...on xx1300000733 Use caution and pull the cable harness out 2 208 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 209: ...nsert Replace if damaged 3HAC055411 001 Cable protection PU rubber Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 652 Standard toolkit Consumables Note Article number Consumable Shell Gadus S2 3HAC042536 001 Grease Used to lubricate o rings D 84 5x3 21522012 429 O ring Used on the SMB BU cover Continues on next page Product man...

Page 210: ...cal fit tings Robot position If the robot axes have been re positioned after the cable harness has been removed make sure to restore the initial robot position before refitting the cable harness See Preparations before removing the cable harness on page 188 Refitting the cable harness base frame and lower arm These procedures describes how to refit the cable harness in base frame and lower arm Pre...

Page 211: ...through the inside of the robot 2 xx1300000733 Run the cable harness through the lower arm 3 xx1300000734 Secure the axis 2 lower arm cable bracket Note Do not secure the axis 3 lower arm cable bracket at this point Note Screws are reached from the outside of the lower arm 4 Continues on next page Product manual IRB 6790 211 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 R...

Page 212: ...ion has come loose the axis 1 motor must be removed to have space for refitting 5 xx1700001807 xx1700001588 Run the R2 MP1 R2 MP2 R2 SMB1 and R2 SMB2 beside the cable protection and out to the axis 1 and axis 2 motors Also run the air hose to the balancing device beside the cable protection 6 Continues on next page 212 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All r...

Page 213: ...sealant for conical fittings Loctite 577 xx1700001583 Seal and refit the air coupling to the con nector R1 MP and reconnect the air pres sure hose 2 Tightening torque for R1 SMB 10 Nm xx1700001582 Connect connectors R1 MP and R1 SMB Also connect the air hose that belongs to the balancing device 3 Continues on next page Product manual IRB 6790 213 3HAC063331 001 Revision B Copyright 2019 2020 ABB A...

Page 214: ...cable 5 Washer dimension 6 4x17x3 xx1700001584 Refit the metal clamp inside the base 6 xx1700002245 Connect the balancing device air hose in side the base 7 Continues on next page 214 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 215: ... Replace if damaged 1 The figure shows the position of the o ring Wipe clean the contact surfaces of the cover as well as the hole it shall fit in 2 xx1300000560 Run the SMB BU cables into the SMB re cess 3 Continues on next page Product manual IRB 6790 215 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 216: ... running through the hole in the frame by carefully moving the SMB BU cover on its screws while at the same time checking the position of the cable harness through the hole Note The cables must be placed so that they don t rub against any part of the robot 5 Screws 4 pcs xx1700002155 Secure the SMB BU cover with its attach ment screws from inside the SMB BU re cess 6 Continues on next page 216 Pro...

Page 217: ...es for electrical power and hydraulic pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 49 2 Continues on next page Product manual IRB 6790 217 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harnes...

Page 218: ...1 3 R1 SMB4 6 and R2 SMB 4 xx1300000730 Push the SMB unit carefully into position and fit the bracket that secures the SMB unit 5 xx1700002154 If removed refit the bracket with the brake re lease unit fitted 6 Continues on next page 218 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 219: ... recess for the battery 8 SMB cover with sealing 3HAC044077 002 Check the sealing on the SMB cover Replace complete cover if sealing is damaged 9 xx1300000669 Secure the SMB cover with its attachment screws If cabling is used for 7th axis option refit the connector R2 FB7 to the SMB cover and tighten with 6 Nm 10 Continues on next page Product manual IRB 6790 219 3HAC063331 001 Revision B Copyrigh...

Page 220: ...067 Refit the cable gland cover Note Replace the gasket if damaged 2 xx1200001066 Connect the motor cables Connect in accordance with the markings on the connectors 3 Continues on next page 220 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 221: ...groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Attachment screws M5x12 Stainless steel A2 70 7 pcs 9ADA619 44 xx1200001135 Refit the motor cover with its attachment screws Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues on next page Product manual IRB 6790 221 3HAC063331...

Page 222: ... it easier to run the cable harness through the inside of the robot 1 xx1300000733 Run the upper end of the cable harness up through the lower arm 2 xx1300000734 Refit the axis 2 lower arm metal clamp located on the inside of the lower arm Note The screws are reached from the outside of the lower arm 3 Continues on next page 222 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020...

Page 223: ...own in the figure Do not change the po sition of the brackets 4 xx1300000558 Refit the axis 3 lower arm metal clamp located on the inside of the lower arm Note The screws are reached from the outside of the lower arm 5 Continues on next page Product manual IRB 6790 223 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 224: ...ween the cable clamps in the upper arm 3 xx1300000668 Tip Use tape and tie the axis 5 and axis 6 connectors and carrier into a bundle if not already done This is done to facilitate the procedure and to avoid damaging the parts during the procedure This will also make it easier to run the cable harness through the inside of the robot 4 Continues on next page 224 Product manual IRB 6790 3HAC063331 0...

Page 225: ...1400000382 A Gasket B Cable guide C Washer D Cover Make sure that the gasket underneath the cover is correctly fitted Replace if dam aged The gasket is covered with adhesive on the side facing the upper arm cover The three washers are pressed into the holes in the gasket Make sure all three washers are fitted 7 Continues on next page Product manual IRB 6790 225 3HAC063331 001 Revision B Copyright ...

Page 226: ...erson 2 working at the back xx1700001569 Person 1 working at the side hole xx1300000745 Use caution and push the cable harness into the wrist Tip This step is best performed by two persons working together Person 1 Put one hand inside the side cover hole and take a hold of the cable harness Person 2 Take a hold of the cable harness from inside the wrist Together Move the cable harness past the axi...

Page 227: ...be through the arm tube side hole 10 xx1700000340 Refit the metal clamp axis 4 inside the arm tube Note The screws are reached from outside the upper arm xx1700000339 Continues on next page Product manual IRB 6790 227 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 228: ...shers 11 xx1300000557 Refit the side cover Note Make sure the gasket is fitted cor rectly on the side cover Use attachment screws made of stainless steel to fit the side cover 12 Continues on next page 228 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 229: ... xx1700001804 xx1200000045 Refit the cover with the tube guiding ring fitted Note Make sure the gasket is fitted cor rectly Use attachment screws made of stainless steel to fit the cover 14 Continues on next page Product manual IRB 6790 229 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 230: ...x1700001810 Secure the cable harness to the cable fixing bracket with the velcro strap 16 Connecting the axis 3 and axis 4 motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 Continues on next page 230 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 231: ...3 O ring axis 1 3HAC067762 001 Inspect the o ring Note Replace if damaged 4 O ring axis 2 3HAC067762 001 O ring axis 3 3HAC067762 001 O ring axis 4 3HAC067744 001 xx1200001070 Wipe clean o ring and o ring groove 5 Continues on next page Product manual IRB 6790 231 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 232: ... 44 xx1200001135 Refit the motor cover with its attachment screws Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Connecting the axis 5 motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 Continues on next page 232 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All ri...

Page 233: ...1200001015 Connect the connectors Connect in accordance with the markings on the connectors 3 O ring axis 5 3HAC067744 001 xx1200001021 Make sure the o ring on the motor is undam aged Replace if damaged 4 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page Product manual IRB 6790 233 3HAC063331 001 Revision B Copyright 2019 2020 A...

Page 234: ...e threads Replace with standard attachment screws Note Make sure the o ring is undamaged and properly fitted 6 xx1500001029 Secure the cable harness with cable straps to the heat protection plate 7 Screws M5x12 xx1500001030 Fit the heat protection plate with the screws 8 Continues on next page 234 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repai...

Page 235: ...nstallation of the cable harness in the wrist If not connect the 24 VDC power supply release the brakes and move axis 5 manually to 90 2 xx1300000667 Push the cable harness into the wrist re cess and up into the axis 6 motor 3 xx1300001113 Push the carrier carefully into position 4 Continues on next page Product manual IRB 6790 235 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reser...

Page 236: ...ficult to fit Make sure the carrier is level and completely pressed against the bottom 5 xx1300000484 Secure the cable bracket with its attach ment screws 6 xx1300000488 Reconnect the connectors to the axis 6 motor Note Place the resolver cable under the motor cable 7 Continues on next page 236 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4...

Page 237: ... be dam aged 9 xx1200001080 Refit the motor cover 10 Concluding procedure Note Action xx1600002061 Make sure that the cable harness is placed in a way that it will not be damaged when the wrist cover is fitted 1 Continues on next page Product manual IRB 6790 237 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 238: ...position 5 Secure the cover with its attachment screws 3 Turn on the air pressure supply to the overpressure system 4 xx1700001593 Check the leak flow value on the flow sensor and compare it to the initial value The value should be the same If the value is higher than the initial value fault trace according to Inspecting the leak flow overpressure unit in the system on page 128 5 Axis Calibration ...

Page 239: ... sure all safety requirements are met when performing the first test run 7 Product manual IRB 6790 239 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 240: ...ber Equipment etc Content is defined in section Standard toolkit on page 652 Standard toolkit Stainless steel fasteners Due to robot protection type Foundry Prime some of the attachment screws and washers used on the robot are made of stainless steel If damaged or lost order new items according to this table Quantity Washers Screws Equipment to be fastened 4 pcs M6x16 A2 70 4 pcs SMB cover 9ADA619...

Page 241: ... the leak flow value on the flow sensor if not already checked and noted Note the value to be able to compare it when repair is completed 3 CAUTION Turn off the air pressure supply 4 xx1700001806 Open the small cover on the SMB cover disconnect the battery cable and remove the battery 5 xx1300000669 Remove the SMB cover CAUTION Clean cover from metal residues before opening Metal residues can caus...

Page 242: ... Remove the screws and washers that secure the SMB unit bracket 3 xx1300000728 Pull out the SMB unit a little and disconnect the con nectors from the SMB board R1 SMB1 3 R1 SMB4 6 and R2 SMB Battery cable connector R2 G Disconnect the battery cable by pressing down the upper lip of the R2 G connector to release the lock while pulling the connector upwards 4 xx1700000993 Continues on next page 242 ...

Page 243: ... ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 49 2 xx1300000729 Connect the battery cable to the SMB unit Make sure the lock snaps into place during refit ting 3 xx1300000728 Connect all connectors to the SMB board R1 SMB1 3 R1 SMB4 6 and R2 SMB 4 Continues on next page Product manual IRB 6790 243 3HAC063331 001 Revision B Copy...

Page 244: ...lease board Be careful not to damage the sockets or pins Make sure the connector and its locking arms are snapped down properly 7 xx1300000834 Pull out the battery cable through the recess for the battery 8 SMB cover with sealing 3HAC044077 002 Check the sealing on the SMB cover Replace complete cover if sealing is damaged 9 Continues on next page 244 Product manual IRB 6790 3HAC063331 001 Revisio...

Page 245: ...ttery cable 2 xx1700001806 Place the battery in the recess 3 Refit the battery cover 4 Concluding procedures Note Action Turn on the air pressure supply to the overpres sure system 1 xx1700001593 Check the leak flow value on the flow sensor and compare it to the initial value The value should be the same If the value is higher than the initial value fault trace according to Inspecting the leak flo...

Page 246: ...Update the revolution counters 3 DANGER Make sure all safety requirements are met when performing the first test run 4 246 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 3 Replacing the SMB Continued ...

Page 247: ...Brake release unit Product manual spare parts IRB 6790 See Battery pack Product manual spare parts IRB 6790 Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 652 Standard toolkit Continues on next page Product manual IRB 6790 247 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 4 Replacing the bra...

Page 248: ...upply to the robot before entering the safeguarded space 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 49 2 xx1700001813 Remove the push button guard from the SMB cover The push button guard must be removed to ensure a correct refitting of the brake release unit 3 xx17000015...

Page 249: ...electrical power and hydraulic pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 49 2 Take a picture or make notes of how the robot cabling is positioned in regard to the brake release board 3 xx1300000670 Remove the connectors X8 X9 and X10 from the brak...

Page 250: ...o ESD on page 49 1 Maximum tightening torque 5 Nm Fasten the brake release unit to the bracket 2 xx1700002154 Refit the bracket with the brake release unit fitted Make sure the unit is placed as straight as possible on the bracket The push buttons can otherwise get jammed when the SMB cover is refitted 3 X9 X8 X10 xx1700000978 Reconnect the connectors X8 X9 and X10 to the brake release unit Be car...

Page 251: ...refit the push button guard at this point 7 WARNING Before continuing any service work follow the safety procedure in section The brake release buttons may be jammed after service work on page 174 8 xx1700001813 Refit the push button guard to the SMB cover 9 Press the push buttons 1 to 6 one at a time to make sure that the buttons are moving freely and do not stay in any locked position 10 Reconne...

Page 252: ...the leak flow overpressure unit in the system on page 128 13 See Updating revolution counters on page 619 Update the revolution counters if the battery has been disconnected 14 DANGER Make sure all safety requirements are met when performing the first test run 15 252 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 4 4 Replacing the brake rel...

Page 253: ...t xx1300000483 Spare part Note Spare part number Spare part See Upper arm Product manual spare parts IRB 6790 Consumables Parts needed to be replaced after removal Note Article number Equipment etc Shell Gadus S2 3HAC042536 001 Grease Used to lubricate o rings Continues on next page Product manual IRB 6790 253 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 1 Rep...

Page 254: ...13x19x2 Stainless Steel M12x40 Stainless Steel 3HAC060866 004 3HAC060786 031 Required tools and equipment Note Article number Equipment etc M12 3HAC16131 1 Lifting eye M12 3HAC16131 1 Lifting eye Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm Fender washer Lifting instruction 3HAC15880 2 en closed 3HAC15556 1 Lifting accessory chain Used for putting down removed part...

Page 255: ...w values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 624 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot...

Page 256: ...hen repair is completed 6 CAUTION Turn off the air pressure supply 7 Position of the robot in the continued process Note Action Jog the robot into position Axis 1 No significance as long as the robot is secured to the founda tion Axis 2 60 Axis 3 60 Axis 4 90 Axis 5 90 Axis 6 No significance 1 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the safe...

Page 257: ...plies for electrical power and hydraulic pressure are turned off 1 xx1300002247 Remove the wrist cover 2 xx1500001030 Remove the heat protection plates from the motor with the cabling still attached to the plate 3 Continues on next page Product manual IRB 6790 257 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 258: ... loosened from the plate 4 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page 258 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 1 Replaci...

Page 259: ...otor 2 Remove the outer screw 3 Slide the cable gland cover away from the inner screw Make sure the gasket is not damaged Tip Make a note in which direction the cable exit hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Continues on next page Product manual IRB 6790 259 3HAC063331 001 Revision B Copyrig...

Page 260: ...0001080 Unscrew the attachment screws and re move the motor cover 2 xx1300000488 Disconnect the motor cables 3 xx1300000484 Unscrew the attachment screws that hold the cable bracket 4 Continues on next page 260 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 261: ...tion 6 xx1300000666 Pull out the axis 6 motor cables by holding the cables with one hand at the motor and the other at the carrier 7 Disconnecting the axis 3 and axis 4 motor cables Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 Continues on next page Product manual IRB 6790 261 3HAC063331 001 Revision B Copyright 2019 2020 ABB All right...

Page 262: ... only Be careful not to damage the air hose or air nipple 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 262 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 263: ...rness wrist and upper arm Note Action A B B B xx1700001802 A Cable protection B Cable ties Remove the cable protection by cutting the cable ties and opening the zipper 1 xx1200000045 Remove the cover Note Use caution not to damage the gasket not to loose the washers on the cover sealing or not to loose the inserts fitted on the cover 2 Continues on next page Product manual IRB 6790 263 3HAC063331 ...

Page 264: ...ate the removal and to avoid damaging the parts This will also make it easier to run the cable harness through the inside of the upper arm 4 xx1300000557 Remove the side cover on the arm tube 5 xx1700001809 Unscrew the screws and remove the seal ing washers holding the metal clamp inside the arm tube 6 Continues on next page 264 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020...

Page 265: ...ube through the arm tube side hole 7 xx1300000543 Remove the arm house metal clamp 8 xx1700001810 Open the velcro strap at the cable fixing bracket 9 Cable fixing bracket Continues on next page Product manual IRB 6790 265 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 266: ... Person 1 Put one hand inside the side hole and take a hold of the cable harness Person 2 Take a hold on the cable harness inside the wrist Together Move the cable harness past the axis 5 motor and into the arm tube 11 Person 2 working at the wrist xx1300000746 Continues on next page 266 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 1 Re...

Page 267: ...m tube 12 Person 2 working at the back xx1700001568 xx1800001380 If changing to a new cable harness Move the air hose nipple from the cable plate to the new harness 13 Attaching the lifting accessories Use this procedure to attach the lifting accessories to the upper arm Note Action CAUTION The weight of the complete upper arm in cluding the wrist is 360 kg All lifting accessories used must be siz...

Page 268: ...13 mm thickness 3 mm xx1200001134 Note Save the stop screw installed to refit after the lifting eye is removed Lifting accessory chain 3HAC15556 1 xx1200001308 Attach the upper arm lifting accessory chain to an overhead crane or similar and then to the lifting eye in the arm house and in the wrist 4 Raise the lifting accessories to take the weight of the upper arm 5 Continues on next page 268 Prod...

Page 269: ...te Make sure that it is the screws that hold the lower arm to the axis 3 gearbox that are removed 1 Guide pin M12x200 3HAC13056 3 Always use guide pins in pairs xx1300000659 Tip Lubricate the guide pins with some grease to make the upper arm slide better xx1300000747 Leave one of the remaining attachment screws fitted remove the other screws 2 Continues on next page Product manual IRB 6790 269 3HA...

Page 270: ...If the cable harness is still fitted or partly fitted use caution when lifting the upper arm over to the other side of the robot in order not to cause any damage to the cable harness 3 xx1300000553 This step is only valid when the upper arm is removed due to replacement of the axis 3 gearbox Place pieces of wood or similar under arm house and wrist Lower the upper arm and let the upper arm rest as...

Page 271: ...essories to the upper arm on page 184 Attach the lifting accessories if not already fitted 2 Lift the upper arm and put it on the guide pins 3 24 VDC power supply If the axis 3 motor is installed to the upper arm 4 Rotation tool In order to release the brakes connect the 24 VDC power supply Connect to R2 MP3 connector pin 2 pin 5 Use the rotation tool and rotate the axis 3 motor to find the correc...

Page 272: ...eel 3HAC060866 004 xx1400000359 xx1300000659 Remove the guide pins and fit the two re maining M12 screws 7 Tightening torque depends on screw dimen sion Secure the upper arm by tightening the at tachment screws 8 Tightening torque M16 300 Nm Tightening torque M12 120 Nm Continues on next page 272 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair...

Page 273: ...tape and tie the axis 5 and axis 6 connectors and carrier into a bundle if not already done This is done to facilitate the procedure and to avoid damaging the parts during the procedure This will also make it easier to run the cable harness through the inside of the robot 4 Continues on next page Product manual IRB 6790 273 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Re...

Page 274: ...xx1400000382 A Gasket B Cable guide C Washer D Cover Make sure that the gasket underneath the cover is correctly fitted Replace if dam aged The gasket is covered with adhesive on the side facing the upper arm cover The three washers are pressed into the holes in the gasket Make sure all three washers are fitted 7 Continues on next page 274 Product manual IRB 6790 3HAC063331 001 Revision B Copyrigh...

Page 275: ... Person 2 working at the back xx1700001569 Person 1 working at the side hole xx1300000745 Use caution and push the cable harness into the wrist Tip This step is best performed by two persons working together Person 1 Put one hand inside the side cover hole and take a hold of the cable harness Person 2 Take a hold of the cable harness from inside the wrist Together Move the cable harness past the a...

Page 276: ...tube through the arm tube side hole 10 xx1700000340 Refit the metal clamp axis 4 inside the arm tube Note The screws are reached from outside the upper arm xx1700000339 Continues on next page 276 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 277: ...washers 11 xx1300000557 Refit the side cover Note Make sure the gasket is fitted cor rectly on the side cover Use attachment screws made of stainless steel to fit the side cover 12 Continues on next page Product manual IRB 6790 277 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 278: ...01 xx1700001804 xx1200000045 Refit the cover with the tube guiding ring fitted Note Make sure the gasket is fitted cor rectly Use attachment screws made of stainless steel to fit the cover 14 Continues on next page 278 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 279: ... xx1700001810 Secure the cable harness to the cable fixing bracket with the velcro strap 16 Connecting the axis 3 and axis 4 motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 Continues on next page Product manual IRB 6790 279 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 280: ...s 3 O ring axis 1 3HAC067762 001 Inspect the o ring Note Replace if damaged 4 O ring axis 2 3HAC067762 001 O ring axis 3 3HAC067762 001 O ring axis 4 3HAC067744 001 xx1200001070 Wipe clean o ring and o ring groove 5 Continues on next page 280 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 281: ...19 44 xx1200001135 Refit the motor cover with its attachment screws Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Connecting the axis 5 motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 Continues on next page Product manual IRB 6790 281 3HAC063331 001 Revision B Copyright 2019 2020 ABB All ...

Page 282: ...xx1200001015 Connect the connectors Connect in accordance with the markings on the connectors 3 O ring axis 5 3HAC067744 001 xx1200001021 Make sure the o ring on the motor is undam aged Replace if damaged 4 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page 282 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020...

Page 283: ...the threads Replace with standard attachment screws Note Make sure the o ring is undamaged and properly fitted 6 xx1500001029 Secure the cable harness with cable straps to the heat protection plate 7 Screws M5x12 xx1500001030 Fit the heat protection plate with the screws 8 Continues on next page Product manual IRB 6790 283 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Rep...

Page 284: ... installation of the cable harness in the wrist If not connect the 24 VDC power supply release the brakes and move axis 5 manually to 90 2 xx1300000667 Push the cable harness into the wrist re cess and up into the axis 6 motor 3 xx1300001113 Push the carrier carefully into position 4 Continues on next page 284 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights res...

Page 285: ...ifficult to fit Make sure the carrier is level and completely pressed against the bottom 5 xx1300000484 Secure the cable bracket with its attach ment screws 6 xx1300000488 Reconnect the connectors to the axis 6 motor Note Place the resolver cable under the motor cable 7 Continues on next page Product manual IRB 6790 285 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair...

Page 286: ...CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 9 xx1200001080 Refit the motor cover 10 Continues on next page 286 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 287: ... an angle 4 Move the upper part of the cover into position 5 Secure the cover with its attachment screws 2 Remove the lifting accessories 3 Refit stop screws in the lifting accessory attachment holes Concluding procedure Note Action Turn on the air pressure supply to the overpressure system 1 xx1700001593 Check the leak flow value on the flow sensor and compare it to the initial value The value sh...

Page 288: ...obot 3 General calibration information is included in section Calibration on page 613 DANGER Make sure all safety requirements are met when performing the first test run 4 288 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 289: ...on the axis 5 gearbox It is strictly forbidden to do any repair work on the axis 5 gearbox xx1300002248 Location of the wrist The wrist is located as shown in the figure xx1300000597 Continues on next page Product manual IRB 6790 289 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist ...

Page 290: ...e of stainless steel If damaged or lost order new items according to this table Quantity Washers Screws Equipment to be fastened 12 pcs 13x19x2 Stainless Steel M12x50 Stainless Steel Wrist 3HAC060866 004 3HAC060786 032 Required tools and equipment Note Article number Equipment etc Length 1 m lifting capacity 1 000 kg Roundsling 1 m Used for putting down removed parts from robot Pallet Used for pro...

Page 291: ...f the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 624 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack ...

Page 292: ...te the value to be able to compare it when repair is completed 6 CAUTION Turn off the air pressure supply 7 Retrieving access to the wrist cabling Use this procedure to remove the wrist cover to retrieve access to the axis 5 and axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 Continues on next page 292 Product manual I...

Page 293: ...able ties that hold the cable har ness to the plate Note Keep the heat protection plate until refitting Tip If removing the plate only for replacing the motor the cabling does not need to be loosened from the plate 4 Continues on next page Product manual IRB 6790 293 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 294: ...200001080 Unscrew the attachment screws and re move the motor cover 2 xx1300000488 Disconnect the motor cables 3 xx1300000484 Unscrew the attachment screws that hold the cable bracket 4 Continues on next page 294 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 295: ...its position 6 xx1300000666 Pull out the axis 6 motor cables by holding the cables with one hand at the motor and the other at the carrier 7 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 Continues on next page Product manual IRB 6790 295 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights r...

Page 296: ...ve the motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 296 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 297: ...ION The weight of the complete wrist is 125 kg All lifting accessories used must be sized accordingly 1 Roundsling 1 m Length 1 m lifting capa city 1 000 kg xx1300000673 Attach a roundsling to the wrist as shown in the figure CAUTION It is very important that the roundsling is placed as shown in the figure to keep the wrist balanced when it is removed Placed at a different position there is a risk...

Page 298: ...ove the remaining attachment screws 2 xx1700001594 A Tubeshaft plate Pull out the wrist a bit onto the guide pins Loosen the cable plate from the wrist by removing the four nuts This is done to be able to remove the cable harness from the wrist in a safe way CAUTION Make sure that the cabling does not get damaged 3 Continues on next page 298 Product manual IRB 6790 3HAC063331 001 Revision B Copyri...

Page 299: ...he plate is fitted with Flange sealant and must be cleaned from old residuals 6 Refitting the wrist These procedures describes how to refit the wrist Preparations before refitting the wrist Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 Continues on next page Product manual IRB 6790 299 3HAC063331 001 Revision B Copyright 2019 2020 ABB A...

Page 300: ...en the flange sealant 3 Flange sealant 12340011 116 Loctite 574 Contact surface against the tubeshaft flange xx1700001876 Contact surface against the upper arm tube xx1700001877 Guide pin M12x150 3HAC13056 2 Fit two guide pins in opposite holes in the wrist Tip Lubricate the guide pins with some grease to make the wrist slide better 4 Always use guide pins in pairs xx1700001595 Continues on next p...

Page 301: ...th 1 m lifting capa city 1 000 kg xx1300000673 Attach a roundsling to the wrist as shown in the figure CAUTION It is very important that the roundsling is placed as shown in the figure to keep the wrist balanced when it is removed Placed at a different position there is a risk of sudden change in the balance which can cause damage or injury Do not attach the roundsling around the axis 5 gearbox 2 ...

Page 302: ...k into the wrist 1 xx1300000769 Run the cabling into the wrist unit Be careful not to damage any part of the cable harness 2 xx1700001594 Slide the wrist into fitting position Make sure that the tubeshaft plate is placed properly in the groove in the wrist 3 Continues on next page 302 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 2 Repla...

Page 303: ... replace them with the remaining attachment screws and washers 5 Tightening torque 120 Nm Tighten the attachment screws 6 Connecting the axis 5 motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 Continues on next page Product manual IRB 6790 303 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Con...

Page 304: ...2 xx1200001015 Connect the connectors Connect in accordance with the markings on the connectors 3 O ring axis 5 3HAC067744 001 xx1200001021 Make sure the o ring on the motor is undam aged Replace if damaged 4 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page 304 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 20...

Page 305: ...e the threads Replace with standard attachment screws Note Make sure the o ring is undamaged and properly fitted 6 xx1500001029 Secure the cable harness with cable straps to the heat protection plate 7 Screws M5x12 xx1500001030 Fit the heat protection plate with the screws 8 Continues on next page Product manual IRB 6790 305 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 R...

Page 306: ...ct installation of the cable harness in the wrist If not connect the 24 VDC power supply release the brakes and move axis 5 manually to 90 2 xx1300000667 Push the cable harness into the wrist re cess and up into the axis 6 motor 3 xx1300001113 Push the carrier carefully into position 4 Continues on next page 306 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights r...

Page 307: ... difficult to fit Make sure the carrier is level and completely pressed against the bottom 5 xx1300000484 Secure the cable bracket with its attach ment screws 6 xx1300000488 Reconnect the connectors to the axis 6 motor Note Place the resolver cable under the motor cable 7 Continues on next page Product manual IRB 6790 307 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repa...

Page 308: ... will be dam aged 9 xx1200001080 Refit the motor cover 10 Concluding procedure Note Action xx1500001672 Make sure that the cable harness is placed in a way so it will not be damaged when the wrist cover is fitted 1 Continues on next page 308 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 309: ... the cover with its attachment screws 3 Turn on the air pressure supply to the overpressure system 4 xx1700001593 Check the leak flow value on the flow sensor and compare it to the initial value The value should be the same If the value is higher than the initial value fault trace according to Inspecting the leak flow overpressure unit in the system on page 128 5 Axis Calibration is described in C...

Page 310: ...Make sure all safety requirements are met when performing the first test run 7 310 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 311: ...arts IRB 6790 The seal is damaged when the turning disc is removed and must be replaced 3HAC060656 002 Turcon Roto VL seal Located on the axis 6 gear box Replace if damaged 3HAC062111 001 Guiding ring Consumables Note Article number Equipment etc Shell Gadus S2 3HAC042536 001 Grease Continues on next page Product manual IRB 6790 311 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights rese...

Page 312: ...on Standard toolkit on page 652 Standard toolkit Removing the turning disc Use these procedures to remove the turning disc Preparations before removing the turning disc Note Action Run the robot to a position most comfort able for the removal of the turning disc 1 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the safe guarded space 2 Remove any eq...

Page 313: ...700001592 Remove the seal from the turning disc Note Replace the seal if damaged 3 Continues on next page Product manual IRB 6790 313 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 3 Replacing the turning disc Continued ...

Page 314: ...g disc when orient ing the seal as shown in the figure 1 Grease 3HAC042536 001 Shell Gadus S2 xx1700001878 xx1700002033 Grease 3HAC042536 001 Shell Gadus S2 xx1700002094 Apply grease all the way around the inner corner of the turning disc Note No grease is allowed on the screw flange 2 Continues on next page 314 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights r...

Page 315: ...C060786 010 24 pcs Washers 8 4x13x1 6 Stainless Steel 3HAC060866 001 24 pcs xx1300000492 Tip Use three M8x35 screws first to pull in the turning disc against the gearbox if needed Then remove the screws and secure the turning disc with the specified attachment screws Concluding procedure Note Action DANGER Make sure all safety requirements are met when performing the first test run 1 Product manua...

Page 316: ...formed 1 Unload the balancing device 2 Remove the shaft in the balancing device front link ear 3 Remove the cabling from the upper and lower arm 4 Remove the upper arm 5 Replace the lower arm Spare part Note Spare part number Spare part See Lower arm Product manual spare parts IRB 6790 Continues on next page 316 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights r...

Page 317: ...d or lost order new items according to this table Quantity Washers Screws Equipment to be fastened 21 pcs 17x15x3 Stainless Steel M16x50 Stainless Steel Lower arm 3HAC060866 005 3HAC060786 041 9 pcs 17x15x3 Stainless Steel M16x50 Stainless Steel Upper arm 3HAC060866 005 3HAC060786 041 27 pcs 13x19x2 Stainless Steel M12x40 Stainless Steel 3HAC060866 004 3HAC060786 031 4 pcs M10x30 Stainless Steel 3...

Page 318: ...ol Used to release the motor brakes 24 VDC power supply Included in the tool kit Dismantle and mounting tool 3HAC028920 001 3HAC047273 001 Anvil Delivered as a set of calibration tools 3HAC055412 001 Calibration tool box Axis Calibration Content is defined in section Standard toolkit on page 652 Standard toolkit Deciding calibration routine Decide which calibration routine to be used based on the ...

Page 319: ...t is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the lower arm Use these procedures to remove the lower arm Preparations before removing the lower arm Note Action Decide which calibration routine to use and take actions accordingly prior to begin ning the repair procedure 1 DANGER Turn off all electric power supply hydraulic...

Page 320: ...01 Note Action DANGER Do not use the Distance tool 3HAC030662 001 to unload or restore the pressure of the balancing device springs This tool is only used to lock the spring unit in a com pressed position after axis 2 has been jogged to 30 or 30 Fitting and removal of the tool shall only be done with axis 2 in this position To unload or restore a new balancing device or if the spring unit of the b...

Page 321: ...f more tightening torque than 45 Nm is used risking that the Distance tool is not properly fitted 5 Attachment screws M10x30 Stainless Steel 3HAC060786 020 4 pcs A xx0800000480 A Distance tool 3HAC030662 001 Turn the power on temporary 6 This is done to compress the balancing device springs making it possible to re move the front shaft of the balancing device Jog axis 2 to the calibration position...

Page 322: ...rded space 2 Remove any equipment if fitted on or close to the balancing device 3 CAUTION The weight of the balancing device exclud ing cradle is 140 kg All lifting accessories used must be sized accordingly 4 Lifting shackle SA 10 8 NA1 xx1300000661 Fit a lifting shackle to the balancing device 5 Lifting accessory chain 3HAC15556 1 Fit the lifting accessory chain to the shackle and raise to unloa...

Page 323: ...001 Use the dismantle and mounting tool and pull the shaft out A B L 1 F 4 xx1700000378 The numbers in the figure refers to the marked tool pieces respectively 3 Hydraulic pump 70 MPa 3HAC13086 1 Hydraulic cylinder 3HAC11731 1 xx1200001280 Continues on next page Product manual IRB 6790 323 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm ...

Page 324: ...to retrieve access to the axis 5 and axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 xx1300002247 Remove the wrist cover 2 Continues on next page 324 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 325: ...tion plate until refitting Tip If removing the plate only for replacing the motor the cabling does not need to be loosened from the plate 4 Removing cable brackets Note Action xx1200001184 Unscrew the screws that hold the bracket and let it hang free 1 Continues on next page Product manual IRB 6790 325 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing t...

Page 326: ...nt screws and washers and remove the motor cover Note Axis 3 and 4 motors only Be careful not to damage the air hose or air nipple 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 326 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 327: ...Use caution and pull out the motor cables 6 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page Product manual IRB 6790 327 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Rep...

Page 328: ...otor 2 Remove the outer screw 3 Slide the cable gland cover away from the inner screw Make sure the gasket is not damaged Tip Make a note in which direction the cable exit hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Continues on next page 328 Product manual IRB 6790 3HAC063331 001 Revision B Copyrig...

Page 329: ...0001080 Unscrew the attachment screws and re move the motor cover 2 xx1300000488 Disconnect the motor cables 3 xx1300000484 Unscrew the attachment screws that hold the cable bracket 4 Continues on next page Product manual IRB 6790 329 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 330: ...577 Remove the part carefully 5 xx1300001113 Pull out the carrier from its position 6 xx1300000666 Pull out the axis 6 motor cables by holding the cables with one hand at the motor and the other at the carrier 7 Continues on next page 330 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 331: ... Use caution not to damage the gasket not to loose the washers on the cover sealing or not to loose the inserts fitted on the cover 2 xx1700001803 If the cabling is to be replaced by a new cable harness remove the cover insert to use it on the new cabling 3 Continues on next page Product manual IRB 6790 331 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Replac...

Page 332: ...1300000557 Remove the side cover on the arm tube 5 xx1700001809 Unscrew the screws and remove the seal ing washers holding the metal clamp inside the arm tube 6 xx1700001567 Remove the four nuts at the cable plate between the wrist and the upper arm tube by reaching into the upper arm tube through the arm tube side hole 7 Continues on next page 332 Product manual IRB 6790 3HAC063331 001 Revision B...

Page 333: ... strap at the cable fixing bracket 9 Cable fixing bracket xx1300000541 Remove the metal clamp on top of the arm house 10 Continues on next page Product manual IRB 6790 333 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 334: ...rist xx1300000746 Person 1 working at side hole xx1300000745 Remove the cable harness out of the arm tube at the back of the upper arm Tip This step is best performed by two persons working together Person 1 Put one hand inside the side hole and take a hold of the cable harness Person 2 Take a hold on the cable harness at the back of the robot Together Move the cable harness out of the arm tube 12...

Page 335: ...ing eye 3HAC16131 1 xx1200001133 Fit a lifting eye to the wrist Note Save the stop screw installed to refit after the lifting eye is removed 2 Lifting eye 3HAC16131 1 Fit a lifting eye in the arm house with a fender washer underneath xx1400002196 3 Fender washer Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm xx1200001134 Note Save the stop screw installed to refit af...

Page 336: ...n 6 Preparations before removing the upper arm Note Action Guide pin M12x150 3HAC13056 2 Remove two attachment screws M12 in opposite holes and replace them with guide pins Note Make sure that it is the screws that hold the lower arm to the axis 3 gearbox that are removed 1 Guide pin M12x200 3HAC13056 3 Always use guide pins in pairs xx1300000659 Tip Lubricate the guide pins with some grease to ma...

Page 337: ...achment screw and let the upper arm slide out from the lower arm with support from the guide pins 2 Lift the upper arm and place it on the pre pared area CAUTION Only valid when the upper arm is removed due to replacement of the axis 3 gearbox If the cable harness is still fitted or partly fitted use caution when lifting the upper arm over to the other side of the robot in order not to cause any d...

Page 338: ...s 3 gearbox if applicable 4 Preparations before removing the lower arm Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 xx1300000540 Loosen the axis 2 lower arm metal clamp and the axis 3 lower arm metal clamp loc ated on the inside of the lower arm by re moving the attachment screws Note The screws are reached from outside the lower arm 2...

Page 339: ...accessory to unload the lower arm 1 Guide pin M16x150 3HAC13120 2 Remove two attachment screws in opposite holes and replace them with guide pins Tip Lubricate the guide pins with some grease to make the lower arm slide better 2 Guide pin M16x200 3HAC13120 3 Always use guide pins in pairs xx1300000788 Continues on next page Product manual IRB 6790 339 3HAC063331 001 Revision B Copyright 2019 2020 ...

Page 340: ...to refit the lower arm Preparations before refitting the lower arm Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 Guide pin M16x150 3HAC13120 2 Fit two guide pins in opposite holes in the axis 2 gearbox Tip Lubricate the guide pins with some grease to make the lower arm slide better 2 Always use guide pins in pairs xx1700000055 Continues...

Page 341: ...ttern of the lower arm and gearbox does not match Remove the motor cover Apply the rotation tool on the motor shaft Connect the 24 VDC power supply Release the brakes Rotate pinion and gear with the rota tional tool until the holes matches Connect 24 VDC the power supply to con nector R2 MP2 pin 2 pin 5 3 24 VDC power supply xx1300000819 xx1300000790 Fit one attachment screw in one of the up per h...

Page 342: ...ed 6 xx1300000788 Remove the guide pins and replace them with the remaining attachment screws 7 Tightening torque M16 300 Nm Secure the remaining attachment screws 8 Remove the lifting accessory from the lower arm 9 Preparations before refitting the upper arm Note Action Wipe clean all contact surfaces 1 Continues on next page 342 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 20...

Page 343: ...ot already fitted 2 Lift the upper arm and put it on the guide pins 3 24 VDC power supply If the axis 3 motor is installed to the upper arm 4 Rotation tool In order to release the brakes connect the 24 VDC power supply Connect to R2 MP3 connector pin 2 pin 5 Use the rotation tool and rotate the axis 3 motor to find the correct position for the guide pins in the lower arm Pinion 3HAC067546 001 If t...

Page 344: ... by tightening the at tachment screws 8 Tightening torque M16 300 Nm Tightening torque M12 120 Nm Refitting the cable harness lower arm Note Action xx1300000668 Tip Use tape and tie the axis 5 and axis 6 connectors and carrier into a bundle if not already done This is done to facilitate the procedure and to avoid damaging the parts during the procedure This will also make it easier to run the cabl...

Page 345: ...f the lower arm 3 xx1300000595 Before fitting the remaining axis 3 lower arm cable bracket inside the lower arm check that it will stay twisted a little between the metal clamps after fitting as shown in the figure Do not change the po sition of the brackets 4 Continues on next page Product manual IRB 6790 345 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Rep...

Page 346: ...he cable harness upper arm Note Action xx1300000541 Refit the metal clamp on top of the arm house 1 xx1300000543 Refit the arm house metal clamp 2 Arrange the cables between the cable clamps in the upper arm 3 Continues on next page 346 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 347: ...ewing it in place Use Locking liquid 5 Fit the air hose from axis 4 motor into the air nipple Make sure that it clicks when connecting it 6 A B C D xx1400000382 A Gasket B Cable guide C Washer D Cover Make sure that the gasket underneath the cover is correctly fitted Replace if dam aged The gasket is covered with adhesive on the side facing the upper arm cover The three washers are pressed into th...

Page 348: ... Person 2 working at the back xx1700001569 Person 1 working at the side hole xx1300000745 Use caution and push the cable harness into the wrist Tip This step is best performed by two persons working together Person 1 Put one hand inside the side cover hole and take a hold of the cable harness Person 2 Take a hold of the cable harness from inside the wrist Together Move the cable harness past the a...

Page 349: ...tube through the arm tube side hole 10 xx1700000340 Refit the metal clamp axis 4 inside the arm tube Note The screws are reached from outside the upper arm xx1700000339 Continues on next page Product manual IRB 6790 349 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 350: ...washers 11 xx1300000557 Refit the side cover Note Make sure the gasket is fitted cor rectly on the side cover Use attachment screws made of stainless steel to fit the side cover 12 Continues on next page 350 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 351: ...01 xx1700001804 xx1200000045 Refit the cover with the tube guiding ring fitted Note Make sure the gasket is fitted cor rectly Use attachment screws made of stainless steel to fit the cover 14 Continues on next page Product manual IRB 6790 351 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 352: ... xx1700001810 Secure the cable harness to the cable fixing bracket with the velcro strap 16 Connecting the axis 3 and axis 4 motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 Continues on next page 352 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 353: ...s 3 O ring axis 1 3HAC067762 001 Inspect the o ring Note Replace if damaged 4 O ring axis 2 3HAC067762 001 O ring axis 3 3HAC067762 001 O ring axis 4 3HAC067744 001 xx1200001070 Wipe clean o ring and o ring groove 5 Continues on next page Product manual IRB 6790 353 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 354: ...19 44 xx1200001135 Refit the motor cover with its attachment screws Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Connecting the axis 5 motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 Continues on next page 354 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All ...

Page 355: ...xx1200001015 Connect the connectors Connect in accordance with the markings on the connectors 3 O ring axis 5 3HAC067744 001 xx1200001021 Make sure the o ring on the motor is undam aged Replace if damaged 4 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page Product manual IRB 6790 355 3HAC063331 001 Revision B Copyright 2019 2020...

Page 356: ...the threads Replace with standard attachment screws Note Make sure the o ring is undamaged and properly fitted 6 xx1500001029 Secure the cable harness with cable straps to the heat protection plate 7 Screws M5x12 xx1500001030 Fit the heat protection plate with the screws 8 Continues on next page 356 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Rep...

Page 357: ... installation of the cable harness in the wrist If not connect the 24 VDC power supply release the brakes and move axis 5 manually to 90 2 xx1300000667 Push the cable harness into the wrist re cess and up into the axis 6 motor 3 xx1300001113 Push the carrier carefully into position 4 Continues on next page Product manual IRB 6790 357 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights res...

Page 358: ...ifficult to fit Make sure the carrier is level and completely pressed against the bottom 5 xx1300000484 Secure the cable bracket with its attach ment screws 6 xx1300000488 Reconnect the connectors to the axis 6 motor Note Place the resolver cable under the motor cable 7 Continues on next page 358 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair...

Page 359: ...CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 9 xx1200001080 Refit the motor cover 10 Continues on next page Product manual IRB 6790 359 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 360: ...1500001030 Fit the heat protection plate with the screws 2 xx1600002061 Make sure that the cable harness is placed so it will not be damaged when the wrist cover is fitted 3 Continues on next page 360 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 361: ... all contamination from all contact surfaces 5 Activator 3HAC064686 001 Loctite 7649 xx1700001875 Apply an activator on the mounting flange of the wrist Note The activator must be used to harden the flange sealant 6 Flange sealant 12340011 116 Loctite 574 xx1700001811 Apply new flange sealant to the wrist cover 7 Continues on next page Product manual IRB 6790 361 3HAC063331 001 Revision B Copyrigh...

Page 362: ...power to the robot on temporarily 1 Use caution and jog the robot to the calibration position if not already done 2 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 3 Lifting shackle SA 10 8 NA1 Apply the lifting accessory to the balancing device if not already done 4 Lifting accessory chain 3HAC15556 1 Remove all residue of Lo...

Page 363: ...ic press tool 9 Hydraulic pump 70 MPa 3HAC13086 1 Hydraulic cylinder 3HAC11731 1 Dismantle and mounting tool 3HAC028920 001 xx1700002238 The item numbers refer to mark ings on the tools xx1300000782 Apply locking liquid Loctite 2701 on the threads of the screw first entering the threads in the frame 10 Continues on next page Product manual IRB 6790 363 3HAC063331 001 Revision B Copyright 2019 2020...

Page 364: ...idual grease Use locking liquid 12 Concluded refitting of the front shaft Note Action Remove the lifting accessory from the bal ancing device 1 xx1200001283 Refit the cable bracket if not already refit ted 2 Continues on next page 364 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 365: ...compressed by jogging the robot only use the hydraulic press tool Dismantle and mounting tool 3HAC028920 001 3 This is done in order to compress the spring unit inside the balancing device be fore refitting or removal of the distance tool Jog axis 2 to 30 or 30 4 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 5 A xx0800000480...

Page 366: ... the value is higher than the initial value fault trace according to Inspecting the leak flow overpressure unit in the system on page 128 3 Axis Calibration is described in Calibrating with Axis Calibration method on page 623 Re calibrate the robot 4 General calibration information is included in section Calibration on page 613 DANGER Make sure all safety requirements are met when performing the f...

Page 367: ...d cover with VL sealing C Shaft D Spherical roller bearing E End cover with VL sealing F Summary of the replacement procedure This is a brief summary of the replacement procedure containing the major actions to be performed 1 Unload the balancing device 2 Replace the spherical roller bearing 3 Restore the balancing device Continues on next page Product manual IRB 6790 367 3HAC063331 001 Revision B...

Page 368: ... the help of the robot itself DANGER Never use this tool to unload or restore a balancing device 3HAC030662 001 Distance tool Used to unload or restore a balancing device 3HAC020902 001 Hydraulic press tool balan cing device Used for removing and fitting shaft and bearings 3HAC028920 001 Dismantle and mounting tool To be used with the press tool 3HAC11731 1 Hydraulic cylinder To be used with the h...

Page 369: ...rent methods using two different tools Distance tool or Hydraulic press tool balancing device The situations when to use which tool are very different The method described in this procedure describes how to use the Distance tool 3HAC030662 001 The Distance tool can not be used to unload or restore the pressure of the balancing device spring unit The Distance tool is only used to keep the balancing...

Page 370: ...ncing device This tool is used to unload or restore a balancing device which cannot be done with the help of the robot itself This press tool shall also be used if the tool shall be fitted on or be removed from a balancing device not fitted on the robot Use this tool 3HAC020902 001 Hydraulic press tool balan cing device xx1300000672 if the balancing device shall be unloaded or restored after it ha...

Page 371: ...balancing device or if the spring unit of the balancing device cannot be compressed by jogging the robot only use the Hydraulic press tool balancing device 3HAC020902 001 1 This is done in order to compress the bal ancing device springs inside the balancing device before fitting the Distance tool Jog axis 2 to 30 or 30 2 DANGER Turn off all electric power supply hydraulic pressure supply to the ro...

Page 372: ...ngs making it possible to re move the front shaft of the balancing device Jog axis 2 to the calibration position The balancing device is now unloaded 7 Let the Distance tool stay fitted during the continued procedure 8 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 9 Preparations before removing the spherical roller bearing N...

Page 373: ...ly to the robot before entering the robot working area 3 Remove any equipment if fitted on or close to the balancing device 4 CAUTION The weight of the balancing device exclud ing cradle is 140 kg All lifting accessories used must be sized accordingly 5 Lifting shackle SA 10 8 NA1 xx1300000661 Fit a lifting shackle to the balancing device 6 Continues on next page Product manual IRB 6790 373 3HAC06...

Page 374: ...t in the front link ear Note Action xx1900002146 Remove the two screws 1 xx1200001279 M16x70 stainless steel Unscrew the attachment screw and washer 2 Continues on next page 374 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 6 1 Replacing spherical roller bearing link ear Continued ...

Page 375: ...x1200001280 xx1200001281 Put down the balancing device and let it rest on the frame 4 Removing the spherical roller bearing link ear Note Action Check that the link ear is in a position where it is possible to apply the dismantle and mounting tool If not adjust with the lifting accessory 1 Continues on next page Product manual IRB 6790 375 3HAC063331 001 Revision B Copyright 2019 2020 ABB All righ...

Page 376: ...e tools xx1700002236 Refitting the spherical roller bearing Refitting the spherical roller bearing link ear Note Action Wipe clean all contact surfaces 1 xx1700001764 Refit the smaller end cover by hand 2 Grease 3HAC042536 001 Apply some grease on the surface for the bearing 3 Continues on next page 376 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4...

Page 377: ...2536 001 xx1700001662 Lubricate the o ring on the end cover and refit the cover by hand Tighten screws 5 Attaching lifting accessory to the balancing device Note Action CAUTION The weight of the balancing device exclud ing cradle is 140 kg All lifting accessories used must be sized accordingly 1 Continues on next page Product manual IRB 6790 377 3HAC063331 001 Revision B Copyright 2019 2020 ABB Al...

Page 378: ...evice or if the spring unit of the balancing device cannot be compressed by jogging the robot only use the Hydraulic press tool balancing device 3HAC020902 001 1 How to unload a new balancing device a spare part not yet fitted to the robot is described in Unloading the balancing device on page 411 Before a new spare part balancing device is fitted the springs must be unloaded us ing the Hydraulic ...

Page 379: ...octite in the screw hole of the shaft 5 Wipe all contact surfaces inside the recess clean from contamination 6 xx1300000784 Align the balancing device link ear with the hole in the lower arm Note Verify that the link ear is correctly turned 7 xx1200001280 Lubricate the shaft and place it to the front ear 8 Continues on next page Product manual IRB 6790 379 3HAC063331 001 Revision B Copyright 2019 ...

Page 380: ...king liquid Loctite 2701 on the threads of the screw first entering the threads in the frame 10 Tightening torque 200 Nm xx1200001279 Secure the shaft with screw and washer 11 Locking liquid Loctite 577 xx1900002146 Refit the two screws and wipe clean from residual grease Use locking liquid 12 Continues on next page 380 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All ...

Page 381: ...e robot before entering the robot working area 4 Remove the Distance tool 5 Screws M10x30 Stainless Steel 3HAC060786 020 Apply flange sealant and refit the cover plate on the back of the balancing device 6 Tightening torque 50 Nm Flange sealant for conical fittings Loctite 577 xx1300000554 Product manual IRB 6790 381 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 ...

Page 382: ... the replacement procedure containing the major actions to be performed 1 Unload the balancing device 2 Replace the balancing device Spare part Note Spare part number Spare parts See Balancing device Product manual spare parts IRB 6790 Continues on next page 382 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing devi...

Page 383: ...ade of stainless steel If damaged or lost order new items according to this table Quantity Washers Screws Equipment to be fastened 4 pcs M10x30 Stainless Steel 3HAC060786 020 Balancing device cover plate Required tools and equipment Note Article number Equipment etc Only used to keep the balancing device in a locked position after the balancing device springs has been unloaded with the help of the...

Page 384: ...moving the balancing device Use these procedures to remove the balancing device Unloading or locking the balancing device springs Compression of the balancing device springs to an unloaded position can be done in two different methods using two different tools Distance tool or Hydraulic press tool balancing device The situations when to use which tool are very different The method described in thi...

Page 385: ...lancing device This tool is used to unload or restore a balancing device which cannot be done with the help of the robot itself This press tool shall also be used if the tool shall be fitted on or be removed from a balancing device not fitted on the robot Use this tool 3HAC020902 001 Hydraulic press tool balan cing device xx1300000672 if the balancing device shall be unloaded or restored after it ...

Page 386: ... new balancing device or if the spring unit of the balancing device cannot be compressed by jogging the robot only use the Hydraulic press tool balancing device 3HAC020902 001 1 This is done in order to compress the bal ancing device springs inside the balancing device before fitting the Distance tool Jog axis 2 to 30 or 30 2 DANGER Turn off all electric power supply hydraulic pressure supply to t...

Page 387: ...alancing device springs making it possible to re move the front shaft of the balancing device Jog axis 2 to the calibration position The balancing device is now unloaded 7 Let the Distance tool stay fitted during the continued procedure 8 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 9 Preparations before removing the balanc...

Page 388: ...ntering the robot working area 3 Remove any equipment if fitted on or close to the balancing device 4 Attaching lifting accessory to the balancing device Note Action CAUTION The weight of the balancing device exclud ing cradle is 140 kg All lifting accessories used must be sized accordingly 1 Lifting shackle SA 10 8 NA1 xx1300000661 Fit a lifting shackle to the balancing device 2 Continues on next...

Page 389: ...enter of the VK cover and bend out the cover If not making a hole in the center of the VK cover there is a risk of damaging the bearing inside The damaged VK cover must be replaced with a new Remove the protection screw from the vent hole and use air pressure through the hole to blow out the cover The cover can be reused if not damaged 1 Vent hole for air pressure xx1700001800 Wipe off any residua...

Page 390: ... 001 Use the removal tool and pull the shaft out a few millimeters just long enough for the balancing device to go free 5 Removing the shaft in the front link ear Note Action xx1900002146 Remove the two screws 1 Continues on next page 390 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing device Continued ...

Page 391: ...0000378 The numbers in the figure refers to the marked tool pieces respectively 3 Hydraulic pump 70 MPa 3HAC13086 1 Hydraulic cylinder 3HAC11731 1 xx1200001280 xx1200001281 Put down the balancing device and let it rest on the frame 4 Continues on next page Product manual IRB 6790 391 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing device...

Page 392: ...ng device fitted to the robot 2 Refitting the balancing device Use this procedure to refit the balancing device Attaching lifting accessory to the balancing device Note Action CAUTION The weight of the balancing device exclud ing cradle is 140 kg All lifting accessories used must be sized accordingly 1 Lifting shackle SA 10 8 NA1 xx1300000661 Fit a lifting shackle to the balancing device 2 Lifting...

Page 393: ...oading the balancing device on page 411 Before a new spare part balancing device is fitted the springs must be unloaded us ing the Hydraulic press tool balancing device 3HAC020902 001 2 Refitting the rear shafts Perform this procedure on both sides Note Action DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 1 Lift the balancin...

Page 394: ...tivator on the corresponding contact surface of the shaft Note The activator must be used to harden the flange sealant xx1300000664 Fit the retaining ring 6 M16x50 stainless steel Apply Loctite 243 on the screws and secure the shafts on both sides 7 Tightening torque 300 Nm xx1300000663 Continues on next page 394 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights ...

Page 395: ...emporarily 1 Use caution and jog the robot to the calibration position if not already done 2 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 3 Lifting shackle SA 10 8 NA1 Apply the lifting accessory to the balancing device if not already done 4 Lifting accessory chain 3HAC15556 1 Remove all residue of Loctite in the screw hole...

Page 396: ...ress tool 9 Hydraulic pump 70 MPa 3HAC13086 1 Hydraulic cylinder 3HAC11731 1 Dismantle and mounting tool 3HAC028920 001 xx1700002238 The item numbers refer to mark ings on the tools xx1300000782 Apply locking liquid Loctite 2701 on the threads of the screw first entering the threads in the frame 10 Continues on next page 396 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB...

Page 397: ...ease Use locking liquid 12 Concluded refitting of the front shaft Note Action Remove the lifting accessory from the bal ancing device 1 xx1200001116 Remove the locking screw M16x120 2 Jog axis 2 to 30 or 30 3 Continues on next page Product manual IRB 6790 397 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing device Continued ...

Page 398: ...ews M10x30 Stainless Steel 3HAC060786 020 Apply flange sealant and refit the cover plate on the back of the balancing device 6 Tightening torque 50 Nm Flange sealant for conical fittings Loctite 577 xx1300000554 398 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing device Continued ...

Page 399: ...an be ordered separately 3HAA2166 36 2 pcs 3HAC064403 001 Maintenance set cradle Consumables Note Article number Equipment Included in the in the Maintenance set cradle 3HAA2166 36 VK cover 90x12 Loctite 243 3HAB7116 1 Locking liquid Loctite 574 12340011 116 Flange sealant Loctite 7649 3HAC064686 001 Activator Loctite 577 Flange sealant for conical fit tings Continues on next page Product manual I...

Page 400: ...ings has been unloaded with the help of the robot itself DANGER Never use this tool to unload or restore a balancing device 3HAC030662 001 Distance tool Used to secure lower arm Lock screw M16x120 SA 10 8 NA1 Lifting shackle Lifting instruction 3HAC15880 2 en closed 3HAC15556 1 Lifting accessory chain Threaded bar M16x340 Used for removing and fitting shaft and bearings 3HAC028920 001 Dismantle an...

Page 401: ... position To unload or restore a new balancing device or if the spring unit of the balancing device cannot be compressed by jogging the robot only use the Hydraulic press tool balancing device 3HAC020902 001 1 This is done in order to compress the bal ancing device springs inside the balancing device before fitting the Distance tool Jog axis 2 to 30 or 30 2 DANGER Turn off all electric power suppl...

Page 402: ...device springs making it possible to re move the front shaft of the balancing device Jog axis 2 to the calibration position The balancing device is now unloaded 7 Let the Distance tool stay fitted during the continued procedure 8 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 9 Preparations before removing the rear bearings N...

Page 403: ...pply to the robot before entering the robot working area 3 Remove any equipment if fitted on or close to the balancing device 4 CAUTION The weight of the balancing device exclud ing cradle is 140 kg All lifting accessories used must be sized accordingly 5 Lifting shackle SA 10 8 NA1 xx1300000661 Fit a lifting shackle to the balancing device 6 Continues on next page Product manual IRB 6790 403 3HAC...

Page 404: ...as close as possible to the center of the VK cover and bend out the cover If not making a hole in the center of the VK cover there is a risk of damaging the bearing inside The damaged VK cover must be replaced with a new Remove the protection screw from the vent hole and use air pressure through the hole to blow out the cover The cover can be reused if not damaged 1 Vent hole for air pressure xx17...

Page 405: ...ll out the shaft end with bearing sealing and distance 6 Refitting the bearing cradle Use these procedures to refit the bearing in the cradle Refitting the shaft end and rear bearings Note Action Wipe clean all contact surfaces from resid ual grease and other contamination inside the recess 1 Continues on next page Product manual IRB 6790 405 3HAC063331 001 Revision B Copyright 2019 2020 ABB All r...

Page 406: ...vator must be used to harden the flange sealant Apply some grease in the hole for the bearing in the cradle Note Do not apply grease on surfaces with Mer casol 3 Part of tool Dismantle and mounting tool 3HAC028920 001 xx1700002296 The item number refers to marking on the tool Apply a threaded bar into the hole in the balancing device 4 Continues on next page 406 Product manual IRB 6790 3HAC063331 ...

Page 407: ... a little 7 Hydraulic pump 70 MPa 3HAC13086 1 Apply the press tool hydraulic pump and nut on the threaded bar Do not press yet 8 Hydraulic cylinder 3HAC11731 1 4 K G C 8 xx1700000406 The item numbers refer to markings on the tools Continues on next page Product manual IRB 6790 407 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 6 3 Replacing the rear bearings on th...

Page 408: ...t screw 13 Tightening torque 300 Nm xx1300000663 While using the screw driver between the cradle and balancing device as a distance tool tighten the attachment screw com pletely Secure the balancing device 14 Fit a VK cover to protect the bearing 15 Remove the lifting accessories Note Action Remove the lifting accessories 1 Continues on next page 408 Product manual IRB 6790 3HAC063331 001 Revision...

Page 409: ...t the screw 2 Wipe clean from residual grease 3 Remove the Distance tool 4 Screws M10x30 Stainless Steel 3HAC060786 020 Apply flange sealant and refit the cover plate on the back of the balancing device 5 Tightening torque 50 Nm Flange sealant for conical fittings Loctite 577 xx1300000554 Continues on next page Product manual IRB 6790 409 3HAC063331 001 Revision B Copyright 2019 2020 ABB All right...

Page 410: ...fety requirements are met when performing the first test run 6 410 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 6 3 Replacing the rear bearings on the balancing device Continued ...

Page 411: ...2 to calibration position lock axis 2 with a M16 lock screw How to secure the lower arm is described in the current repair activity for example removal of the balancing device DANGER There is a high tensioned spring inside the balancing device incorrect handling may cause injuries and damage property Continues on next page Product manual IRB 6790 411 3HAC063331 001 Revision B Copyright 2019 2020 A...

Page 412: ...g E Bolt 4 pcs F Pin attached to the fix plate G Required equipment Note Article number Equipment etc Used to unload or restore a balancing device 3HAC020902 001 Hydraulic press tool balan cing device To be used with the press tool 3HAC11731 1 Hydraulic cylinder To be used with the hydraulic cylinder 3HAC13086 1 Hydraulic pump 70 MPa Continues on next page 412 Product manual IRB 6790 3HAC063331 00...

Page 413: ...pin is shown in the figure Press tool and hydraulic cylinder on page 412 The bolt is shown in the figure Press tool and hydraulic cylinder on page412 Fit the correct press device and moving pin to the press tool Secure with the bolt press device Note Make sure the bolt is secured properly 2 xx1300000554 Remove the rear cover of the balancing device by unscrewing the attachment screws DANGER DO NOT...

Page 414: ... until the marking on the moving pin indicates the cor rect position in level with the pressure block 7 Turn the fix plate to position Closed in order to lock the tool in loaded condition 8 Hydraulic cylinder 3HAC11731 1 Hydraulic pump 70 MPa 3HAC13086 1 Do not apply more pressure than neces sary it could damage bearings and sealings at the shaft Unload the hydraulic cylinder 9 The hydraulic cylin...

Page 415: ...ress tool and hydraulic cylinder The figure below shows the hydraulic cylinder mounted on the press tool The press tool includes two press devices that are used to different models of the balancing device xx0200000174 Press block A Hydraulic cylinder B Press device C Bolt press device D Moving pin with marking E Continues on next page Product manual IRB 6790 415 3HAC063331 001 Revision B Copyright...

Page 416: ...74 Press block A Hydraulic cylinder B Press device C Bolt press device D Moving pin with marking E Bolt 4 pcs F Pin attached to the fix plate G Refit the hydraulic cylinder to the press tool in case it has been removed 1 Press with the cylinder and the hydraulic pump until the fix plate is movable again Turn the pin on the fix plate to position Open CAUTION Do not apply more pressure than neces sa...

Page 417: ...nt for conical fittings Loctite 577 xx1300000554 DANGER The rear cover of the balancing device is a safety device for the piston rod during operation Make sure the cover is properly secured before commissioning of the ro bot 7 Product manual IRB 6790 417 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 6 5 Restoring the balancing device Continued ...

Page 418: ...protection type Foundry Prime some of the attachment screws and washers used on the robot are made of stainless steel If damaged or lost order new items according to this table Quantity Washers Screws Equipment to be fastened 1 pcs M10x20 Stainless Steel Mechanical stop 9ADJ400914P1259 Continues on next page 418 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights r...

Page 419: ...ing the stop pin Note Action xx1300000479 Jog the robot to this position axis 1 5 1 xx1300000478 Note If the axis 1 is not in this position the stop pin will not be able to go free from the axis 1 oil plug draining when removed 2 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 3 Continues on next page Product manual IRB 6790 4...

Page 420: ...x1300000477 Remove the stop pin 5 Refitting the stop pin Note Action Rust preventive 3HAC034903 001 Mer casol 3110 Waxcoat Recommended drying time is 24h xx1400000378 Apply Mercasol on the surfaces shown in the figure on stop pin and in the hole as shown in the figure 1 Continues on next page 420 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair...

Page 421: ...ocking liquid on the set screw and secure the stop pin 3 Set screw M10x20 Stainless Steel 9ADJ400914P1259 xx1300000476 Product manual IRB 6790 421 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 6 6 Replacing the stop pin Continued ...

Page 422: ... replacement procedure containing the major actions to be performed 1 Attach the lifting tools 2 Replace the motor 3 Remove the lifting tools Spare parts Note Spare part number Spare part See Axis 1 motor Product manual spare parts IRB 6790 Continues on next page 422 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 mo...

Page 423: ...4 Required tools and equipment Note Article number Equipment etc 3HAC14459 1 Lifting accessory motor Length 1 m lifting capacity 1 000 kg Roundsling 1 m Used to push out the motor if neces sary Always use removal tools in pairs 3HAC057339 002 Removal tool Always use guide pins in pairs 3HAC15521 2 Guide pin M10x150 300 mm bits 1 2 3HAC12342 1 Bits extender Used to rotate the motor pinion 3HAB7887 ...

Page 424: ...r calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 624 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable pack...

Page 425: ...R Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover Note Axis 3 and 4 motors only Be careful not to damage the air hose or air nipple 2 Continues on next page Product manual IRB 6790 425 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 1 Replaci...

Page 426: ...acing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the axis 1 motor Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 Continues on next page 426 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4...

Page 427: ...rew the attachment screws and washers Use a bits extender to reach the screws 5 Guide pin M12x150 3HAC13056 2 Fit guide pins in opposite holes 6 Always use guide pins in pairs CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 7 Removal tool M12 3HAC057339 002 If needed use removal tools to help re move the motor 8 Always use removal tools in pa...

Page 428: ...otor Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 Remove any old paint residues or other contam ination from the contact surfaces on both the motor and the mating parts 2 Wipe clean the contact surfaces and the o ring groove O ring 3HAB3772 107 xx1200001019 Check the o ring Replace if damaged 3 Continues on next page 428 Product manual...

Page 429: ...AUTION The motor weighs 25 kg All lifting accessories used must be sized accordingly 2 Lifting accessory motor 3HAC14459 1 Apply the lifting accessory 3 Rotation tool 3HAB7887 1 Fit the rotation tool 4 Connect the 24 VDC power supply to re lease the brakes 5 To release the brakes connect the 24 VDC power supply as described in the list Connect to R2 MP1 connector pin 2 pin 5 Continues on next page...

Page 430: ...ccessory motor 3HAC14459 1 xx1200001072 Bits extender 3HAC12342 1 Secure the motor with its attachment screws and washers 8 Tightening torque 50 Nm Use a bits extender to reach the screws Screws M10x30 Stainless Steel 3HAC060786 020 4 pcs Washers 13x17x2 Stainless Steel 3HAC060866 003 4 pcs xx1200001071 See Performing a leak down test on page 166 Perform a leak down test if not already done 9 Disc...

Page 431: ...the cable gland cover Note Replace the gasket if damaged 2 xx1200001066 Connect the motor cables Connect in accordance with the markings on the connectors 3 Continues on next page Product manual IRB 6790 431 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor Continued ...

Page 432: ... groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Attachment screws M5x12 Stainless steel A2 70 7 pcs 9ADA619 44 xx1200001135 Refit the motor cover with its attachment screws Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues on next page 432 Product manual IRB 6790 3HAC06333...

Page 433: ...t trace according to Inspecting the leak flow overpressure unit in the system on page 128 2 Axis Calibration is described in Calibrating with Axis Calibration method on page 623 Re calibrate the robot 3 General calibration information is included in section Calibration on page 613 DANGER Make sure all safety requirements are met when performing the first test run 4 Product manual IRB 6790 433 3HAC...

Page 434: ...or actions to be performed 1 Drain the axis 2 gearbox 2 Attach the lifting tools 3 Replace the motor 4 Remove the lifting tools 5 Refill the axis 2 gearbox with oil Spare parts Note Spare part number Spare part See Axis 2 motor Product manual spare parts IRB 6790 Continues on next page 434 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 2 ...

Page 435: ... number Equipment etc Lifting instruction 3HAC15640 2 en closed 3HAC15534 1 Lifting accessory motor Length 1 m lifting capacity 1 000 kg Roundsling 1 m Used to push out the motor if neces sary Always use removal tools in pairs 3HAC057339 002 Removal tool Always use guide pins in pairs 3HAC15521 2 Guide pin M10x150 300 mm bits 1 2 3HAC12342 1 Bits extender Used to rotate the motor pinion 3HAB7887 1...

Page 436: ...sibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 624 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the motor T...

Page 437: ...d 5 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the safe guarded space 6 Remove any equipment hindering access to the motor 7 xx1700001593 Check the leak flow value on the flow sensor Note the value to be able to compare it when repair is completed 8 CAUTION Turn off the air pressure supply 9 Continues on next page Product manual IRB 6790 437 3H...

Page 438: ...nd washers and remove the motor cover Note Axis 3 and 4 motors only Be careful not to damage the air hose or air nipple 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 438 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 2 Replacing the axis 2 motor Continued ...

Page 439: ...ed 1 DANGER When releasing the holding brakes of the motor the lower arm will be movable and may fall down if not secured Verify that the lower arm is secured as previously de scribed before continuing 2 To release the brake connect the 24 VDC power supply 3 Connect to connector R2 MP2 axis 2 mo tor pin 2 pin 5 Bits extender 3HAC12342 1 xx1200001117 Remove the attachment screws Use a bits extender...

Page 440: ...y lift the motor out on the guide pins in order to get the pinion away from the gear and let it rest on the guide pins 10 Lifting accessory motor 3HAC15534 1 Fasten the lifting accessory Attach the lifting chain to the accessory and an over head crane 11 Lifting accessory chain 3HAC15556 1 Make sure the pinion is not damaged xx1200001118 Remove the motor by sliding it out on the guide pins and lif...

Page 441: ...he o ring is seated in the groove Tip Lubricate the o ring with some grease for a better fitting in the groove 4 xx1200001135 If the motor is a new spare part remove the cover 5 Securing the axis 2 motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs Continues on next page Product manual IRB 6790 441 3HAC063331 001 Revision B Copyright 2...

Page 442: ...e pinion when mating it into the gear 7 To release the brakes connect the 24 VDC power supply 8 Connect to connector R2 MP2 axis 2 mo tor pin 2 pin 5 CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 9 Use caution and fit the motor in its final position while at the same time rotating the motor pinion slightly using the rotation tool Make sure ...

Page 443: ... Nm Use a bits extender in order to reach the screws Screw dimension M10x30 Stainless Steel 3HAC060786 020 4 pcs Washers 13x17x2 Stainless Steel 3HAC060866 003 4 pcs xx1200001117 See Performing a leak down test on page 166 Perform a leak down test 14 Connecting the motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 Continues on next page Product manual IR...

Page 444: ... 3 O ring axis 1 3HAC067762 001 Inspect the o ring Note Replace if damaged 4 O ring axis 2 3HAC067762 001 O ring axis 3 3HAC067762 001 O ring axis 4 3HAC067744 001 xx1200001070 Wipe clean o ring and o ring groove 5 Continues on next page 444 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 2 Replacing the axis 2 motor Continued ...

Page 445: ... with its attachment screws Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Concluding procedure Note Action Use caution and jog axis 2 a little to facilit ate the removal of the lock screw 1 Lock screw M16x120 xx1200001115 Remove the lock screw securing the lower arm 2 Continues on next page Product manual IRB 6790 445 3HAC063331 001 Rev...

Page 446: ...e fault trace according to Inspecting the leak flow overpressure unit in the system on page 128 5 Axis Calibration is described in Calibrating with Axis Calibration method on page 623 Re calibrate the robot 6 General calibration information is included in section Calibration on page 613 DANGER Make sure all safety requirements are met when performing the first test run 7 446 Product manual IRB 679...

Page 447: ...anual spare parts IRB 6790 Consumables Note Article number Equipment etc Shell Gadus S2 3HAC042536 001 Grease Used to lubricate o rings D 169 5x3 3HAC067762 001 O ring Used on motor cover D 102x3 3HAB3772 107 O ring Used on motor flange Continues on next page Product manual IRB 6790 447 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 3 Replacing the axis 3 motor ...

Page 448: ... Guide pin M10x150 300 mm bits 1 2 3HAC12342 1 Bits extender Used to rotate the motor pinion 3HAB7887 1 Rotation tool Used to release the motor brakes 24 VDC power supply Leak down tester Delivered as a set of calibration tools 3HAC055412 001 Calibration tool box Axis Calibration Content is defined in section Standard toolkit on page 652 Standard toolkit Deciding calibration routine Decide which c...

Page 449: ...ese procedures describes how to remove the motor Preparations before removing the axis 3 motor Use this procedure to do the necessary preparations before removing the motor Note Action Decide which calibration routine to use and take actions accordingly prior to begin ning the repair procedure 1 See Draining the axis 3 gearbox on page 143 Drain the axis 3 gearbox 2 Unload the upper arm using one o...

Page 450: ...e motor cables Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover Note Axis 3 and 4 motors only Be careful not to damage the air hose or air nipple 2 Continues on next page 450 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights...

Page 451: ...e is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the axis 3 motor Note Action Before removing the motor make sure that the axis 3 gearbox is completely drained 1 Continues on next page Product manual IRB 6790 451 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 3 R...

Page 452: ...to make the motor slide better 5 Always use guide pins in pairs CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 6 Removal tool M12 3HAC057339 002 If required press the motor out of position by using the removal tool in the remaining holes for the motor 7 Always use removal tools in pairs Use caution and lift the motor out on the guide pins in...

Page 453: ...If not there is a risk of damaging the pinion and gear 11 Disconnect the 24 VDC power supply 12 Make sure the pinion is not damaged xx1200001131 Remove the motor by lifting it straight out 13 Refitting the motor These procedures describes how to refit the motor Preparations prior to refitting motor Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turne...

Page 454: ...ove 4 xx1200001135 If the motor is a new spare part remove the cover 5 Securing the axis 3 motor Use this procedure to secure the motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs Continues on next page 454 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 3 Replacing the axis 3...

Page 455: ... pins Do not push the motor pinion into the gear yet This is done in order to fit the motor with the axis 4 motor still fitted 4 Remove the lifting accessory and allow the motor to rest on the guide pins 5 Rotation tool 3HAB7887 1 Apply the rotation tool and use it to rotate the pinion when mating it into the gear 6 To release the brakes connect the 24 VDC power supply 7 Connect to connector R2 MP...

Page 456: ...nless Steel 3HAC060866 003 Remove the guide pins 11 Screws M10x30 Stainless Steel 3HAC060786 020 Fit the remaining attachment screws and washers 12 Washers 13x17x2 Stainless Steel 3HAC060866 003 Tightening torque 50 Nm Tighten the screws 13 Remove the rotation tool 14 See Performing a leak down test on page 166 Perform a leak down test 15 Disconnect the 24 VDC power supply 16 Connecting the motor ...

Page 457: ... 3 O ring axis 1 3HAC067762 001 Inspect the o ring Note Replace if damaged 4 O ring axis 2 3HAC067762 001 O ring axis 3 3HAC067762 001 O ring axis 4 3HAC067744 001 xx1200001070 Wipe clean o ring and o ring groove 5 Continues on next page Product manual IRB 6790 457 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 3 Replacing the axis 3 motor Continued ...

Page 458: ... properly fitted 8 Make sure that the covers are tightly sealed 9 Concluding procedure Use this procedure for the concluding refitting Note Action Remove the equipment used to unload the upper arm 1 See Filling oil into the axis 3 gearbox on page 144 Refill the gearbox with oil 2 Connect the air hose to the nipple on the connection box 3 Turn on the air pressure supply to the overpressure system 4...

Page 459: ...n the system on page 128 5 Axis Calibration is described in Calibrating with Axis Calibration method on page 623 Re calibrate the robot 6 General calibration information is included in section Calibration on page 613 DANGER Make sure all safety requirements are met when performing the first test run 7 Product manual IRB 6790 459 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved...

Page 460: ...manual spare parts IRB 6790 Consumables Note Article number Equipment etc Shell Gadus S2 3HAC042536 001 Grease Used to lubricate o rings D 119x3 3HAC067744 001 O ring Used on motor cover D 102x3 3HAB3772 107 O ring Used on motor flange Continues on next page 460 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 4 motor ...

Page 461: ...7 1 Rotation tool Used to release the motor brakes 24 VDC power supply Leak down tester Delivered as a set of calibration tools 3HAC055412 001 Calibration tool box Axis Calibration Content is defined in section Standard toolkit on page 652 Standard toolkit Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is ch...

Page 462: ...l external cable packages DressPack and tools from the robot Removing the motor These procedures describes how to remove the motor Preparations before removing the axis 4 motor Note Action Decide which calibration routine to use and take actions accordingly prior to begin ning the repair procedure 1 Jog the robot into position axis 1 no significance axis 2 65 axis 3 upper arm pointing straight up ...

Page 463: ...e motor cables Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover Note Axis 3 and 4 motors only Be careful not to damage the air hose or air nipple 2 Continues on next page Product manual IRB 6790 463 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights...

Page 464: ... hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the axis 4 motor Note Action CAUTION Use caution when releasing the brakes Axis 4 can move unexpectedly 1 Continues on next page 464 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 4 Repl...

Page 465: ...C057339 002 Press the motor out of position by fitting the removal tool in the remaining attach ment holes for the motor 6 Always use removal tools in pairs CAUTION The motor weighs 13 kg All lifting accessories used must be sized accordingly 7 Disconnect the 24 VDC power supply 8 xx1200001138 Remove the motor by carefully lifting it straight out straight up if the upper arm points upwards Make su...

Page 466: ...t surfaces on both the motor and the mating parts 2 Wipe clean the contact surfaces and the o ring groove O ring 3HAB3772 107 xx1200001019 Check the o ring Replace if damaged 3 xx1200001020 Make sure the o ring is seated in the groove Tip Lubricate the o ring with some grease for a better fitting in the groove 4 Continues on next page 466 Product manual IRB 6790 3HAC063331 001 Revision B Copyright...

Page 467: ...de pin M8x150 3HAC15520 2 Apply two guide pins in opposite holes 1 Always use guide pins in pairs xx1700000291 Put the motor onto the guide pins 2 Continues on next page Product manual IRB 6790 467 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 4 motor Continued ...

Page 468: ... supply 6 Connect to connector R2 MP2 pin 2 pin 5 CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 7 Push the motor carefully in position while at the same time rotating the motor pinion slightly Make sure that the motor pinion is properly mated to the gear of the gearbox Make sure that the motor pinion does not get damaged Make sure that the ...

Page 469: ...test on page 166 Perform a leak down test 11 Disconnect the 24 VDC power supply 12 Connecting the motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page Product manual IRB 6790 469 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair ...

Page 470: ... ring axis 4 3HAC067744 001 xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring Tip Lubricate the o ring with some grease for a better fitting in the groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page 470 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repai...

Page 471: ... system 3 xx1700001593 Check the leak flow value on the flow sensor and compare it to the initial value The value should be the same If the value is higher than the initial value fault trace according to Inspecting the leak flow overpressure unit in the system on page 128 4 Axis Calibration is described in Calibrating with Axis Calibration method on page 623 Re calibrate the robot 5 General calibr...

Page 472: ...02x3 3HAB3772 107 O ring Used on motor flange Loctite 7649 3HAC064686 001 Activator Loctite 574 12340011 116 Flange sealant Required tools Note Article number Equipment etc Used to push out the motor if neces sary Always use removal tools in pairs 3HAC057339 002 Removal tool M12 Length 140 mm Long AllenKeySocketIN19L 6 140 Always use guide pins in pairs 3HAC15520 1 Guide pin M8x100 Used to rotate ...

Page 473: ...e reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration ro...

Page 474: ... Axis 4 90 3 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the safe guarded space 4 xx1700001593 Check the leak flow value on the flow sensor Note the value to be able to compare it when repair is completed 5 Continues on next page 474 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 5 Repl...

Page 475: ...GER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 xx1300002247 Remove the wrist cover 2 xx1500001030 Remove the heat protection plates from the motor with the cabling still attached to the plate 3 Continues on next page Product manual IRB 6790 475 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 5 mot...

Page 476: ...be loosened from the plate 4 Disconnecting the motor cables Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page 476 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 5 Replacing th...

Page 477: ...or 2 Remove the outer screw 3 Slide the cable gland cover away from the inner screw Make sure the gasket is not damaged Tip Make a note in which direction the cable exit hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Continues on next page Product manual IRB 6790 477 3HAC063331 001 Revision B Copyright...

Page 478: ...y be damaged if excess ive force is used 2 Removal tool M12 3HAC057339 002 If needed fit removal tools in opposite holes 3 Always use removal tools in pairs CAUTION The motor weighs 12 kg All lifting accessories used must be sized accordingly 4 Continues on next page 478 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis ...

Page 479: ...the motor Preparations before refitting the axis 5 motor Note Action DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the safe guarded space 1 Continues on next page Product manual IRB 6790 479 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 5 motor Continued ...

Page 480: ...ke sure the o ring is seated in the groove 5 Guide pin M8x100 3HAC15520 1 Apply two guide pins in opposite holes 6 Securing the axis 5 motor Note Action CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 1 Continues on next page 480 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 5 Repla...

Page 481: ...ool 3HAB7887 1 xx1200001018 Use caution and lower the motor into posi tion on the guide pins while at the same time rotating the motor pinion slightly Make sure that the motor pinion is properly mated to the gear of the gearbox the motor pinion does not get dam aged the direction of the cable exit is fa cing the same way as before remov al 5 Remove the guide pins 6 Continues on next page Product m...

Page 482: ...leak down test on page 166 Perform a leak down test 8 Disconnect the 24 VDC power supply 9 Connecting the motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 Continues on next page 482 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 5 motor Continued ...

Page 483: ...x1200001015 Connect the connectors Connect in accordance with the markings on the connectors 3 O ring axis 5 3HAC067744 001 xx1200001021 Make sure the o ring on the motor is undam aged Replace if damaged 4 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page Product manual IRB 6790 483 3HAC063331 001 Revision B Copyright 2019 2020 ...

Page 484: ...e threads Replace with standard attachment screws Note Make sure the o ring is undamaged and properly fitted 6 xx1500001029 Secure the cable harness with cable straps to the heat protection plate 7 Screws M5x12 xx1500001030 Fit the heat protection plate with the screws 8 Continues on next page 484 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repai...

Page 485: ...g torque 10 Nm xx1300000772 Refit the wrist cover In order not to dam age the cable harness when the wrist cover is refitted use this method 1 Hold the cover slightly tilted below the wrist 2 Put the cable harness inside the cover 3 Lift the cover still tilted 4 Move the upper part of the cover into position 5 Secure the cover with its attachment screws 3 Turn on the air pressure supply to the ove...

Page 486: ...n the system on page 128 5 Axis Calibration is described in Calibrating with Axis Calibration method on page 623 Re calibrate the robot 6 General calibration information is included in section Calibration on page 613 DANGER Make sure all safety requirements are met when performing the first test run 7 486 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved...

Page 487: ...es Note Article number Equipment etc Shell Gadus S2 3HAC042536 001 Grease Used to lubricate o rings Used on motor cover 3HAC033489 002 Gasket D 102x3 3HAB3772 107 O ring Used on motor flange Loctite 7649 3HAC064686 001 Activator Loctite 574 12340011 116 Flange sealant Continues on next page Product manual IRB 6790 487 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4...

Page 488: ...ending on which routine is chosen action might be required prior to beginning the repair work of the robot see the table Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow t...

Page 489: ... 5 can be positioned with the motor pointing straight up at an acceptable working posi tion With axis 5 in this position it is possible to replace the motor without draining the oil from the axis 6 gearbox 2 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the safe guarded space 3 xx1700001593 Check the leak flow value on the flow sensor Note the val...

Page 490: ...n DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 xx1200001080 Unscrew the attachment screws and re move the motor cover 2 Continues on next page 490 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 491: ...the M4 screw that holds the carri er Note The screw is located at the bottom of the carrier Note The parts are sealed with flange sealant Loctite 577 Remove the part carefully 5 Continues on next page Product manual IRB 6790 491 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 492: ...rrier 7 Removing the axis 6 motor Note Action 24 VDC power supply To release the brakes connect the 24 VDC power supply 1 Connect to R2 MP6 connector pin 2 pin 5 xx1200001090 Unscrew the motor attachment screws 2 Continues on next page 492 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 493: ...pairs CAUTION The motor weighs 9 kg All lifting accessories used must be sized accordingly 5 xx1200001091 Remove the motor by lifting it straight up from the gear while at the same time pick ing out the motor cables from the motor Make sure the motor pinion is not dam aged 6 xx1200001096 Disconnect the 24 VDC power supply 7 Continues on next page Product manual IRB 6790 493 3HAC063331 001 Revision...

Page 494: ...surfaces on both the motor and the mating parts 2 Wipe clean the contact surfaces and the o ring groove O ring 3HAB3772 107 xx1200001019 Check the o ring Replace if damaged 3 xx1200001020 Make sure the o ring is seated in the groove Tip Lubricate the o ring with some grease for a better fitting in the groove 4 Continues on next page 494 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2...

Page 495: ...ease the brakes connect the 24 VDC power supply 2 Connect to connector R2 MP6 pin 2 pin 5 CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 3 xx1200001094 Check the gasket Replace if damaged 4 Continues on next page Product manual IRB 6790 495 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 6 Replacing the axi...

Page 496: ...g the motor cables in through the cable gland Make sure the motor pinion is properly mated with the gear of the axis 6 gearbox Make sure the motor pinion is not dam aged 6 xx1200001097 Continues on next page 496 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 497: ...xx1200001090 xx1300001113 Refit the axis 6 motor cables by carefully pushing them and the carrier into position 8 xx1300000485 Tighten the M4 screw that holds the carrier Seal the screw with Loctite 577 Note The screw is located at the bottom of the carrier 9 Continues on next page Product manual IRB 6790 497 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 6 Repl...

Page 498: ...Disconnect the 24 V DC power supply 12 xx1200001084 Reconnect the connectors 13 Gasket 3HAC033489 002 xx1200001095 Check the gasket Replace if damaged 14 Continues on next page 498 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 499: ...amaged when the wrist cover is fitted 1 xx1900002085 Make sure that the gasket is undam aged on the cover Replace com plete cover if gasket is damaged Put washers in the holes of the gas ket Use attachment screws made of stainless steel to fit the wrist cover 2 Continues on next page Product manual IRB 6790 499 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 7 6 Re...

Page 500: ...eak flow value on the flow sensor and compare it to the initial value The value should be the same If the value is higher than the initial value fault trace according to Inspecting the leak flow overpressure unit in the system on page 128 5 Axis Calibration is described in Calibrating with Axis Calibration method on page 623 Re calibrate the robot 6 General calibration information is included in s...

Page 501: ...ure containing the major actions to be performed 1 Drain the axis 1 gearbox 2 Remove the cabling from the base 3 Remove the axis 1 motor 4 Remove the complete arm system including frame and balancing device as a package 5 Replace the axis 1 gearbox 6 Refit in reverse order Continues on next page Product manual IRB 6790 501 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Rep...

Page 502: ...Cable ties Sealing ring Stainless steel fasteners Due to robot protection type Foundry Prime some of the attachment screws and washers used on the robot are made of stainless steel If damaged or lost order new items according to this table Quantity Washers Screws Equipment to be fastened 16 pcs 13x19x2 Stainless Steel M12x90 Stainless Steel Gearbox 3HAC060866 004 3HAC060786 036 16 pcs 17x15x3 Stai...

Page 503: ...m Length 1 m lifting capacity 1 000 kg Roundsling 1 m Used to rotate the motor pinion 3HAB7887 1 Rotation tool Used for aligning the gearbox against the frame so that the play in the motor does not need to be adjusted 3HAC046645 003 Aligning tool Used to release the motor brakes 24 VDC power supply Used to guide axis 1 gear and frame during refitting 3HAC043870 009 Guide for reduction gear Always ...

Page 504: ...ng new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 624 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the ...

Page 505: ...uarded space 5 xx1300000476 Hold the mechanical stop pin in a firm grip and remove it by unscrewing the set screw CAUTION The mechanical stop pin weighs 5 kg and may fall down when the set screw is removed 6 xx1200001184 Unscrew the attachment screws that secure the cable bracket 7 Continues on next page Product manual IRB 6790 505 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reser...

Page 506: ...to reach all attach ment screws inside the recess 9 xx1200001189 Unscrew five of the six attachment screws inside the frame recess that secure the frame to the gearbox Note Leave the outermost screw fitted as a safety precaution xx1200001185 10 Continues on next page 506 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis ...

Page 507: ...n off the air pressure supply 13 Robot position Use this procedure to jog the robot into position Note Action xx1200001132 Jog the robot into position Axis 1 no significance as long as the robot is secured to the foundation Axis 2 40 Axis 3 65 approximately Axis 4 calibration position 0 Axis 5 90 Axis 6 calibration position 0 1 Continues on next page Product manual IRB 6790 507 3HAC063331 001 Revi...

Page 508: ...ION The complete arm system weigh according to variants 1 100 kg All lifting accessories used must be sized accord ingly 2 Lifting eye 3HAC16131 1 xx1200001133 Fit a lifting eye to the wrist Note Save the stop screw installed to refit after the lifting eye is removed 3 Lifting shackle SA 10 8 NA1 xx1200001234 Fit a lifting shackle in the wrist lifting eye 4 Continues on next page 508 Product manua...

Page 509: ...g the weight of the lower arm and frame is applied to the axis 3 gear during lifting which risks to damage the gear 7 Lifting eye 3HAC16131 1 Fit a lifting eye in the arm house with a fender washer underneath xx1400002196 Fender washer 8 Fender washer Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm xx1200001134 Note Save the stop screw installed to refit after the lif...

Page 510: ... cables Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover Note Axis 3 and 4 motors only Be careful not to damage the air hose or air nipple 2 xx1200001070 Make sure the o ring is present 3 Continues on next page 510 Product manual IRB 6790 3HAC063331 001 Revis...

Page 511: ... sure that all supplies for electrical power and hydraulic pressure are turned off 1 Lifting accessory chain 3HAC15556 1 Attach the lifting accessories 2 Lifting accessory motor 3HAC14459 1 24 VDC power supply To release the brakes connect the 24 VDC power supply 3 Connect to R2 MP1 connector pin 2 pin 5 CAUTION The weight of the motor is 25 kg All lifting accessories used must be sized accordingl...

Page 512: ...e force is used 7 Removal tool M12 3HAC057339 002 If needed use removal tools to help re move the motor 8 Always use removal tools in pairs Lifting accessory chain 3HAC15556 1 Use caution and lift the motor straight up to get the pinion parted from the gear 9 Lifting accessory motor 3HAC14459 1 xx1200001072 Disconnect the 24 VDC power supply 10 Continues on next page 512 Product manual IRB 6790 3H...

Page 513: ...N Turn off the air pressure supply 2 xx1700001580 Remove the base cover 3 xx1700001584 Remove the metal clamp inside the base 4 xx1700002245 Disconnect the balancing device air hose inside the base 5 Continues on next page Product manual IRB 6790 513 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox Continued ...

Page 514: ...16 Disconnect the earth cable 8 Washer dimension 6 4x17x3 Removing the cable harness in the base Note Action xx1700002036 Open the hose clamp on the black cable protection and loosen the protection from the frame 1 Continues on next page 514 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox Continued ...

Page 515: ...base and place it on for example the upper arm 2 Removing the frame cable protection Note Action xx1700001633 Cut the flange sealant and remove the protection ring 1 Lifting away the complete arm system Use this procedure to lift away the complete arm system Note Action Raise the overhead crane to stretch the chains and roundslings 1 Make sure that the roundsling between the wrist and the frame is...

Page 516: ...M16x200 3HAC13120 3 xx1700001636 Always use guide pins in pairs Remove the remaining attachment screws that hold the frame to the axis 1 gearbox 3 CAUTION The complete arm system weighs 1 100 kg All lifting accessories used must be sized accordingly 4 Continues on next page 516 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing th...

Page 517: ...moving the lifting accessories Do not change the position of the axes from the position described earlier 7 Removing the gearbox Note Action xx1200001186 Remove the attachment screws and washers that secure the gearbox to the base 1 Continues on next page Product manual IRB 6790 517 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox Co...

Page 518: ...0 3HAC13056 3 xx1700001653 Always use guide pins in pairs Lifting eye 3HAC14457 4 xx1700002193 Fit two lifting eyes manually in opposite holes in the gearbox CAUTION Leave a couple of millimeters of space between the lug and the surface of the gear box The surface of the gearbox is a sealing surface not to be damaged 4 CAUTION The weight of the gearbox is 92 kg All lifting accessories used must be...

Page 519: ... gearbox 6 xx1700001655 Protect the sealing areas on top of the protec tion tube to avoid damaging them 7 Lift away the gearbox 8 Continues on next page Product manual IRB 6790 519 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox Continued ...

Page 520: ... the radial sealing seals prop erly against the tube 1 Guide pin M12x150 3HAC13056 2 Fit guide pins in opposite holes in the base Tip Lubricate the guide pins with some grease to make the gearbox slide better 2 Guide pin M12x200 3HAC13056 3 Always use guide pins in pairs xx1700001642 Wipe clean the contact surfaces on the base and the surfaces of the protection tube from any contamination 3 Put gr...

Page 521: ...ce of the gearbox is a sealing surface not to be damaged 1 Lifting accessory chain 3HAC15556 1 xx1700002191 Attach the lifting accessory chain 2 CAUTION The weight of the gearbox is 92 kg All lifting accessories used must be sized accordingly 3 xx1200001245 Wipe clean the contact surfaces from any contamination Also wipe clean the o ring groove 4 Continues on next page Product manual IRB 6790 521 ...

Page 522: ...use an old o ring 5 Fit the o ring in the groove of the gearbox 6 xx1700002192 Wipe clean the surfaces of the hole in axis 1 gearbox 7 Continues on next page 522 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox Continued ...

Page 523: ...d 1 xx1700001641 Lower the gearbox very carefully onto the guide pins and onto the protection tube Note Make sure that the o ring is still fitted cor rectly when the gearbox is being fitted 2 Remove the guide pins 3 Remove the lifting accessory and the lifting eyes 4 Continues on next page Product manual IRB 6790 523 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 ...

Page 524: ...ng the arm system Note Action Special tools are required for replacement xx1700001639 Check the radial sealing Replace if damaged 1 Remove old residues of flange sealant and other contamination from the contact sur faces on the gearbox 2 Wipe clean the contact surfaces from any remaining contamination 3 Continues on next page 524 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 202...

Page 525: ...e The activator must be used to harden the flange sealant Hex socket head cap screw 3HAC060786 036 Wipe clean the o ring groove in the gearbox and the new o ring 5 Grease 3HAC042536 001 xx1700001658 Lubricate the new o ring with grease and fit it to the gearbox 6 Continues on next page Product manual IRB 6790 525 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 1 ...

Page 526: ... the frame slide better 7 Guide pin M16x150 3HAC13120 2 xx1700002197 Always use guide pins in pairs Guide for reduction gear 3HAC043870 009 xx1700002096 Fit the guide for the gear on top of the pro tection tube It protects the radial sealing from being damaged during refitting 8 Continues on next page 526 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved...

Page 527: ...st be sized accordingly 1 Make sure that all lifting accessories still is fitted correctly on the arm system 2 For a more detailed description see Attach ing the lifting accessories on page 508 Attach the upper arm lifting accessory chain to an overhead crane or similar and then to the lifting eye in the arm house and to a roundsling run through the wrist 3 Lifting accessory chain 3HAC15556 1 Roun...

Page 528: ... the guide pins will enter the correct holes in the frame Note The amount of screw holes differ between the frame and the gearbox See figures for correct entering holes for the guide pins 8 Position of Guide pin M16x150 xx1700002197 Continues on next page 528 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox Co...

Page 529: ...le in the gearbox next to the motor pinion hole is not used 9 Position of Guide pin M16x150 xx1700002197 Lower the arm system to align the other guide pin into the hole 10 Continues on next page Product manual IRB 6790 529 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox Continued ...

Page 530: ...41 A C B xx1300001118 A Aligning tool B Attachment screws 2 pcs C Correct fitting of the aligning tool Tightening torque 50 Nm Fit the aligning tool according to figure 12 Continues on next page 530 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox Continued ...

Page 531: ...AC060786 041 16 pcs Washers 17x15x3 Stainless Steel 3HAC060866 005 16 pcs Use caution and lower the complete arm system into position on top of the gearbox 15 Tightening torque 300 Nm Secure the complete arm system to the axis 1 gearbox with its attachment screws 16 Tightening torque 300 Nm Remove the two guide pins and replace with attachment screws 17 Tighten the remaining accessible attach ment...

Page 532: ... Insert the cabling into the base and refit the cable protection while pushing down the cabling Fasten with the hose clamp around the protection ring 3 Preparations prior to refitting motor Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 Remove any old paint residues or other contam ination from the contact surfaces on both the motor and ...

Page 533: ...fitting in the groove 4 xx1200001135 If the motor is a new spare part remove the cover 5 Securing the axis 1 motor Note Action Guide pin M12x150 3HAC13056 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs Continues on next page Product manual IRB 6790 533 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox Continued ...

Page 534: ... Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 6 Lifting accessory chain 3HAC15556 1 Lower the motor into position Make sure that the motor pinion is properly mated to the gear in the gearbox Make sure that the motor pinion does not get damaged Make sure that the direction of the cable gland exit is facing the correct way 7 Lifting accessory motor ...

Page 535: ... Perform a leak down test if not already done 9 Disconnect the 24 VDC power supply 10 Refitting the cable harness in the base Note Action xx1700001808 Make sure that the cables are not twisted Each cable must be in line with its position on the base plate Make sure that the R1 SMB cable will run on the correct side of the R1 MP1 see the figure 1 Continues on next page Product manual IRB 6790 535 3...

Page 536: ...ect connectors R1 MP and R1 SMB Also connect the air hose that belongs to the balancing device 3 xx1700001581 Refit the cover that protects the R1 MP and R1 SMB connectors 4 Screw dimension M6x16 Connect the earth cable 5 Washer dimension 6 4x17x3 Continues on next page 536 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the ax...

Page 537: ...02245 Connect the balancing device air hose in side the base 7 xx1700001580 Refit the base cover 8 Continues on next page Product manual IRB 6790 537 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox Continued ...

Page 538: ...it the cable gland cover Note Replace the gasket if damaged 2 xx1200001066 Connect the motor cables Connect in accordance with the markings on the connectors 3 Continues on next page 538 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox Continued ...

Page 539: ...groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Attachment screws M5x12 Stainless steel A2 70 7 pcs 9ADA619 44 xx1200001135 Refit the motor cover with its attachment screws Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues on next page Product manual IRB 6790 539 3HAC063331...

Page 540: ...at Recommended drying time is 24h xx1400000378 Apply Mercasol on the surfaces shown in the figure on stop pin and in the hole as shown in the figure 4 Screw M10x20 Stainless Steel 9ADJ400914P1259 Refit the mechanical stop pin and secure it with the attachment screw 5 Locking liquid 3HAB7116 1 Loctite 243 Apply locking liquid on the screw Tightening torque 24 Nm xx1300000476 Continues on next page ...

Page 541: ...e initial value fault trace according to Inspecting the leak flow overpressure unit in the system on page 128 9 Axis Calibration is described in Calibrating with Axis Calibration method on page 623 Re calibrate the robot 10 General calibration information is included in section Calibration on page 613 DANGER Make sure all safety requirements are met when performing the first test run 11 Product ma...

Page 542: ...bration position There should be enough space to place two pallets as shown in the figures in the procedures below DANGER The base shall be fitted to the foundation when performing this procedure Valid in both examples described below xx1300002303 Example 1 Position with space for pallets in front of the robot Axis 1 in calibration position Continues on next page 542 Product manual IRB 6790 3HAC06...

Page 543: ... method to replace the gearbox with cable harness and DressPack fitted is only a recommendation If it is not possible to put the arm system close enough to the robot and keep the cable harness partly fitted it may by necessary to remove the cable harness and DressPack in base and frame first Continues on next page Product manual IRB 6790 543 3HAC063331 001 Revision B Copyright 2019 2020 ABB All ri...

Page 544: ...c Shell Gadus S2 3HAC042536 001 Grease Used to lubricate o rings D 102x3 3HAB3772 107 O ring Used on motor flange D 169 5x3 3HAC067762 001 O ring Used on motor cover 319 3x5 7 3HAB3772 48 O ring nitrile rubber VK 28x7 3HAA2166 28 VK cover Locking liquid Loctite 2701 Continues on next page 544 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8...

Page 545: ...131 1 Lifting eye M16 3HAC14457 4 Lifting eye Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm Fender washer SA 10 8 NA1 Lifting shackle Length 1 5 m Lifting capacity 2 000 kg Roundsling 1 5 m Length 1 m lifting capacity 1 000 kg Roundsling 1 m Lifting instruction 3HAC15880 2 en closed 3HAC15556 1 Lifting accessory chain Used to rotate the motor pinion 3HAB7887 1 Rotat...

Page 546: ...ting the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous ref...

Page 547: ...y prior to begin ning the repair procedure 1 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 2 See Draining the axis 2 gearbox on page 138 Begin draining the gearbox 3 xx1700001593 Check the leak flow value on the flow sensor Note the value to be able to compare it when repair is completed 4 CAUTION Turn off the air pressure s...

Page 548: ...a new balancing device or if the spring unit of the balancing device cannot be compressed by jogging the robot only use the Hydraulic press tool balancing device 3HAC020902 001 1 This is done in order to compress the bal ancing device springs inside the balancing device before fitting the Distance tool Jog axis 2 to 30 or 30 2 DANGER Turn off all electric power supply hydraulic pressure supply to ...

Page 549: ...ing it possible to re move the front shaft of the balancing device Jog axis 2 to the calibration position The balancing device is now unloaded 7 Let the Distance tool stay fitted during the continued procedure 8 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 9 Attaching lifting accessory to the balancing device Note Action CA...

Page 550: ...e and raise to unload the weight 3 Removing the shaft in the front link ear Note Action xx1900002146 Remove the two screws 1 xx1200001279 M16x70 stainless steel Unscrew the attachment screw and washer 2 Continues on next page 550 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 2 gearbox Continued ...

Page 551: ...1731 1 xx1200001280 xx1200001281 Put down the balancing device and let it rest on the frame 4 Robot position Use this procedure to jog the robot into position Note Action Note When jogging the axis 2 into position check that the balancing device ear and the ear on the lower arm is not colliding 1 Continues on next page Product manual IRB 6790 551 3HAC063331 001 Revision B Copyright 2019 2020 ABB A...

Page 552: ...the lower and upper arm Use this procedure to attach the lifting accessories Note Action CAUTION The lower and upper arms together weigh accord ing to variants 510 kg All lifting accessories used must be sized accord ingly 1 Lifting eye 3HAC16131 1 xx1200001133 Fit a lifting eye to the wrist Note Save the stop screw installed to refit after the lifting eye is removed 2 Continues on next page 552 P...

Page 553: ...he lower arm beneath the securing screw 5 xx1200001253 Adjust the roundsling on the other side of the lower arm so that the roundsling runs on the left side of the most lower of the four bosses This will prevent the roundsling from gliding 6 Attach the roundsling to the shackle on the wrist 7 Stretch the roundsling between the wrist and the lower arm by slowly jogging the axis 3 Note Make sure the...

Page 554: ...he lifting eye is removed Lifting accessory chain 3HAC15556 1 Attach the Lifting accessory chain to an over head crane or similar then to the lifting eye in the arm house and to a roundsling run through the wrist 11 Roundsling 1 m Length 1 m lift ing capacity 1 000 kg xx1200001254 Raise the overhead crane to stretch the chains and roundslings 12 Verify that the roundsling between the wrist and the...

Page 555: ...lies for electrical power and hydraulic pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover Note Axis 3 and 4 motors only Be careful not to damage the air hose or air nipple 2 xx1200001070 Make sure the o ring is present 3 Continues on next page Product manual IRB 6790 555 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved ...

Page 556: ... Before removing the motor make sure that the axis 2 gearbox is completely drained 1 DANGER When releasing the holding brakes of the motor the lower arm will be movable and may fall down if not secured Verify that the lower arm is secured as previously de scribed before continuing 2 To release the brake connect the 24 VDC power supply 3 Connect to connector R2 MP2 axis 2 mo tor pin 2 pin 5 Continu...

Page 557: ...lways use removal tools in pairs Disconnect the 24 VDC power supply 8 CAUTION The motor weighs 28 kg All lifting accessories used must be sized accordingly 9 Carefully lift the motor out on the guide pins in order to get the pinion away from the gear and let it rest on the guide pins 10 Lifting accessory motor 3HAC15534 1 Fasten the lifting accessory Attach the lifting chain to the accessory and a...

Page 558: ... metal clamp located on the inside of the lower arm by removing the attachment screws Note The screws are reached from outside the lower arm 1 xx1200001283 Unscrew the attachment screws of the cable bracket on the frame and let it hang loose 2 Continues on next page 558 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 2...

Page 559: ...ace them with guide pins Tip Lubricate the guide pins with some grease to make the lower arm slide better 1 Guide pin M16x200 3HAC13120 3 Always use guide pins in pairs xx1300000788 xx1300000789 Remove all but one of the remaining attach ment screws that secure the lower arm to the axis 2 gearbox 2 Continues on next page Product manual IRB 6790 559 3HAC063331 001 Revision B Copyright 2019 2020 ABB...

Page 560: ...her weigh 510 kg All lifting accessories used must be sized accordingly 2 xx1300000790 Use caution and remove the remaining screw and slowly lift away the lower and upper arm together Let the cabling run in the lower arm Make sure not to stretch any cabling CAUTION Use extreme caution when lifting the upper arm The cable harness is still partly con nected 3 Use a piece of wood or similar as a supp...

Page 561: ...left in the gearbox 4 Use two fully threaded attachment screws M12 as removal tools to press the gear box out of position 5 Lifting accessory gearbox 3HAC046128 001 Attach the lifting accessory to the gearbox 6 Use caution and let the gearbox slide out on the guide pins 7 Remove the gearbox 8 Refitting the axis 2 gearbox Use these procedures to refit the gearbox Follow the order of the procedures ...

Page 562: ...tion Note Also wipe clean the o ring groove 5 O ring nitrile rubber 3HAB3772 48 Check the condition of the o ring 6 319 3x5 7 Replace if damaged Lubricate the o ring with some grease for a better fitting in the groove 7 Fit the o ring in the groove 8 Guide pin M12x150 3HAC13056 2 Fit two guide pins in opposite holes M12 Tip Lubricate the guide pins with some grease to make the gearbox slide better...

Page 563: ...and washers 14 Tightening torque 120 Nm Secure the gearbox with its attachment screws 15 Preparations prior to refitting motor Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 Remove any old paint residues or other contam ination from the contact surfaces on both the motor and the mating parts 2 Wipe clean the contact surfaces and the o ri...

Page 564: ...fitting in the groove 4 xx1200001135 If the motor is a new spare part remove the cover 5 Securing the axis 2 motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs Continues on next page 564 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 2 gearbox Continued ...

Page 565: ... pinion when mating it into the gear 7 To release the brakes connect the 24 VDC power supply 8 Connect to connector R2 MP2 axis 2 mo tor pin 2 pin 5 CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 9 Use caution and fit the motor in its final position while at the same time rotating the motor pinion slightly using the rotation tool Make sure t...

Page 566: ... test on page 166 Perform a leak down test 14 Lifting back and refitting the lower and upper arm Use this procedure to lift back and refit the lower and upper arm un separated Note Action Connect the 24 VDC power supply to the axis 2 motor to release the brakes of the motor 1 Rotation tool 3HAB7887 1 Fit the rotation tool if not already fitted 2 Guide pin M16x150 3HAC13120 2 Fit two guide pins in ...

Page 567: ...utting the arms on the guide pins make sure that the hole pattern is matched and in the correct position for all screws 7 Rotation tool 3HAB7887 1 xx1300000819 If the hole pattern is not matching use the rotation tool and adjust 8 Slide the lower arm on to the guide pins 9 Use caution and move the arms into posi tion at the axis 2 gearbox on the guide pins 10 Continues on next page Product manual ...

Page 568: ... 3HAC060866 005 Tightening torque M16 300 Nm Secure the lower arm to the axis 2 gearbox with its attachment screws 13 Disconnect the 24 VDC power supply 14 Remove the lifting accessories 15 Refit stop screws in the lifting accessory attachment holes Connecting the axis 2 motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 Continues on next page 568 Product...

Page 569: ...3 O ring axis 1 3HAC067762 001 Inspect the o ring Note Replace if damaged 4 O ring axis 2 3HAC067762 001 O ring axis 3 3HAC067762 001 O ring axis 4 3HAC067744 001 xx1200001070 Wipe clean o ring and o ring groove 5 Continues on next page Product manual IRB 6790 569 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 2 gearbox Continued ...

Page 570: ...00001135 Refit the motor cover with its attachment screws Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Refitting the cabling Use this procedure to refit the cabling Note Action Use caution and push the cable harness into the lower arm 1 Continues on next page 570 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB...

Page 571: ...ration position if not already done 2 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 3 Lifting shackle SA 10 8 NA1 Apply the lifting accessory to the balancing device if not already done 4 Lifting accessory chain 3HAC15556 1 Remove all residue of Loctite in the screw hole of the shaft 5 Wipe all contact surfaces inside the re...

Page 572: ...press tool 9 Hydraulic pump 70 MPa 3HAC13086 1 Hydraulic cylinder 3HAC11731 1 Dismantle and mounting tool 3HAC028920 001 xx1700002238 The item numbers refer to mark ings on the tools xx1300000782 Apply locking liquid Loctite 2701 on the threads of the screw first entering the threads in the frame 10 Continues on next page 572 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 AB...

Page 573: ...ual grease Use locking liquid 12 Concluded refitting of the front shaft Note Action Remove the lifting accessory from the bal ancing device 1 xx1200001283 Refit the cable bracket if not already refit ted 2 Continues on next page Product manual IRB 6790 573 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 2 gearbox Continued ...

Page 574: ...pressed by jogging the robot only use the hydraulic press tool Dismantle and mounting tool 3HAC028920 001 3 This is done in order to compress the spring unit inside the balancing device be fore refitting or removal of the distance tool Jog axis 2 to 30 or 30 4 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the robot working area 5 A xx0800000480 A ...

Page 575: ...alue should be the same If the value is higher than the initial value fault trace according to Inspecting the leak flow overpressure unit in the system on page 128 3 Axis Calibration is described in Calibrating with Axis Calibration method on page 623 Re calibrate the robot 4 General calibration information is included in section Calibration on page 613 DANGER Make sure all safety requirements are...

Page 576: ...e enough space to place two pallets in a row If needed run axis 1 into a position that gives the required space at the right hand side of the balancing device DANGER Do not unscrew the attachment screws that secure the robot to the foundation If unscrewed the robot will be unstable Location of the axis 3 gearbox The axis 3 gearbox is located as shown in the figure xx1300000515 Continues on next pa...

Page 577: ...Note Article number Equipment etc Shell Gadus S2 3HAC042536 001 Grease Used to lubricate o rings D 102x3 3HAB3772 107 O ring Used on motor flange D 169 5x3 3HAC067762 001 O ring Used on motor cover 183 74x3 53 3HAB3772 150 O ring NBR Stainless steel fasteners Due to robot protection type Foundry Prime some of the attachment screws and washers used on the robot are made of stainless steel If damage...

Page 578: ...closed 3HAC15556 1 Lifting accessory chain Used for putting down removed parts from robot Pallet 3HAC046128 001 Lifting accessory gearbox Used to push out the motor if neces sary Always use removal tools in pairs 3HAC057339 002 Removal tool Used to push out the gearbox if neces sary ScrewsM8x75 fully threaded Used for putting down removed parts from robot Pallet Always use guide pins in pairs 3HAC...

Page 579: ...er the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 624 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the robot is to be calibrated with fine ca...

Page 580: ...tinuing 3 Release the holding brakes for the axis 3 motor to make the upper arm rest tightly against the mechanical stop 4 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the safe guarded space 5 See Draining the axis 3 gearbox on page 143 Begin draining the gearbox 6 Put two pallets on the floor at the right hand side of the robot Note This positio...

Page 581: ...on the axis 3 and axis 4 motors Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover Note Axis 3 and 4 motors only Be careful not to damage the air hose or air nipple 2 Continues on next page Product manual IRB 6790 581 3HAC063331 001 Revision B Copyright 2019 20...

Page 582: ... is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the axis 3 motor Note Action Before removing the motor make sure that the axis 3 gearbox is completely drained 1 Continues on next page 582 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 3 Re...

Page 583: ...o make the motor slide better 5 Always use guide pins in pairs CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 6 Removal tool M12 3HAC057339 002 If required press the motor out of position by using the removal tool in the remaining holes for the motor 7 Always use removal tools in pairs Use caution and lift the motor out on the guide pins in ...

Page 584: ...l hang in an angle This position makes it easier to re move the axis 3 motor with the axis 4 mo tor still fitted CAUTION The pinion must have been parted from the gear before the motor is angled If not there is a risk of damaging the pinion and gear 11 Disconnect the 24 VDC power supply 12 Make sure the pinion is not damaged xx1200001131 Remove the motor by lifting it straight out 13 Continues on ...

Page 585: ...e longest possible length of the cable harness between the lower and upper arm Note Action xx1800000042 Unscrew the attachment screws that hold the axis 3 lower arm metal clamp the one closest to the axis 3 gearbox located on the inside of the lower arm Note The screw is reached from the outside of the lower arm 1 xx1300000541 Unscrew the attachment screws that hold the cable bracket on top of the...

Page 586: ...Use this procedure to attach the lifting accessories to the upper arm Note Action CAUTION The weight of the complete upper arm in cluding the wrist is 360 kg All lifting accessories used must be sized accordingly 1 Lifting eye 3HAC16131 1 xx1200001133 Fit a lifting eye to the wrist Note Save the stop screw installed to refit after the lifting eye is removed 2 Continues on next page 586 Product man...

Page 587: ...56 1 xx1200001308 Attach the upper arm lifting accessory chain to an overhead crane or similar and then to the lifting eye in the arm house and in the wrist 4 Raise the lifting accessories to take the weight of the upper arm 5 xx1400002197 In case of necessary adjustments use the shortening loops on the lifting accessory chain to find the level position 6 Continues on next page Product manual IRB ...

Page 588: ... with some grease to make the upper arm slide better xx1300000747 Leave one of the remaining attachment screws fitted remove the other screws 2 Removing the upper arm Note Action xx1400002197 Note Make sure the lift is done completely leveled In case of necessary adjustments use the shortening loops on the lifting ac cessory chain and make sure to place the chain the right way through the loops 1 ...

Page 589: ... 3 gearbox Place pieces of wood or similar under arm house and wrist Lower the upper arm and let the upper arm rest as shown in the fig ure This is done in order to keep the axis 3 gearbox in a vertical position and to get the best position to replace the axis 3 gearbox if applicable 4 Removing the axis 3 gearbox Use this procedure to remove the gearbox Note Action Guide pin M12x150 3HAC13056 2 Re...

Page 590: ...t to far 5 CAUTION The axis 3 gearbox weighs 56 kg All lifting accessories used must be sized accordingly 6 Lifting accessory gearbox 3HAC046128 001 Apply the lifting accessory to the gearbox 7 Note There will be some oil spill when the gear box is removed Put some oil absorbent cloth or paper below the gearbox 8 With the gearbox attached to the lifting ac cessory remove the gearbox by letting it ...

Page 591: ...all also be done on a new spare part 5 O ring NBR 3HAB3772 150 Check the condition of the o ring 6 Replace if damaged Wipe clean the contact surfaces both on the gearbox and in the upper arm 7 Also wipe clean the o ring groove Lubricate the o ring with some grease 8 Fit the o ring in the groove 9 Guide pin M12x150 3HAC13056 2 Fit two guide pins in opposite holes Tip Lubricate the guide pins with s...

Page 592: ... guide pins and replace with the remaining attachment screws and washers 2 Washers 13x19x2 Stainless Steel 3HAC060866 004 xx1300001969 Tightening torque 120 Nm Secure the remaining attachment screws 3 Remove the lifting accessory 4 Preparations before refitting the upper arm Note Action Wipe clean all contact surfaces 1 Continues on next page 592 Product manual IRB 6790 3HAC063331 001 Revision B C...

Page 593: ...already fitted 2 Lift the upper arm and put it on the guide pins 3 24 VDC power supply If the axis 3 motor is installed to the upper arm 4 Rotation tool In order to release the brakes connect the 24 VDC power supply Connect to R2 MP3 connector pin 2 pin 5 Use the rotation tool and rotate the axis 3 motor to find the correct position for the guide pins in the lower arm Pinion 3HAC067546 001 If the ...

Page 594: ... upper arm by tightening the at tachment screws 8 Tightening torque M16 300 Nm Tightening torque M12 120 Nm Preparations prior to refitting motor Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 Remove any old paint residues or other contam ination from the contact surfaces on both the motor and the mating parts 2 Wipe clean the contact su...

Page 595: ...ve 4 xx1200001135 If the motor is a new spare part remove the cover 5 Securing the axis 3 motor Use this procedure to secure the motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs Continues on next page Product manual IRB 6790 595 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 3 ...

Page 596: ...pins Do not push the motor pinion into the gear yet This is done in order to fit the motor with the axis 4 motor still fitted 4 Remove the lifting accessory and allow the motor to rest on the guide pins 5 Rotation tool 3HAB7887 1 Apply the rotation tool and use it to rotate the pinion when mating it into the gear 6 To release the brakes connect the 24 VDC power supply 7 Connect to connector R2 MP3...

Page 597: ...Steel 3HAC060866 003 Tightening torque 50 Nm Tighten the screws 13 Remove the rotation tool 14 See Performing a leak down test on page 166 Perform a leak down test 15 Disconnect the 24 VDC power supply 16 Refitting cable brackets This procedure is valid if the cabling has been kept installed in the upper arm when removing the upper arm from the robot If the cable harness in the upper arm instead h...

Page 598: ...screw is reached from the outside of the lower arm 3 xx1300000541 Fasten the cable bracket on top of the arm house 4 xx1300000543 Fasten the cable bracket under the arm house 5 Continues on next page 598 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 3 gearbox Continued ...

Page 599: ...ure to connect the motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page Product manual IRB 6790 599 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 3 gearbox Continued ...

Page 600: ...ring axis 4 3HAC067744 001 xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring Tip Lubricate the o ring with some grease for a better fitting in the groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page 600 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair...

Page 601: ...lue on the flow sensor and compare it to the initial value The value should be the same If the value is higher than the initial value fault trace according to Inspecting the leak flow overpressure unit in the system on page 128 3 Axis Calibration is described in Calibrating with Axis Calibration method on page 623 Re calibrate the robot 4 General calibration information is included in section Cali...

Page 602: ...tc Shell Gadus S2 3HAC042536 001 Grease Used to lubricate o rings D 102x3 3HAB3772 107 O ring Used on motor flange Used on motor cover 3HAC033489 002 Gasket D 151 99x3 53 3HAB3772 58 O ring Used on gearbox The seal is damaged when the turning disc is removed and must be replaced 3HAC060656 002 Turcon Roto VL seal Continues on next page 602 Product manual IRB 6790 3HAC063331 001 Revision B Copyrigh...

Page 603: ...he robot see the table Note Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference...

Page 604: ...axis 6 gearbox on page 154 Drain the gearbox 3 Remove all equipment fitted on the turning disc 4 Jog the robot to Axis 1 No significance as long as the robot is secured to the founda tion Axis 2 25 Axis 3 20 Axis 4 0 Axis 5 55 Axis 6 10 5 DANGER Turn off all electric power supply hydraulic pressure supply to the robot before entering the safe guarded space 6 xx1300000825 Remove the synchronization...

Page 605: ... disc 1 xx1300000493 Remove the turning disc 2 xx1700001592 Remove the seal from the turning disc Note Replace the seal if damaged 3 Continues on next page Product manual IRB 6790 605 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 6 gearbox Continued ...

Page 606: ...ove the gearbox If required fit two attachment screws and press out the gearbox 3 Refitting the axis 6 gearbox Use these procedures to refit the gearbox Preparations before refitting the axis 6 gearbox Note Action DANGER Make sure that all supplies for electrical power and hydraulic pressure are turned off 1 Continues on next page 606 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 201...

Page 607: ... o ring 5 Fit the o ring in the groove of the gearbox 6 Refitting the axis 6 gearbox Note Action CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 1 xx1700001601 Fit the gearbox to the wrist CAUTION Be careful not to damage motor pinion or gears 2 Continues on next page Product manual IRB 6790 607 3HAC063331 001 Revision B Copyright 2019 2020 A...

Page 608: ...que 35 Nm xx1700001600 See Performing a leak down test on page 166 Perform a leak down test 4 Jog axis 5 to horizontal position 5 See Filling oil into the axis 6 gearbox on page 156 Refill oil in the gearbox 6 Continues on next page 608 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 6 gearbox Continued ...

Page 609: ...own in the figure 1 Grease 3HAC042536 001 Shell Gadus S2 xx1700001878 xx1700002033 Grease 3HAC042536 001 Shell Gadus S2 xx1700002094 Apply grease all the way around the inner corner of the turning disc Note No grease is allowed on the screw flange 2 Continues on next page Product manual IRB 6790 609 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the ...

Page 610: ... Use three M8x35 screws first to pull in the turning disc against the gearbox if needed Then remove the screws and secure the turning disc with the specified attachment screws Concluding procedure Note Action xx1300000825 Refit the synchronization plate axis 6 1 Axis Calibration is described in Calibrating with Axis Calibration method on page 623 Re calibrate the robot 2 General calibration inform...

Page 611: ...sure all safety requirements are met when performing the first test run 3 Product manual IRB 6790 611 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 6 gearbox Continued ...

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Page 613: ...eneric term for all calibration methods that aim to move the robot to calibration position Standard calibration A calibration routine that generates a new zero posi tion of the robot Fine calibration A calibration routine that in the first step generates a reference to current zero position of the robot The same calibration routine can later on be used to re calibrate the robot back to the same po...

Page 614: ...rances in the robot structure Deflection due to load Absolute accuracy calibration focuses on pos itioning accuracy in the Cartesian coordinate system for the robot Absolute accuracy calibration option al Absolute accuracy calibration data is found on the SMB serial measurement board in the robot For robots with RobotWare 5 05 or older the absolute accuracy calibration data is delivered in a file ...

Page 615: ...re and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step CalibWare Absolute Accuracy calibration The CalibWare tool guides through the calibration process and calculates new compensation parameters This is further detailed in the Application manual CalibWare Field If a service operation is done to a robot with the option Absolute ...

Page 616: ...unter memory is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 619 This will occur when The battery is discharged A resolver error occurs The signal between a resolver and measurement board is interrupted A robot axis is moved with the control system disconnected The revolution counters must also be updated after the robot and co...

Page 617: ...tion marks and the synchronization position for each axis Synchronization marks IRB 6790 Axis 2 xx1300000869 Axis 1 xx1300000868 Axis 4 xx1300000871 Axis 3 xx1300000870 Axis 6 xx1500000845 Axis 5 xx1300000872 Product manual IRB 6790 617 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes ...

Page 618: ...nes will handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions 6 axes Note The graphic shows an IRB 7600 The positive direction is the same for all 6 axis robots except the positive direction of axis 3 for IRB 6400R which is in the opposite direction xx0200000089 618 Product manual IRB 6790 3HAC063331 001 Rev...

Page 619: ...esulting in an incorrect manipulator calibration Make sure the axes are positioned according to the correct calibration values not only according to the synchronization marks The correct values are found on a label located either on the lower arm underneath the flange plate on the base or on the frame At delivery the manipulator is in the correct position Do NOT rotate axis 4 or 6 at power up befo...

Page 620: ...ABB menu tap Calibration xx1500000942 1 All mechanical units connected to the system are shown with their calibration status 2 Tap the mechanical unit in question xx1500000943 Continues on next page 620 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 621: ... calibration method used during last field calibration Tap Manual Method Advanced xx1500000944 A screen is displayed tap Rev Counters en0400000771 4 Continues on next page Product manual IRB 6790 621 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 622: ...e updating operation cannot be undone Tap Update to proceed with updating the revolution counters Tap Cancel to cancel updating the revolution counters Tapping Update updates the selected revolution counters and removes the tick from the list of axes 7 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn may cause damage or injury Ch...

Page 623: ...able calibration tool is inserted by the operator into a calibration bushing on the axis chosen for calibration according to instructions on the FlexPendant WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB Using other pins in the calibration bushings may cause severe damage to the robot and or personnel WARNING The calibration tool must be fully inser...

Page 624: ...B factory The reference value will be named according to tool name date etc Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values When reference calibration is performed the robot is restored to the status given by the reference values Update revolution counters Choose this routine to make a rough calibration of each manipulator axis by up...

Page 625: ...he axes Requirements for axis positioning during calibration Axis to calibrate Axis 6 Axis 5 Axis 4 Axis 3 Axis 2 Axis 1 Required position of axis Axis 1 0 0 Axis 2 0 0 Axis 3 Axis 4 Axis 5 Axis 6 Axis to be calibrated Unrestricted Axis is allowed to be jogged to other position than 0 degrees Axis must be put in position 0 degrees 0 Product manual IRB 6790 625 3HAC063331 001 Revision B Copyright 2...

Page 626: ...g other pins in the calibration bushings may cause severe damage to the robot and or personnel Note Article number Equipment etc Delivered as a set of calibration tools 3HAC055412 001 Calibration tool box Axis Calibration Examining the calibration tool Check prior to usage Before using the calibration tool make sure that the tube insert the plastic protection and the steel spring ring are present ...

Page 627: ...solution Note Action It is possible to use any RFID solution with the correct dimensions ABB has verifed function on some suppliers fulfilling the requirements of NFC compatible devices 13 56 Mhz according to ISO 14443 or ISO 15693 Note The maximum dimensions on the RFID chip must not exceed Ø7 9 mm x 8 0 mm Ø5 9 mm x 8 0 mm or Ø3 9 mm x 8 0 mm depending on calibra tion tool size 1 There is a cavi...

Page 628: ... as follows xx1500000890 Spare parts When calibration is not being performed a protective cover and an o ring should always be installed on the fixed calibration pin as well as a protective plug included a sealing in the bushing Replace damaged parts with new Note Article number Spare part Contains replacement calibration pin covers and protective plugs for the bushing 3HAC064875 001 Protection co...

Page 629: ...on procedure and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step Use the following list to learn about the calibration procedure before running the RobotWare program on the FlexPendant It gives you a brief overview of the calibration procedure sequence After the calibration method has been called for on the FlexPendant the follo...

Page 630: ...ER While conducting the calibration the robot needs to be connected to power Make sure that the robot s working area is empty as the robot can make unpredictable movements 1 Use a clean cloth Wipe the calibration tool clean Note The calibration method is exact Dust dirt or color flakes will affect the calibration value 2 Starting the calibration procedure Use this procedure to start the Axis Calib...

Page 631: ...n the FlexPendant is given in Overview of the calibra tion procedure on the FlexPendant on page 629 Follow the instructions given on the FlexPendant 4 Restarting an interrupted calibration procedure If the Axis Calibration procedure is interrupted before the calibration is finished the RobotWare program needs to be started again Use this procedure to take required action Action Situation Press and...

Page 632: ...and will force SafeMove to unsynchronize automatically However SafeMove may generate other warning messages anytime during the Axis Calibration routine When a warning message is displayed tap Acknowledge to confirm the unsynchronized state and continue Axis Calibration procedure CAUTION SafeMove must be synchronized after the calibration is completed After calibration Note Action xx1600002102 Chec...

Page 633: ...that the sealing washer is just about fastened between the plug and the bushing Then tighten 1 4 turn more Replace the plug and the sealing with new spare part if missing or damaged 3 Protection cover and plug set 3HAC064875 001 Product manual IRB 6790 633 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 5 Calibration 5 4 4 Axis Calibration Running the calibration procedure Co...

Page 634: ...to save reference values for all axes that is to be replaced Make sure that the values are saved in RobotStudio or FTP program The files are located in Active system folder name HOME RefCalibFiles 7 Perform the repair 8 Make sure that the tooling and process equipment are the same as when creating the reference Use Reference calibration to update the system with new calibration offset value for th...

Page 635: ...ie 96 3 94 2 2 1 degrees 8 Manually jog axis 4 the calculated angle difference 2 1 NOTE The direction shall be the same direction as the direction used when axis 4 was manually jogged to coincide with the verification process In the example 2 1 degrees 9 Make a new manual fine calibration of axis 4 with axis in 2 1 degrees position 10 Check again against the verification position 11 Repeat the man...

Page 636: ...ion program twice Do not change the position of the robot axes after running the program 1 This is detailed in section Synchronization marks and synchronization position for axes on page 617 Adjust the synchronization marks when the calibration is done if necessary 2 Write down the values on a new label and stick it on top of the calibration label 3 The label is located on the lower arm 636 Produc...

Page 637: ... page 617 and Updating revolution counters on page 619 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis...

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Page 639: ... to local regulations to prevent health or environmental hazards Example application Material Serial measurement board Batteries Lithium Cables motors Copper Base lower arm upper arm Cast iron nodular iron Gears screws base frame and so on Steel Screws washers Stainless steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearboxes Oil grease Covers synchronization ...

Page 640: ...ncineration must be carried out under controlled conditions in accordance with local regulations Also note that Spills can form a film on water surfaces causing damage to organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 640 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 6 Decommissioni...

Page 641: ...attery is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire When motors are removed from the robot the robot will collapse if it is not properly supported before the motor is removed Product manual IRB 6790 641 3HAC063331 001 Revision B Copyright 2019 2020 ABB All r...

Page 642: ... procedures in the step by step in structions below DANGER Do not under any circumstances deal with the balancing device in any other way than that detailed in the product documentation For example attempting to open the balancing device is potentially lethal Action on field decommissioning The procedure below details the actions to perform on field when the balancing device is to be decommissione...

Page 643: ...pring coils are cut from a safe distance and somewhat from above 2 DANGER The hole must be cut as specified in the figure Pieces of the spring can be thrown out from the cylinder at high speed if the hole is cut larger than specified 3 Use a cutting torch with a long shaft 400 m m 200 mm xx0700000391 Cut a hole in the housing as shown in the figure 4 Use a cutting torch with a long shaft Cut the c...

Page 644: ...This page is intentionally left blank ...

Page 645: ...pter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 6790 645 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 7 Reference information 7 1 Introduction ...

Page 646: ...and robotic devices Coordinate systems and motion nomenclatures ISO 9787 2013 Manipulating industrial robots performance criteria and related test methods ISO 9283 1998 Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 IEC 61000 6 2 2005 Safety of machinery E...

Page 647: ...39 37 in 3 28 ft 1 m Length 2 21 lb 1 kg Weight 0 035 ounces 1 g Weight 14 5 psi 100 kPa 1 bar Pressure 0 225 lbf 1 N Force 0 738 lbf ft 1 Nm Moment 0 264 US gal 1 L Volume Product manual IRB 6790 647 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 7 Reference information 7 3 Unit conversion ...

Page 648: ...es of nitrile rubber type should be used Stainless steel screws Stainless steel screws should be secured by hand at least 2 turns before using an electric screwdriver Screws lubricated in other ways Screws lubricated with Molycote 1000 should only be used when specified in the repair maintenance or installation procedure descriptions In such cases proceed as follows 1 Apply lubricant to the screw ...

Page 649: ...Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Oil lubricated screws with allen head screws The following table specifies the recommended standard tightening torque for oil lubricated screws with allen head screws Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque Tight...

Page 650: ...cified in the repair maintenance or installation procedure overrides the standard torque Tightening torque Nm Class 12 9 lubricated i Tightening torque Nm Class 10 9 lubricated i Dimension 35 28 M8 70 55 M10 120 96 M12 280 235 M16 550 460 M20 950 790 M24 i Lubricated with Molycote 1000 Gleitmo 603 or equivalent 650 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All right...

Page 651: ...sory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The robot weighs 1300 kg All lifting accessories used must be sized accord ingly Product manual IRB 6790 651 3HAC063331 001 Revision B Copyright 2019 2020 ABB...

Page 652: ...it Comment Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 2 5 17 mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 10 100 Nm 1 Torque wrench 75 400 Nm 1 Ratchet head for torque wrench 1 2 1 Hexagon headed screw M10x100 2 Hexagon headed screw M16x90 1 Hex bit socket head cap no 14 socket 40 mm L 100 mm 1 To be shortened to 12 mm Hex bit socket head cap no 14 socket 40 mm L 20 mm...

Page 653: ... sum of standard tools defined in the section Standard toolkit on page 652 and of special tools listed directly in the instructions and also gathered in this section Special tools Continues on next page Product manual IRB 6790 653 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 7 Reference information 7 7 Special tools ...

Page 654: ...150 3HAC13056 2 x x x x x Guide pin M12x200 3HAC13056 3 x x x Guide pin M16x150 3HAC13120 2 x x x Guide pin M16x200 3HAC13120 3 Lifting accessories x x x x x x xx1200001241 Lifting accessory chain 3HAC15556 1 x x Lifting accessory motor 3HAC14459 1 x x x Lifting accessory motor 3HAC15534 1 x Lifting accessory gearbox 3HAC046128 001 x Lifting accessory gearbox 3HAC046128 001 2 2 2 2 2 xx1200001242 ...

Page 655: ... 1 5 m Length 1 5 m Lifting capacity 2 000 kg x x x x x x x x x x Roundsling 1 m Length 1 m lifting capacity 1 000 kg x x x x x Fork lift accessory set 3HAC047054 003 Press puller and unloading tools x x x AdapterM20 M16 3HAC12475 6 x x x x x Dismantle and mounting tool 3HAC028920 001 x x x x xx1400000726 Distance tool 3HAC030662 001 x x x x Hydraulic cylinder 3HAC11731 1 x x x x Hydraulic pump 70...

Page 656: ...195 Guide for reduction gear 3HAC043870 009 x x x x x x x x x x Leak down tester x x x x Lock screw M16x120 x x x x x x Oil collecting vessel x x x x x x Oil dispenser x x x x x Pallet x xx1800001147 Pinion 3HAC067546 001 x x x x x x x x x x x x Rotation tool 3HAB7887 1 IRB 6790 235 2 65 IRB 6790 205 2 80 IRB 6700 200 2 60 IRB 6700 155 2 85 Included in Dismantle and mounting tool 3HAC028920 001 ii...

Page 657: ...ting accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference Product manual IRB 6790 657 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 7 Reference information 7 8 Lifting accessories and lifting ...

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Page 659: ...ews are not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRB 6790 659 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 8 Spare parts 8 1 Spare part lists and illustrations ...

Page 660: ...This page is intentionally left blank ...

Page 661: ...B 140 type C 3HAC025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB ...

Page 662: ...B 6650S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 IRB 6790 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram IRB 14000 3HAC056159 002 Circuit diagram IRB 910SC 662 Product manual IRB 6790 3HAC063331 001 Revision B Copyright 2019 2020 ABB All rights reserved 9 Circuit diagrams 9 1 Circuit diagrams C...

Page 663: ...ice routine 158 brake release 78 brake release unit replacing 247 brakes testing function 35 BRU replacing 247 buttons for brake release 78 C cabinet lock 29 cable harness replacing 187 209 cable harness attachments 118 cabling robot 92 cabling between robot and controller 92 calibrating robot 623 roughly 619 calibrating robot 623 calibration Absolute Accuracy type 614 rough 619 standard type 614 ...

Page 664: ...additional mechanical stop 122 cable harness 118 dampers 126 mechanical stop 120 inspecting balancing device 114 inspecting oil levels axis 1 100 axis 2 103 axis 3 105 axis 4 107 axis 5 109 axis 6 111 installation mechanical stop axis 1 90 instructions for assembly 39 integrator responsibility 28 intervals for maintenance 97 L labels robot 21 leak down test 166 lifting complete arm system 175 lowe...

Page 665: ...rm 253 wrist 289 xx 55 68 88 128 399 report replacements 165 requirements on foundation 42 responsibility and validity 17 restoring balancing device 415 restricting working range axis 1 90 revolution counters storing on FlexPendant 620 updating 619 risk of tipping 47 robot labels 21 lifting 60 61 protection class 43 protection types 43 securing to foundation 67 symbols 21 roundslings lifting the r...

Page 666: ...ng 311 U unloading balancing device 411 updating revolution counters 619 upper arm replacing 253 users requirements 18 V validity and responsibility 17 velocity adjusting 94 verifying calibration 636 W weight 40 axis 1 gearbox 518 521 axis 1 motor 427 429 511 534 balancing device 322 373 377 388 392 403 549 base plate 56 59 robot 63 516 527 651 upper arm complete 185 267 271 335 343 586 593 workin...

Page 667: ......

Page 668: ...Telephone 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics and Motion No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics and Motion 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC063331 001 Rev B en Copyright 2019 2020 ABB All rights reserved Specifications subject to change without notice ...

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