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ABB DressPack IRB 6700, Product Manual

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ABB DressPack IRB 6700 Product Manual Download Page 24

1.2.3.5 Safety risks during operational disturbances

General

•

The industrial manipulator is a flexible tool that can be used in many different
industrial applications.

•

All work must be carried out professionally and in accordance with the
applicable safety regulations.

•

Care must be taken at all times.

Qualified personnel

Corrective maintenance must only be carried out by qualified personnel who are
familiar with the entire installation as well as the special risks associated with its
different parts.

Extraordinary risks

If the working process is interrupted, extra care must be taken due to risks other
than those associated with regular operation. Such an interruption may have to be
rectified manually.

24

3HAC044266-001 Revision: -

© Copyright 2013 ABB. All rights reserved.

1 Safety

1.2.3.5 Safety risks during operational disturbances

Summary of Contents for DressPack IRB 6700

Page 1: ...ABB Robotics Product manual IRB 6700 ...

Page 2: ...Trace back information Workspace R13 2 version a3 Checked in 2013 10 15 Skribenta version 4 0 378 ...

Page 3: ...Product manual IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05 IRB 6700 150 3 20 IRC5 Document ID 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved ...

Page 4: ...s or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Additional copies of this manual may be obtained from ABB The original language for this publication is English A...

Page 5: ... 3 Safety related instructions 36 1 3 1 Safety signals in the manual 38 1 3 2 Safety symbols on manipulator labels 43 1 3 3 DANGER Moving manipulators are potentially lethal 44 1 3 4 DANGER First test run may cause injury or damage 45 1 3 5 WARNING The brake release buttons may be jammed after service work 46 1 3 6 DANGER Make sure that the main power has been switched off 47 1 3 7 WARNING The uni...

Page 6: ... mechanical stops 132 3 3 12 Inspecting the fork lift device set 134 3 3 13 Inspecting the dampers 136 3 3 14 Inspecting signal lamp option 137 3 4 Replacement changing activities 137 3 4 1 Type of lubrication in gearboxes 138 3 4 2 Changing oil axis 1 gearbox 143 3 4 3 Changing oil axis 2 gearbox 148 3 4 4 Changing oil axis 3 gearbox 153 3 4 5 Changing oil axis 4 gearbox 157 3 4 6 Changing oil ax...

Page 7: ...Replacing the axis 2 gearbox 505 4 8 3 Replacing the axis 3 gearbox 529 4 8 4 Replacing the axis 6 gearbox 537 5 Calibration information 537 5 1 Introduction 538 5 2 Calibration methods 540 5 3 Calibration scale and correct axis position 541 5 4 Calibration movement directions for all axes 542 5 5 Updating revolution counters 544 5 6 Checking the calibration position 545 6 Decommissioning 545 6 1 ...

Page 8: ...This page is intentionally left blank ...

Page 9: ...e performing any installation or service work on robot Contains general safety aspects as well as more specific information on how to avoid personal injuries and damage to the product Safety service Required information about lifting and installation of the robot Installation and commis sioning Step by step procedures that describe how to perform mainten ance of the robot Based on a maintenance sc...

Page 10: ...it diagram IRB 6700 3HAC044270 001 Product manual DressPack SpotPack IRB 6700 3HAC047136 001 Product manual IRC5 IRC5 with main computer DSQC1000 3HAC021313 001 Product manual IRC5 IRC5 with main computer DSQC 639 3HAC16590 1 Operating manual IRC5 with FlexPendant 3HAC16578 1 Operating manual Calibration Pendulum 3HAC042927 001 Technical reference manual Lubrication in gearboxes 3HAC17076 1 Techni...

Page 11: ...rew joints lists of tools Spare parts list with exploded views or references to separate spare parts lists Circuit diagrams or references to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products Technical reference manual Lubrication in gearboxes Description of types and volumes of lubrication for the manipulator gearboxes...

Page 12: ... The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and trouble shooters The group of manuals includes among others Operating manual Emergency safety information Operating manual General safety information Operating manual Getting started IRC5 and RobotStudio Operating manual Introduction to RAPID Operating manual IRC...

Page 13: ...n the procedures and completed with a reference to the section where the equipment is listed with further information that is article number and dimensions The designation in the procedure for the component or attachment point corresponds to the designation in the referenced list The table below shows an example of a reference to a list of required equipment from a step in a procedure Note Illustr...

Page 14: ...This page is intentionally left blank ...

Page 15: ...are applicable for all service work and are found in General safety information on page 16 Specific safety information pointed out in the procedures How to avoid and eliminate the danger is either described directly in the procedure or in specific instructions in the section Safety related instructions on page 36 3HAC044266 001 Revision 15 Copyright 2013 ABB All rights reserved 1 Safety 1 1 Introd...

Page 16: ...sks during installation or service risks associated with live electrical parts Safety risks lists dangers relevant when working with the product The dangers are split into different categories fire extinguishing safe use of the FlexPendant Safety actions describes actions which may be taken to remedy or avoid dangers stopping functions description of emergency stop description of safety stop descr...

Page 17: ...th FlexPendant Product manual Connection of external safety devices Apart from the built in safety functions the manipulator is also supplied with an interface for the connection of external safety devices An external safety function can interact with other machines and peripheral equipment via this interface This means that control signals can act on safety signals received from the peripheral eq...

Page 18: ...d in any safety matters associated with it Spare parts and special equipment ABB does not supply spare parts and special equipment which have not been tested and approved by ABB The installation and or use of such products could negatively affect the structural properties of the manipulator and as a result of that affect the active or passive safety operation ABB is not liable for damages caused b...

Page 19: ... interlocked in accordance with the applicable standards for that function The supplier of the complete system must ensure that all circuits used in the emergency stop function are interlocked in a safe manner in accordance with the applicable standards for the emergency stop function Complete manipulator Description Safety risk CAUTION Motors and gears are HOT after running the manipulator Touchi...

Page 20: ...ars may be damaged if excessive force is used Gears may be damaged if excessive force is used Balancing device Description Safety risk WARNING Do not under any circumstances deal with the balancing device in any other way than that detailed in the product documentation For example attempting to open the balan cing device is potentially lethal Dangerous balancing device 20 3HAC044266 001 Revision C...

Page 21: ...faces on the manipulator get hot and may result in burns Elimination The instructions below detail how to avoid the dangers specified above Info Action Always use your hand at some distance to feel if heat is radiating from the potentially hot component before actually touching it 1 Wait until the potentially hot component has cooled if it is to be removed or handled in any other way 2 3HAC044266 ...

Page 22: ...n work pieces in the event of a power failure or a disturbance to the controller Unauthorized modifications of the originally delivered manipulator are prohibited Without the consent of ABB it is forbidden to attach additional parts through welding riveting or drilling of new holes into the castings The strength could be affected CAUTION Ensure that a gripper is prevented from dropping a work piec...

Page 23: ... be taken The pressure must be released in the complete pneumatic or hydraulic systems before starting to repair them Work on hydraulic equipment may only be performed by persons with special knowledge and experience of hydraulics All pipes hoses and connections have to be checked regularly for leaks and damage Damage must be repaired immediately Splashed oil may cause injury or fire Safe design G...

Page 24: ...nnel Corrective maintenance must only be carried out by qualified personnel who are familiar with the entire installation as well as the special risks associated with its different parts Extraordinary risks If the working process is interrupted extra care must be taken due to risks other than those associated with regular operation Such an interruption may have to be rectified manually 24 3HAC0442...

Page 25: ...lid regulations are followed All work must be performed by qualified personnel on machine manipulator system in deadlock in an isolated state disconnected from power supply and protected against reconnection Voltage related risks IRC5 controller A danger of high voltage is associated with for example the following parts Be aware of stored electrical energy DC link Ultracapacitor bank unit in the c...

Page 26: ...ee chapter Installation and commissioning on page 51 Voltage related risks tools material handling devices etc Tools material handling devices etc may be live even if the robot system is in the OFF position Power supply cables which are in motion during the working process may be damaged 26 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 1 Safety 1 2 3 6 Risks associated with live e...

Page 27: ...is dropped or released at maximum speed Determine the maximum speed from the maximum velocities of the manipulator axes and from the position at which the manipulator is working in the work cell see the section Robot motion in the Product specification Also consider the maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the manipulator 3HAC044266...

Page 28: ...hing Note Use a CARBON DIOXIDE CO2 extinguisher in the event of a fire in the manipulator system manipulator or controller 28 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 1 Safety 1 2 4 2 Fire extinguishing ...

Page 29: ...easing the brakes on page 82 The manipulator arm may be moved manually on smaller manipulator models but larger models may require using an overhead crane or similar equipment Increased injury Before releasing the brakes make sure that the weight of the arms does not increase the pressure on the trapped person further increasing any injury 3HAC044266 001 Revision 29 Copyright 2013 ABB All rights r...

Page 30: ...low 1 Run each manipulator axis to a position where the combined weight of the manipulator arm and any load is maximized max static load 2 Switch the motor to the MOTORS OFF position with the operating mode selector on the controller 3 Check 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 30 3HAC044...

Page 31: ... Transm gear ratio or other kinematic system parameters from the FlexPendant or a PC This will affect the safety function Reduced speed 250 mm s 3HAC044266 001 Revision 31 Copyright 2013 ABB All rights reserved 1 Safety 1 2 4 5 Risk of disabling function Reduced speed 250 mm s ...

Page 32: ...s to the MOTORS OFF state To ensure safe use of the FlexPendant the following must be implemented The enabling device must never be rendered inoperational in any way During programming and testing the enabling device must be released as soon as there is no need for the manipulator to move Anyone entering the manipulator working space must always bring the FlexPendant with him her This is to preven...

Page 33: ...available in USA or Canada Pay attention to the rotating axes of the manipulator Keep away from axes to not get entangled with hair or clothing Also be aware of any danger that may be caused by rotating tools or other devices mounted on the manipulator or inside the cell Test the motor brake on each axis according to the section Brake testing on page 30 To prevent anyone else from taking control o...

Page 34: ...tions with power available to the motors so that the manipulator path can be maintained When completed power is disconnected from the motors The default setting is an uncontrolled stop However controlled stops are preferred since they minimize extra unnecessary wear on the manipulator and the actions needed to return the manipulator system back to production Please consult your plant or cell docum...

Page 35: ...l emergency stop devices that can be operated in order to achieve an emergency stop There are emergency stop buttons available on the FlexPendant and on the controller cabinet on the Control Module on a Dual Cabinet Controller There can also be other types of emergency stops on your manipulator Consult your plant or cell documentation to see how your manipulator system is configured 3HAC044266 001...

Page 36: ...accident may occur if the instructions are not followed that can lead to serious injury pos sibly fatal and or great damage to the product It applies to warnings that apply to danger with for example contact with high voltage electrical units explosion or fire risk risk of poisonous gases risk of crushing impact fall from height etc WARNING xx0100000002 Warns for electrical hazards which could res...

Page 37: ...and conditions NOTE xx0100000004 Describes where to find additional information or how to do an operation in an easier way TIP xx0100000098 3HAC044266 001 Revision 37 Copyright 2013 ABB All rights reserved 1 Safety 1 3 1 Safety signals in the manual Continued ...

Page 38: ...in information in text English German and French 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 voltage electrical units explosion or fire risk risk of...

Page 39: ...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 manipulator arm can fall down Tip risk when loosening bolts xx0900000810 The manipulator can tip over if the bolts are not securely fastened Continues on next page 3HAC044266 001 Revis...

Page 40: ...t that can cause burns Moving robot xx0900000819 The robot can move unexpectedly xx1000001141 Brake release buttons xx0900000820 xx1000001140 Continues on next page 40 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 1 Safety 1 3 2 Safety symbols on manipulator labels Continued ...

Page 41: ...prohibition if oil is not allowed Mechanical stop xx0900000824 No mechanical stop xx1000001144 Stored energy xx0900000825 Warns that this part contains stored energy Used in combination with Do not dismantle symbol Continues on next page 3HAC044266 001 Revision 41 Copyright 2013 ABB All rights reserved 1 Safety 1 3 2 Safety symbols on manipulator labels Continued ...

Page 42: ...ressurized Usually contains additional text with the pressure level Shut off with handle xx0900000827 Use the power switch on the controller 42 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 1 Safety 1 3 2 Safety symbols on manipulator labels Continued ...

Page 43: ... make sure all emergency stop equipment is correctly installed and connected 1 How to use the hold to run function is de scribed in section How to use the hold to run function in the Operating manual IRC5 with FlexPendant Usually the hold to run function is active only in manual full speed mode To in crease safety it is also possible to activate hold to run for manual reduced speed with a system p...

Page 44: ...ts from the robot and its working area 1 Check that the fixture and workpiece are well secured if applicable 2 Install all safety equipment properly 3 Make sure all personnel are standing at a safe distance from the robot that is out of its reach behind safety fences and so on 4 Pay special attention to the function of the part previously serviced 5 Collision risks CAUTION When programming the mov...

Page 45: ...nal injuries and damage to the manipulator 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 Check the push buttons of the brake release unit by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a butto...

Page 46: ...ow Elimination Single Cabinet Controller Note illustration Action xx0600002782 Switch off the main switch on the controller cabinet 1 A Main switch Elimination Dual Cabinet Controller Note illustration Action xx0600002783 Switch off the main switch on the Drive Module 1 K Main switch Drive Module A Main switch Control Module Switch off the main switch on the Control Module 2 46 3HAC044266 001 Revi...

Page 47: ... tested frequently to ensure that they are not damaged and are operating cor rectly Use a wrist strap 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 grounded Use a dissipative table mat 3 Location of wrist strap button The location of the wrist strap button is shown in th...

Page 48: ... vent explosion fire may follow depending upon the circumstances Note Appropriate disposal regulations must be observed Elimination Note Action Operating temperatures are listed in Pre install ation procedure on page 52 Do not short circuit recharge puncture incinerate crush immerse force discharge or expose to temperatures above the declared operating temperature range of the product Risk of fire...

Page 49: ...iption 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 hot lubricant heated up to 90 C xx0100000002 Hot oil or grease Make sure that protective gear like goggles and gloves are al ways worn When working with gearbox lub ricant there is a risk of an allergic reaction xx0100000002 A...

Page 50: ...urer Mixing types of oil may cause severe damage to the gearbox xx0100000002 Do not mix types of oil When changing gearbox oil first run the robot for a time to heat up the oil Warm oil drains quicker than cold oil xx0100000098 Heat up the oil After refilling check the lubricant level The specified amount of oil or grease is based on the total volume of the gearbox When changing the lubricant the ...

Page 51: ...hat 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 chapter Safety on page 15 before performing any installation work Note If the robot is connected to power always make sure that the robot is connected to protective earth before s...

Page 52: ...ted operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 54 4 Before taking the robot to its installation site make sure that the site conforms to Loads on foundation robot on page 53 Protection classes robot on page 54 Requirements foundation on page 54 5 Before moving the robot please observe the stability of the robot Risk of tippi...

Page 53: ...rces 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 Floor mounted Max load emergency stop Endurance load in operation Force 19 8 kN 7 4 kN Force xy 14 6 15 7 kN 14 6 4 5 kN Force z 37 1 kNm 21 0 kNm Torque xy 11 4 kNm 5 0 kNm...

Page 54: ...tions for the robot Value Parameter 25 C 13 F Minimum ambient temperature 55 C 131 F Maximum ambient temperature 70 C 158 F Maximum ambient temperature less than 24 hrs Maximum 95 at constant temper ature Maximum ambient humidity Operating conditions robot The table shows the allowed operating conditions for the robot Value Parameter 5 Ci 41 F Minimum ambient temperature 50 C 122 F Maximum ambient...

Page 55: ...Working range 120 to 120 for robots with LeanID option 780 4 ii Working range 220 to 220 for robots with LeanID option 780 4 Working range axis 5 and axis 6 for LeanID option 780 4 Allowed working area for axis 6 related to axis 5 position is shown in the figure below 270 240 210 180 150 120 90 60 30 0 30 60 90 120 150 180 210 240 270 120 110 100 90 80 70 60 50 40 30 20 10 0 10 20 30 40 50 60 70 8...

Page 56: ...h m Handling capacity kg Robot type 2 65 235 IRB 6700 Illustration working range IRB 6700 205 2 80 This illustration shows the unrestricted working range of the robot 308 3259 1281 2039 958 2794 xx1300000282 Continues on next page 56 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 57: ...ng range IRB 6700 175 3 05 1527 2314 1109 3056 726 3520 xx1300000283 Reach m Handling capacity kg Robot type 3 05 175 IRB 6700 Continues on next page 3HAC044266 001 Revision 57 Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 58: ...04 2445 1067 3200 713 3665 xx1300000284 Reach m Handling capacity kg Robot type 3 20 150 IRB 6700 Continues on next page 58 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 59: ...t 2650 mm 920 mm IRB 6700 235 2 65 2794 mm 958 mm IRB 6700 205 2 80 3056 mm 1109 mm IRB 6700 175 3 05 3200 mm 1067 mm IRB 6700 150 3 20 3HAC044266 001 Revision 59 Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 60: ... most stable position Do not change the robot position before securing it to the foundation Shipping and transport position This figure shows the robot in its shipping position which also is a recommended transport position 45 2 0 6 5 70 890 50 570 55 xx1300000356 WARNING The robot is likely to be mechanically unstable if not secured to the foundation 60 3HAC044266 001 Revision Copyright 2013 ABB ...

Page 61: ...front side B Radius 634 mm axis 1 back side C Dimensions for different robot variants G F E D Robot variant 1182 5 1670 1135 2300 IRB 6700 235 2 65 1182 5 1670 1280 2445 IRB 6700 205 2 80 1592 5 2080 1135 2300 IRB 6700 175 3 05 1592 5 2080 1280 2445 IRB 6700 150 3 20 3HAC044266 001 Revision 61 Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 2 4 Main dimensions ...

Page 62: ...le use method 2 Transportation in any other way than method 1 or 2 can seriously damage the robot If the robot is incorrectly transported and the instructions are not followed the robot is not covered by the warranty and ABB will not accept any compensation claim Method 1 Transportation according to method 1 is strongly recommended by ABB xx0800000030 Continues on next page 62 3HAC044266 001 Revis...

Page 63: ...hod 1 is not possible Always follow these instructions when transporting an ABB robot according to method 2 Always read and follow the instructions in section Securing the robot on page 67 Always place the robot in the ABB recommended transport position for robot with tool described in sub section Transport position with a transport support on page 65 Always use the recommended transport support d...

Page 64: ...Hexagon socket head cap screw M16x140 B Threaded bar M10x200 C Nut M10 D Continues on next page 64 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 3 1 Robot transportation precautions Continued ...

Page 65: ...ortation of the robot with tool must follow these instructions IRB 6700 xx0800000040 Continues on next page 3HAC044266 001 Revision 65 Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 3 1 Robot transportation precautions Continued ...

Page 66: ...R 9 0 R 1 1 0 200 30 65 130 10 R 3 M10 52 62 B 50 50 40 18 60 12 R 2 0 30 A 5 IRB6700 2 65 2 8 3 05 3 2 Lower arm L 1135 1280 1135 1280 A 1000 1160 630 860 B 21 21 21 21 xx1300001603 66 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 3 1 Robot transportation precautions Continued ...

Page 67: ...ng the brakes is a hazardous action that may cause injury and damage property It must be done with great care and only when absolutely necessary Securing the robot xx0800000062 Continues on next page 3HAC044266 001 Revision 67 Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 3 2 Securing the robot ...

Page 68: ...he section Transport position with a transport support on page 65 Use the brake release for axis 3 to reach the final resting position on the transport support see the section Manually releasing the brakes on page 82 3 CAUTION Do not attempt to tighten any attachment screws without first releasing the brakes This can seriously damage the robot Tighten all the attachment screws A and B in the figur...

Page 69: ...device set The fork lift device set is fitted to the robot as shown in the figure A B xx1300001602 Fork lift device 4 pcs A Hex socket head cap screw M20x60 quality steel 8 8 A3F 2 pcs per fork lift device B Required equipment Note Art no Equipment 3HAC047054 002 Fork lift device set Continues on next page 3HAC044266 001 Revision 69 Copyright 2013 ABB All rights reserved 2 Installation and commiss...

Page 70: ...electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 2 Tightening torque 280 Nm Fit the four fork lift pockets on the base of the robot with its attach ment screws 3 Make sure the original screws are always used or replacements of equivalent quality M20x60 quality 8 8 A B xx1300001602 A Fork lift pocket B ...

Page 71: ...ng with fewer than four fork lift pockets fitted there is a risk of accidents happen 6 Carefully lift the robot and move it to its installation site Note Move the robot with low speed 7 WARNING Personnel must not under any cir cumstances be present under the suspended load 8 3HAC044266 001 Revision 71 Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 4 1 Lifting robot with ...

Page 72: ...es x3 A Lifting base plate Note Action CAUTION The base plate weighs 353 kg All lifting accessories used must be sized accordingly 1 Shown in figure Hole configur ation on page 72 Fit lifting eyes in specified holes 2 Fit lifting slings to the eyes and to the lifting accessory 3 72 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 4 2 Lifting the bas...

Page 73: ... 4 8 1 3 2 1 6 3x45º 0 2 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 3HAC044266 001 Revision 73 Copyright 2013 ABB All rights reserved 2 Installation and commission...

Page 74: ...5 565 748 800 882 923 4x Ø16 5x Ø22 16x 861 2x 358 2x 18 0 905 813 475 137 45 0 0 37 2x 87 2x 293 2x 450 2x 630 2x 813 2x 947 2x 991 2x A xx1000001054 Four holes for alternative clamping 4x Ø18 Color RAL 9005 Thickness 80 100 µm A Continues on next page 74 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 4 3 Securing the base plate Continued ...

Page 75: ...ation below shows the orienting grooves and guide sleeve holes in the base plate xx0300000045 Guide sleeve holes 2 pcs A Orienting grooves 3 pcs B Continues on next page 3HAC044266 001 Revision 75 Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 4 3 Securing the base plate Continued ...

Page 76: ...Steel fibre reinforced concrete foundation 30 kg m3 class C30 i Recommended foundation quality 1 Sturdy concrete foundation double reinforced by ø10 mm steel bars distance 140 mm class C25 i Recommended foundation quality 2 i See recommended depth of drill hole minimum base material thickness etc in standards from the bolt supplier When choosing bolts from Hilti see standard AFTM2011 Base plate Th...

Page 77: ...e 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 2 mm Recheck the four contact surfaces on the base plate to make sure the base plate is level and flat 9 If it is...

Page 78: ... strain B Length Roundsling 1 pc Do not strain C 2 m IRB 6700 235 2 65 2 m IRB 6700 205 2 80 2 5 m IRB 6700 175 3 05 2 5 m IRB 6700 150 3 20 Lifting eye M20 4 pcs D Continues on next page 78 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 4 4 Lifting the robot with roundslings ...

Page 79: ...e robot with roundslings Use this procedure to lift the robot with roundslings Note Action 45 2 0 6 5 70 890 50 570 55 xx1300000356 Jog the robot into position Axis 1 calibration position 0 Axis 2 45 Axis 3 65 Axis 4 no significance Axis 5 70 Axis 6 no significance WARNING The robot is likely to be mechanically un stable if not secured to the foundation 1 Continues on next page 3HAC044266 001 Revi...

Page 80: ...t might damage the roundslings lifting shackles must be used to attach the roundslings to the lifting eyes 3 Roundsling 2 5 m 4 pcs xx1300001572 Roundsling 2 m xx1300001573 Attach a securing roundsling at the rear according to figure Note The securing sling must not be strained at lifting It only secures for tipping 4 Continues on next page 80 3HAC044266 001 Revision Copyright 2013 ABB All rights ...

Page 81: ... All lifting accessories used must be sized accordingly 6 WARNING Personnel must not under any circum stances be present under the suspended load 7 Raise the overhead crane to lift the robot CAUTION Make sure that the roundsling running from the front left corner is positioned on the correct side of the brake release unit plate when stretching the roundslings with the crane 8 3HAC044266 001 Revisi...

Page 82: ...ake release unit on page 82 The internal brake release unit is equipped with buttons for controlling the axes brakes The but tons 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 con nector R1 MP on page 83 1 DANGER When releasing the holding brakes the robot a...

Page 83: ...connected to the 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 3HAC044266 001 Revision 83 Copyright 2013 ABB All rights reserved 2 Installation and...

Page 84: ... 4 9 5 0 3 A 0 12 A 800 4x 90 5 2 5 4 x 1 5 7 5 D D E E 4x 25 H8 2 0 2 5 H 8 4 x 2 x 4 5 4 x 2 4 5 0 12 E E xx1300000243 Attachment screws The table below specifies the type of securing screws and washers to be used for securing the robot to the base plate foundation M24 x 100 Suitable screws lightly lubricated 4 pcs Quantity 8 8 Quality Continues on next page 84 3HAC044266 001 Revision Copyright ...

Page 85: ... Fit two guide sleeves to the guide sleeve holes in the base plate 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 84 Note Lightly lubricate screws before as sembly Fit the bolts and washers in the base attachment holes 5 Tighten bolts in a criss c...

Page 86: ...mage to the robot References Load diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must also be defined in the software as detailed in Operating manual IRC5 with FlexPendant Stop time and braking distances Robot motor brake performance depends on any loads attached For information about brake performance read the product specificatio...

Page 87: ...er of gravity of arm load and robot payload 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 including bracket and harness 250 kg R xx130000026...

Page 88: ...stance 500 mm from the center of gravity in the axis 3 extension A M1 M1 a xx1000000417 Mass center A 200 400 A xx1300000866 Center of gravity 50 kg A Continues on next page 88 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 4 8 Fitting equipment to the robot Continued ...

Page 89: ... 52 5 117 R 1 3 4 x M 8 M12 20 52 5 A A 400 150 150 109 B 270 A C C B A A B 104 2x M12 19 210 M12 19 C L Axis 4 B B B B xx1300000263 Allowed position for attachment holes M12 through Be careful not to touch the cables when drilling A Smallest circumscribed radius axis 4 R 216 mm B Continues on next page 3HAC044266 001 Revision 89 Copyright 2013 ABB All rights reserved 2 Installation and commission...

Page 90: ...x1300000264 R 456 A IRB 6700 235 2 65 IRB 6700 175 3 05 433 mm IRB 6700 205 2 80 IRB 6700 150 3 20 438 mm B IRB 6700 235 2 65 IRB 6700 175 3 05 418 mm IRB 6700 205 2 80 IRB 6700 150 3 20 438 mm C IRB 6700 235 2 65 IRB 6700 175 3 05 403 mm IRB 6700 205 2 80 IRB 6700 150 3 20 438 mm D Continues on next page 90 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 2 Installation and commissi...

Page 91: ... 2 x 3 0 C B 0 05 B B 0 3 C 10 11x M12 22 h8 100 200 H7 H7 15 18 12 1x45 B B B B xx1300000280 Continues on next page 3HAC044266 001 Revision 91 Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 4 8 Fitting equipment to the robot Continued ...

Page 92: ...on 780 4 LeanID C C 200 h8 12 H7 15 100 H7 11x M12 18 8 15 0 05 D 0 3 D E D E 160 1 2 x 3 0 C C xx1300000290 92 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 4 8 Fitting equipment to the robot Continued ...

Page 93: ... following axes 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 3HAC044266 001 Revision 93 Copyright 2013 ABB...

Page 94: ...tion 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 Movable mechanical stop B Mechanical stop pin axis 1 C Required equipment Note Art no Equipment etc Includes attachment screws and an assembly drawing 3HAC044287 001 Movable mechanical stop set axis 1 15 C...

Page 95: ...15 Nm Fit the additional mechanical stop to the frame according to the figure Mechanical stops axis 1 on page 94 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 If the m...

Page 96: ...ndle databus 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 control cabinet to the ro...

Page 97: ...alling the signal lamp option Signal lamp See the assembly instruction delivered with the signal lamp 3HAC044266 001 Revision 97 Copyright 2013 ABB All rights reserved 2 Installation and commissioning 2 7 1 Installing the signal lamp option ...

Page 98: ...This page is intentionally left blank ...

Page 99: ...d in different sections and divided up 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 15 before performing any serv...

Page 100: ...ce activity to be carried out and the working conditions of the IRB 6700 Calendar time specified 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 100 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 3 Maintenance 3 2 1 Specification of maintenance intervals ...

Page 101: ...ies Inspecting the oil level in axis 1 gearbox on page 105 x Inspecting the oil level in axis 1 gearbox Inspecting the oil level in axis 2 gearbox on page 108 x Inspecting the oil level in axis 2 gearbox Inspecting the oil level in axis 3 gearbox on page 109 x Inspecting the oil level in axis 3 gearbox Inspecting the oil level in axis 4 gearbox on page 111 x Inspecting the oil level in axis 4 gear...

Page 102: ...ox Changing oil axis 6 gearbox on page 161 x Changing the oil in axis 6 gearbox Replacing the SMB battery on page 165 x iii Replacing the SMB battery pack Lubrication activities Lubricating the spherical roller bearing balancing device on page 168 x iv Lubricating the balancing device bearings Overhaul x Overhaul of complete robot i Operating hours counted by the DTC Duty time counter ii Replace w...

Page 103: ...ge in regard to movement most material handling applications ii Severe chemical or thermal environments or similar environments can result in shortened life expectancy iii Examples of extreme usage in regard to movement press tending very severe palletizing applications major use of axis 1 movement iv The given life for the balancing device is based on a test cycle of 4 000 000 cycles that starts ...

Page 104: ... in section Standard toolkit on page 559 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 104 3HAC044266 001 Revision Copyright 2013 ...

Page 105: ...involves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 49 2 xx1200000950 Open the oil plug 3 xx1300000692 Check the oil level Required oil level is 58 mm 5 mm below the sealing surface of the oil plug 4 Continues on next page 3HAC044266 001 Revision 105 Copyright 2013 ABB All r...

Page 106: ...n Changing oil axis 1 gearbox on page 138 Tightening torque 24 Nm Refit the oil plug 6 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 7 106 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 3 Maintenance 3 3 1 Inspecting the oil level in axis 1 gea...

Page 107: ...toolkit on page 559 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 3HAC044266 001 Revision 107 Copyright 2013 ABB All rights reserv...

Page 108: ...ug 3 Check the oil level 4 Required oil level is 0 10 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 5 Further information about how to drain or fill with oil is found in section Chan ging oil axis 2 gearbox on page 143 Tightening torque 24 Nm Refit the oil plug 6 DANGER Make sure all safety r...

Page 109: ... 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 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 ...

Page 110: ...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 6 Further information about how to drain or fill with oil is found in section Changing oil axis 3 gearbox on page 148 Tightening torque 24 Nm Refit the oil plug 7 DANGER Make sure all safety requirements are met when performing the first test ru...

Page 111: ... 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 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 ...

Page 112: ...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 6 Further information about how to drain or fill with oil is found in section Changing oil axis 4 gearbox on page 153 Tightening torque 24 Nm Refit the oil plug 7 DANGER Make sure all safety requirements are met when performing the first test ru...

Page 113: ...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 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 air pressure ...

Page 114: ...in Technical reference manual Lubrication in gearboxes Add or drain oil if required 6 Further information about how to drain or fill with oil is found in section Changing oil axis 5 gearbox on page 157 Tightening torque 24 Nm Refit the oil plug 7 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may c...

Page 115: ...ference 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 6 gearbox Use this procedure to inspect the oil level in the gearbox The procedure includes two alternative positions for axis 5 where one of the positions makes it possible to use the filling p...

Page 116: ...00000693 Method 1 Check the oil level Required oil level is 50 mm 5 mm below the sealing surface of the oil plug 5 Method 2 6 Rotate axis 5 77º Required oil level is 0 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...

Page 117: ...ements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 9 3HAC044266 001 Revision 117 Copyright 2013 ABB All rights reserved 3 Maintenance 3 3 6 Inspecting the oil level in axis 6 gearbox Continued ...

Page 118: ...e The balancing 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 rear bearing C Required tools Visual inspection no tools are required Continues on next page 118 3HAC044266 001 Revision Copyright...

Page 119: ...page354 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 insufficient lubrica tion 3 Check for damage Check for damages such as scratches general wear uneven surfaces or incorrect p...

Page 120: ...sure supply to the robot Before entering the robot working area 3 Check the o rings at the front ear for leakage 4 The o rings are included in the Main tenance kit bearings and seals already assembled with sealing spacers and sealing rings Art no for the kit is specified in Required material on page 119 Replace o rings if leaks are detected 5 Replacement of the complete bearing is also described i...

Page 121: ...fore entering the robot working area 1 xx1300000423 Check that there are no obstacles inside the frame that could prevent the balancing device from moving freely Keep the areas around the balancing device clean and free from objects such as service tools 2 3HAC044266 001 Revision 121 Copyright 2013 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting the balancing device Continued ...

Page 122: ...ss The cable harness is located as shown in the figure xx1300001096 Required tools Visual inspection no tools are needed Continues on next page 122 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the cable harness ...

Page 123: ...kets velcro straps and attachments are properly se cured by following the cable harness from the base to the wrist 3 Check the motor 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 cable...

Page 124: ...ation labels to be inspected The symbols are described in section Safety symbols on manipulator labels on page38 Illustration 1 of 2 H J N N E F F F E E E E B K M Continues on next page 124 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 3 Maintenance 3 3 9 Inspection information labels ...

Page 125: ...B 45 20 70 890 50 570 55 6 5 4x IRB 6700 m 1160 1600 kg 2557 3527 lbs 3HAC 046732 001 00 4x 2000kg 2 5 m 1x 2000 kg 2 m 2 5 m 1x 2000 kg 2 m 45 20 70 890 50 570 55 6 5 xx1300001084 Instruction label Lifting of robot C Continues on next page 3HAC044266 001 Revision 125 Copyright 2013 ABB All rights reserved 3 Maintenance 3 3 9 Inspection information labels Continued ...

Page 126: ...dismantle Stored energy H 3HAC 4431 1 06 xx1300001087 Warning label Heat J 3HAC 9191 1 02 xx1300001088 Warning label Tip risk when loosening bolts K 5 1 2 3 4 6 0 1 3HAC 17804 1 02 xx1300001089 Warning label Moving robot Shut off with handle Before dismantling see product manual L Continues on next page 126 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 3 Maintenance 3 3 9 Inspecti...

Page 127: ...nt Visual inspection no tools are required Inspecting labels Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Check the labels located as shown in the figures 2 Article numbers for the labels and plate set is specified in Spare parts on page 565 Replace any missing or damaged labels 3 3HAC04426...

Page 128: ...witch is used Location of mechanical stop pin The mechanical stop axis 1 is located at the base as shown in the figure xx1200001073 Required equipment Visual inspection no tools are required Continues on next page 128 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting mechanical stop pin axis 1 ...

Page 129: ...robot working area 1 Shown in figure Location of mechan ical stop pin on page 128 Inspect the mechanical stop pin axis 1 If the mechanical stop pin is bent or damaged it must be replaced Note The expected life of gearboxes can be reduced as a result of collisions with the mechanical stop 2 3HAC044266 001 Revision 129 Copyright 2013 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting mechanical...

Page 130: ...red equipment Note Art no Equipment etc Limits the robot working range by 15 3HAC044287 001 Movable mechanical stop axis 1 Includes attachment screws and an as sembly drawing Mechanical stop Attachment screws M12x70 quality 12 9 Gleitmo 603 and washers Document for mechanical stop Content is defined in section Standard toolkit on page 559 Standard toolkit Continues on next page 130 3HAC044266 001 ...

Page 131: ...ge 130 Check the additional stops for damage 2 Make sure stops are properly attached 3 Correct tightening torque mechanical stops Axis 1 115 Nm Art no is specified in Required equipment on page 130 If any damage is detected the mechanical stops must be replaced Correct attachment screws M12x70 quality 12 9 Gleitmo 603 2 pcs per additional mechanical stop 4 3HAC044266 001 Revision 131 Copyright 201...

Page 132: ...s A Hex socket head cap screw M20x60 quality steel 8 8 A3F 2 pcs per fork lift device B Required equipment Note Art no Equipment 3HAC047054 002 Fork lift device set Content is defined in section Standard toolkit on page 559 Standard toolkit Continues on next page 132 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 3 Maintenance 3 3 12 Inspecting the fork lift device set ...

Page 133: ...eformation and other type of damage 3 Make sure fork lift device set is properly attached 4 Correct tightening torque fork lift devices 280 Nm Art no is specified in Required equipment on page 130 If any damage is detected the fork lift device and attachment screws must be replaced Correct attachment screws M12x70 quality 12 9 Gleitmo 603 2 pcs per additional mechanical stop 5 3HAC044266 001 Revis...

Page 134: ...quired A damper must be replaced if damaged Inspecting dampers The procedure below details how to inspect the dampers Note Action DANGER Turn off all electric power supply to the robot hydraulic pressure supply to the robot air pressure supply to the robot Before entering the robot working area 1 Continues on next page 134 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 3 Maintenanc...

Page 135: ...m 2 Check attachment screws for deformation 3 Spare part number is found in Product manual spare parts IRB 6700 If any damage is detected the damper must be replaced with a new one 4 Attachment screws M6x60 Locking liquid Loctite 243 3HAC044266 001 Revision 135 Copyright 2013 ABB All rights reserved 3 Maintenance 3 3 13 Inspecting the dampers Continued ...

Page 136: ...below Inspecting signal lamp Use this procedure to inspect the function of the signal lamp Note Action Check that signal lamp is lit when motors are put in operation MOTORS ON 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Art no is specified in Required equipment on page 136 If the lamp is not lit tra...

Page 137: ...y inspection maintenance or changing activities of lubrication always check ABB Library for the latest revision of this manual The revision of the manual published on the Documentation DVD released twice a year will only contain the latest updates when the Documentation DVD is released Any updates of the manual in between these releases will be published on ABB Library Therefore the manual publish...

Page 138: ...formation about the oil is found in Technical refer ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page137 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 can be found in section Type of lubrication in ge...

Page 139: ...olves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 49 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 xx1200000948 Remove the protective cap from the nipple of the oil hole and...

Page 140: ... section Decommissioning on page545 for more in formation 7 Remove the oil dispenser and refit the protective cap to the nipple 8 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 air pressure supply to the robot before entering the ...

Page 141: ... dis penser 3 xx1200000950 Remove the plug from the vent hole Note 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 3HAC04426...

Page 142: ... cap to the nipple 7 Tightening torque 24 Nm Refit the vent hole plug 8 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 9 142 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 3 Maintenance 3 4 2 Changing oil axis 1 gearbox Continued ...

Page 143: ... oil is found in Technical refer ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page137 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 can be found in section Type of lubrication in gearboxes on page 137...

Page 144: ...olves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 49 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 3 xx1200000951 Remove the protective cap from the nipple of the oil hole and...

Page 145: ... section Decommissioning on page545 for more in formation 7 Remove the oil dispenser and refit the protective cap to the nipple 8 Tightening torque 24 Nm Refit the vent hole plug 9 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 air pressure supply to the robot before entering the ...

Page 146: ...nect the oil dis penser 3 xx1200000952 Remove the plug from the vent hole Note 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 Note The amount of oil to be filled depends on the amount previously being drained 5 Continues on next page 146 3HAC044266 001 Re...

Page 147: ... the oil dispenser and refit the protective cap to the nipple 7 Tightening torque 24 Nm Refit the level plug 8 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 9 3HAC044266 001 Revision 147 Copyright 2013 ABB All rights reserved 3 Maintenance 3 4 3 Changing oil a...

Page 148: ...earboxes Lubricating oil See Type and amount of oil in gearboxes on page137 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 can be found in section Type of lubrication in gearboxes on page 137 Oil dispenser Content is defined in section Standard toolkit...

Page 149: ...ing please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 49 3 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 4 xx1200000954 Remove the protective cap from the nipple of the oil hole and connect the oil dis penser 5 Continues o...

Page 150: ...e 9 Tightening torque 24 Nm Refit the vent hole plug 10 Filling oil into the axis 3 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 air pressure supply to the robot before entering the robot working area 2 WARNING Handling gearbox oil involves several safety risks Befor...

Page 151: ... oil Note The amount of oil to be filled depends on the amount previously being drained 6 xx1200000955 Inspect the oil level at the vent hole level plug 7 Required oil level is 0 10 mm below the oil plug hole More information is found in Inspecting the oil level in axis 3 gearbox on page 109 Remove the oil dispenser and refit the protective cap to the nipple 8 Tightening torque 24 Nm Refit the lev...

Page 152: ...hen performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 10 152 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 3 Maintenance 3 4 4 Changing oil axis 3 gearbox Continued ...

Page 153: ...ment etc The capacity 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 137 Oil dispenser Content is defined in section Standard toolkit on page 559 Standard toolkit Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lub...

Page 154: ...can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 4 Place the oil collecting vessel underneath the oil drain plug 5 Remove the oil plug from the fill hole Note The fill hole is opened to speed up the drainage 6 xx1200000956 Remove the oil plug from the drain hole and let the oil run into the vessel 7 WARNING Used oil is hazardous material and must be disposed of...

Page 155: ...volves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 49 3 xx1200000957 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 prev...

Page 156: ...4 gear box on page 111 Tightening torque 24 Nm Refit the oil plug 7 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 8 156 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 3 Maintenance 3 4 5 Changing oil axis 4 gearbox Continued ...

Page 157: ...ment etc The capacity 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 137 Oil dispenser Content is defined in section Standard toolkit on page 559 Standard toolkit Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lub...

Page 158: ...the oil plug carefully in order to let out the ex cess pressure 4 Remove the oil plug from the fill hole Note The fill hole is opened to speed up the drainage 5 Place the oil collecting vessel underneath the oil drain plug 6 xx1200000958 Remove the oil plug from the drain hole and let the oil run into the vessel 7 WARNING Used oil is hazardous material and must be disposed of in a safe way See sec...

Page 159: ...l or grease on page 49 3 xx1200000959 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 previously being drained 5 xx1200000959 Inspect the oil level at the oil fill hole level plug 6 Required oil level is 0 10 mm below the oil plug hole More info...

Page 160: ...when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 8 160 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 3 Maintenance 3 4 6 Changing oil axis 5 gearbox Continued ...

Page 161: ...etc The capacity 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 137 Oil dispenser Content is defined in section Standard toolkit on page 559 Standard toolkit Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lubricat...

Page 162: ...49 3 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let out the ex cess pressure 4 Place the oil collecting vessel underneath the oil drain plug 5 xx1200000963 Remove the oil plug from the fill hole Note The fill hole is opened to speed up the drainage 6 xx1200000962 Remove the oil plug from the drain hole and let the oil run int...

Page 163: ...re entering the robot working area 2 WARNING Handling gearbox oil involves several safety risks Before proceeding please read the safety information in the section WARNING Safety risks during work with gearbox lubricants oil or grease on page 49 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 wit...

Page 164: ...pecting the oil level in axis 6 gearbox on page 115 Tightening torque 24 Nm Refit the oil plug 7 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 8 164 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 3 Maintenance 3 4 7 Changing oil axis 6 gearbox ...

Page 165: ...ions for batteries WARNING Safety risks during handling of batteries on page 48 Location of SMB battery The SMB battery SMB serial measurement board is located on the left hand side of the frame as shown in the figure below xx1200001069 Required tools Note Article number Equipment Content is defined in section Standard toolkit on page 559 Standard toolkit Continues on next page 3HAC044266 001 Revi...

Page 166: ...pressure supply to the robot before entering the robot working area 2 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the sec tion WARNING The unit is sensitive to ESD on page 47 3 xx1200001069 Remove the SMB battery cover by unscrewing the attachment screws 4 Pull out the battery and disconnect the battery cable 5 Remove the ...

Page 167: ...age 47 2 xx1200001069 Reconnect the battery cable and install the battery pack into the SMB battery recess 3 Secure the SMB battery cover with its attachment screws 4 Detailed in chapter Calibration section Updating revolution coun ters on page 542 Update the revolution counters 5 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the ...

Page 168: ...ws M6x10 quality 8 8 A2F 2 pcs A End cover B Radial sealing with dustlip 50x68x8 2 pcs C O ring 85x3 D Spherical roller bearing E Washer F Consumables Note Art no Equipment etc Optimol PD0 50 ml 3HAC042534 001 Grease Used for lubrication of the spherical roller bearing Continues on next page 168 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 3 Maintenance 3 5 1 Lubricating the sphe...

Page 169: ...efore entering the robot working area 1 Grease 3HAC042534 001 xx1300000783 Unscrew both screws in link ear and fill the bearing with grease from the upper hole until the grease appears in the lower hole 2 Refit the two screws and wipe clean from residual grease 3 3HAC044266 001 Revision 169 Copyright 2013 ABB All rights reserved 3 Maintenance 3 5 1 Lubricating the spherical roller bearing balancin...

Page 170: ...th water Wipe with cloth Vacuum cleaner No Yes It is highly re commended that water contain a rust prevention solution and that the robot be dried afterwards Yes With light cleaning deter gent Yes Standard Yes i It is highly recom mended that water and steam contains rust pre ventive without cleaning detergents Yes It is highly re commended that water contain a rust prevention solution Yes With li...

Page 171: ...ve a crusty surface for example from dry release agents Dos and don ts The section below specifies some special considerations when cleaning the robot Always Always use cleaning equipment as specified above 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 Never point the water jet at connectors join...

Page 172: ...This page is intentionally left blank ...

Page 173: ...a specific repair activity are listed in the respective procedures The details of equipment are also available in different lists in the chapter Reference information on page 551 Safety information There are general safety information and specific safety information The specific safety information describes the danger and safety risks while performing specific steps in a procedure Make sure to rea...

Page 174: ...l the correct value is shown on the manometer CAUTION The 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 Wa...

Page 175: ...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 until the recommended pre tension is achieved Note The roller elements must be rotated a specified number of turns before pre tensioning is carried out and also rotated during the...

Page 176: ...ings 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 176 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 2 2 Mounting instructions for bearings Continued ...

Page 177: ...eck the seal to ensure that The seal is of the correct type provided with cutting edge There is no damage to the sealing edge feel with a fingernail 1 Inspect the sealing surface before mounting If scratches or damage are found the seal must be replaced since it may result in future leakage 2 Art no is specified in Equipment on page 177 Lubricate the seal with grease just before fitting Not too ea...

Page 178: ...ver the surface preferably with a brush 3 Tighten 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 may not be used Check the o ring for surface defects burrs shape accuracy and so on 2 Defective o rings may not be used Check the o ring grooves 3 The grooves mu...

Page 179: ...em consists of 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 3HAC044266 001 Revision 179 Copyright 2013 ABB All rights reserved 4 Repair 4 3 1 Arm system including the frame ...

Page 180: ... Robot 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 45 Axis 3 50 to 55 approximately Axis 4 5 and 6 calibration position 0 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Attaching the lifting accessories No...

Page 181: ... 3 CAUTION The complete arm system weigh 1100 kg All lifting accessories used must be sized accord ingly 4 Roundsling 1 5 m Length 1 5 m Lifting capacity 1 000 kg xx1200001209 Run a roundsling through the hole in the frame 5 Continues on next page 3HAC044266 001 Revision 181 Copyright 2013 ABB All rights reserved 4 Repair 4 3 1 Arm system including the frame Continued ...

Page 182: ... underneath 7 Fender washer Outer diameter minimum 26 mm hole diameter 13 mm thickness 3 mm xx1200001134 Lifting accessory chain 3HAC15556 1 Attach the upper arm lifting accessory to an overhead crane or similar and then to the lifting eye in the arm house and to a roundsling run through the wrist 8 Roundsling 1 m Length 1 m Lift ing capacity 1 000 kg xx1200001236 182 3HAC044266 001 Revision Copyr...

Page 183: ...inimum 26 mm hole diameter 13 mm thickness 3 mm Fender washer SA 10 8 NA1 Lifting shackle Length 1 5 m Lifting capacity 1 000 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 3HAC044266 001 Revision 183 Copyright 2013 ABB All rights reserved 4 Repair 4 3 2 Lower and upper arm...

Page 184: ... not colliding 1 xx1200001250 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 70 approximately Axis 4 0 Axis 5 0 Axis 6 0 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 Continues on next page 184 3HAC044266 001 Revision Copyright 20...

Page 185: ...ng from gliding when lifting No DressPack cable package installed In sert a M12x50 securing screw not more than 10 15 mm into the screw hole shown in the figure With DressPack cable package installed Use the ball joint housing in the same way 3 CAUTION The lower and upper arms together weigh 335 kg All lifting accessories used must be sized accord ingly 4 Continues on next page 3HAC044266 001 Revi...

Page 186: ...undsling 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 roundsling is stretched in order to carry the weight of the lower arm 8 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 9 Lif...

Page 187: ...sory to an overhead crane or similar then to the lifting eye in the arm house and to a roundsling run through the wrist 13 Roundsling 1 m Length 1 m Lift ing capacity 1 000 kg xx1200001254 Raise the overhead crane to stretch the chains and roundslings 14 Verifiy that the roundsling between the wrist and the lower arm is stretched To release the brake connect the 24 VDC power supply 15 Connect to c...

Page 188: ...Lifting instruction 3HAC15880 2 en closed 3HAC15556 1 Lifting accessory chain Content is defined in section Standard toolkit on page 559 Standard toolkit Robot position Note Action xx1200001255 Jog the robot to the position Axis 1 No significance Axis 2 65 Axis 3 65 Axis 4 Calibration position Axis 5 No significance Axis 6 No significance 1 Continues on next page 188 3HAC044266 001 Revision Copyri...

Page 189: ...iameter 13 mm thickness 3 mm xx1200001134 CAUTION The complete upper arm including the wrist weighs 200 kg All lifting accessories used must be sized accordingly 3 Lifting accessory chain 3HAC15556 1 xx1200001308 Attach the upper arm lifting accessory 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 ...

Page 190: ...ght way through the loops 6 Release the brakes in order to find the most level lifting position of the upper arm as possible before lifting 7 24 VDC power supply In order to release the brakes connect the 24 VDC power supply 8 190 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 3 3 Lifting the upper arm Continued ...

Page 191: ...ed as shown in the figure xx1300000555 Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 559 Standard toolkit Continues on next page 3HAC044266 001 Revision 191 Copyright 2013 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness ...

Page 192: ...ound or in the wrong position keep axis 5 as close as possible to 90 Jog the robot to the specified position Axis 1 0 Axis 2 60 Axis 3 60 Axis 4 0 Axis 5 90 Axis 6 No significance Note Axis 5 must be oriented as close as pos sible to 90 to be able to open the axis 6 motor cover and to remove the axis 6 motor cables 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure ...

Page 193: ...000052 If used disconnect the DressPack hoses in the base 6 If used use caution and pull out the DressPack hoses through the protection tube in the base Note There is no need to pull out the DressPack cables at this point 7 Retrieving access to the wrist cabling Use this procedure to open the wrist and access the axis 5 and axis 6 motor cables Note Action DANGER Make sure that all supplies for ele...

Page 194: ...e axis manually into that position Connect to R2 MP5 connector pin 2 pin 5 2 xx1300000486 Remove the wrist cover 3 xx1300000489 Cut the cable straps that hold the cable harness to the heat protection plate 4 Continues on next page 194 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 195: ... 5 Disconnecting the axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001080 Unscrew the attachment screws and re move the motor cover 2 Continues on next page 3HAC044266 001 Revision 195 Copyright 2013 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 196: ...for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 xx1200001066 Disconnect the motor cables 3 Continues on next page 196 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 197: ... exit hole is facing if the motor also will be removed The motor shall be refitted in the same position 4 Use caution and pull out the motor cables 5 Disconnecting the axis 3 and axis 4 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cove...

Page 198: ... removed The motor shall be refitted in the same position 4 Use caution and pull out the motor cables 5 Removing the cable harness wrist and upper arm Note Action xx1200000045 If used remove the DressPack cover with the tube guiding ring fitted by unscrewing the attachment screws 1 Continues on next page 198 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 4 1 Removing the...

Page 199: ...ng the DressPack a little backwards 4 The figure show IRB 6640 xx1300000668 Tie the axis 5 and axis 6 connectors and carrier into a bundle with tape 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 5 Continues on next page 3HAC044266 001 Revision 1...

Page 200: ... the cable harness inside the arm tube by unscrewing the attachment screws Note The screws are reached from outside the upper arm 7 xx1300000543 Remove the armhouse metal clamp 8 Continues on next page 200 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 201: ...sPack is fitted the cable fixing bracket is replaced by the cable guide xx1300001973 9 xx1300000541 Remove the metal clamp on top of the armhouse 10 Continues on next page 3HAC044266 001 Revision 201 Copyright 2013 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 202: ...ack of the robot 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 Use caution and move the cable harness out of the arm tube 12 Person 2 working at the back xx1300000594 Use caution and remove the cable harness from the upper arm To be able to remove the cable harness if DressPack is fitted t...

Page 203: ...e cable harness Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1300000561 Remove the base cover 2 xx1300000591 Remove connectors in the base R1 MP R1 SMB 3 Continues on next page 3HAC044266 001 Revision 203 Copyright 2013 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 204: ...bles Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page 204 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 205: ...he motor cables 5 Preparations before disconnecting the SMB unit Note Action DANGER Make sure that all supplies for electrical power hy draulic pressure and air 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 WARNING The unit is sensitive to ESD on page 47 2 Continues on next page 3HAC0442...

Page 206: ...ressure and air 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 WARNING The unit is sensitive to ESD on page 47 2 xx1300000670 Use caution and remove the connectors X8 X9 and X10 from the brake release board 3 Continues on next page 206 3HAC044266 001 Revision Copyright 2013 ABB All rights...

Page 207: ...e 3 Place the cable harness over the balancing device 4 Removing the cable harness in the frame Note Action The best way to remove the cable harness from the frame is to follow the order presented in the procedure 1 xx1300000542 Unscrew the attachment screws that hold the metal clamp frame 2 If used remove the metal clamp that hold the DressPack on the frame 3 Cut the cable tie that hold the cable...

Page 208: ... unit 6 xx1300000730 Unscrew the screws and washers that holds the bracket with the SMB unit and remove the SMB unit 7 Put the SMB unit in an ESD bag until it shall be refitted 8 Continues on next page 208 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 209: ...ss 9 xx1300000560 Use caution and pull out the cable harness from the SMB recess 10 xx1300000593 Use caution and pull out the cable harness through the hole in the frame 11 Continues on next page 3HAC044266 001 Revision 209 Copyright 2013 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 210: ...l 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 xx1300000733 Use caution and pull the cable harness out of the lower arm 2 210 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 211: ...e part number Spare part See Product manual spare parts IRB 6700 Cable harness Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 559 Standard toolkit Continues on next page 3HAC044266 001 Revision 211 Copyright 2013 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness ...

Page 212: ...itting the cable harness base frame and lower arm These procedures describes how to refit the cable harness in base frame and lower arm Preparations Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 xx1300000668 Tie the axis 5 and axis 6 connectors and carrier into a bundle with tape This is don...

Page 213: ...000735 Run the cable harness into the hole in the frame in this order R1 MP R1 SMB R2 MP2 R2 MP1 5 Refitting the cable harness in the frame and the upper arm Note Action O ring 21522012 429 Check the o ring located on the SMB BU cover Replace if damaged 1 Wipe clean the contact surfaces of the cover as well as the hole it shall fit in 2 Continues on next page 3HAC044266 001 Revision 213 Copyright ...

Page 214: ...d fit the SMB BU cover in its hole with three attachment screws from inside the SMB recess without damaging the o ring Note Do not tighten the screws fully It must still be possible to adjust the position of the cable harness by rotating the SMB BU cover in its hole a little 6 Continues on next page 214 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 4 2 Refitting the cab...

Page 215: ...s must be placed so that they don t rub against any part of the robot 7 xx1300000655 Secure the SMB BU cover with its attach ment screws from inside the SMB BU re cess 8 If used fit the bracket that hold the DressPack to the frame 9 Fit the cable harness to the frame with a cable tie 10 Continues on next page 3HAC044266 001 Revision 215 Copyright 2013 ABB All rights reserved 4 Repair 4 4 2 Refitti...

Page 216: ... the cables are not twisted The cables shall be in line with its position on the base plate Make sure that the R1 SMB will be on the right side seen from behind the robot Make sure that the R1 MP will be on the left side 2 Make sure that the markings on the cables are facing upwards when connected 3 Continues on next page 216 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair ...

Page 217: ...rotection tube in the base 6 If used run the DressPack hoses down through the protection tube in the base 7 Make sure that the hoses are running cor rectly and are not twisted xx1200000052 If used connect the DressPack cable package on the base plate 8 Continues on next page 3HAC044266 001 Revision 217 Copyright 2013 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 218: ...e turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section WARNING The unit is sensitive to ESD on page 47 2 xx1300000729 Connect the battery cable to the SMB unit 3 Continues on next page 218 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 219: ...nd fit the bracket that hold the SMB unit 5 xx1300000670 If disconnected reconnect the connectors X8 X9 and X10 to the brake release board 6 xx1300000834 Pull out the battery cable through the recess for the battery 7 Continues on next page 3HAC044266 001 Revision 219 Copyright 2013 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 220: ...or cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page 220 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 221: ...g and o ring groove 5 Refit the o ring 6 xx1200001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws The threads will otherwise be damaged Note Make sure the o ring is undamaged and properly fitted 7 Make sure that the covers are tightly sealed 8 Continues on next page 3HAC044266 001 Revision 221 Copyr...

Page 222: ...y twisted between the metal clamps after fitting as shown in the figure 1 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 2 Continues on next page 222 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 223: ...ot arrange the cables into a loop between the cable clamps in the upper arm as shown in the figure Note The variant with a long upper arm does not have a loop 3 xx1300000668 Tie the axis 5 and axis 6 motor cables into bundles if not already done to avoid damaging them during the continued pro cedure This will also make it easier to run the cable harness through the inside of the robot 4 Continues ...

Page 224: ...e the bracket of the cable harness on the upper right hand side to be able to remove the cable harness See figure 5 Person 2 working at the back xx1300000594 The blue ring show the position of the DressPack tube if one is fitted xx1300000739 A Tube for DressPack LeanID Run the cable harness through the cable guide and then into the upper arm tube Note The cable harness is best placed at the upper ...

Page 225: ...of the cable harness Person 2 Take a hold of the cable harness from inside the wrist Together Use caution and move the cable harness past the axis 5 motor and into the wrist 9 Person 2 working at the wrist xx1300000746 xx1300000592 Refit the metal clamp axis 4 inside the arm tube Note The screws are reached from outside the upper arm 10 xx1300000557 Refit the side cover 11 Continues on next page 3...

Page 226: ...e show IRB 6640 xx1300000658 If used refit the tube containing the DressPack into the insert 13 The figure show IRB 6640 xx1200000045 If used refit the cover with the tube guiding ring fitted 14 Continues on next page 226 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 227: ...ble guide xx1300001973 15 Connecting the axis 3 and axis 4 motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page 3HAC044266 001 Revision 227 Copyright 2013 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 228: ...g and o ring groove 5 Refit the o ring 6 xx1200001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws The threads will otherwise be damaged Note Make sure the o ring is undamaged and properly fitted 7 Make sure that the covers are tightly sealed 8 Continues on next page 228 3HAC044266 001 Revision Copyr...

Page 229: ...e gland cover onto the inner screw Refit and tighten the outer screw Tighten the inner screw Make sure that the gasket is not damaged Note Replace the gasket if damaged 2 xx1200001015 Connect the connectors Connect in accordance with the markings on the connectors 3 Continues on next page 3HAC044266 001 Revision 229 Copyright 2013 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness ...

Page 230: ...n plate at this point Note Do not reuse the self threading attachment screws Replace with standard attachment screws The threads will otherwise be damaged Note Make sure the o ring is undamaged and properly fitted 5 xx1300000490 Fit the heat protection plate with the re maing screws 6 Continues on next page 230 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 4 2 Refitting...

Page 231: ...ill be placed in a way that it will not be damaged when the cover is fitted 1 xx1200001081 Note Axis 5 must be in position 90 or as close as possible for a correct 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 Continues on next page 3HAC044266 001 Revision 231 Copyright 2013 ABB All rights reserved 4 Repair...

Page 232: ... M4 screw Note The screw is located at the bottom of the carrier Tip The attachment screw securing the carrier may be difficult to fit Check that the carrier is level and completely pressed against the bottom 5 xx1300000484 Secure the cable bracket with its attach ment screws 6 Continues on next page 232 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 4 2 Refitting the ca...

Page 233: ...motor cable 7 Gasket 3HAC033489 001 xx1200001095 Check the gasket Replace if damaged 8 xx1200001080 Refit the motor cover 9 Disconnect the 24 VDC power supply if used 10 Continues on next page 3HAC044266 001 Revision 233 Copyright 2013 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 234: ...cover still held in an angle 4 Move the upper part of the cover into posi tion 5 Secure the cover with its attachment screws 1 See Updating revolution counters on page 542 Update the revolution counters 2 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 3 234 3HA...

Page 235: ...no Equipment etc See Product manual spare parts IRB 6700 SMB unit See Product manual spare parts IRB 6700 Battery pack Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 559 Standard toolkit Continues on next page 3HAC044266 001 Revision 235 Copyright 2013 ABB All rights reserved 4 Repair 4 4 3 Replacing the SMB ...

Page 236: ...ge 47 2 xx1300000829 Open the small cover on the SMB cover disconnect the battery cable and remove the battery 3 xx1300000669 Remove the SMB cover 4 Disconnecting and removing the SMB unit Note Action DANGER Make sure that all supplies for electrical power hy draulic pressure and air pressure are turned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please ...

Page 237: ...in an ESD bag 5 Refitting the SMB unit Refitting the SMB unit Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air 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 WARNING The unit is sensitive to ESD on page 47 2 Continues on next page 3HAC044266 0...

Page 238: ...d R2 SMB 4 xx1300000730 Use caution push in the SMB unit into position and fit the bracket that hold the SMB unit 5 xx1300000670 If disconnected reconnect the connectors X8 X9 and X10 to the brake release board 6 Continues on next page 238 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 4 3 Replacing the SMB Continued ...

Page 239: ...is sensitive to ESD Before handling the unit please read the safety information in the section WARNING The unit is sensitive to ESD on page 47 1 Get a hold of the battery cable in the recess for the battery and reconnect 2 xx1300000829 Place the battery in the recess 3 Refit the battery cover 4 Continues on next page 3HAC044266 001 Revision 239 Copyright 2013 ABB All rights reserved 4 Repair 4 4 3...

Page 240: ...unter 1 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 2 240 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 4 3 Replacing the SMB Continued ...

Page 241: ...etc See Product manual spare parts IRB 6700 Brake release unit See Product manual spare parts IRB 6700 Battery pack Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 559 Standard toolkit Continues on next page 3HAC044266 001 Revision 241 Copyright 2013 ABB All rights reserved 4 Repair 4 4 4 Replacing the brake release unit ...

Page 242: ... on page 47 2 xx1300000743 Remove the push button guard from the SMB cover The push button guard must be removed to ensure a correct refitting of the brake relase unit 3 xx1300000742 Remove the SMB cover 4 The battery can stay connected to avoid the need of synchronizing the robot CAUTION If the battery stays connected put or hold the SMB cover in a safe position The battery cable connectors can o...

Page 243: ...on WARNING The unit is sensitive to ESD on page 47 2 xx1300000670 Use caution and remove the connectors X8 X9 and X10 from the brake release board 3 Concluding procedure Note Action Unscrew the attachment screws securing the bracket with the brake release unit 1 xx1300000744 Remove the bracket with the brake release unit fitted 2 Continues on next page 3HAC044266 001 Revision 243 Copyright 2013 AB...

Page 244: ...the bracket The push buttons can otherwise get jammed when the SMB cover is refitted 2 xx1300000670 Reconnect the connectors X8 X9 and X10 to the brake release unit 3 xx1300000742 Refit the SMB cover with its attachment screws Note Do not refit the push button guard at this point 4 WARNING Before continuing any service work please observe the safety information in section WARNING The brake release...

Page 245: ...ted if the battery has been disconnected 7 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 8 3HAC044266 001 Revision 245 Copyright 2013 ABB All rights reserved 4 Repair 4 4 4 Replacing the brake release unit Continued ...

Page 246: ...er Spare part See Product manual spare parts IRB 6700 Upper arm Required tools and equipment Note Article number Equipment etc M12 3HAC16131 1 Lifting eye M12 3HAC16131 1 Lifting eye Outer diameter minimum 26 mm hole diameter 13 mm thickness 3 mm Fender washer Lifting instruction 3HAC15880 2 en closed 3HAC15556 1 Lifting accessory chain Continues on next page 246 3HAC044266 001 Revision Copyright ...

Page 247: ...ings 3HAB3537 1 Grease D 169 5x3 3HAB3772 111 O ring Used on axis 3 motor cover D 119x3 3HAB3772 110 Used on axis 4 motor cover D 119x3 3HAB3772 110 Used on axis 5 motor cover Used on axis 6 motor cover 3HAC033489 001 Gasket Removing the upper arm Use these procedures to remove the upper arm Preparations Note Action Remove all equipment fitted to upper arm and wrist 1 Jog the robot into position A...

Page 248: ...motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 24 VDC power supply xx1200001081 If axis 5 is not already in position 90 connect the 24 VDC power supply release the brakes and move the axis manually into that position Connect to R2 MP5 connector pin 2 pin 5 2 Continues on next page 248 3HAC044266 001 Revision Cop...

Page 249: ... the heat protection plate Note Keep the heat protection plate somewhere safe until it shall be refitted 5 Disconnecting the axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 3HAC044266 001 Revision 249 Copyright 2013 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Conti...

Page 250: ...otor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page 250 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 251: ...asket is not damaged Tip Make a note in which direction the cable exit hole is facing if the motor also will be removed The motor shall be refitted in the same position 4 Use caution and pull out the motor cables 5 Disconnecting the axis 3 and axis 4 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on ne...

Page 252: ... cover Make sure the gasket is not damaged Tip Make a note in which direction the cable exit hole is facing if the motor also will be removed The motor shall be refitted in the same position 4 Use caution and pull out the motor cables 5 Continues on next page 252 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 253: ... 1 xx1300000657 Remove the cable guide by unscrewing the attachment screws 2 xx1200000042 If used remove the insert that guides the DressPack through the hole in the upper arm by unscrewing the attachment screws 3 The figure show IRB 6640 Continues on next page 3HAC044266 001 Revision 253 Copyright 2013 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 254: ...parts during the procedure This will also make it easier to run the cable harness through the inside of the robot 5 xx1300000557 Remove the side cover on the arm tube 6 xx1300000592 Loosen the axis 4 metal clamp that holds the cable harness inside the arm tube by unscrewing the attachment screws Note The screws are reached from outside the upper arm 7 Continues on next page 254 3HAC044266 001 Revi...

Page 255: ...xing bracket Note If DressPack is fitted the cable fixing bracket is replaced by the cable guide xx1300001973 9 xx1300000541 Remove the metal clamp on top of the armhouse 10 Continues on next page 3HAC044266 001 Revision 255 Copyright 2013 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 256: ...s Person 2 Take a hold on the cable harness at the back of the robot Together Use caution and move the cable harness out of the arm tube 12 Person 2 working at the back xx1300000594 Use caution and remove the cable harness from the upper arm To be able to remove the cable harness if DressPack is fitted the DressPack tube needs to be pulled out a little then be placed on the lower left side in the ...

Page 257: ...m thickness 3 mm xx1200001134 CAUTION The complete upper arm including the wrist weighs 200 kg All lifting accessories used must be sized accordingly 3 Lifting accessory chain 3HAC15556 1 xx1200001308 Attach the upper arm lifting accessory 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 ar...

Page 258: ... xx1300000659 Screws that secure the lower arm to the axis 3 gearbox Tip Lubricate the guide pins with some grease to make the upper arm slide better xx1300000747 Remove all but one of the remaining attach ment screws 2 Pallet Only valid when replacing the axis 3 gearbox with the cable harness still partly fitted 3 Put two pallets on the floor in front of the robot as shown in the figure Note This...

Page 259: ... the cable harness Use caution and lift the upper arm and place it on the pallets 6 xx1300000553 Place a piece of wood or similar under the arm house and lower the upper arm 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 gearbox 7 Refitting the upper arm Use these procedures to refit...

Page 260: ...fitted 4 Lift the upper arm and put it on the guide pins 5 24 VDC power supply In order to release the brakes connect the 24 VDC power supply 6 Connect to R2 MP3 connector pin 2 pin 5 Rotation tool Use the rotation tool and rotate the axis 3 motor to find the correct position for the guide pins in the lower arm 7 xx1300000747 Insert all nine M16 screws and 25 of the 27 M12 screws 8 M16 tightening ...

Page 261: ... metal clamp on top of the arm house 1 xx1300000543 Refit the arm house metal clamp 2 Make sure that the cable loop is intact If not arrange the cables into a loop between the cable clamps in the upper arm as shown in the figure Note The variant with a long upper arm does not have a loop 3 Continues on next page 3HAC044266 001 Revision 261 Copyright 2013 ABB All rights reserved 4 Repair 4 5 1 Repl...

Page 262: ... is fitted it is needed to pull out the DressPack tube a little and then place it on the lower left side in the arm tube and then place the bracket of the cable harness on the upper right hand side to be able to remove the cable harness See figure 5 Person 2 working at the back xx1300000594 The blue ring show the position of the DressPack tube if one is fitted xx1300000739 A Tube for DressPack Lea...

Page 263: ...harness into the wrist like this 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 Use caution and move the cable harness past the axis 5 motor and into the wrist 9 Person 2 working at the wrist xx1300000746 Continues on next page 3HAC044266 001 Revision 263 Copyright 2013 ABB All rights re...

Page 264: ...r arm 10 xx1300000557 Refit the side cover 11 xx1200000042 If used refit the insert that guides the DressPack cable package through the hole in the upper arm 12 The figure show IRB 6640 Continues on next page 264 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 265: ...et with the velcro strap Note If DressPack is fitted the cable fixing bracket is replaced by the cable guide xx1300001973 15 Refitting the DressPack cable package How to refit the DressPack cable package is described in more detail in the product manual IRB 6700 DressPack For article number see References on page 10 Continues on next page 3HAC044266 001 Revision 265 Copyright 2013 ABB All rights r...

Page 266: ...pening 1 xx1200001067 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 266 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 267: ...001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws The threads will otherwise be damaged Note Make sure the o ring is undamaged and properly fitted 7 Make sure that the covers are tightly sealed 8 Continues on next page 3HAC044266 001 Revision 267 Copyright 2013 ABB All rights reserved 4 Repair 4 5 ...

Page 268: ...ble gland cover onto the inner screw Refit and tighten the outer screw Tighten the inner screw Make sure that the gasket is not damaged Note Replace the gasket if damaged 2 xx1200001015 Connect the connectors Connect in accordance with the markings on the connectors 3 Continues on next page 268 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Co...

Page 269: ...ion plate at this point Note Do not reuse the self threading attachment screws Replace with standard attachment screws The threads will otherwise be damaged Note Make sure the o ring is undamaged and properly fitted 5 xx1300000490 Fit the heat protection plate with the re maing screws 6 Continues on next page 3HAC044266 001 Revision 269 Copyright 2013 ABB All rights reserved 4 Repair 4 5 1 Replaci...

Page 270: ... will be placed in a way that it will not be damaged when the cover is fitted 1 xx1200001081 Note Axis 5 must be in position 90 or as close as possible for a correct 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 Continues on next page 270 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repa...

Page 271: ...he M4 screw Note The screw is located at the bottom of the carrier Tip The attachment screw securing the carrier may be difficult to fit Check that the carrier is level and completely pressed against the bottom 5 xx1300000484 Secure the cable bracket with its attach ment screws 6 Continues on next page 3HAC044266 001 Revision 271 Copyright 2013 ABB All rights reserved 4 Repair 4 5 1 Replacing the ...

Page 272: ...e motor cable 7 Gasket 3HAC033489 001 xx1200001095 Check the gasket Replace if damaged 8 xx1200001080 Refit the motor cover 9 Disconnect the 24 VDC power supply if used 10 Continues on next page 272 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 273: ...cure the cover with its attachment screws 1 Remove the lifting accessories 2 Calibration is detailed in a separate calibra tion manual enclosed with the calibration tools Recalibrate the robot 3 General calibration information is included in section Calibration information on page 537 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in ...

Page 274: ...putting down removed parts from robot Pallet Used for protection Cardboard Always use guide pins in pairs 3HAC13056 2 Guide pin M12x150 Used to release the motor brakes 24 VDC power supply 3HAC15716 1 Calibration Pendulum toolkit Content is defined in section Standard toolkit on page 559 Standard toolkit Consumables Note Art no Equipment etc Cable tie Used to lubricate o rings 3HAB3537 1 Grease Co...

Page 275: ...remove the complete DressPack ball joint housing fitted on the wrist cover 2 This is done to be able to reach the two hidden screws that secure the wrist cover Remove the bracket 3 If used remove the DressPack metal clamp with the ball joint housing still fitted 4 Leave the DressPack fitted in the ball joint housing xx1200000036 If used open the DressPack axis 6 cable support and remove the DressP...

Page 276: ...ply to the robot before entering the robot working area 7 Prepare a pallet with cardboard in front of the robot or where it is possible to be used for putting down the wrist unit on 8 Removing the turning disk Note Action xx1300000492 Remove the attachment screws securing the turning disk 1 xx1300000493 Remove the turning disk 2 Continues on next page 276 3HAC044266 001 Revision Copyright 2013 ABB...

Page 277: ... Remove the process turning disk 2 The figure show IRB 6640 Retrieving access to the wrist cabling Use this procedure to open the wrist and access the axis 5 and axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 3HAC044266 001 Revision 277 Copyright 2013 ABB All rights reserved 4 Repai...

Page 278: ... the axis manually into that position Connect to R2 MP5 connector pin 2 pin 5 2 xx1300000486 Remove the wrist cover 3 xx1300000489 Cut the cable straps that hold the cable harness to the heat protection plate 4 Continues on next page 278 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 279: ...tted 5 Disconnecting the axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001080 Unscrew the attachment screws and re move the motor cover 2 Continues on next page 3HAC044266 001 Revision 279 Copyright 2013 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 280: ...es for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 xx1200001066 Disconnect the motor cables 3 Continues on next page 280 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 281: ...UTION The complete wrist weighs 110 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 in order to keep the wrist balanced when it is re moved Placed at a different position there is a ri...

Page 282: ...0000749 Remove the remaining attachment screws 2 xx1300000750 Use caution and pull out the wrist a little onto the guide pins 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 xx1300000769 Use caution and pull out the cabling from the wrist unit 4 Continues on next page 282 3HAC044266 001 Revision Copyright 20...

Page 283: ...n CAUTION The complete wrist weighs 110 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 in order to keep the wrist balanced when it is re moved Placed at a different position there is ...

Page 284: ...between wrist and arm tube it will be easier to run the cable harness back into the wrist 1 xx1300000769 Use caution and run the cabling into the wrist unit Be careful not to damage any part of the cable harness 2 xx1300000771 Slide the wrist on the guide pins into posi tion 3 Continues on next page 284 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 2 Replacing the wri...

Page 285: ... 115 Nm Tighten all attachment screws 6 24 VDC power supply In order to release the brakes connect the 24 VDC power supply 7 Connect to R2 MP5 connector pin 2 pin 5 xx1200001081 Manually move the the axis 5 to 90 if not already in this position 8 Continues on next page 3HAC044266 001 Revision 285 Copyright 2013 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 286: ...cable gland cover onto the inner screw Refit and tighten the outer screw Tighten the inner screw Make sure that the gasket is not damaged Note Replace the gasket if damaged 2 xx1200001015 Connect the connectors Connect in accordance with the markings on the connectors 3 Continues on next page 286 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Cont...

Page 287: ...ction plate at this point Note Do not reuse the self threading attachment screws Replace with standard attachment screws The threads will otherwise be damaged Note Make sure the o ring is undamaged and properly fitted 5 xx1300000490 Fit the heat protection plate with the re maing screws 6 Continues on next page 3HAC044266 001 Revision 287 Copyright 2013 ABB All rights reserved 4 Repair 4 5 2 Repla...

Page 288: ...ss will be placed in a way that it will not be damaged when the cover is fitted 1 xx1200001081 Note Axis 5 must be in position 90 or as close as possible for a correct 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 Continues on next page 288 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Re...

Page 289: ... the M4 screw Note The screw is located at the bottom of the carrier Tip The attachment screw securing the carrier may be difficult to fit Check that the carrier is level and completely pressed against the bottom 5 xx1300000484 Secure the cable bracket with its attach ment screws 6 Continues on next page 3HAC044266 001 Revision 289 Copyright 2013 ABB All rights reserved 4 Repair 4 5 2 Replacing th...

Page 290: ...01 xx1200001095 Check the gasket Replace if damaged 8 xx1200001080 Refit the motor cover 9 Disconnect the 24 VDC power supply if used 10 Refitting the turning disk Note Action Wipe clean the contacts surfaces 1 Continues on next page 290 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 291: ...ing disk If used use this procedure to refit the process turning disk Note Action Wipe clean the contacts surfaces 1 xx1300000600 Refit the process turning disk 2 The figure show IRB 6640 xx1300000599 Refit the attachment screws that secure the process turning disk 3 The figure show IRB 6640 Continues on next page 3HAC044266 001 Revision 291 Copyright 2013 ABB All rights reserved 4 Repair 4 5 2 Re...

Page 292: ... motor cables to the heat protec tion plate with a cable tie 2 xx1300000596 Check that the cable harness will be placed in a way that it will not be damaged when the wrist cover is fitted 3 Continues on next page 292 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 293: ...nual enclosed with the calibration tools Recalibrate the robot 5 General calibration information is included in section Calibration information on page 537 If the robot is equipped with DressPack cable package Refit the distance to the wrist cover Refit the ball joint housing to the distance Refit the metal clamp with the ball joint housing to the upper arm tube 6 DANGER Make sure all safety requi...

Page 294: ...sk Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 559 Standard toolkit Removing the turning disk Use these procedures to remove the turning disk Preparations Note Action Run the robot to a position most comfort able for the removal of the turning disk 1 Continues on next page 294 3HAC044266 001 Revision Copyright 2013 ABB All r...

Page 295: ...urning disk Note Action xx1300000492 Remove the attachment screws securing the turning disk 1 xx1300000493 Remove the turning disk 2 Refitting the turning disk Use this procedure to refit the turning disk Refitting the turning disk Note Action Wipe clean the contacts surfaces 1 Continues on next page 3HAC044266 001 Revision 295 Copyright 2013 ABB All rights reserved 4 Repair 4 5 3 Replacing the tu...

Page 296: ...8 4x13x1 5 24 pcs xx1300000492 Concluding procedure Note Action DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 1 296 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 3 Replacing the turning disk Continued ...

Page 297: ...A1 Lifting shackle Lifting instruction 3HAC15880 2 en closed 3HAC15556 1 Lifting accessory chain Used for removing and fitting shaft and bearings 3HAC028920 001 Dismantle and mounting tool M12 3HAC16131 1 Lifting eye M12 3HAC16131 1 Lifting eye Lifting instruction 3HAC15880 2 en closed 3HAC15556 1 Lifting accessory chain Always use guide pins in pairs 3HAC13056 2 Guide pin M12x150 Always use guide...

Page 298: ... of the front bearing of the balancing device Used to lubricate o rings 3HAB3537 1 Grease D 169 5x3 3HAB3772 111 O ring Used on axis 3 motor cover D 119x3 3HAB3772 110 Used on axis 4 motor cover D 119x3 3HAB3772 110 Used on axis 5 motor cover Used on axis 6 motor cover 3HAC033489 001 Gasket Removing the lower arm Use these procedures to remove the lower arm Preparations Note Action Remove all equi...

Page 299: ...ol 3HAC030662 001 to unload or restore the pressure of the balancing device spring unit This tool is only used to lock the spring unit in a compressed position after axis 2 has been jogged to 20 or 20 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 balancing device cannot be compressed by joggi...

Page 300: ...roperly fitted 5 Attachment screws M10 quality 12 9 4 pcs A xx0800000480 A Distance tool 3HAC030662 001 This is done to compress the spring unit making it possible to remove the front shaft of the balancing device Jog axis 2 to the calibration position The balancing device is now unloaded 6 Let the distance tool stay fitted during the continued procedure 7 DANGER Turn off all electric power supply...

Page 301: ...vice 3 Lifting shackle SA 10 8 NA1 xx1300000661 Fit a lifting shackle to the balancing device 4 Lifting accessory chain 3HAC15556 1 Fit the lifting accessory to the shackle and raise to unload the weight 5 Removing the shaft in the link ear Note Action xx1200001278 Remove the small VK cover Note It is almost impossible to remove the VK cover without damage New VK covers are needed 1 Continues on n...

Page 302: ...n the balancing device and let it rest on the frame 4 Retrieving access to the wrist cabling Use this procedure to open the wrist and access the axis 5 and axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 302 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 ...

Page 303: ...he axis manually into that position Connect to R2 MP5 connector pin 2 pin 5 2 xx1300000486 Remove the wrist cover 3 xx1300000489 Cut the cable straps that hold the cable harness to the heat protection plate 4 Continues on next page 3HAC044266 001 Revision 303 Copyright 2013 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 304: ...l be refitted 5 Removing brackets Note Action xx1200001184 Unscrew the screws that hold the bracket and let it hang free 1 xx1200000054 Open the ball joint housings on the lower arm and remove the DressPack if one is fitted 2 Continues on next page 304 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 305: ... 4 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page 3HAC044266 001 Revision 305 Copyright 2013 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 306: ...also will be removed The motor shall be refitted in the same position 4 Use caution and pull out the motor cables 5 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 306 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower ...

Page 307: ...t No need to remove this screw 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 also will be removed The motor shall be refitted in the same position 4 Use caution and pull out the motor cables 5 Continues on next page 3HAC044266 001 Revision 307 Copyrig...

Page 308: ...screws and re move the motor cover 2 xx1300000488 Disconnect the motor cables 3 Removing the cable harness wrist and upper arm Note Action xx1200000045 If used remove the DressPack cover with the tube guiding ring fitted by unscrewing the attachment screws 1 Continues on next page 308 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 309: ...ing the DressPack a little backwards 4 The figure show IRB 6640 xx1300000668 Tie the axis 5 and axis 6 connectors and carrier into a bundle with tape 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 5 Continues on next page 3HAC044266 001 Revision ...

Page 310: ...s the cable harness inside the arm tube by unscrewing the attachment screws Note The screws are reached from outside the upper arm 7 xx1300000543 Remove the armhouse metal clamp 8 Continues on next page 310 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 311: ...ssPack is fitted the cable fixing bracket is replaced by the cable guide xx1300001973 9 xx1300000541 Remove the metal clamp on top of the armhouse 10 Continues on next page 3HAC044266 001 Revision 311 Copyright 2013 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 312: ...back of the robot 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 Use caution and move the cable harness out of the arm tube 12 Person 2 working at the back xx1300000594 Use caution and remove the cable harness from the upper arm To be able to remove the cable harness if DressPack is fitted ...

Page 313: ...m thickness 3 mm xx1200001134 CAUTION The complete upper arm including the wrist weighs 200 kg All lifting accessories used must be sized accordingly 3 Lifting accessory chain 3HAC15556 1 xx1200001308 Attach the upper arm lifting accessory 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 ar...

Page 314: ... xx1300000659 Screws that secure the lower arm to the axis 3 gearbox Tip Lubricate the guide pins with some grease to make the upper arm slide better xx1300000747 Remove all but one of the remaining attach ment screws 2 Pallet Only valid when replacing the axis 3 gearbox with the cable harness still partly fitted 3 Put two pallets on the floor in front of the robot as shown in the figure Note This...

Page 315: ...able harness Use caution and lift the upper arm and place it on the pallets 6 xx1300000553 Place a piece of wood or similar under the arm house and lower the upper arm 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 gearbox 7 Removing the lower arm Note Action DANGER Turn off all elec...

Page 316: ...rews Note The screws are reached from outside the lower arm 4 xx1300000733 Remove the cable harness from inside the lower arm 5 Apply the lifting accessory to the lower arm 6 CAUTION The lower arm weighs 135 kg All lifting accessories used must be sized accordingly 7 Raise the tool to unload the lower arm 8 Continues on next page 316 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4...

Page 317: ...t on the guide pins and remove the lower arm Put it some where safe 11 Refitting the lower arm Use these procedures to refit the lower arm Refitting the lower arm Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 Continues on next page 3HAC044266 001 Revision 317 Copyright 2013 ABB All rights re...

Page 318: ...o position 6 Rotation tool In case the hole pattern 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 untill the holes matches Connect 24 VDC the power supply to con nector R2 MP2 pin 2 pin 5 7 24 VDC power supply xx1300000819 Continues on ...

Page 319: ...3 21 pcs Disconnect the 24 VDC power supply if used 10 Tightening torque 280 Nm xx1300000788 Remove the guide pins and replace them with the remaining attachment screws 11 Remove the lifting accessory from the lower arm 12 Refitting the upper arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 3HAC04426...

Page 320: ...fitted 4 Lift the upper arm and put it on the guide pins 5 24 VDC power supply In order to release the brakes connect the 24 VDC power supply 6 Connect to R2 MP3 connector pin 2 pin 5 Rotation tool Use the rotation tool and rotate the axis 3 motor to find the correct position for the guide pins in the lower arm 7 xx1300000747 Insert all nine M16 screws and 25 of the 27 M12 screws 8 M16 tightening ...

Page 321: ... to the robot before entering the robot working area 1 xx1300000668 Tie the axis 5 and axis 6 motor cables into bundles if not already done to avoid damaging them during the continued pro cedure This will also make it easier to run the cables through the inside of the robot 2 xx1300000733 Run the upper end of the cable harness up through the lower arm 3 Continues on next page 3HAC044266 001 Revisi...

Page 322: ...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 5 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 6 Continues on next page 322 3HAC044266 001 Revision Copyright 2013 ABB All rights reser...

Page 323: ...xx1300000668 Tie the axis 5 and axis 6 motor cables into bundles if not already done to avoid damaging them during the continued pro cedure This will also make it easier to run the cables through the inside of the robot 3 Continues on next page 3HAC044266 001 Revision 323 Copyright 2013 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 324: ...then place the bracket of the cable harness on the upper right hand side to be able to remove the cable harness See figure 4 Person 2 working at the back xx1300000594 The grey ring show the position of the DressPack tube if one is fitted xx1300000739 A Tube for DressPack LeanID Run the cabling through the cable guide and then into the arm upper arm tube Note The cable harness is best placed at the...

Page 325: ... 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 Use caution and move the cable harness past the axis 5 motor and into the wrist 8 Person 2 working at the wrist xx1300000746 xx1300000592 Refit the metal clamp axis 4 inside the arm tube Note The screws are reached from outside the upper arm 9 Conti...

Page 326: ...arm 11 The figure show IRB 6640 xx1300000658 If used refit the tube containing the DressPack into the insert 12 The figure show IRB 6640 xx1200000045 If used refit the DressPack cover with the tube guiding ring fitted 13 Continues on next page 326 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 327: ...the cable guide 14 Connecting the axis 3 and axis 4 motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page 3HAC044266 001 Revision 327 Copyright 2013 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 328: ...ing and o ring groove 5 Refit the o ring 6 xx1200001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws The threads will otherwise be damaged Note Make sure the o ring is undamaged and properly fitted 7 Make sure that the covers are tightly sealed 8 Continues on next page 328 3HAC044266 001 Revision Cop...

Page 329: ...ble gland cover onto the inner screw Refit and tighten the outer screw Tighten the inner screw Make sure that the gasket is not damaged Note Replace the gasket if damaged 2 xx1200001015 Connect the connectors Connect in accordance with the markings on the connectors 3 Continues on next page 3HAC044266 001 Revision 329 Copyright 2013 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Co...

Page 330: ...ion plate at this point Note Do not reuse the self threading attachment screws Replace with standard attachment screws The threads will otherwise be damaged Note Make sure the o ring is undamaged and properly fitted 5 xx1300000490 Fit the heat protection plate with the re maing screws 6 Continues on next page 330 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 4 Replaci...

Page 331: ...nd the rest of the cable harness will be placed in a way that it will not be damaged when the cover is fitted Note The variant with long upper arm does not have a loop 1 xx1200001081 Note Axis 5 must be as close as possible in position 90 for a correct installation of the cable harness in the wrist 2 Continues on next page 3HAC044266 001 Revision 331 Copyright 2013 ABB All rights reserved 4 Repair...

Page 332: ... M4 screw Note The screw is located at the bottom of the carrier Tip The attachment screw securing the carrier may be difficult to fit Make sure that the carrier is level and completely pressed against the bottom 5 xx1300000484 Secure the cable bracket with its attach ment screws 6 Continues on next page 332 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 5 4 Replacing th...

Page 333: ... Place the resolver cable under the motor cable 7 xx1200001095 Check the gasket Replace if damaged 8 xx1200001080 Refit the motor cover 9 Continues on next page 3HAC044266 001 Revision 333 Copyright 2013 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued ...

Page 334: ...d 3 Tightening torque 10 Nm xx1300000772 Use caution in order not to damage the cable harness when the wrist cover is refit ted by following this method 1 Hold the cover in an angle See fig ure 2 Catch any part of the cable harness hanging down 3 Lift the cover still held in an angle 4 Move the upper part of the cover into position 5 Secure the cover with its attachment screws 4 Continues on next ...

Page 335: ... Refit the ball joint housing to the distance Refit the bracket with the ball joint housing to the upper arm tube Refit the process turning disk 5 xx1200001184 Refit the bracket to the frame 6 xx1200001332 Refit the connection plate 7 xx1200000054 If used refit the DressPack in the ball joint housings on the lower arm 8 Continues on next page 3HAC044266 001 Revision 335 Copyright 2013 ABB All righ...

Page 336: ...lready done 4 Lifting accessory chain 3HAC15556 1 xx1300000784 Align the balancing device link ear with the hole in the lower arm Note Check that the link ear is turned correctly See figure 5 xx1200001280 Lubricate the shaft and place it to the front ear 6 Dismantle and mounting tool 3HAC028920 001 Press the shaft in with the hydraulic press tool 7 xx1300000782 Apply locking liquid Loctite 2701 on...

Page 337: ...l the bear ing with grease from the upper hole until the grease appears in the lower hole 11 Refit the two screws and wipe clean from residual grease 12 Concluded refitting of the front shaft Note Action Remove the lifting accessory from the bal ancing device 1 Continues on next page 3HAC044266 001 Revision 337 Copyright 2013 ABB All rights reserved 4 Repair 4 5 4 Replacing the lower arm Continued...

Page 338: ... balancing device or if the spring unit of the balancing device cannot be 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 20 or 20 4 DANGER Turn off all electric power supply hydraulic pressure s...

Page 339: ...osed with the calibration tools Recalibrate the robot 2 General calibration information is included in section Calibration information on page 537 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 3 3HAC044266 001 Revision 339 Copyright 2013 ABB All rights reserve...

Page 340: ...he link ear of the balancing device xx1300000773 Attachment screws M6x10 quality 8 8 A2F 2 pcs A End cover B Radial sealing with dustlip 50x68x8 2 pcs C O ring 85x3 D Spherical roller bearing E Washer F Continues on next page 340 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 6 1 Replacing spherical roller bearing link ear ...

Page 341: ...ounting tool Content is defined in section Standard toolkit on page 559 Standard toolkit Consumables Note Art no Equipment etc See Product manual spare parts IRB 6700 VK cover Optimol PD0 50 ml 3HAC042534 001 Grease Used for lubrication of the spherical roller bearing Removing the spherical roller bearing Unloading the balancing device Note The method described in this procedure using the distance...

Page 342: ... use the hydraulic press tool Dismantle and mounting tool 3HAC028920 001 1 This is done in order to compress the spring unit inside the balancing device be fore fitting the unloading tool Jog axis 2 to 20 or 20 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 xx1300000554 Remove the cover plate on the ba...

Page 343: ...pring unit making it possible to remove the front shaft of the balancing device Jog axis 2 to the calibration position The balancing device is now unloaded 6 Let the distance tool stay fitted during the continued procedure 7 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 8 Preparations Note Action Jog axis...

Page 344: ...draulic pressure supply air pressure supply to the robot before entering the robot working area 3 Remove any equipment if fitted on or close to the balancing device 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 to the shackle and raise to unload the weight 6 Continues on next page 344 3HAC044...

Page 345: ... needed 1 xx1200001279 M16x70 quality steel 8 8 A3F Unscrew the attachment screw and washer 2 Dismantle and mounting tool 3HAC028920 001 xx1200001280 Use the dismantle and mounting tool and pull out the shaft 3 Continues on next page 3HAC044266 001 Revision 345 Copyright 2013 ABB All rights reserved 4 Repair 4 6 1 Replacing spherical roller bearing link ear Continued ...

Page 346: ...ismantle and mounting tool 1 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 2 xx1300000774 Unscrew the attachment screws securing the end cover use caution and remove end cover and radial sealing with a screwdriver 3 Continues on next page 346 3HAC044266 001 Revision Copyright 2013 ABB All rights reser...

Page 347: ...erical roller bearing together with the radial sealing and washer 5 Refitting the spherical roller bearing Refitting the spherical roller bearing link ear Note Action Wipe clean all contact surfaces from resid ual grease 1 xx1300000778 Refit the washer 2 Continues on next page 3HAC044266 001 Revision 347 Copyright 2013 ABB All rights reserved 4 Repair 4 6 1 Replacing spherical roller bearing link ...

Page 348: ...AC034037 001 and refit the radial sealing 4 Apply some grease on the surface for the bearing 5 Dismantle and mounting tool 3HAC028920 001 xx1300000776 Apply the dismantle and mounting tool and press in the spherical roller bearing 6 Continues on next page 348 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 6 1 Replacing spherical roller bearing link ear Continued ...

Page 349: ...e radial sealing ring 8 Preparations lifting accessory Note Action Fit a lifting shackle 1 Fit the lifting accessory to the shackle and raise to unload the weight 2 Continues on next page 3HAC044266 001 Revision 349 Copyright 2013 ABB All rights reserved 4 Repair 4 6 1 Replacing spherical roller bearing link ear Continued ...

Page 350: ...e on page 379 Before a new spare part balancing device is fitted the springs must be unloaded us ing the press tool balancing device 3HAC020902 001 2 Refitting the front shaft of the balancing device Note Action Turn on the power to the robot 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 air pre...

Page 351: ...00782 Apply locking liquid Loctite 2701 on the threads of the screw first entering the threads in the frame 8 Tightening torque 200 Nm xx1200001279 Secure the shaft with screw and washer 9 xx1200001278 Fit the VK cover 10 Continues on next page 3HAC044266 001 Revision 351 Copyright 2013 ABB All rights reserved 4 Repair 4 6 1 Replacing spherical roller bearing link ear Continued ...

Page 352: ...esidual grease 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 xx1200001116 Remove the locking screw M16x120 3 Jog axis 2 to 20 or 20 4 Continues on next page 352 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 6 1 Replacing spherical roller bear...

Page 353: ...ure supply air pressure supply to the robot before entering the robot working area 5 Remove the distance tool 6 Refit the cover plate 7 3HAC044266 001 Revision 353 Copyright 2013 ABB All rights reserved 4 Repair 4 6 1 Replacing spherical roller bearing link ear Continued ...

Page 354: ...t manual spare parts IRB 6700 Balancing device VK 90x12 3HAA2166 28 VK cover 2 pcs VK 28x7 3HAA2166 28 VK cover Required tools and equipment Note Article number Equipment etc Used for unloading a balancing device fitted to the robot 3HAC030662 001 Distance tool Continues on next page 354 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing device ...

Page 355: ...it Consumables Note Art no Equipment etc Optimol PD0 3HAC042534 001 Grease Used for lubrication of the bearings at the cradle Optimol PD0 50 ml 3HAC042534 001 Grease Used for lubrication of the spherical roller bearing Removing the balancing device Use these procedures to remove the balancing device Unloading the balancing device Note The method described in this procedure using the distance tool ...

Page 356: ...ot only use the hydraulic press tool Dismantle and mounting tool 3HAC028920 001 1 This is done in order to compress the spring unit inside the balancing device be fore fitting the unloading tool Jog axis 2 to 20 or 20 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 xx1300000554 Remove the cover plate on...

Page 357: ... the spring unit making it possible to remove the front shaft of the balancing device Jog axis 2 to the calibration position The balancing device is now unloaded 6 Let the distance tool stay fitted during the continued procedure 7 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 8 Preparations Note Action Jo...

Page 358: ...ydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 Remove any equipment if fitted on or close to the balancing device 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 to the shackle and raise to unload the weight 6 Continues on next page 358 3HAC04...

Page 359: ...is a risk of damaging the bearing inside Note It is almost impossible to remove the VK cover without damage New VK covers are needed 1 Wipe off all residual grease inside the re cess 2 xx1300000663 Unscrew the attachment screws on each shaft 3 M16x70 quality steel 12 9 Gleitmo 603 xx1300000664 Remove retaining ring bore on one side 4 Continues on next page 3HAC044266 001 Revision 359 Copyright 201...

Page 360: ...ost impossible to remove the VK cover without damage New VK covers are needed 1 xx1200001279 M16x70 quality steel 8 8 A3F Unscrew the attachment screw and washer 2 Dismantle and mounting tool 3HAC028920 001 xx1200001280 Use the dismantle and mounting tool and pull out the shaft 3 Continues on next page 360 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 6 2 Replacing the ...

Page 361: ...d from a balancing device that not is fitted to the robot Fitting and removing this tool can only be done in a safe way with axis 2 in 20 or 20 position and with the balancing device fitted to the robot 2 Refitting the balancing device Use this procedure to refit the balancing device Preparations Note Action Lifting shackle SA 10 8 NA1 Fit a lifting shackle 1 Lifting accessory chain 3HAC15556 1 Fi...

Page 362: ...tted to the robot is described in Unloading the balancing device on page 379 Before a new spare part balancing device is fitted the springs must be unloaded us ing the 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 air pressure supply to the robot before ente...

Page 363: ...00837 Refit new VK covers 7 Grease 3HAC042534 001 xx1300000832 Unscrew both screws in the cradle and fill the bearing with grease from the inner hole see figure until grease appears in the outer hole 8 Continues on next page 3HAC044266 001 Revision 363 Copyright 2013 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing device Continued ...

Page 364: ...ulic pressure supply air 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 xx1300000784 Align the balancing device link ear with the hole in the lower arm Note Check that the link ear is turned correctly See figure 5 xx1200001280 Lubricate th...

Page 365: ...9 xx1200001278 Fit the VK cover 10 Grease 3HAC042534 001 xx1300000783 Unscrew both screws in link ear and fill the bear ing with grease from the upper hole until the grease appears in the lower hole 11 Refit the two screws and wipe clean from residual grease 12 Continues on next page 3HAC044266 001 Revision 365 Copyright 2013 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing device Co...

Page 366: ...01116 Remove the locking screw M16x120 3 Jog axis 2 to 20 or 20 4 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 5 Remove the distance tool 6 Refit the cover plate 7 366 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing device Continued ...

Page 367: ...ial sealing 2 pcs 3HAC043841 001 Spacer 2 pcs 3HAB3643 36 Groove ball bearing 2 pcs 3HAA2166 28 VK cov er 2 pcs Can be ordered separately See Product manual spare parts IRB 6700 Maintenance kit cradle Required tools and equipment Note Article number Equipment etc Used for unloading a balancing device fitted to the robot 3HAC030662 001 Distance tool Continues on next page 3HAC044266 001 Revision 36...

Page 368: ...alancing device shall be refitted If a new balancing device shall replace the removed one another tool 3HAC020902 001 press tool balancing device must be used See Unloading the balancing device on page 379 Note Action DANGER Do not use the Distance tool 3HAC030662 001 to unload or restore the pressure of the balancing device spring unit This tool is only used to lock the spring unit in a compresse...

Page 369: ...l on the back of the balancing device using the four screws DANGER Use caution when tightening the screws The threads in the cover can be damaged if more tightening torque than 45 Nm is used risking that the unloading tool is not properly fitted 5 Attachment screws M10 quality 12 9 4 pcs A xx0800000480 A Distance tool 3HAC030662 001 This is done to compress the spring unit making it possible to re...

Page 370: ...he hole for the lock screw in the frame and into the lower arm or using a lifting accessory or similar The lock screw is used to secure the weight of the lower arm in order to avoid acci dents or damage 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 Remove any equipment if fitted on or close to the bal...

Page 371: ...ote Action xx1300000662 Remove the VK cover by driving a screw driver or similar through the VK cover as close as possible to the center of the VK cover If not making a hole in the center of the VK cover there is a risk of damaging the bearing inside Note It is almost impossible to remove the VK cover without damage New VK covers are needed 1 Wipe off all residual grease inside the re cess 2 Conti...

Page 372: ...ply the press tool and pull 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 Note Action Wipe clean all contact surfaces from resid ual grease and other contamination inside the recess 1 Continues on next page 372 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair ...

Page 373: ... little 6 Apply the press tool 3HAC027146 001 and hydraulic pump and nut on the threaded bar 7 xx1300000838 Before pressing the shaft end into position put a big screw driver between the cradle and balancing device and use it as a dis tance tool 8 Use caution and press the shaft end in po sition 9 Remove the press tool and the threaded bar 10 Apply some locking liquid Loctite 243 on the attachment...

Page 374: ...Tightening torque 280 Nm xx1300000663 Secure the balancing device 13 Concluding procedure Note Action xx1300000664 Refit the retaining ring bore 1 xx1300000837 Refit the VK cover 2 Continues on next page 374 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 6 3 Replacing the rear bearing of the balancing device Continued ...

Page 375: ...lean from residual grease 5 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 6 3HAC044266 001 Revision 375 Copyright 2013 ABB All rights reserved 4 Repair 4 6 3 Replacing the rear bearing of the balancing device Continued ...

Page 376: ...t no Equipment etc See Product manual spare parts IRB 6700 Stop pin Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 559 Standard toolkit Continues on next page 376 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 6 4 Replacing the stop pin ...

Page 377: ... from the axis 1 oil plug draining when removed See figure 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 xx1300000476 Unscrew the set screw cup point 4 Continues on next page 3HAC044266 001 Revision 377 Copyright 2013 ABB All rights reserved 4 Repair 4 6 4 Replacing the stop pin Continued ...

Page 378: ...in Note Action xx1300000477 Fit the stop pin 1 xx1300000476 Secure the stop pin with the set screw cup point Locking liquid Loctite 243 on screw 2 M10x20 378 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 6 4 Replacing the stop pin Continued ...

Page 379: ...ember to jog axis 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 3HAC044266 001 Revision 379 Copyright 2013 ABB All rights...

Page 380: ...marking E Bolt 4 pcs F Pin attached to the fix plate G Required equipment Note Article number Equipment etc 3HAC020902 001 Press tool balancing device To be used with the press tool 3HAC11731 1 Hydraulic cylinder To be used with the hydraulic cylinder 3HAC13086 1 Hydraulic pump 80 MPa Content is defined in section Standard toolkit on page 559 Standard toolkit Continues on next page 380 3HAC044266 ...

Page 381: ...nd hydraulic cylinder on page 380 The bolt is shown in the figure Press tool and hydraulic cylinder on page380 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 remove any other screws then the rear ...

Page 382: ... and press 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 80 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 hydra...

Page 383: ...amage property Press 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 3HAC044266 001 Revision 383 Copyright 2013 ABB ...

Page 384: ...linder 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 sary it could damage bearings a...

Page 385: ...ce is a safety device for the piston rod during operation Make sure the cover is properly secured before commissioning of the ro bot 7 3HAC044266 001 Revision 385 Copyright 2013 ABB All rights reserved 4 Repair 4 6 6 Restoring the balancing device Continued ...

Page 386: ...te 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 3HAC047108 001 Removal tool M14 Always use guide pins in pairs 3HAC13056 2 Guide pin M12x150 300 mm bits 1 2 3HAC12342 1 Bits extender Continues on next page 386 3HAC044266 001 Revision Copyright 2013 ABB ...

Page 387: ... D 102x3 3HAB3772 107 O ring Used on motor flange Removing the axis 1 motor These procedures describe how to remove the motor Preparations Note Action Jog the robot to the calibration position 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Disconnecting the motor cables Note Action DANGER Make sure tha...

Page 388: ... note in which direction the cable exit hole is facing if the motor also will be removed The motor shall be refitted in the same position 4 Use caution and pull out the motor cables 5 Removing the axis 1 motor Note Action Lifting accessory motor 3HAC14459 1 Apply the lifting accessory 1 Continues on next page 388 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 7 1 Replaci...

Page 389: ...washers Use a bits extender in order to reach the screws 4 Guide pin M12x150 3HAC13056 2 Fit guide pins in opposite holes 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 M14 3HAC047108 001 If needed use removal tools to help re move the motor 7 Continues on next page 3HAC044266 001 Revision 389 ...

Page 390: ...tting motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove old paint residues and other contamina tion from the contact surfaces on both motor and gearbox 2 Wipe clean the contact surfaces from any remain ing contamination 3 Also wipe clean the o ring groove Continues on next page 390 3HAC044266 001 Revision Copyright...

Page 391: ...ase for a better fitting in the groove 5 xx1200001135 Remove the cover if the motor is a new spare part 6 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 3HAC044266 001 Revision 391 Copyright 2013 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor Continued ...

Page 392: ...2 pin 5 CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 6 xx1200001072 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 exit is facing the correct way See figure 7 Continues on next page 392 ...

Page 393: ...leitmo 4 pcs xx1200001071 See Performing a leak down test on page 174 Perform a leak down test if not already done 9 Disconnect the 24 VDC power supply 10 Connecting the motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 Continues on next page 3HAC044266 001 Revision 393 Copyright 2013 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor C...

Page 394: ...he connectors 3 O ring axis 1 3HAB3772 111 Check the o ring 4 O ring axis 2 3HAB3772 111 Replace if damaged O ring axis 3 3HAB3772 111 O ring axis 4 3HAB3772 110 xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring 6 Continues on next page 394 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor Continued ...

Page 395: ...or the concluding refitting Note Action Calibration is described in a separate calib ration manual enclosed with the calibration tools Recalibrate the robot 1 General calibration information is included in section Calibration information on page 537 DANGER Make sure all safety requirements are met when performing the first test run These are further described in the section DANGER First test run m...

Page 396: ...640 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 3HAC047108 001 Removal tool M14 Always use guide pins in pairs 3HAC13056 2 Guide pin M12x150 300 mm bits 1 2 3HAC12342 1 Bits extender Used to rotate the motor pinion 3HAC7887 1 Rotation tool Continues on next page 396 3H...

Page 397: ...ocedures describes how to remove the motor Preparations Note Action See Draining the axis 2 gearbox on page 144 Drain the oil from the gearbox 1 Jog the robot to the calibration position 2 If needed adjust the position of axis 2 to make it possible to insert the lock screw 3 DANGER Secure the weight of the lower arm with a lock screw before releasing the brakes on the axis 2 motor as well as befor...

Page 398: ...robot before entering the robot working area 6 Remove any equipment hindering access to the motor 7 Disconnecting the motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page 398 3HAC044266 001 Revision Copyright 201...

Page 399: ...oving the axis 2 motor Note Action 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 Before continuing the lower arm must be secured See above 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 Continues ...

Page 400: ... the removal tool in opposite holes of the motor 7 CAUTION The motor weighs 26 kg All lifting accessories used must be sized accordingly 8 Lifting accessory motor 3HAC15534 1 Apply the lifting accessory 9 Use caution and 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 Disconnect the 24 VDC power supply 11 xx1200001118 Use caut...

Page 401: ...tact surfaces on both motor and gearbox 2 Wipe clean the contact surfaces from any remain ing contamination 3 Also wipe clean the o ring groove O ring 3HAB3772 107 xx1200001019 Check the o ring Replace if damaged 4 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 5 Continues on next page 3HAC044266 001 Revision 4...

Page 402: ...hole is turned the correct way 4 Lift the motor and put it on the guide pins as close as possible to its final position without pushing the motor pinion into the gear 5 Remove the lifting accessory and allow the motor to rest on the guide pins 6 Rotation tool 3HAC7887 1 Apply the rotation tool and use it to rotate the pinion when mating it into the gear 7 To release the brakes connect the 24 VDC p...

Page 403: ...tion of the cable exit is facing the correct way See figure 10 Fit two of the attachment screws 11 Remove the guide pins and replace with the remaining attachment screws 12 Bits extender 3HAC12342 1 Secure the motor with its attachment screws and washers 13 Tightening torque 47 Nm Use a bits extender in order to reach the screws Screw dimension M10x40 quality 12 9 Gleitmo 4 pcs xx1200001117 See Pe...

Page 404: ...1200001067 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 404 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 7 2 Replacing the axis 2 motor Continued ...

Page 405: ...Do not reuse the self threading attachment screws Replace with standard attachment screws The threads will otherwise be damaged Note Make sure the o ring is undamaged and properly fitted 7 Make sure that the covers are tightly sealed 8 Concluding procedure Note Action Use caution and jog axis 2 a little to fa ciltate the removel of the M16 lock screw 1 Continues on next page 3HAC044266 001 Revisio...

Page 406: ...alibration tools Recalibrate the robot 4 General calibration information is included in section Calibration information on page 537 DANGER Make sure all safety requirements are met when performing the first test run These are further described in the section DANGER First test run may cause injury or damage on page 44 5 406 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 7...

Page 407: ...2 en closed 3HAC15556 1 Lifting accessory chain 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 3HAC047108 001 Removal tool M14 Always use guide pins in pairs 3HAC13056 2 Guide pin M12x150 300 mm bits 1 2 3HAC12342 1 Bits extender Continues on...

Page 408: ...s procedure to do the necessary preparations before removing the motor Note Action See Draining the axis 3 gearbox on page 149 Drain the axis 3 gearbox 1 Unload the upper arm using one of these methods Use caution and jog axis 3 to maxim um position Release the brakes and let the upper arm rest against the axis 3 damper Use a fork lift to rest the upper arm onto it Use lifting slings and an overhe...

Page 409: ...otor cover 2 xx1200001066 Disconnect the motor cables 3 xx1200001067 Remove the cable gland cover Make sure the gasket is not damaged Tip Make a note in which direction the cable exit hole is facing if the motor also will be removed The motor shall be refitted in the same position 4 Continues on next page 3HAC044266 001 Revision 409 Copyright 2013 ABB All rights reserved 4 Repair 4 7 3 Replacing t...

Page 410: ...otor Use a bits extender to reach the screws 4 Guide pin M12x150 3HAC13056 2 Fit guide pins in opposite holes 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 M14 3HAC047108 001 If required press the motor out of position by using the removal tool in the remaining holes for the motor 7 Always use...

Page 411: ...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 in the process xx1200001131 Use caution and remove the motor by lift ing it straight out Put the motor somewhere safe 13 Refitting the motor These procedures describes how to refit the motor Preparations prior to refitting motor Note Action DANGER Make sure tha...

Page 412: ...is seated in the groove Tip Lubricate the o ring with some grease for a better fitting in the groove 5 xx1200001135 Remove the cover if the motor is a new spare part 6 Securing the axis 3 motor Use this procedure to secure the motor Note Action Fit guide pins in opposite holes 1 Continues on next page 412 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 7 3 Replacing the a...

Page 413: ... into the gear yet This is done in order to fit the motor with the axis 4 motor still fitted 5 Remove the lifting accessory and allow the motor to rest on the guide pins 6 Rotation tool 3HAC7887 1 Apply the rotation tool and use it to rotate the pinion when mating it into the gear 7 To release the brakes connect the 24 VDC power supply 8 Connect to connector R2 MP3 pin 2 pin 5 CAUTION Whenever par...

Page 414: ...he motor pinion 10 Attach two attachment screws 11 Remove the guide pins 12 Attach the remaining attachment screws 13 Tightening torque 47 Nm Secure the motor 14 Screw dimension M10x30 quality 12 9 Gleitmo 4 pcs xx1200001126 Remove the rotation tool 15 See Performing a leak down test on page 174 Perform a leak down test 16 Disconnect the 24 VDC power supply 17 Continues on next page 414 3HAC044266...

Page 415: ...1200001067 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 3HAC044266 001 Revision 415 Copyright 2013 ABB All rights reserved 4 Repair 4 7 3 Replacing the axis 3 motor Continued ...

Page 416: ...s Replace with standard attachment screws The threads will otherwise be damaged Note Make sure the o ring is undamaged and properly fitted 7 Make sure that the covers are tightly sealed 8 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 150 Refill the gearbox with oil...

Page 417: ...s included in section Calibration information on page 537 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 4 3HAC044266 001 Revision 417 Copyright 2013 ABB All rights reserved 4 Repair 4 7 3 Replacing the axis 3 motor Continued ...

Page 418: ...t the motor if neces sary Always use removal tools in pairs 3HAC14631 1 Removal tool M12 Always use guide pins in pairs 3HAC15521 2 Guide pin M10x150 Length 140 mm Long AllenKeySocketIN19L 6 140 Used to rotate the motor pinion 3HAC7887 1 Rotation tool Used to release the motor brakes 24 VDC power supply 3HAC0207 1 Leak down tester 3HAC15716 1 Calibration Pendulum toolkit Continues on next page 418...

Page 419: ...nting straight up if possible With the robot in this position there is no need to drain oil from the axis 4 gearbox when the motor is replaced 1 If there is no space to position the upper arm pointed straight up drain the axis 4 gearbox 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 Disconnecting the m...

Page 420: ...cover Make sure the gasket is not damaged Tip Make a note in which direction the cable exit hole is facing if the motor also will be removed The motor shall be refitted in the same position 4 Use caution and pull out the motor cables 5 Continues on next page 420 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 4 motor Continued ...

Page 421: ... box the gears may be damaged if excess ive force is used 5 Removal tool M12 3HAC14631 1 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 11 kg All lifting accessories used must be sized accordingly 7 Disconnect the 24 VDC power supply 8 xx1200001138 Remove the motor by carefull...

Page 422: ...tact surfaces on both motor and gearbox 2 Wipe clean the contact surfaces from any remain ing contamination 3 Also wipe clean the o ring groove O ring 3HAB3772 107 xx1200001019 Check the o ring Replace if damaged 4 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 5 Continues on next page 422 3HAC044266 001 Revisi...

Page 423: ... The motor weighs 11 kg All lifting accessories used must be sized accordingly 4 Rotation tool 3HAC7887 1 Apply the rotation tool and use it to rotate the pinion when mating it into the gear 5 To release the brakes connect the 24 VDC power 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 Conti...

Page 424: ...he guide pins 9 Tightening torque 35 Nm Secure the motor with its attachment screws and washers 10 Screw dimension M8x30 quality 12 9 Gleitmo 4 pcs xx1200001137 See Performing a leak down test on page 174 Perform a leak down test 11 Disconnect the 24 VDC power supply 12 Connecting the motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 Continues on next...

Page 425: ...he connectors 3 O ring axis 1 3HAB3772 111 Check the o ring 4 O ring axis 2 3HAB3772 111 Replace if damaged O ring axis 3 3HAB3772 111 O ring axis 4 3HAB3772 110 xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring 6 Continues on next page 3HAC044266 001 Revision 425 Copyright 2013 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 4 motor Continued ...

Page 426: ...x on page 155 Refill the gearbox with oil if gearbox has been drained 1 Calibration is detailed in a separate calibra tion manual enclosed with the calibration tools Recalibrate the robot 2 General calibration information is included in section Calibration information on page 537 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the s...

Page 427: ... neces sary Removal tool M10 Length 140 mm Long AllenKeySocketIN19L 6 140 Always use guide pins in pairs 3HAC15520 1 Guide pin M8x100 Used to rotate the motor pinion 3HAC7887 1 Rotation tool Used to release the motor brakes 24 VDC power supply 3HAC0207 1 Leak down tester 3HAC15716 1 Calibration Pendulum toolkit Content is defined in section Standard toolkit on page 559 Standard toolkit Continues o...

Page 428: ...flange Removing the axis 5 motor Use these procedures to remove the motor Preparations Note Action xx1200001005 Jog the robot to this position Axis 2 25 Axis 3 35 1 With the robot in this position there is no need to drain oil from the axis 5 gearbox when the motor is replaced xx1200001006 Jog axis 4 to this position Axis 4 90 2 Continues on next page 428 3HAC044266 001 Revision Copyright 2013 ABB...

Page 429: ...eving access to the wrist cabling Use this procedure to open the wrist and access the axis 5 and axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 24 VDC power supply xx1200001081 If axis 5 is not already in position 90 connect the 24 VDC power supply release the brakes and move the axis manually into that p...

Page 430: ...ve the heat protection plate Note Keep the heat protection plate somewhere safe until it shall be refitted 5 Disconnecting the motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 430 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 5 motor Continu...

Page 431: ... No need to remove this screw 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 also will be removed The motor shall be refitted in the same position 4 Use caution and pull out the motor cables 5 Continues on next page 3HAC044266 001 Revision 431 Copyrigh...

Page 432: ...rting mating motor and gear box the gears may be damaged if excess ive force is used 2 Removal tool M10 If needed fit removal tools in opposite holes 3 xx1200001018 Use caution and lift out the motor out and put it somewhere safe 4 Continues on next page 432 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 5 motor Continued ...

Page 433: ...the robot before entering the robot working area 1 xx1200001019 Clean the contact surfaces from any con tamination including the recess for the o ring 2 O ring 3HAB3772 107 Check the o ring 3 Replace if damaged Lubricate the o ring with some grease 4 Continues on next page 3HAC044266 001 Revision 433 Copyright 2013 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 5 motor Continued ...

Page 434: ... box the gears may be damaged if excess ive force is used 1 Rotation tool 3HAC7887 1 Apply the rotation tool and use it to rotate the pinion when mating it into the gear 2 24 VDC power supply To release the brakes connect the 24 VDC power supply 3 Connect to connector R2 MP5 pin 2 pin 5 Continues on next page 434 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 7 5 Replaci...

Page 435: ... get dam aged the direction of the cable exit is fa cing the correct way 4 xx1200001018 Remove the guide pins 5 Tightening torque 24 Nm Secure the motor with its attachment screws and washers 6 Screw dimension M8x30 quality 12 9 Gleitmo 4 pcs xx1200001017 See Performing a leak down test on page 174 Perform a leak down test 7 Disconnect the 24 VDC power supply 8 Continues on next page 3HAC044266 00...

Page 436: ...land cover onto the inner screw Refit and tighten the outer screw Tighten the inner screw Make sure that the gasket is not damaged Note Replace the gasket if damaged 2 xx1200001015 Connect the connectors Connect in accordance with the markings on the connectors 3 Continues on next page 436 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 5 motor Cont...

Page 437: ...on plate at this point Note Do not reuse the self threading attachment screws Replace with standard attachment screws The threads will otherwise be damaged Note Make sure the o ring is undamaged and properly fitted 5 xx1300000490 Fit the heat protection plate with the re maing screws 6 Continues on next page 3HAC044266 001 Revision 437 Copyright 2013 ABB All rights reserved 4 Repair 4 7 5 Replacin...

Page 438: ... tightly sealed 8 Concluding procedure Note Action xx1200001011 Refit the heat protection plate 1 xx1200001009 Secure the cable harness to the heat pro tection plate with two cable straps 2 Continues on next page 438 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 5 motor Continued ...

Page 439: ...st cover 4 Refit the complete ball joint housing with the DressPack still fitted 5 Refit the DressPack in the ball joint housing on the arm tube 6 Calibration is detailed in a separate calibra tion manual enclosed with the calibration tools Recalibrate the robot 7 General calibration information is included in section Calibration information on page 537 DANGER Make sure all safety requirements are...

Page 440: ... and equipment Note Article number Equipment etc Used to rotate the motor pinion 3HAC7887 1 Rotation tool Used to release the motor brakes 24 VDC power supply 3HAC0207 1 Leak down tester 3HAC15716 1 Calibration Pendulum toolkit Content is defined in section Standard toolkit on page 559 Standard toolkit Continues on next page 440 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repa...

Page 441: ... 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 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Disconnecting the axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydrau...

Page 442: ... 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 442 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 443: ...t tachment holes of the motor 4 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 5 xx1200001096 Disconnect the 24 VDC power supply 6 Continues on next page 3HAC044266 001 Revision 443 Copyright 2013 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Con...

Page 444: ...ct surfaces on both motor and gearbox 2 Wipe clean the contact surfaces from any remain ing contamination 3 Also wipe clean the o ring groove O ring 3HAB3772 107 xx1200001019 Check the o ring Replace if damaged 4 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 5 Continues on next page 444 3HAC044266 001 Revision...

Page 445: ...to the robot before entering the robot working area 1 To release 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 Continues on next page 3HAC044266 001 Revision 445 Copyright 2013 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 446: ...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 5 xx1200001097 Continues on next page 446 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 447: ...tted correctly See Performing a leak down test on page 174 Perform a leak down test 7 Disconnect the 24 V DC power supply 8 xx1200001084 Reconnect the connectors 9 3HAC033489 001 xx1200001095 Check the gasket Replace if damaged 10 Continues on next page 3HAC044266 001 Revision 447 Copyright 2013 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 448: ...ation information is included in section Calibration information on page 537 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 13 448 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 449: ... parts See Product manual spare parts IRB 6700 Axis 1 gearbox Consumables Note Article number Equipment etc Used to lubricate o rings 3HAB3537 1 Grease D 380 59x3 53 3HAB3772 93 O ring Used on gearbox D 169 5x3 3HAB3772 111 O ring Used on motor cover Continues on next page 3HAC044266 001 Revision 449 Copyright 2013 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox ...

Page 450: ...ting capacity 1 000 kg Roundsling 1 m Lifting instruction 3HAC15880 2 en closed 3HAC15556 1 Lifting accessory chain M16 3HAC14457 4 Lifting eye 3HAC14459 1 Lifting accessory motor Used to push out the motor if neces sary Always use removal tools in pairs 3HAC047108 001 Removal tool M14 Used to rotate the motor pinion 3HAC7887 1 Rotation tool Used for aligning the gearbox against the frame so that ...

Page 451: ...f the complete arm system when it is resting by itself after it has been removed Remove tools and other equipment fitted on the robot 1 See Draining the axis 1 gearbox on page 139 Begin draining the axis 1 gearbox 2 The posiition of axis 1 is needed Other wise it will not be possible to remove the mechanical stop pin xx1300000478 Jog the robot into position axis 1 5º axis 2 10º 3 DANGER Turn off a...

Page 452: ...7 Cut the cable strap inside the frame recess 7 xx1200001240 Lift up the part of the cable harness shown in the figure and let it rest against the bracket This is done in order to be able to reach all attachment screws inside the recess 8 Continues on next page 452 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox Continued ...

Page 453: ...der the balancing device Note Leave the screw closest to the axis 1 motor fitted xx1200001239 10 Robot 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 45 Axis 3 50 to 55 approximately Axis 4 5 and 6 calibration position 0 1 Continues on next page 3HAC044266 001 Revision 453 Copyright 2013 ABB All rights r...

Page 454: ...ydraulic pressure and air pressure are turned off 1 Lifting eye 3HAC16131 1 xx1200001133 Fit a lifting eye to the wrist 2 Lifting shackle SA 10 8 NA1 xx1200001234 Fit a lifting shackle in the wrist lifting eye 3 CAUTION The complete arm system weigh 1100 kg All lifting accessories used must be sized accord ingly 4 Continues on next page 454 3HAC044266 001 Revision Copyright 2013 ABB All rights res...

Page 455: ...the roundsling Note Make sure the roundsling is stretched so it can carry the weight of the frame 6 Lifting eye 3HAC16131 1 Fit a lifting eye in the arm house with a fender washer underneath 7 Fender washer Outer diameter minimum 26 mm hole diameter 13 mm thickness 3 mm xx1200001134 Continues on next page 3HAC044266 001 Revision 455 Copyright 2013 ABB All rights reserved 4 Repair 4 8 1 Replacing t...

Page 456: ... 1 000 kg xx1200001236 Disconnecting the axis 1 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 xx1200001066 Disconnect the motor cables 3 Continues on next page 456 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4...

Page 457: ...sory 1 24 VDC power supply To release the brakes connect the 24 VDC power supply 2 Connect to R2 MP1 connector pin 2 pin 5 CAUTION The motor weighs 21 kg All lifting accessories used must be sized accordingly 3 Bits extender 3HAC12342 1 xx1200001071 Unscrew the attachment screws and washers Use a bits extender in order to reach the screws 4 Guide pin M12x150 3HAC13056 2 Fit guide pins in opposite ...

Page 458: ... up to get the pinion away from the gear 8 Disconnect the 24 VDC power supply 9 Put the motor somewhere safe 10 Preparations before removing the cable harness Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1300000561 Remove the base cover 2 Continues on next page 458 3HAC044266 001 Revision Copyright 2013 ABB All rights re...

Page 459: ...in the base Note Action If used use caution and pull out the DressPack hoses through the protection tube in the base 1 If used use caution and pull out the DressPack cables through the protection tube and place it safely over the balancing device 2 Continues on next page 3HAC044266 001 Revision 459 Copyright 2013 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox Continued ...

Page 460: ...ake the frame slide better 2 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 1100 kg All lifting accessories used must be sized accordingly 4 Use caution and lift the complete arm sys tem 5 Move the complete arm system and put it down somewhere safe 6 DANGER When the complete arm system is remo...

Page 461: ...ION Leave a couple of milimeters of space between the lug and the surface of the gear box This is done in order not to damage the surface of the gearbox which is a sealing surface 3 CAUTION The gearbox weighs 92 kg All lifting accessories used must be sized accordingly 4 Lifting accessory gearbox Article number depends on robot variant i Apply the lifting accessory to the gearbox 5 xx1200001187 Pr...

Page 462: ...e for damages Especially check the surface for the sealing ring See figure Replace if damaged 1 Lifting eye 3HAC14457 4 Fit two lifting eyes manually in opposite holes in the gearbox CAUTION Leave a couple of milimeters of space between the lug and the surface of the gear box This is done in order not to damage the surface of the gearbox which is a sealing surface 2 Lifting accessory gearbox Artic...

Page 463: ...d wipe it clean Note The o ring needs to be cleaned also on a new spare part 6 xx1200001231 Wipe clean the contact surfaces from any contamination Also wipe clean the o ring groove xx1200001245 7 Put some grease on the o ring 8 Continues on next page 3HAC044266 001 Revision 463 Copyright 2013 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox Continued ...

Page 464: ...grease to make the gearbox slide better 12 Guide pin M12x200 3HAC13056 3 Always use guide pins in pairs i Robot variants IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 3HAC046112 001 Securing the gearbox Note Action Attach the guide reduction gear on top of the sealing tube 1 It will be used to protect the sealing tube from getting damaged when the gearbox is fitted Continues on next page 464 3HAC04...

Page 465: ...ment screws 5 Tightening torque 115 Nm xx1200001186 Tighten the screws 6 Refitting the armsystem Note Action Remove old residues of flange sealant and other contamination from the contact sur faces on frame and gearbox 1 Wipe clean the contact surfaces from any remaining contamination 2 Apply flange sealant Loctite 574 on the contact surface of the gearbox 3 Continues on next page 3HAC044266 001 R...

Page 466: ...ip Lubricate the guide pins with some grease to make the frame slide better Position of guide pin two xx1300000823 Aligning tool 3HAC046645 001 Put som grease on the o ring of the aligning tool 5 Put some grease on the part of the aligning tool that will mate with the hole in the gearbox 6 Also put some grease in the matching hole in the gearbox Continues on next page 466 3HAC044266 001 Revision C...

Page 467: ...e While lowering the complete arm system check that the cylindrical pin is fitted cor rectly 11 This is done to be sure that all screws will enter the gears correctly When the arm system is almost in position fit the attachment screws now accessable Do not use any tools Fit screws manually 12 Use caution and lower the complete arm system down into position on top of the gearbox 13 Tightening torqu...

Page 468: ...box 2 Wipe clean the contact surfaces from any remain ing contamination 3 Also wipe clean the o ring groove O ring 3HAB3772 107 xx1200001019 Check the o ring Replace if damaged 4 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 5 Continues on next page 468 3HAC044266 001 Revision Copyright 2013 ABB All rights res...

Page 469: ...d accordingly 2 Lifting accessory motor 3HAC14459 1 Apply the lifting accessory 3 Rotation tool 3HAC7887 1 Fit the rotation tool 4 In order to release the brakes connect the 24 VDC power supply 5 Connect to R2 MP1 connector pin 2 pin 5 CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 6 Continues on next page 3HAC044266 001 Revision 469 Copyrig...

Page 470: ...der 3HAC12342 1 Secure the motor with its attachment screws and washers 8 Tightening torque 47 Nm Use a bits extender in order to reach the screws Screw dimension M10x40 quality 12 9 Gleitmo 4 pcs xx1200001071 See Performing a leak down test on page 174 Perform a leak down test if not already done 9 Disconnect the 24 VDC power supply 10 Continues on next page 470 3HAC044266 001 Revision Copyright ...

Page 471: ...n line with its position on the base plate Make sure that the R1 SMB will be on the right side seen from behind the robot Make sure that the R1 MP will be on the left side 2 Make sure that the markings on the cables are facing upwards when connected 3 xx1300000591 Connect R1 MP and R1 SMB 4 Continues on next page 3HAC044266 001 Revision 471 Copyright 2013 ABB All rights reserved 4 Repair 4 8 1 Rep...

Page 472: ...un the DressPack hoses down through the protection tube in the base 7 Make sure that the hoses are running cor rectly and are not twisted xx1200000052 If used connect the DressPack cable package on the base plate 8 xx1300000561 Refit the base cover 9 Continues on next page 472 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox Continued ...

Page 473: ... xx1200001067 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 3HAC044266 001 Revision 473 Copyright 2013 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox Continued ...

Page 474: ...te Do not reuse the self threading attachment screws Replace with standard attachment screws The threads will otherwise be damaged Note Make sure the o ring is undamaged and properly fitted 7 Make sure that the covers are tightly sealed 8 Concluding procedure Note Action Turn on the power to the robot and jog to axis 1 5 degrees axis 2 10 degrees 1 Continues on next page 474 3HAC044266 001 Revisio...

Page 475: ... the mechanical stop pin and secure it with the attachment screw Locking liquid Loctite 243 on screw 4 Tightening torque 280 Nm xx1200001189 Refit the remaining attachment screws in the frame hole and under the balancing device 5 xx1200001237 Secure the cable harness inside the frame hole with a cable strap 6 Continues on next page 3HAC044266 001 Revision 475 Copyright 2013 ABB All rights reserved...

Page 476: ...calibration information is included in section Calibration information on page 537 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 9 476 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 8 1 Replacing the axis 1 gearbox Continued ...

Page 477: ...sition that gives the required space Location of the axis 2 gearbox The axis 2 gearbox is located as shown in the figure xx1200001276 Spare parts Note Article number Spare parts See Product manual spare parts IRB 6700 Axis 2 gearbox 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 O...

Page 478: ...n M12x150 Always use guide pins in pairs 3HAC13056 3 Guide pin M12x200 Used for aligning the gearbox against the frame so that the play in the motor does not need to be adjusted 3HAC046645 001 Aligning tool Always use guide pins in pairs 3HAC15521 2 Guide pin M10x150 Article number de pends on robot vari ant i Lifting accessory gearbox To be used with the press tool 3HAC11731 1 Hydraulic cylinder ...

Page 479: ...rness Preparations Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 1 See Draining the axis 2 gearbox on page 144 Begin draining the gearbox 2 Unloading the balancing device Note The method described in this procedure using the distance tool 3HAC030662 001 is used when the same balancing device s...

Page 480: ...bot only use the hydraulic press tool Dismantle and mounting tool 3HAC028920 001 1 This is done in order to compress the spring unit inside the balancing device be fore fitting the unloading tool Jog axis 2 to 20 or 20 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 xx1300000554 Remove the cover plate o...

Page 481: ...tion position The balancing device is now unloaded 6 Let the distance tool stay fitted during the continued procedure 7 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 8 Removing the front shaft of the balancing device Note Action Apply the lifting accessory to the balancing device 1 Raise the lifting acces...

Page 482: ... washer 4 xx1200001280 Apply the puller tool and remove the shaft in the front ear 5 xx1200001281 Put down the balancing device and let it rest on the frame 6 Continues on next page 482 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 2 gearbox Continued ...

Page 483: ...founda tion Axis 2 60 Axis 3 70 approximately Axis 4 0 Axis 5 0 Axis 6 0 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 3 Attaching the lifting accessories Use this procedure to attach the lifting accessories Note Action Lifting eye 3HAC16131 1 xx1200001133 Fit a lifting eye to the wrist 1 Continues on n...

Page 484: ... m Length 1 5 m Lifting capacity 1 000 kg xx1200001252 Run a roundsling around the lower arm place it accordingly No DressPack cable package installed Place the roundsling beneath the securing screw With DressPack cable package installed Place the roundsling beneath the ball joint housing on the outside of the lower arm 5 xx1200001253 Adjust the roundsling on the other side of the lower arm so tha...

Page 485: ... eye in the arm house with a fender washer underneath 10 Fender washer Outer diameter minimum 26 mm hole diameter 13 mm thickness 3 mm xx1200001134 If the robot is equipped with DressPack unscrew the attachment screws of the brackets that holds the ball joint housings on the wrist 11 Then move the DressPack cable package over to the other side of where the lifting accessory will be attached to the...

Page 486: ...Verifiy that the roundsling between the wrist and the lower arm is stretched To release the brake connect the 24 VDC power supply 15 Connect to connector R2 MP2 axis 2 motor pin 2 pin 5 Disconnecting the axis 2 motor cables Use this procedure to disconnect the motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Conti...

Page 487: ...hich direction the cable exit hole is facing if the motor also will be removed The motor shall be refitted in the same position 4 Use caution and pull out the motor cables 5 Removing the axis 2 motor Note Action Before removing the motor make sure that the axis 2 gearbox is completely drained 1 Continues on next page 3HAC044266 001 Revision 487 Copyright 2013 ABB All rights reserved 4 Repair 4 8 2...

Page 488: ...rs CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 6 Removal tool M14 3HAC047108 001 If required press the motor out of position by using the removal tool in opposite holes of the motor 7 CAUTION The motor weighs 26 kg All lifting accessories used must be sized accordingly 8 Lifting accessory motor 3HAC15534 1 Apply the lifting accessory 9 Us...

Page 489: ...rticle number see References on page10 xx1200000054 If robot is equipped with DressPack Open the two ball joint housings from the lower arm and lift away the cabling from the housings 1 xx1200001282 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 lowe...

Page 490: ...chment 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 1 Guide pin M16x150 3HAC13120 2 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 490 3HA...

Page 491: ...TION Use extreme caution when lifting the upper arm The cable harness is still partly con nected 5 Use a piece of wood or similar as a support under the arm house when the arm system is put down on the pallets 6 This is done in order not to damage any parts of the cable harness and DressPack Use caution and lift the arms and lay them down safely on the pallets 7 Removing the axis 2 gearbox Use the...

Page 492: ...75 3 05 150 3 20 3HAC046112 001 Refitting the axis 2 gearbox Use these procedures to refit the gearbox Follow the order of the separate procedures according to the order they are presented CAUTION When performing these procedures the cable harness will still be fitted or partly fitted to the robot Use extreme caution not to cause any damage to the cable harness Refitting the axis 2 gearbox Use thi...

Page 493: ...he gearbox into position 11 Fit the attachment screws now accessable 12 Remove the lifting accessory 13 Remove the guide pins and fit the remain ing attachment screws 14 Tightening torque 115 Nm Secure the gearbox with its attachment screws 15 i Robot variants IRB 6700 235 2 65 205 2 80 175 3 05 150 3 20 3HAC046112 001 Preparations prior to refitting motor Note Action DANGER Make sure that all sup...

Page 494: ...se for a better fitting in the groove 5 xx1200001135 Remove the cover if the motor is a new spare part 6 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 494 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 2 gearbox Continued ...

Page 495: ...ect 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 that the motor pinion is properly mated to the gear of the gearbox...

Page 496: ... 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 3 Guide pin M16x150 3HAC13120 2 Always use guide pins in pairs CAUTION The lower and upper arms together weigh 335 kg All lifting accessories used must be sized accordingly 4 See Attaching the lifting accessories on page 483 Attach the lifting accessories if not alre...

Page 497: ...he remaining attachment screws 12 The tightening torque depends on variant Secure the remaining attachment screws 13 Tightening torque 280 Nm Disconnect the 24 VDC power supply 14 Remove the lifting accessories 15 Connecting the axis 2 motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if...

Page 498: ...g and o ring groove 5 Refit the o ring 6 xx1200001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws The threads will otherwise be damaged Note Make sure the o ring is undamaged and properly fitted 7 Make sure that the covers are tightly sealed 8 Continues on next page 498 3HAC044266 001 Revision Copyr...

Page 499: ...efit the cable bracket on the frame 3 How to refit the DressPack is described in the product manual IRB 6700 DressPack For article number see References on page 10 xx1200000054 If robot is equipped with DressPack Place the cabling in the two ball joint housings on the lower arm and close the housings 4 Refitting the front shaft of the balancing device Note Action Turn on the power to the robot 1 C...

Page 500: ...556 1 xx1300000784 Align the balancing device link ear with the hole in the lower arm Note Check that the link ear is turned correctly See figure 5 xx1200001280 Lubricate the shaft and place it to the front ear 6 Dismantle and mounting tool 3HAC028920 001 Press the shaft in with the hydraulic press tool 7 xx1300000782 Apply locking liquid Loctite 2701 on the threads of the screw first entering the...

Page 501: ...he bear ing with grease from the upper hole until the grease appears in the lower hole 11 Refit the two screws and wipe clean from residual grease 12 Concluded refitting of the front shaft Note Action Remove the lifting accessory from the bal ancing device 1 Continues on next page 3HAC044266 001 Revision 501 Copyright 2013 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 2 gearbox Continu...

Page 502: ...lancing device or if the spring unit of the balancing device cannot be 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 20 or 20 4 DANGER Turn off all electric power supply hydraulic pressure supp...

Page 503: ... wrist 1 See Filling oil into the axis 2 gearbox on page 145 Refill oil to the axis 2 gearbox 2 Calibration is detailed in a separate calibra tion manual enclosed with the calibration tools Recalibrate the robot 3 General calibration information is included in section Calibration information on page 537 Continues on next page 3HAC044266 001 Revision 503 Copyright 2013 ABB All rights reserved 4 Rep...

Page 504: ...t when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 4 504 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 2 gearbox Continued ...

Page 505: ...n axis 1 into a position that gives the required space at the right hand side of the balancing device Location of the axis 3 gearbox The axis 3 gearbox is located as shown in the figure xx1300000515 Spare parts Note Spare part number Spare parts See Product manu al spare parts IRB 6700 Axis 3 gearbox Required tools and equipment Note Article number Equipment etc The capacity of the vessel must be ...

Page 506: ...parts from robot Pallet Always use guide pins in pairs 3HAC13056 2 Guide pin M12x150 Always use guide pins in pairs 3HAC13120 3 Guide pin M16x200 Used to rotate the motor pinion 3HAC7887 1 Rotation tool Used to release the motor brakes 24 VDC power supply 3HAC0207 1 Leak down tester 3HAC15716 1 Calibration Pendulum toolkit Content is defined in section Standard toolkit on page 559 Standard toolkit...

Page 507: ...e founda tion See Note Axis 2 60 Axis 3 60 Axis 4 0 Axis 5 0 Axis 6 0 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 xx1200001331 A Attachment screw to be removed B Attachment screw not to be removed Unscrew the uppermost attachment screw that holds the bracket of the DressPack cable package if one is ...

Page 508: ...connecting the axis 3 and axis 4 motor cables Use this procedure to disconnect the motor cables on the axis 3 and axis 4 motors Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page 508 3HAC044266 001 Revision Copyright 2013 A...

Page 509: ...e this procedure to loosen required cable brackets of the robot cable harness in order to get the longest possible length of the cable harness between the lower and upper arm Note Action xx1300000558 Loosen the axis 3 lower arm metal clamp the one closest to the axis 3 gearbox located on the inside of the lower arm by removing the attachment screw Note The screw is reached from the outside of the ...

Page 510: ...acket under the arm house by removing the screws 3 xx1300000544 Open the velcro strap on cable fixing bracket If equipped with DressPack instead open the velcro straps on the cable guide 4 Continues on next page 510 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 3 gearbox Continued ...

Page 511: ... away the cabling from the ball joint housings 6 If robot is equipped with DressPack 7 Lift the DressPack cable package at the arm house up and put the cable bracket on the cable guide where the velcro strap normally is fitted Secure the temporary position with a velcro strap or similar to ensure it will not fall down or damage any thing Attaching the lifting accessories Use this procedure to atta...

Page 512: ...he wrist 4 Raise the lifting accessories to take the weight of the upper arm 5 In case of necessary adjustments use the shortening loops on the lifting accessory chain making sure to place the chain the right way through the loops 6 Release the brakes in order to find the most level lifting position of the upper arm as possible before lifting 7 24 VDC power supply In order to release the brakes co...

Page 513: ...g mating motor and gear box the gears may be damaged if excess ive force is used 6 Removal tool M14 3HAC047108 001 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 order to get the pinion away from the gear and let the motor rest on the guide pins 8 ...

Page 514: ...y 12 Make sure the pinion is not damaged in the process xx1200001131 Use caution and remove the motor by lift ing it straight out Put the motor somewhere safe 13 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 1 Guide pin M12x200 3HAC13056 3 Always use guide pins in pairs xx1300000659 Screws that s...

Page 515: ... Make sure the lift is done completely level In case of necessary adjustments use the shortening loops on the lifting accessory chain but make sure to place the chain the right way through the loops 4 xx1300001610 Remove the remaining attachment screw and slide the upper arm on to the guide pins 5 CAUTION If the cable harness is still fitted or partly fitted use extreme caution when lifting the up...

Page 516: ...2x150 3HAC13056 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 gearbox slide better 1 Always use guide pins in pairs xx1300001969 xx1300001970 Remove all but one of the remaining attach ment screws 2 ScrewsM8x75 fully threaded Used to push out the gearbox if necessary Fit three fully threaded screws and us...

Page 517: ...e guide pins 8 Remove the gearbox and put it somewhere safe 9 Refitting the axis 3 gearbox Use these procedures to refit the axis 3 gearbox Follow the order of the separate procedures according to the order they are presented CAUTION When performing the following procedures the cable harness will still be fitted or partly fitted to the robot Use extreme caution not to cause any damage to the cable...

Page 518: ...arbox slide better 10 Always use guide pins in pairs Use caution and lift the gearbox and let it rest on the guide pins 11 Secure the gearbox with its attachment screws 12 Remove the guide pins and replace with the remaining attachment screws 13 Remove the lifting accessory 14 See Performing a leak down test on page 174 Perform a leak down test 15 Tightening torque 115 Nm Tighten the attachment sc...

Page 519: ...tted 4 Lift the upper arm and put it on the guide pins 5 24 VDC power supply In order to release the brakes connect the 24 VDC power supply 6 Connect to R2 MP3 connector pin 2 pin 5 Rotation tool Use the rotation tool and rotate the axis 3 motor to find the correct position for the guide pins in the lower arm 7 xx1300000747 Insert all nine M16 screws and 25 of the 27 M12 screws 8 M16 tightening to...

Page 520: ...ulic pressure and air pressure are turned off 1 Remove old paint residues and other contamina tion from the contact surfaces on both motor and gearbox 2 Wipe clean the contact surfaces from any remain ing contamination 3 Also wipe clean the o ring groove O ring 3HAB3772 107 xx1200001019 Check the o ring Replace if damaged 4 Continues on next page 520 3HAC044266 001 Revision Copyright 2013 ABB All ...

Page 521: ... secure the motor Note Action Fit guide pins in opposite holes 1 CAUTION The motor weighs 24 kg All lifting accessories used must be sized accordingly 2 Lifting accessory motor 3HAC15534 1 Apply the lifting accessory to the motor 3 xx1200001129 Note Make sure the cable exit hole is turned the correct way See figure 4 Continues on next page 3HAC044266 001 Revision 521 Copyright 2013 ABB All rights ...

Page 522: ...upply 8 Connect to connector R2 MP3 pin 2 pin 5 CAUTION Whenever parting mating motor and gearbox the gears may be damaged if excessive force is used 9 xx1200001129 Use caution and push the motor in position while at the same time the motor pinion is slightly rotated Pay attention to following points Make sure the cable exit hole is turned the correct way See figure Mate the motor pinion properly ...

Page 523: ...rocedure to refit the cable brackets Note Action Remove the lifting accessories 1 Move the cable harness and DressPack back to the correct side of the robot 2 xx1300000558 Refit 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 3 Continues on next page 3HAC044266 001 Revision 523...

Page 524: ...00000544 Secure the cable harness with the velcro strap on the cable fixing bracket If equipped with DressPack instead secure both DressPack and cable harness with velcro straps on the cable guide 6 Continues on next page 524 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 3 gearbox Continued ...

Page 525: ...r cables Use this procedure to connect the motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page 3HAC044266 001 Revision 525 Copyright 2013 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 3 gearbox Continued ...

Page 526: ...g and o ring groove 5 Refit the o ring 6 xx1200001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws The threads will otherwise be damaged Note Make sure the o ring is undamaged and properly fitted 7 Make sure that the covers are tightly sealed 8 Continues on next page 526 3HAC044266 001 Revision Copyr...

Page 527: ...ckage if one is fitted with its attachment screws Note It is not needed to disconnect the lower end of the DressPack as the figure shows Connectors are only hidden here to get a better view of which screw to refit 4 Calibration is detailed in a separate calibra tion manual enclosed with the calibration tools Recalibrate the robot 5 General calibration information is included in section Calibration...

Page 528: ...t when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 6 528 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 3 gearbox Continued ...

Page 529: ... the motor pinion 3HAC7887 1 Rotation tool Used to release the motor brakes 24 VDC power supply 3HAC0207 1 Leak down tester 3HAC15716 1 Calibration Pendulum toolkit Content is defined in section Standard toolkit on page 559 Standard toolkit Consumables Note Article number Equipment etc Used to lubricate o rings 3HAB3537 1 Grease D 102x3 3HAB3772 107 O ring Used on motor flange Continues on next pa...

Page 530: ...obot is secured to the founda tion Axis 2 25 Axis 3 20 Axis 4 0 Axis 5 37 Axis 6 10 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 2 Remove all equipment fitted on the turning disk 3 See Draining the axis 6 gearbox on page 161 Drain the gearbox 4 Continues on next page 530 3HAC044266 001 Revision Copyrig...

Page 531: ...Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the robot working area 7 xx1300000825 Remove the synchronization plate axis 6 8 Continues on next page 3HAC044266 001 Revision 531 Copyright 2013 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 6 gearbox Continued ...

Page 532: ...the process turning disk Use the procedure to remove the DressPack process disk if one is fitted Note Action xx1300000599 Remove the attachment screws that secure the process turning disk 1 The figure show IRB 6640 Continues on next page 532 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 6 gearbox Continued ...

Page 533: ...g motor and gear box the gears may be damaged if excess ive force is used 2 Screw dimension depends on variant If required fit two attachment screws and press out the gearbox 3 xx1300000827 Use caution and remove the gearbox CAUTION Be careful not to damage motor pinion or gears 4 Continues on next page 3HAC044266 001 Revision 533 Copyright 2013 ABB All rights reserved 4 Repair 4 8 4 Replacing the...

Page 534: ... the contact surfaces from any contamination 4 Also wipe clean the o ring groove Put some grease on the 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 xx1300000827 Use caution and refit the gearbox to the wrist CAUTION Be careful not to damage m...

Page 535: ...nto the axis 6 gearbox on page 163 Refill oil in the gearbox 6 Refitting the turning disk Note Action Wipe clean the contacts surfaces 1 Tightening torque 35 Nm Secure the turning disk with its attachment screws and washers 2 Attachment screws M8x25 Steel 12 9 Gleitmo 603 24 pcs Washers steel 8 4x13x1 5 24 pcs xx1300000492 Continues on next page 3HAC044266 001 Revision 535 Copyright 2013 ABB All r...

Page 536: ...t 2 General calibration information is included in section Calibration information on page 537 DANGER Make sure all safety requirements are met when performing the first test run These are further detailed in the section DANGER First test run may cause injury or damage on page 44 3 536 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 6 gearbox Contin...

Page 537: ...ays necessary to calibrate for new absolute accuracy The resolver values will change when parts affecting the calibration position are replaced on the robot for example motors or parts of the transmission The revolution counter memory is lost If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 542 This will occur when The battery is discha...

Page 538: ...he Absolute accuracy calibration also com pensates for Mechanical tolerances 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 o...

Page 539: ...sian coordinate system Absolute Accuracy calibration is used as a TCP calibration The CalibWare tool guides through the calibration process and calculates new compensation parameters This is further detailed in the Application manual CalibWare Field 5 0 If a service operation is done to a robot with the option Absolute Accuracy a new absolute accuracy calibration is required in order to establish ...

Page 540: ...t axis position for all robot models Calibration scales marks IRB 6700 Axis 2 xx1300000869 Axis 1 xx1300000868 Axis 4 xx1300000871 Axis 3 xx1300000870 Axis 6 xx1300000873 Axis 5 xx1300000872 540 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 5 Calibration information 5 3 Calibration scale and correct axis position ...

Page 541: ... shown in the graphic below This is normally handled by the robot calibration software Calibration 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 3HAC044266 001 Revision 541 Copyright 2013 ABB All rights reserved 5 Calibration...

Page 542: ...cording to the correct calibration values not only according to the calibration 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 before the revolution counters are updated If one of the following mentioned axes are rotated...

Page 543: ...xes Then tap Update 4 A dialog box is displayed warning that the 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 ticked revolution counters and removes the tick from the list of axes 5 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipul...

Page 544: ...on on page540 and Updat ing revolution counters on page542 Check that the calibration marks for the axes align correctly If they do not update the revolution counters 6 Using the jogging window Use this procedure to jog the robot to the zero 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 1 2 or 3 3 ...

Page 545: ...m Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with local regulations Do not dispose of oil and grease near lakes ponds ditches down drains or onto soil Incineration must be carried out under controlled conditions in accordance with local regulations Also note that Spills can form a film on water surfaces causi...

Page 546: ...e all batteries from the robot If a battery is exposed to heat for example from a blow torch it will explode Always remove all oil in gearboxes If exposed to heat for example from a blow torch the oil will catch fire When motors are removed from the robot the robot will collaps if not properly supported before motor removal 546 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 6 Decom...

Page 547: ...to these 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 decom...

Page 548: ...ance 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 Cut a hole in the housing as shown in the figure 4 The measurements shown below are maxim um values 400 m m 200 mm xx0700000391 DANGER There is stored energy buil...

Page 549: ... cut at least five coils Middle spring cut at least four coils Inner spring cut at least four coils 6 Double check the number of coils cut and make sure all the tension in the springs is removed 7 3HAC044266 001 Revision 549 Copyright 2013 ABB All rights reserved 6 Decommissioning 6 3 Decommissioning of balancing device Continued ...

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Page 551: ...General This chapter includes general information complementing the more specific information in the different procedures in the manual 3HAC044266 001 Revision 551 Copyright 2013 ABB All rights reserved 7 Reference information 7 1 Introduction ...

Page 552: ...1 EMC Generic immunity EN IEC 61000 6 2 Arc welding equipment Part 1 Welding power sources EN IEC 60974 1iii Arc welding equipment Part 10 EMC requirements EN IEC 60974 10iii Safety of machinery Electrical equipment of machines Part 1 General requirements EN IEC 60204 1 Degrees of protection provided by enclosures IP code IEC 60529 i There is a deviation from paragraph 6 2 in that only worst case ...

Page 553: ...quipment ANSI UL 1740 option 429 1 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 03 option 429 1 3HAC044266 001 Revision 553 Copyright 2013 ABB All rights reserved 7 Reference information 7 2 Applicable safety standards Continued ...

Page 554: ...Units Quantity 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 554 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 7 Reference information 7 3 Unit conversion ...

Page 555: ...rile rubber type should be used 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 thread 2 Apply lubricant between the plain washer and screw head 3 Screw dimensions of M8 or larger must be tightened with a torque wre...

Page 556: ...torque for oil lubricated screws with allen head screws Tightening torque Nm Class 12 9 oil lubric ated Tightening torque Nm Class 10 9 oil lubric ated Tightening torque Nm Class 8 8 oil lubricated Dimension 6 M5 10 M6 40 34 24 M8 80 67 47 M10 140 115 82 M12 340 290 200 M16 670 560 400 M20 1150 960 680 M24 Lubricated screws Molycote Gleitmo or equivalent with allen head screws The following table ...

Page 557: ...ng table specifies the recommended standard tightening torque for water and air connectors when one or both connectors are made of brass Tightening torque Nm Max Tightening torque Nm Min Tightening torque Nm Nominal Dimension 15 8 12 1 8 20 10 15 1 4 25 15 20 3 8 50 30 40 1 2 90 55 70 3 4 3HAC044266 001 Revision 557 Copyright 2013 ABB All rights reserved 7 Reference information 7 4 Screw joints Co...

Page 558: ...a lifting accessory 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 558 3HAC044266 001 Revision Copyright 2013 ABB All rights rese...

Page 559: ... standard toolkit 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 socke...

Page 560: ...ired tools are a sum of standard tools defined in the section Standard toolkit on page 559 and of special tools listed directly in the instructions and also gathered in this section Special tools Continues on next page 560 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 7 Reference information 7 7 Special tools ...

Page 561: ...2 2 2 x x Guide pin M12x150 3HAC13056 2 x x x x x Guide pin M12x200 3HAC13056 3 Guide pin M12x250 3HAC13056 4 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 Article number depends on r...

Page 562: ... x Roundsling 1 5 m Length 1 5 m Lifting capacity 1 000 kg x x x x x x x x x x Roundsling 1 m Length 1 m Lifting capacity 1 000 kg Press puller and unloading tools x x ii x AdapterM20 M16 3HAC12475 6 x x x ii x xx1300000675 Anvil 3HAC047273 001 x x x x x Dismantle and mounting tool 3HAC028920 001 x x x x Distance tool 3HAC030662 001 x x x x Hydraulic cylinder 3HAC11731 1 x x x x Hydraulic pump 80 ...

Page 563: ...08 001 Other tools x x x x x x x x x x x x x 24 VDC power supply x Aligning tool 3HAC046645 001 x x x Long AllenKeySocketIN19L 6 140 x x x x x Bits extender 3HAC12342 1 x x x x x x x x x x x x x x Calibration Pendulum toolkit 3HAC15716 1 x x x x x x x x x x Leak down tester 3HAC0207 1 x x x x Lock screw M16x120 Measuring ring radial seal 3HAC043870 015 x x x x x x Oil collecting vessel x x x x x x...

Page 564: ...ch piece of lifting 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 564 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 7 Reference information 7 8 Lifting accessories and lifting instructions ...

Page 565: ... Location Spare parts and exploded views are not included in the manual but delivered as a separate document on the documentation DVD 3HAC044266 001 Revision 565 Copyright 2013 ABB All rights reserved 8 Spare parts 8 1 Spare part lists and illustrations ...

Page 566: ...This page is intentionally left blank ...

Page 567: ...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 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 type A 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB 2400 3HAC029570 007 Circuit diagram IRB 2600 3HAC...

Page 568: ...t diagram IRB 6650S 3HAC025744 001 3HAC025744 001 Circuit diagram IRB 6660 3HAC029940 001 3HAC043446 005 Circuit diagram IRB 6700 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 568 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved 9 Circuit diagrams 9 1 About circuit diagrams Continued ...

Page 569: ...pe 538 rough 542 standard type 538 when to calibrate 537 calibration Absolute Accuracy 539 calibration manuals 539 calibration marks 540 calibration position 542 checking 544 jogging to 544 scales 540 calibration scales 540 CalibWare 538 carbon dioxide extinguisher 28 cast iron disposal 545 changing oil axis 1 138 axis 2 143 axis 3 148 axis 4 153 axis 5 157 axis 6 161 cleaning robot 170 connecting...

Page 570: ...179 lower and upper arm together 183 robot 78 upper arm 188 lifting accessory 558 lifting robot with fork lift 69 Lithium disposal 545 lower arm replacing 297 lubricating spherical roller bearing 168 lubrication amount in gearboxes 137 type of lubrication 137 M main power switching off 46 main switch controller cabinet 46 control module 46 drive module 46 maintenance intervals 101 maintenance sche...

Page 571: ...pulators 43 reduced speed function 31 release manipulator arm 29 service 17 signals 36 signals in manual 36 symbols 36 symbols on manipulator 38 test run 44 working range 33 wrist strap 47 safety equipment mechanical stop 94 signal lamp 136 safety risk electric parts 25 hot parts 21 hydraulic system 23 installation 18 oil change 49 operational disturbance 24 pneumatic system 23 service work 18 too...

Page 572: ...eight axis 1 motor 389 392 457 469 base plate 72 76 robot 71 81 460 467 558 working range restricting axis 1 94 wrist replacing 274 572 3HAC044266 001 Revision Copyright 2013 ABB All rights reserved Index ...

Page 573: ......

Page 574: ...one 46 0 21 344 400 ABB AS Robotics Discrete Automation and Motion Box 265 N 4349 BRYNE Norway Telephone 47 51489000 ABB Engineering Shanghai Ltd 5 Lane 369 ChuangYe Road KangQiao Town PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 www abb com robotics 3HAC044266 001 Rev en ...

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