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2 Installation and commissioning

2.1 Introduction to installation and commissioning

General

This chapter contains assembly instructions and information for installing the IRB
6700Inv controller at the working site.

See also the product manual for the robot controller.

The installation must be done by qualified installation personnel in accordance
with the safety requirements set forth in the applicable national and regional
standards and regulations.

Safety information

Before any installation work is commenced, it is extremely important that all safety
information is observed.

There are general safety aspects that must be read through, as well as more specific
safety information that describes the danger and safety risks when performing the
procedures. Read the chapter

Safety on page 17

before performing any installation

work.

Note

If the IRB 6700Inv is connected to power, always make sure that the robot is
connected to protective earth and a residual current device (RCD) before starting
any installation work.

For more information see:

•

Product manual - IRC5

Product manual - IRB 6700Inv

41

3HAC058254-001 Revision: L

© Copyright 2017 - 2020 ABB. All rights reserved.

2 Installation and commissioning

2.1 Introduction to installation and commissioning

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Summary of Contents for IRB 6700I

Page 1: ...ROBOTICS Product manual IRB 6700Inv ...

Page 2: ...Trace back information Workspace 20D version a8 Checked in 2020 12 11 Skribenta version 5 3 075 ...

Page 3: ...Product manual IRB 6700Inv 300 2 60 IRB 6700Inv 245 2 90 IRC5 Document ID 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved Specifications subject to change without notice ...

Page 4: ...ty by ABB for losses damage to persons or property fitness for a specific purpose or the like In no event shall ABB be liable for incidental or consequential damages arising from use of this manual and products described herein This manual and parts thereof must not be reproduced or copied without ABB s written permission Keep for future reference Additional copies of this manual may be obtained f...

Page 5: ...4 2 3 1 Robot transportation precautions 55 2 3 2 Securing the robot arm position for lift rotation and transportation 58 2 4 On site installation 58 2 4 1 Brief installation procedure 59 2 4 2 Lifting the robot 59 2 4 2 1 Lifting the robot with fork lift 60 2 4 2 2 Lifting the robot with roundslings 64 2 4 3 Orienting rotating and securing the robot 68 2 4 4 Manually releasing the brakes 70 2 4 5...

Page 6: ...placing the SMB battery 177 3 5 Lubrication activities 177 3 5 1 Lubricating the spherical roller bearing balancing device 179 3 6 Cleaning activities 179 3 6 1 Cleaning the IRB 6700Inv 183 4 Repair 183 4 1 Introduction 184 4 2 General procedures 184 4 2 1 Performing a leak down test 185 4 2 2 Mounting instructions for bearings 187 4 2 3 Mounting instructions for sealings 190 4 2 4 Service stops 1...

Page 7: ... for axes 679 5 2 2 Calibration movement directions for all axes 680 5 3 Updating revolution counters 683 5 4 Calibrating with Axis Calibration method 683 5 4 1 Description of Axis Calibration 686 5 4 2 Calibration tools for Axis Calibration 688 5 4 3 Installation locations for the calibration tools 689 5 4 4 Axis Calibration Running the calibration procedure 694 5 4 5 Reference calibration 696 5 ...

Page 8: ...725 Index 8 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved Table of contents ...

Page 9: ...the IRB 6700Inv Some variants and designs may have been removed from the business offer and are no longer available for purchase Organization of chapters The manual is organized in the following chapters Contents Chapter Safety information that must be read through before performing any installation or service work on robot Contains general safety aspects as well as more specific information on ho...

Page 10: ...tion IRB 6700 3HAC060303 001 Directions for use Fork lift accessory for IRB 6700Inv 3HAC043446 005 Circuit diagram IRB 6700 IRB 6790 3HAC044270 001 Product manual DressPack SpotPack IRB 6700 3HAC031045 001 Safety manual for robot Manipulator and IRC5 or OmniCore con troller i 3HAC047136 001 Product manual IRC5 IRC5 with main computer DSQC1000 3HAC021313 001 IRC5 with main computer DSQC 639 3HAC050...

Page 11: ...ng disconnecting and reconnecting battery cable to serial measurement board Information about high stress on mounting screws added Repair procedure for axis 1 gearbox is updated regarding removal of VK covers small o ring beneath the gearbox and applying flange sealant Definition of reference calibration clarified B Published in release R18 1 The following updates are made in this revi sion Inform...

Page 12: ... for the front link ear Replaced article number and name of grease previously 3HAB3537 1 Clarified and added information in mounting instructions for rotat ing sealings see Mounting instructions for sealings on page 187 Clarified text about position of robot and added table with depend encies between axes during Axis Calibration H Published in release 20B The following updates are made in this rev...

Page 13: ...ing Reference information safety standards unit conversions screw joints lists of tools Spare parts list with corresponding figures or references to separate spare parts lists References to circuit diagrams Technical reference manuals The technical reference manuals describe reference information for robotics products for example lubrication the RAPID language and system parameters Application man...

Page 14: ... The manuals are aimed at those having first hand operational contact with the product that is production cell operators programmers and troubleshooters 14 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved Product documentation Continued ...

Page 15: ...nclude specific safety information when dangerous steps are to be performed Read more in the chapter Safety on page 17 Illustrations The product is illustrated with general figures that does not take painting or protection type in consideration Likewise certain work methods or general information that is valid for several product models can be illustrated with illustrations that show a different p...

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

Page 18: ...ce of alcohol drugs or any other intoxicating substances are not allowed to install maintain service repair or use the robot The plant liable must make sure that the personnel is trained on the robot and on responding to emergency or abnormal situations Personal protective equipment Use personal protective equipment as stated in the product manual 18 Product manual IRB 6700Inv 3HAC058254 001 Revis...

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

Page 20: ... to indicate where to find additional information or how to do an operation in an easier way TIP 20 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 1 Safety 1 2 1 Safety signals in the manual Continued ...

Page 21: ...ption 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 poisonous gases risk of crushing impact fall from height etc Caution xx09000008...

Page 22: ...not disassemble xx0900000815 Disassembling this part can cause injury Extended rotation xx0900000814 This axis has extended rotation working area compared to standard Brake release xx0900000808 Pressing this button will release the brakes This means that the robot arm can fall down Continues on next page 22 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights res...

Page 23: ...ver if the bolts are not securely fastened xx1500002402 Crush xx0900000817 Risk of crush injuries Continues on next page Product manual IRB 6700Inv 23 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 24: ... to move in opposite direction in regard to gravity due to the pushing force from the balancing device Current arm load and position of the lower and upper arm determines the occurring movement when releasing the holding brakes of the axis 2 motor Lifting of balancing device xx1700000520 Center of gravity will cause the balancing device to tip over when released in the front ear Continues on next ...

Page 25: ...n move unexpectedly when floor standing Always use transportation lock screw in floor standing position Brake release buttons xx0900000820 xx1000001140 Lifting bolt xx0900000821 Continues on next page Product manual IRB 6700Inv 25 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 26: ...ed Mechanical stop xx0900000824 No mechanical stop xx1000001144 Stored energy xx0900000825 Warns that this part contains stored energy Used in combination with Do not disassemble symbol Continues on next page 26 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 27: ...level Shut off with handle xx0900000827 Use the power switch on the controller Do not step xx1400002648 Warns that stepping on these parts can cause damage to the parts Product manual IRB 6700Inv 27 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 1 Safety 1 2 2 Safety symbols on manipulator labels Continued ...

Page 28: ...otective stops and emergency stops are described in the product manual for the controller For more information see Product manual IRC5 28 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 1 Safety 1 3 Robot stopping functions ...

Page 29: ... if dropped or released at maximum speed The maximum possible impact caused by a breaking or malfunctioning rotating tool or other device fitted to the robot The maximum TCP speed and the maximum velocity of the robot axes are detailed in the section Robot motion in the product specification for the respective manipulator Consider exposure to hazards such as slipping tripping and falling Consider ...

Page 30: ...hen integrating the robot with external devices to a robot system The integrator of the robot system must ensure that emergency stop functions are interlocked in accordance with applicable standards The integrator of the robot system must ensure that safety functions are interlocked in accordance with applicable standards Other hazards WARNING Never stay beneath a robot arm Gravity and the release...

Page 31: ...o drop Dump valves should be used in case of emergency Shot bolts should be used to prevent tools etc from falling due to gravity All pipes hoses and connections have to be inspected regularly for leaks and damage Damage must be repaired immediately Verify the safety functions Before the robot system is put into operation verify that the safety functions are working as intended and that any remain...

Page 32: ...release of braking devices can create additional hazards A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment 32 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 1 Safety 1 5 1 Unexpected movement of robot arm ...

Page 33: ...bricants oil or grease When handling oil grease or other chemical substances the safety information of the respective manufacturer must be observed Note Take special care when handling hot lubricants Elimination Action Description Warning Make sure that protective gear like goggles and gloves are al ways worn during this activity Changing and draining gearbox oil or grease may require hand ling ho...

Page 34: ...cified amount de pends on drained volume For lifetime reasons always drain as much oil as possible from the gearbox The magnetic oil plugs will gather residual metal chips Contaminated oil in gearboxes Hazards related to batteries Under rated conditions the electrode materials and liquid electrolyte in the batteries are sealed and not exposed to the outside There is a hazard in case of abuse mecha...

Page 35: ...form unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Related information See also the safety information related to installation and operation Product manual IRB 6700Inv 35 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 1 Safety 1 6 1 Maintenance and repair Continued ...

Page 36: ...son Make sure that stored energy from the balancing device does not result in additional hazards such as even more severe injuries on a trapped person DANGER When releasing the holding brakes the robot axes may move very quickly and sometimes in unexpected ways Release of the axis 2 motor holding brakes can cause the axis 2 to move in opposite direction in regard to gravity due to the pushing forc...

Page 37: ... described below 1 Run each axis to a position where the combined weight of the manipulator and any load is maximized maximum static load 2 Switch the motor to the MOTORS OFF 3 Inspect and verify that the axis maintains its position If the manipulator does not change position as the motors are switched off then the brake function is adequate Product manual IRB 6700Inv 37 3HAC058254 001 Revision L ...

Page 38: ...engineers A risk assessment must be done to address both robot and robot system specific hazards WARNING Never stay beneath a robot arm Gravity and the release of braking devices can create additional hazards A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Related information See also the safety information ...

Page 39: ... Gravity and the release of braking devices can create additional hazards A robot may perform unexpected limited movement WARNING Manipulator movements can cause serious injuries on users and may damage equipment Product manual IRB 6700Inv 39 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 1 Safety 1 8 Decommissioning ...

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Page 41: ...xtremely important that all safety information is observed There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page17 before performing any installation work Note If the IRB 6700Inv is connected to power always make sure that the robot is connected...

Page 42: ...ired is suitable to handle the weight of the robot as specified in Weight robot on page 43 5 If the robot is not installed directly it must be stored as described in Storage condi tions robot on page 44 6 Make sure that the expected operating environment of the robot conforms to the specifications as described in Operating conditions robot on page 45 7 Before taking the robot to its installation s...

Page 43: ... robots xy xy z z T F F T xx1100000521 Force in any direction in the XY plane Fxy Force in the Z plane Fz Bending torque in any direction in the XY plane Txy Bending torque in the Z plane Tz The table shows the various forces and torques working on the robot during different kinds of operation Note These forces and torques are extreme values that are rarely encountered during operation The values ...

Page 44: ... interpreted as the frequency of the robot mass inertia robot assumed stiff when a foundation translational torsional elasticity is added i e the stiffness of the pedestal where the robot is mounted The minimum resonance frequency should not be interpreted as the resonance frequency of the building floor etc For example if the equivalent mass of the floor is very high it will not affect robot move...

Page 45: ...ecommended to be run with the robot Otherwise there is a risk that the robot stops or runs with lower performance due to temperature dependent oil and grease viscosity Protection classes robot The table shows the available protection types of the robot with the corresponding protection class Protection class Protection type IP67 Manipulator protection type Standard IP67 Manipulator protection type...

Page 46: ... some areas to avoid collision with balancing See Working range axis 2 and axis 3 for IRB 6700Inv 300 2 60 and 245 2 90 on page 48 ii Working range 120 to 120 for robots with LeanID option 780 4 iii Working range 220 to 220 for robots with LeanID option 780 4 Illustration working range IRB 6700Inv 300 2 60 This illustration shows the unrestricted working range of the robot 957 3204 1321 1812 2617 ...

Page 47: ...g range of the robot 2864 162 1057 2060 3451 1518 Reach Handling capacity Robot type 2 90 m 245 kg IRB 6700Inv Continues on next page Product manual IRB 6700Inv 47 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 48: ...245 2 90 Limited in some areas to avoid collision with balancing xx1700000510 Continues on next page 48 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 49: ...000575 R1 mm Robot variant 2617 IRB 6700Inv 300 2 60 2864 IRB 6700Inv 245 2 90 Product manual IRB 6700Inv 49 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and commissioning 2 2 2 Working range Continued ...

Page 50: ...tation lock screw The robot arm system must always be locked in a secure position during lift transport or rotation to inverted or standing position This is done by locking the lower arm in position with a transportation lock screw At delivery the robot and the lower arm is already locked in the correct position with the transportation lock screw Continues on next page 50 Product manual IRB 6700In...

Page 51: ...transportation lock screw and sleeve to lock the lower arm at transportation turning and floor standing WARNING The robot will be mechanically unstable if not properly secured to the foundation Product manual IRB 6700Inv 51 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and commissioning 2 2 3 Risk of tipping stability Continued ...

Page 52: ...6 mm B Radius ax1 back 910 mm C J H G F LeanID F E D A LeanID A Robot variant 187 222 5 1212 5 1878 5 1718 5 1145 2372 380 220 IRB 6700Inv 300 2 60 186 222 5 1468 5 2128 5 1968 5 1145 2372 380 220 IRB 6700Inv 245 2 90 52 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and commissioning 2 2 4 Main dimensions ...

Page 53: ...dling Note Action Wrist straps must be tested frequently to ensure that they are not damaged and are operating cor rectly Product manual IRC5 Use a wrist strap The wrist strap button is located inside the control ler 1 The mat must be grounded through a current limit ing resistor Use an ESD protective floor mat 2 The mat should provide a controlled discharge of static voltages and must be grounded...

Page 54: ... method 1 is strongly recommended by ABB xx0800000030 Always follow these instructions when transporting an ABB robot according to method 1 Always remove the tool before transportation of the robot Always place the robot in the ABB recommended transport position described in section Risk of tipping stability on page 50 Always read and follow the instructions in section Pre installation procedure o...

Page 55: ... robot when it is lifted transported or rotated Temporarily floor standing of the robot Always keep the the transportation lock screw and sleeve in locked position when the robot is floor standing During some repair activities the transportation lock screw and sleeve is replaced with service stops These situations are clearly stated in the current repair activities in this manual The service stops...

Page 56: ...t is lifted transported or rotated 1 Securing the lower arm Use this procedure to secure the lower arm Note Action If lifting rotating or transporting the robot all axes angles have to be defined See Orienting rotating and securing the robot on page64 Jog axis 2 to 35 1 xx1700000270 Remove the transportation lock screw and the yellow sleeve from the parking position 2 Continues on next page 56 Pro...

Page 57: ...ansportation lock screw and sleeve to lock the lower arm at transportation turning and floor standing 3 xx1600002114 Storing the transportation lock screw when not in use Note Action xx1600002008 Keep the transportation lock screw stored in the parking position when not in use 1 Product manual IRB 6700Inv 57 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and c...

Page 58: ...e manipulator to the plat form foundation 3 See Orienting rotating and secur ing the robot on page 64 See Product manual IRC5 Connect the manipulator to the controller 4 See Product manual IRC5 Configure the safety settings 5 See Product manual IRC5 How to start and run the robot is described in the product manual for the controller 6 Install required equipment if any Signal lamp option on page 85...

Page 59: ... lift pockets and all required hardware for installation User instructions are enclosed with the tool see Directions for use Fork lift accessory for IRB 6700Inv In order to rotate the robot either use the turning tool or a fork lift truck with a rotator attachment 3HAC058825 001 Fork lift accessory set User instructions are enclosed 3HAC061162 001 Turning tool Required documents Document number Do...

Page 60: ...gth B 1 pc Do not strain Length A 1 pc Do not strain Variant Roundsling 2 5 m Roundsling 2 5 m IRB 6700Inv 300 2 60 Roundsling 2 5 m Roundsling 2 5 m IRB 6700Inv 245 2 90 Roundsling 2 5 m 4 pcs C Lifting eye M20 4 pcs D Required equipment See quantity of roundslings in figure Attaching the roundslings on page 60 Note Article number Equipment etc Overhead crane Working load limit 2 000 kg Lifting e...

Page 61: ...sportation lock screw in the locking position 1 See Securing the robot arm position for lift rotation and transportation on page55 xx1200001301 Fit lifting eyes to the outer holes on each corner of the base 2 xx1200001302 Continues on next page Product manual IRB 6700Inv 61 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and commissioning 2 4 2 2 Lifting the ro...

Page 62: ...ing sling must not be strained at lifting It only secures for tipping 4 Length for the roundsling is given in the table Attaching the roundslings on page 60 xx1300001574 Attach a securing roundsling at the front according to figure Note The securing sling must not be strained at lifting It only secures for tipping 5 CAUTION The IRB 6700Inv robot weighs 1 750 kg All lifting accessories used must be...

Page 63: ...nt left corner is positioned on the correct side of the brake release unit plate when stretching the roundslings with the crane 8 Product manual IRB 6700Inv 63 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and commissioning 2 4 2 2 Lifting the robot with roundslings Continued ...

Page 64: ...n positioning and securing the robot D D 8x 30 8x 53 4x 45 H7 4 x 3 x 4 5 1 6 8 x 4 9 5 0 3 A 0 12 A 800 4x 90 5 2 5 4 x 1 5 D D E E 2x 25 H8 2 0 2 5 H 8 2 x 4 5 2 4 5 2 x 0 12 E E A A xx1300000243 Description Pos Holes for guide pins x2 A Continues on next page 64 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and commissioning 2 4 ...

Page 65: ... tool or a fork lift truck with a rotator attachment 3HAC058825 001 Fork lift accessory set User instructions are enclosed 3HAC061162 001 Turning tool Required documents Document number Document 3HAC060303 Directions for use Fork lift accessory for IRB 6700Inv User instructions for turning tool enclosed with the turning tool Securing the robot Use this procedure to secure the robot to the foundati...

Page 66: ... 70 Nm 15 Nm xx1700000347 Insert the yellow sleeve and the transportation lock screw in the hole at the locking position Insert the sleeve all the way so that the marking in the sleeve is aligned with the casting see fig ure Tighten the screw DANGER Always use the transportation lock screw and sleeve to lock the lower arm at transportation turning and floor standing 3 xx1600002114 Continues on nex...

Page 67: ... Note Lightly lubricate screws before assembly 5 Suitable washer 4 mm flat washer Screw tightening yield point utiliza tion factor v according to VDI2230 90 v 0 9 Tightening torque CAUTION If high stress on screws are suspected replace used screws with new ones 550 Nm screws lubricated with Molykote 1000 600 725 Nm typical 650 Nm screws none or lightly lubricated Tighten bolts in a crosswise patte...

Page 68: ... release unit Note Action Buttons are shown in figure Loca tion of brake release unit on page 68 The internal brake release unit is equipped with buttons for controlling the axes brakes The buttons are numbered according to the numbers of the axes If the robot is not connected to the controller power must be supplied to the connector R1 MP according to the section Supplying power to connector R1 M...

Page 69: ... the holding brakes of the axis 2 motor Make sure no personnel is near or beneath the ro bot 2 Release the holding brake on a particular robot axis by pressing the corresponding button on the internal brake release unit 3 The brake will function again as soon as the button is released Supplying power to connector R1 MP If the robot is not connected to the controller power must be supplied to conne...

Page 70: ...obot References Load diagrams permitted extra loads equipment and their positions are specified in the product specification The loads must be defined in the software Operating manual IRC5 with FlexPendant Stopping time and braking distances The performance of the motor brake depends on if there are any loads attached to the robot For more information see product specification for the robot 70 Pro...

Page 71: ...ables used on the robot must be designed and fitted not to damage the robot and or its parts Frame hip load Extra load can be fitted on the frame Description JH 100 kgm2 Permitted extra load on frame JH JH0 M4 x R2 Recommended position see the fol lowing figure where JH0 is the moment of inertia of the equipment R is the radius m from the center of axis 1 M4 is the total mass kg of the equipment i...

Page 72: ...0 kg with a distance a 500 mm from the center of gravity in the axis 3 extension a A M1 M1 xx1400002019 Mass center A Continues on next page 72 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and commissioning 2 4 6 Fitting equipment to the robot Continued ...

Page 73: ...nter of gravity 50 kg A Continues on next page Product manual IRB 6700Inv 73 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and commissioning 2 4 6 Fitting equipment to the robot Continued ...

Page 74: ...3 4 x M 8 M12 20 52 5 H H 150 150 109 J K K A A J 2x M12 19 M12 19 C L Axis 4 B B A B E L H J M K C D F G 12 N B B xx1300000263 Allowed position for attachment holes M12 through Be careful not to touch the cables when drilling A Continues on next page 74 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and commissioning 2 4 6 Fitting e...

Page 75: ... 5 98 5 117 12 152 405 467 376 652 5 450 310 R 230 IRB 6700Inv 245 2 90 i Smallest circumscribed radius axis 4 Continues on next page Product manual IRB 6700Inv 75 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and commissioning 2 4 6 Fitting equipment to the robot Continued ...

Page 76: ... L Axis 1 L xx1300000264 M L K J H G F E D C B Ai Variant 15 523 5 273 5 350 265 187 222 5 80 423 438 453 R 468 IRB 6700Inv 300 2 60 15 523 5 273 5 350 265 187 222 5 80 423 438 453 R 468 IRB 6700Inv 245 2 90 i Smallest circumscribed radius axis 3 Continues on next page 76 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and commissioni...

Page 77: ...min 23 max B B C L C D 1 6 0 2 A B 0 3 C D 0 2 C D B 12 H7 0 0 018 6x R11 3x R70 160 11x 30 18 A A B B 0 04 A B 1 6 16 1 0 5 45 X M12 A A 200 h8 0 072 0 100 H7 0 0 035 0 02 A xx1300000280 Thread length 18 mm A Fastener quality Use suitable screws and tightening torque for your application Continues on next page Product manual IRB 6700Inv 77 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rig...

Page 78: ...C C 12 H7 15 11xM12 18 200 h8 8 100 H7 1x45 100 H7 0 07 E 0 3 E F F E xx1300000290 Thread length 18 mm A Fastener quality Use suitable screws and tightening torque for your application 78 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and commissioning 2 4 6 Fitting equipment to the robot Continued ...

Page 79: ...ware 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 Service stops for axis 2 There are service stops available for restricting the movement of axis 2 during floor standing service activities Never use these service stops as mechanical stops for restr...

Page 80: ... and one of the additional mechanical stops available for axis 1 A B C xx1600002066 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 Article number Equipment etc Includes attachment screws and an assembly drawing 3HAC048533 003 Movable mechanical stop set axis 1 15 Continues on ne...

Page 81: ... to the frame according to the figure Mechanical stops axis 1 on page 80 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 mechanical stop pin is deformed after a h...

Page 82: ...tomer cables also handle databus communication See the product manual for the controller see document number in References on page 10 Handles signals process media and power feeding for customer use regarding material handling or spot welding DressPack cables option See the Product manual DressPack SpotPack IRB 6700 see document number in References on page 10 Robot cables These cables are include...

Page 83: ... static floor cables A B xx1600002016 Diameter A Diameter x10 B Grounding and bonding point on manipulator There is a grounding bonding point on the manipulator base The grounding bonding point is used for potential equalizing between control cabinet manipulator and any peripheral devices xx1500001600 Continues on next page Product manual IRB 6700Inv 83 3HAC058254 001 Revision L Copyright 2017 202...

Page 84: ...y from the robot base to the inside of the cabinet Fans can also be ordered without cables If equipping the robot with cooling fans use the cabling specified below The cables for cooling fans listed below are used together with a distributing cable also specified below Connection point Art no Cable Distributing cable R1 FAN SW2 3 3HAC022723 001 Harness cooling 7 m Inside cabinet A43 X10 and A43 X1...

Page 85: ...bly instruction delivered with the signal lamp Function The lamp is active in MOTORS ON mode Further information Further information about the MOTORS ON MOTORS OFF mode may be found in the product manual for the controller Product manual IRB 6700Inv 85 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and commissioning 2 7 1 Signal lamp option ...

Page 86: ...s Portal www abb com myABB Note Article number Spare part Only available for the axis 1 motor Can not be used together with protec tion type Foundry Plus Includes fan unit fan cable harness customer connection plate and re quired fasteners 3HAC051149 001 Fan unit set Required tools and equipment Note Article number Equipment Content is defined in section Stand ard toolkit on page 713 Standard tool...

Page 87: ...air pressure supply to the robot before entering the safeguarded space 2 xx1800000157 Remove the metal sheet frame from the fan unit assembly by loosening the six screws 3 xx1800000159 Loosen the two tightening screws so they don t damage the motor surface during installation 4 Continues on next page Product manual IRB 6700Inv 87 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserve...

Page 88: ...h the two tightening screws Tighten them properly so that the box is firmly attached to the motor 6 Connecting the fan cabling Note Action xx1800000161 Remove the rear cover plate 1 xx1800000162 Fit the customer connection plate 2 Continues on next page 88 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and commissioning 2 7 2 Install...

Page 89: ...adjustment 3 xx1300000542 Loosen the frame cable clamp by unscrewing the screws 4 Cable straps xx1800000164 Run the cabling up through the base and frame Make a loop of the fan cable and use cable straps to strap it to the other cables 5 xx1800000166 Secure the cable bracket inside the frame with the two enclosed nuts 6 Continues on next page Product manual IRB 6700Inv 89 3HAC058254 001 Revision L...

Page 90: ...ble clamp with the screws 9 xx1800000167 Connect the connector R1 SW2 3 to the base of the robot Make sure that the cabling run through the frame and base is not twisted and runs freely from the robot cabling 10 xx1800000161 Refit the rear cover plate to the robot base 11 Continues on next page 90 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 In...

Page 91: ... by using the Modify Controller System Wizard in the System Builder of RobotStu dio Read more about modifying the system in Operating manu al RobotStudio Modify the settings in RobotWare to include the cooling fans 1 Product manual IRB 6700Inv 91 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 2 Installation and commissioning 2 7 2 Installing the motor cooling fan option Cont...

Page 92: ...egulated with the RAPID instruction VelSet Start the robot with its normal program but with reduced speed 1 Adjusting the speed and acceleration during warm up Depending on how cold the environment is and what program is being used the speed might need to be ramped up until reached maximum The table shows examples of how to adjust the speed Speed velocity AccSet Work cycles v100 100 mm s 20 20 3 W...

Page 93: ...enance activity Safety information Observe all safety information before conducting any service work There are general safety aspects that must be read through as well as more specific safety information that describes the danger and safety risks when performing the procedures Read the chapter Safety on page 17 before performing any service work Note If the IRB 6700Inv is connected to power always...

Page 94: ...with the functionality Service Information System activated can show active counters in the device browser in RobotStudio or on the FlexPendant Overhaul Depending on application and operational environment a complete overhaul may be necessary in average around 40000 hours ABB Connected Services and its Assessment tools can help you to identify the real stress level of your robot and define the opt...

Page 95: ...aning the IRB 6700Inv on page 179 x Cleaning the robot Inspection activities Inspecting the motor seal on page 98 x Inspecting the motor seal Inspect the oil level in the actual gearbox if there is a suspected leakage after an oil change or a maintenance or repair activity where draining and filling oil is required Inspecting the oil level in gearboxes Inspecting the balancing device on page 118 x...

Page 96: ...xis 6 gearbox Replacing the SMB battery on page 174 x iii Replacing the SMB battery pack Lubrication activities Lubricating the spherical roller bearing balancing device on page 177 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 when damage or cracks is detected or life limit is approaching that...

Page 97: ...ovement 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 from the initial ...

Page 98: ... 1 motor as an example xx1500001057 Plug in the evacuation hole Robots with protection type Standard have a protection filter installed in the evacuation hole Robots with protection type Foundry Plus have a transparent plug sight glass installed in the evacuation holes xx1800000102 xx1800000101 Transparent plug Foundry Plus Protection filter Standard Continues on next page 98 Product manual IRB 67...

Page 99: ... grease on page33 2 xx1500001057 Do a leakage check of the sight glass evacuation hole of each motor If any oil is available on the sight glass or if any oil has been spilled out from the evacuation hole replacement of the motor is recommended 3 Replacing of motors is described in the repair chapter Motors on page 453 Product manual IRB 6700Inv 99 3HAC058254 001 Revision L Copyright 2017 2020 ABB ...

Page 100: ...evel is inspected is located as shown in the figure xx1600002030 Oil plug A Venting hole B Required tools Note Article number Equipment Content is defined in section Standard toolkit on page 713 Standard toolkit Assemble the extender to be able to use the oil level gauge when the fork lift accessories are mounted The tool also includes an air vent 3HAC061881 001 Oil level gauge Continues on next p...

Page 101: ...draulic pressure supply air pressure supply to the robot before entering the robot working area 1 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 33 2 Make sure that the oil temperature is 25 C 10 C CAUTION The gearbox can contain an excess pres sure that can be hazardous Open the oil plug carefully in order to let the excess pressure out 3 x...

Page 102: ...he oil level using the Oil level gauge Required oil level is Between level meas urement marks on tool 7 If the Fork lift accessory set is assembled fasten the extender screw in the fork lift pocket xx1700000314 Continues on next page 102 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 3 2 Inspecting the oil level in axis 1 gearbox Co...

Page 103: ...rocedure to inspect the oil level in the gearbox when the robot is floor standing 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 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 33 2 Make sure that the oil temperature is 25 C 10 C 3 xx150...

Page 104: ...rther information about how to drain or fill with oil is found in section Changing oil axis 1 gearbox on page 144 Tightening torque 24 Nm Refit the oil plug 7 DANGER Make sure all safety requirements are met when performing the first test run 8 104 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 3 2 Inspecting the oil level in axis 1...

Page 105: ...it on page 713 Standard toolkit Required consumables Note Article number Consumables Information about the oil is found in Technical reference manual Lubrica tion in gearboxes Lubricating oil Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page Product manual IRB 6700Inv 105 3HAC058254 001 Revision L Copyright 20...

Page 106: ... oil plug 4 Check the oil level 5 Required oil level is 0 15 mm below the oil plug hole Type of oil and total amount is detailed in Technical reference manual Lubric ation in gearboxes Add or drain oil if required 6 Further information about how to drain or fill with oil is found in section Chan ging oil axis 2 gearbox on page 151 Tightening torque 24 Nm Refit the oil plug 7 DANGER Make sure all s...

Page 107: ...13 Standard toolkit Required consumables Note Article number Consumables Information about the oil is found in Technical reference manual Lubrica tion in gearboxes Lubricating oil Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page Product manual IRB 6700Inv 107 3HAC058254 001 Revision L Copyright 2017 2020 ABB ...

Page 108: ...ox oil involves several safety risks see Gearbox lubricants oil or grease on page 33 4 xx1600002046 Open the oil plug 5 Check the oil level 6 Required oil level is 0 20 mm below the oil plug hole Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Add or drain oil if required 7 Further information about how to drain or fill with oil is found in section C...

Page 109: ...DANGER Make sure all safety requirements are met when performing the first test run 9 Product manual IRB 6700Inv 109 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 3 4 Inspecting the oil level in axis 3 gearbox Continued ...

Page 110: ...13 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 110 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB ...

Page 111: ...ty risks see Gearbox lubricants oil or grease on page 33 4 xx1600002048 Open the oil plug 5 Check the oil level 6 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 Changing oil axis 4 gearbox o...

Page 112: ...fety requirements are met when performing the first test run 9 112 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 3 5 Inspecting the oil level in axis 4 gearbox Continued ...

Page 113: ...13 Standard toolkit Required consumables Note Article number Consumables Information about the oil is found in Technical reference manual Lubrica tion in gearboxes Lubricating oil Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page Product manual IRB 6700Inv 113 3HAC058254 001 Revision L Copyright 2017 2020 ABB ...

Page 114: ...oil or grease on page 33 4 xx1200000959 Open the oil plug 5 Check the oil level 6 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 Changing oil axis 5 gearbox on page 166 Tightening torque 24 ...

Page 115: ... on page 713 Standard toolkit Required consumables Note Article number Consumable Information about the oil is found in Technical reference manual Lubrica tion in gearboxes Lubricating oil Required documents Document number Document name 3HAC042927 001 Technical reference manual Lubrication in gearboxes Continues on next page Product manual IRB 6700Inv 115 3HAC058254 001 Revision L Copyright 2017 ...

Page 116: ...essure supply to the robot before entering the robot working area 2 Make sure that the oil temperature is 25 C 10 C 3 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 33 4 xx1600002049 Open the oil plug 5 xx1300000693 Method 1 Check the oil level Required oil level is 50 mm 5 mm below the sealing surface of the oil plug 6 Continues on next pag...

Page 117: ... Further information about how to drain or fill with oil is found in section Changing oil axis 6 gearbox on page 170 Tightening torque 24 Nm Refit the oil plug 9 DANGER Make sure all safety requirements are met when performing the first test run 10 Product manual IRB 6700Inv 117 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 3 7 Inspecting the oil level in ax...

Page 118: ...evice 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 xx1600002052 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 Product manual IRB 6700Inv 3HAC058254 001 Revision...

Page 119: ...sed by the springs inside the cylinder 2 How to replace the device is detailed in section Repla cing the balancing device on page409 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...

Page 120: ... robot air pressure supply to the robot Before entering the robot working area 3 Check the area around the o ring and radial sealings at the front ear for leakage 4 The o ring and radial sealings are in cluded in the Maintenance kit bear ings and seals already assembled with sealing spacers and sealing rings Article number for the kit is specified in Required material on page 119 Replace o ring an...

Page 121: ... 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 Product manual IRB 6700Inv 121 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 3 8 Inspecting the balancing device Continu...

Page 122: ...ess is located as shown in the figure xx1600002063 Required tools Visual inspection no tools are needed Continues on next page 122 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 3 9 Inspecting the cable harness ...

Page 123: ...t all visible cable brackets 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 cabl...

Page 124: ...ess on page 211 Replace the cable harness if wear cracks or damage is detected 7 124 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 3 9 Inspecting the cable harness Continued ...

Page 125: ... be inspected The symbols are described in section Safety symbols on manipulator labels on page21 Illustration 1 H J N N E F F F E E E E B K M Continues on next page Product manual IRB 6700Inv 125 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting the information labels ...

Page 126: ...ration 3 xx1600002059 Illustration Description Calibration label A Continues on next page 126 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting the information labels Continued ...

Page 127: ...25 1 xx xx1300001083 Instruction label Brake release Moving robot Brake release buttons D Oil specification label E Grease specification label F Complete oil specification G 3HAC 9526 1 04 xx1300001086 Warning label Do not dismantle Stored energy H Continues on next page Product manual IRB 6700Inv 127 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 3 10 Inspec...

Page 128: ...ng robot Shut off with handle Before dismantling see product manual L 3HAC 020611 001 03 xx1300001090 Warning label Keep areas around the balancing device free from objects M xx1300001091 Warning label Flash N Rating label P Continues on next page 128 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting the information lab...

Page 129: ...ized See user documentation V 3HAC059516 001 2 xx1600002060 Caution label Center of gravity and lifting of balancing device Risk of squeezing See user documentation W 3HAC062777 001 xx1700000814 Warning label The robot can move unexpectedly when floor standing Always use transportation lock screw in floor standing position X Continues on next page Product manual IRB 6700Inv 129 3HAC058254 001 Revi...

Page 130: ...he robot before entering the safeguarded space 1 Inspect the labels located as shown in the figures 2 Article numbers for the labels and plate set is specified in Spare parts on page 721 Replace any missing or damaged labels 3 130 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 3 10 Inspecting the information labels Continued ...

Page 131: ... when not used This section describes how to move the screw to the locking position in order to secure the lower arm At delivery the robot and the lower arm is already locked in the correct position with the transportation lock screw CAUTION No tool is permitted to be fitted on the robot when it is lifted transported or rotated Required tools Note Article number Equipment etc Content is defined in...

Page 132: ...g rotating and transportation position 2 Make sure that there are no deformations or damage to the sleeve or the screw 3 Make sure that the screw and sleeve are in their correct position when lifting rotating or transport ing the robot 4 Tightening torque 75 Nm 15 Nm Check the tightening torque 5 xx1600002008 Always keep the transportation lock screw and sleeve in the parking position when not in ...

Page 133: ... Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 1 Inspect the axis 1 mechanical stop pin 2 If the mechanical stop pin is bent or damaged it must be replaced Note The expected life of gearboxes can be reduced after collision with the mechanical stop Product manual IRB 6700Inv 133 3HAC058254 001 Revisi...

Page 134: ... 3HAC048533 003 Movable mechanical stop axis 1 Limits the robot working range by 15 Includes attachment screws and an as sembly drawing Mechanical stop Attachment screws M12x70 stain less steel and washers stainless steel Document for mechanical stop Content is defined in section Standard toolkit on page 713 Standard toolkit Continues on next page 134 Product manual IRB 6700Inv 3HAC058254 001 Revi...

Page 135: ...stops are damaged 2 Make sure the stops are properly attached 3 Correct tightening torque additional mechanical stops Axis 1 60 Nm Article number is specified in Required equipment on page134 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 Product manual IRB 6700Inv 135 3HAC058254 001 R...

Page 136: ...the figure Required equipment Note Article number Equipment 3HAC058825 001 Fork lift accessory set Content is defined in section Standard toolkit on page 713 Standard toolkit Inspection The fork lift accessory shall be inspected regularly according to Standard SS 7685006 Periodical Inspection Continues on next page 136 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB Al...

Page 137: ... 1 Check the fork lift pockets for damage 2 Check attachment screws for deformation and or other types of damage 3 Make sure that the fork lift pockets are properly at tached 4 If any damage is detected on the fork lift pockets or attachment screws they must be replaced 5 Correct attachments Screw M16x50 12 9 Gleitmo 603 2x10 pcs Washer 17x25 3 mm thick 2x10 pcs Product manual IRB 6700Inv 137 3HAC...

Page 138: ...amper 2 pcs B Required equipment Visual inspection no tools are required Inspecting dampers The procedure below details how to inspect the dampers Note A damaged damper must be replaced Continues on next page 138 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 3 15 Inspecting the dampers ...

Page 139: ...age cracks or exist ing impressions larger than 1 mm 2 Check attachment screws for deformation 3 Spare part number is found in Product manual spare parts IRB 6700 IRB 6700Inv If any damage is detected the damper must be replaced with a new one Attachment screws M6x60 4 Locking liquid Loctite 243 Product manual IRB 6700Inv 139 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 ...

Page 140: ... 721 Signal lamp kit Content is defined in section Stand ard toolkit on page 713 Standard toolkit Inspecting signal lamp Use this procedure to inspect the function of the signal lamp Note Action Inspect that signal lamp is lit when motors are put in operation MOTORS ON 1 Continues on next page 140 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Ma...

Page 141: ... If the lamp is not lit trace the fault by inspecting whether the signal lamp is broken If so replace it inspecting cable connections measuring the voltage in the connectors of motor axis 3 24V inspecting the cabling Replace the cabling if a fault is detected 3 Product manual IRB 6700Inv 141 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 3 16 Inspecting the s...

Page 142: ...working with lubrication Type and amount of oil in gearboxes Information about the type of lubrication article number as well as the amount in the specific gearbox can be found in Technical reference manual Lubrication in gearboxes available for registered users on myABB Business Portal www abb com myABB Continues on next page 142 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017...

Page 143: ...penser or a similar one Orion OriCan article number 22590 pneumatic Nipple for quick connect fitting with o ring Used to check the oil level in axis 1 gearbox Oil level gauge Assemble the extender to be able to use the oil level gauge when the fork lift accessories are mounted The tool also includes an air vent Product manual IRB 6700Inv 143 3HAC058254 001 Revision L Copyright 2017 2020 ABB All ri...

Page 144: ...osition it is recommended to let the oil be circulated through the gear and not drained Usage of oil dispenser The oil change procedure in this section describes usage of an oil dispenser Location of oil plugs The oil plugs of the gearbox is located as shown in the figure xx1600002030 Oil plug Tightening torque 24 Nm A B Used for both filling ventilation and level measurement Continues on next pag...

Page 145: ...Lubricating oil See Type and amount of oil in gearboxes on page142 Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lubrication in gearboxes Circulate the oil in the axis 1 gearbox inverted CAUTION Because of the risk of getting air bubbles into axis 1 gear in inverted position it is recommended to let the oil be circulated through the gear and not d...

Page 146: ... oil dispenser to the oil plug 5 Approximately 5 l Press in new oil to be circulated with the old oil with the oil dispenser 6 Remove the oil dispenser and oil collecting vessel 7 Refit the protective cap on the oil plug Note After all repair and maintenance work involving oil always wipe the robot clean from all surplus oil 8 DANGER Make sure all safety requirements are met when performing the fi...

Page 147: ...e supply to the robot before entering the safe guarded space 1 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 33 2 CAUTION The gearbox can contain an excess of pressure that can be hazardous Open the oil plug carefully in order to let the excess pressure out 3 xx1200000948 Remove the protective cap from the nipple of the oil hole and connect...

Page 148: ...9 for more in formation 7 Remove the oil dispenser 8 Refit the protective cap on the nipple Tightening torque 24 Nm Refit the vent hole plug 9 Filling axis 1 gearbox with oil floor standing 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 safe guarded space 1 Contin...

Page 149: ...he vent hole is opened to let out air during the filling process 4 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil with the oil dis penser Note The amount of oil to be filled depends on the amount previously being drained 5 Continues on next page Product manual IRB 6700Inv 149 3HAC058254 001 Revision L Copyright 2017 2020 ...

Page 150: ...hole plug 8 Note After all repair and maintenance work in volving oil always wipe the robot clean from all surplus oil The robot color can otherwise be discolored 9 DANGER Make sure all safety requirements are met when performing the first test run 10 150 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 4 2 Changing oil axis 1 gearbox...

Page 151: ...tc 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 142 Oil dispenser Content is defined in section Standard toolkit on page 713 Standard toolkit Required consumable Note Material Information about the oil is found in Technical refer ence manual Lubric...

Page 152: ...y to the robot before entering the safe guarded space 1 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 33 2 CAUTION The gearbox can contain an excess pres sure that can be hazardous Open the oil plug carefully in order to let the excess pressure out 3 Continues on next page 152 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2...

Page 153: ...he robot has been taken down to floor standing for example due to axis 2 gear box replacement refer to the below figure instead xx1200000951 Continues on next page Product manual IRB 6700Inv 153 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 4 3 Changing oil axis 2 gearbox Continued ...

Page 154: ...enser Note There will be some oil left in the gear after draining 6 WARNING Used oil is hazardous material and must be disposed of in a safe way See section Decommissioning on page699 for more in formation 7 Vent hole plug tightening torque 24 Nm Refill oil or 1 Remove the oil dispenser 2 Refit the protective cap on the nipple 3 Refit the vent hole plug 8 Continues on next page 154 Product manual ...

Page 155: ... several safety risks see Gearbox lubricants oil or grease on page 33 2 xx1600002141 Remove the protective cap from the nipple of the oil hole and connect the oil dis penser 3 xx1600002044 Remove the plug from the vent hole Note The vent hole is opened to let air out during the filling process 4 Continues on next page Product manual IRB 6700Inv 155 3HAC058254 001 Revision L Copyright 2017 2020 ABB...

Page 156: ...ired oil level is 0 15 mm below the oil plug hole More information is found in Inspecting the oil level in axis 2 gearbox on page 106 Remove the oil dispenser 7 Refit the protective cap on the nipple Tightening torque 24 Nm Refit the level plug 8 DANGER Make sure all safety requirements are met when performing the first test run 9 156 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright ...

Page 157: ...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 142 Oil dispenser Content is defined in section Standard toolkit on page 713 Standard toolkit Consumable Note Material Information about the oil is found in Technical refer ence manual Lubrication in...

Page 158: ...he safe guarded space 2 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 33 3 CAUTION The gearbox can contain an excess pres sure that can be hazardous Open the oil plug carefully in order to let the excess pressure out 4 xx1600002145 Remove the protective cap from the nipple of the oil hole and connect the oil dis penser 5 Continues on next p...

Page 159: ...issioning on page 699 for more informa tion 8 Remove the oil dispenser 9 Refit the protective cap on the nipple 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 Jog the robot into position Axis 1 Axis 2 0 Axis 3 180 horizontal Axis 4 Axis 5 Axis 6 no significance 1 Continues on next page Product ma...

Page 160: ...connect the oil dis penser 4 xx1600002046 Remove the plug from the vent hole Note The vent hole is opened to let air out during the filling process 5 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 6 Continues on next page 160 Product manual...

Page 161: ...n axis 3 gearbox on page 108 Remove the oil dispenser 8 Refit the protective cap on the nipple Tightening torque 24 Nm Refit the level plug 9 DANGER Make sure all safety requirements are met when performing the first test run 10 Product manual IRB 6700Inv 161 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 4 4 Changing oil axis 3 gearbox Continued ...

Page 162: ...n be found in section Type of lubrication in gearboxes on page 142 Oil dispenser Content is defined in section Standard toolkit on page 713 Standard toolkit Consumable Note Material Information about the oil is found in Technical refer ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page142 Required documents Note Document number Document name 3HAC04...

Page 163: ...ox lubricants oil or grease on page 33 3 CAUTION The gearbox can contain an excess pres sure that can be hazardous Open the oil plug carefully in order to let the excess pressure out 4 Place the oil collecting vessel underneath the oil drain plug 5 xx1700000010 Remove the oil plug from the drain hole and let the oil run into the vessel 6 Continues on next page Product manual IRB 6700Inv 163 3HAC05...

Page 164: ...he axis 4 gearbox Use this procedure to refill the gearbox with oil Note Action Jog axis 3 to position 180 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 2 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 33 3 Continues on next page 164 Product manua...

Page 165: ...l is measured at the fill hole xx1600002048 Inspect the oil level 6 Required oil level is 0 10 mm below the oil plug hole See Inspecting the oil level in axis 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 8 Product manual IRB 6700Inv 165 3HAC058254 001 Revision L Copyright 2017 2020 ABB All ri...

Page 166: ...page 142 Oil dispenser Content is defined in section Standard toolkit on page 713 Standard toolkit Consumable Note Material Information about the oil is found in Technical refer ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page142 Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lubrication in gearbo...

Page 167: ...the oil plug from the drain hole and let the oil run into the vessel 5 Place the oil collecting vessel underneath the oil drain plug 6 xx1200000959 Remove the oil plug from the fill level hole Note The fill hole is opened to speed up the drainage 7 WARNING Used oil is hazardous material and must be disposed of in a safe way See section Decommissioning on page699 for more in formation 8 Tightening ...

Page 168: ... 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 level hole level plug 6 Required oil level is 0 10 mm below the oil plug hole More information is found in Inspecting the oil level in axis 5 gearbox o...

Page 169: ...e all safety requirements are met when performing the first test run 8 Product manual IRB 6700Inv 169 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 4 6 Changing oil axis 5 gearbox Continued ...

Page 170: ...n page 142 Oil dispenser Content is defined in section Standard toolkit on page 713 Standard toolkit Consumable Note Material Information about the oil is found in Technical refer ence manual Lubrication in gearboxes Lubricating oil See Type and amount of oil in gearboxes on page142 Required documents Note Document number Document name 3HAC042927 001 Technical reference manu al Lubrication in gear...

Page 171: ...e hazardous Open the oil plug carefully in order to let the excess pressure out 4 Place the oil collecting vessel underneath the oil drain plug 5 xx1200000962 Remove the oil plug from the drain hole and let the oil run into the vessel 6 xx1200000963 Remove the oil plug from the fill hole Note The fill hole is opened to speed up the drainage 7 Continues on next page Product manual IRB 6700Inv 171 3...

Page 172: ...ply air pressure supply to the robot before entering the safe guarded space 2 WARNING Handling gearbox oil involves several safety risks see Gearbox lubricants oil or grease on page 33 3 xx1200000963 Open the fill plug 4 Type of oil and total amount is detailed in Technical reference manual Lubrication in gearboxes Refill the gearbox with oil Note The amount of oil to be filled depends on the amou...

Page 173: ...pecting the oil level in axis 6 gearbox on page 116 Method 2 Rotate axis 5 77 Required oil level is 0 10 mm below the oil plug hole Tightening torque 24 Nm Refit the oil plug 7 DANGER Make sure all safety requirements are met when performing the first test run 8 Product manual IRB 6700Inv 173 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 4 7 Changing oil axi...

Page 174: ...ARNING See Hazards related to batteries on page 34 Location of SMB battery The SMB battery SMB serial measurement board is located on the frame as shown in the figure below xx1700000045 Required tools Note Article number Equipment Content is defined in section Standard toolkit on page 713 Standard toolkit Continues on next page 174 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 201...

Page 175: ...safeguarded space 2 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit read the safety information in section The unit is sensitive to ESD on page 53 3 xx1700000045 Remove the SMB battery cover by unscrewing the attachment screws CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failur...

Page 176: ... in section The unit is sensitive to ESD on page 53 2 xx1700000045 Connect the battery cable and install the battery pack into the SMB battery recess 3 Secure the SMB battery cover with its attachment screws 4 See Updating revolution counters on page 680 Update the revolution counters 5 DANGER Make sure all safety requirements are met when performing the first test run 6 176 Product manual IRB 670...

Page 177: ...e Used for lubrication of the spherical roller bearing Lubricating the spherical roller bearing Use this procedure to lubricate the spherical roller bearing Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 1 Continues on next page Product manual IRB 6700Inv 177 3HAC058254 001 Revision L Copyright...

Page 178: ...C042536 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 3 Refit the two screws and wipe clean from residual grease 4 178 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 5 1 Lubricating the spherical roller bearing balancing device Continu...

Page 179: ...ndations see Inspection activities on page 98 2 Write down the oil level 3 Inspect the oil level again after for example 6 months 4 If the oil level is decreased then replace the gearbox Special cleaning considerations This section specifies some special considerations when cleaning the robot Always use cleaning equipment as specified Any other cleaning equipment may shorten the life of the robot ...

Page 180: ...leaner 1 The following list defines the prerequisites Maximum water pressure at the nozzle 700 kN m2 7 bar I Fan jet nozzle should be used min 45 spread Minimum distance from nozzle to encapsulation 0 4 meters Maximum flow 20 liters minI I Typical tap water pressure and flow Instructions for steam or high pressure water cleaning ABB robots with protection types Foundry Plus Wash or Foundry Prime c...

Page 181: ...ing fans Inspect the air supply inlet of the the motor cooling fans Clean to remove any contamination that could hinder the air supply Product manual IRB 6700Inv 181 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 3 Maintenance 3 6 1 Cleaning the IRB 6700Inv Continued ...

Page 182: ...This page is intentionally left blank ...

Page 183: ...nit and the replacement unit This is particularly important for safety equipment to maintain the safety integrity of the installation Safety information Make sure to read through the chapter Safety on page 17 before commencing any service work Note The robot should be secured with the transportation brackets during removing from refitting to the foundation Note If the IRB 6700Inv is connected to p...

Page 184: ...e pressure must under no circumstance be higher than 0 25 bar 20 25 kPa Also during the time when the pressure is raised 3 0 2 0 25 bar 20 25 kPa Disconnect the compressed air supply 4 If the compressed air is signific antly colder or warmer than the gearbox to be tested a slight pressure increase or decrease may occur This is quite normal Wait for approximately 8 10 minutes and make sure that no ...

Page 185: ...xposed to any stresses during the assembly work 3 Assembly of tapered bearings Follow the preceding instructions for the assembly of the bearings when mounting a tapered bearing on the robot In addition to those instructions the following procedure must be carried out to enable the roller elements to adjust to the correct position against the race flange Note Action Tension the bearing gradually u...

Page 186: ...rted During operation the bearing should be filled to 70 80 of the available volume Ensure that grease is handled and stored properly to avoid contamination Grease the different types of bearings as following description Grooved ball bearings must be filled with grease from both sides Tapered roller bearings and axial needle bearings must be greased in the split condition 186 Product manual IRB 67...

Page 187: ...ion Check the sealing to ensure that The sealing is of the correct type There is no damage on the main lip 1 Inspect the shaft surface before mounting If scratches or damage are found the shaft must be replaced since it may result in future leakage Do not try to grind or polish the shaft surface to get rid of the defect 2 Article number is specified in Equipment on page 187 A B C xx2000000071 A Ma...

Page 188: ... because leakage could occur Clean the surfaces properly in accordance with the recommendations of ABB 2 Distribute the sealing compound evenly over 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 including damage...

Page 189: ...tamination Lubricate the o ring with grease 4 Tighten the screws evenly while assembling 5 Check that the o ring is not squashed outside the o ring groove 6 Product manual IRB 6700Inv 189 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 2 3 Mounting instructions for sealings Continued ...

Page 190: ... current repair procedures The service stops are stored at a parking position at the robot frame when not in use Always return the service stops to their parking position after the repair activity is completed according to the repair procedure WARNING Never use the service stops as additional mechanical stops for restriction of the robot working range during operation DANGER Only use the service s...

Page 191: ...arking positions xx1700000576 Required tools Note Article number Spare part Screws 3HAB3409 88 Tightening torque 70 Nm 15 Nm 3HAC058167 001 Service stop Product manual IRB 6700Inv 191 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 2 4 Service stops Continued ...

Page 192: ...the tool parts are needed in each procedure The procedure specifies which tool part to be used The complete tool set 3HAC028920 001 as follows A xx1700000383 Part A hydraulic cylinder is ordered separately 3HAC11731 1 Hydraulic pump is ordered separately 3HAC13086 1 192 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 2 5 Dismantle and mou...

Page 193: ...ite 3HAC067974 001 Touch up paint Standard Foundry Plus Removing Description Action xx0900000121 Cut the paint with a knife in the joint between the part that will be removed and the struc ture to avoid that the paint cracks 1 Carefully grind the paint edge that is left on the structure to a smooth surface 2 Product manual IRB 6700Inv 193 3HAC058254 001 Revision L Copyright 2017 2020 ABB All right...

Page 194: ... to the robot Elimination To eliminate the danger after service work has been performed inside the SMB recess follow the procedure below Action Make sure the power is turned off 1 Remove the push button guard if necessary 2 Verify that the push buttons of the brake release unit are working by pressing them down one by one 3 Make sure none of the buttons are jammed in the tube If a button gets jamm...

Page 195: ...of the following parts of the robot upper arm wrist lower arm frame including the balancing device Attachment points of lifting accessory If using the Lifting accessory chain Continues on next page Product manual IRB 6700Inv 195 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 3 1 Attaching lifting accessories to complete arm system ...

Page 196: ...ticle number Equipment etc Contains fork lift pockets and all re quired hardware for installation User instructions are enclosed with the tool see Directions for use Fork lift accessory for IRB 6700Inv In order to rotate the robot either use the turning tool or a fork lift truck with a rotator attachment 3HAC058825 001 Fork lift accessory set Continues on next page 196 Product manual IRB 6700Inv 3...

Page 197: ...Take down and secure the robot floor standing in order to attach the lifting accessories for lift of the arm system 1 Attaching the lifting accessories to the arm system This procedure contains two alternative methods for lifting the arm system either by using the turning tool or by using lifting chains Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air ...

Page 198: ...ting accessory to use Attach the lifting chains on page 199 Attach the Turning tool on page 200 Con venient if the tool is already partly mounted on the robot after rotation from inverted position to floor standing 5 Continues on next page 198 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 3 1 Attaching lifting accessories to complete ar...

Page 199: ...ling from gliding A B C D A Upper arm B Shackle C Roundsling D Hole in frame 1 Lifting shackle 2 pcs SA 10 8 NA1 Connect the roundsling with a shackle 2 Use caution and jog axis 3 slowly to stretch the roundsling Note Make sure the roundsling is stretched so it can carry the weight of the frame The position of axis 3 will be approximately 45 3 Continues on next page Product manual IRB 6700Inv 199 ...

Page 200: ...The angle between the two chains may not exceed 90 5 Attach the Turning tool Use this procedure to attach the Turning tool for lift of the arm system Note Action Turning tool 3HAC061162 001 Secure the turning tool chain block to the lifting eye in the wrist Shorten the chain to make the lift horizontal 1 Fit a roundsling between the overhead crane hook and the lifting eye in the arm house 2 200 Pr...

Page 201: ...ser instructions are enclosed with the tool see Directions for use Fork lift accessory for IRB 6700Inv In order to rotate the robot either use the turning tool or a fork lift truck with a rotator attachment 3HAC058825 001 Fork lift accessory set User instructions are enclosed 3HAC061162 001 Turning tool 3HAC16131 1 Lifting eye M12 Continues on next page Product manual IRB 6700Inv 201 3HAC058254 00...

Page 202: ...ng the axis 2 gearbox to get the robot prepared for at tachment of the lifting accessories for lift of the un separated lower and upper arm 1 xx1700000374 Jog the robot into position Axis 1 position the axis 1 to be able to put down the arm system after removal Axis 2 15 Axis 3 70 approximately Axis 4 0 Axis 5 0 90 if DressPack is in stalled Axis 6 0 90 if DressPack is in stalled 2 DANGER Turn off...

Page 203: ... minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm xx1700000376 Lifting accessory chain 3HAC15556 1 xx1700000377 Attach the Lifting accessory chain to an over head crane or similar then to the lifting eye in the arm house 3 Raise the overhead crane to stretch the chain 4 To release the brake connect the 24 VDC power supply 5 Connect to connector R2 MP2 axis 2 motor pin 2 pin 5 Product...

Page 204: ...ng capacity 2 000 kg Roundsling 2 m Content is defined in section Standard toolkit on page 713 Standard toolkit Robot position Note Action xx1700000450 Jog the robot to the position Axis 1 a position that allows best possible access to fit the lifting accessories to the upper arm Axis 2 35 Axis 3 143 so that the upper arm is hori zontal Axis 4 0 Axis 5 90 Axis 6 0 1 Continues on next page 204 Prod...

Page 205: ...400002196 3 Fender washer Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm xx1200001134 Roundsling 2 m Lifting capacity 2 000 kg 2 pcs xx1700000693 Attach a lifting sling to an overhead crane or similar and then to the lifting eye in the arm house 4 Attach a lifting sling to an overhead crane or similar and then to the lifting eye in the wrist Note Lifting slings are u...

Page 206: ...pper arm 6 xx1800000047 Remove the lifting sling between the upper arm and the balancing device 7 206 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 3 3 Attaching lifting accessories to the upper arm Continued ...

Page 207: ...ins fork lift pockets and all required hardware for installation User instructions are enclosed with the tool see Directions for use Fork lift accessory for IRB 6700Inv In order to rotate the robot either use the turning tool or a fork lift truck with a rotator attachment 3HAC058825 001 Fork lift accessory set User instructions are enclosed 3HAC061162 001 Turning tool Required documents Document n...

Page 208: ...wn the robot from inverted position Note Action Suitable screws lightly lubricated If the robot is to be secured to the floor prepare an area where the robot can be secured with the attachment bolts 1 M24x100 8 pcs For hole configuration see Hole configuration base on page 64 The robot must always be secured to the floor if any kind of repair or maintenance work is to be performed Verify that the ...

Page 209: ...tions enclosed with the fork lift accessory set Install the fork lift pockets to the robot if not already installed 8 Fork lift accessory set 3HAC058825 001 If lifting and turning with the fork lift rotator attach ment required 1 Insert the forks of the fork lift truck into the fork lift pockets as far as possible 2 Raise the forks of the fork lift truck to make sure that the weight of the robot r...

Page 210: ...2098 Remove the bolts that secure the robot to the foundation 11 Only one direction for rotation is allowed with the turning tool Fol low the user instructions enclosed with the turning tool Rotate the robot to floor standing position using the turning tool or using the fork lift truck with a rotator attachment 12 Attachment screws M24x100 8 pcs Lower and secure the robot to the floor 13 210 Produ...

Page 211: ...e figure xx1600002063 Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 713 Standard toolkit Continues on next page Product manual IRB 6700Inv 211 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness ...

Page 212: ...t 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 and in order to avoid the spiral of the cable harness in the carrier being un wound or placed in the wrong position Depending on what tool is used the other axes may need to be jogged to another position 1 xx1700000348 Remove the transportation lock screw and the yellow sleeve ...

Page 213: ...ock the lower arm at trans portation turning and floor standing 3 xx1600002114 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 4 xx1400000208 Note If only the manipulator harness shall be removed the DressPack cable package can stay fitted on the process turning disk 5 Continues on next page Product manual ...

Page 214: ...aulic pressure and air pressure are turned off 1 xx1400000355 If DressPack is installed Remove the bracket with the com plete ball joint housing still fitted as shown in the figure This is done to be able to reach the two hidden screws that secure the wrist cover 2 xx1400000206 If used open the ball joint housing on the arm tube and remove the DressPack cable package 3 Continues on next page 214 P...

Page 215: ...ties that hold the cable har ness to the plate Note Keep the heat protection plate until refitting Tip If removing the plate only for replacing the motor the cabling does not need to be loosened from the plate 6 Continues on next page Product manual IRB 6700Inv 215 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 216: ...1200001080 Unscrew the attachment screws and re move the motor cover 2 xx1300000488 Disconnect the motor cables 3 xx1300000484 Unscrew the attachment screws that hold the cable bracket 4 Continues on next page 216 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 217: ...cables by holding the cables with one hand at the motor and the other at the carrier 7 Disconnecting the axis 5 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 6700Inv 217 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the ca...

Page 218: ...e motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 218 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 219: ...e is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 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 cover 2 Conti...

Page 220: ...maged Tip Make a note in which direction the cable gland hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Continues on next page 220 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 221: ... or not to loose the inserts fitted on the cover 1 xx1700001803 If the cabling is to be replaced by a new cable harness remove the cover insert to use it on the new cabling 2 xx1700000690 If used loosen the insert 3 Continues on next page Product manual IRB 6700Inv 221 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 222: ...This is done to facilitate the removal and to avoid damaging the parts This will also make it easier to run the cable harness through the inside of the upper arm 5 xx1300000557 Remove the side cover on the arm tube 6 Continues on next page 222 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 223: ... arm tube Note The screw is reached from outside the up per arm 7 xx1700000339 xx1300000543 Remove the arm house metal clamp 8 Continues on next page Product manual IRB 6700Inv 223 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 224: ...ket is replaced by the cable guide xx1300001973 Cable guide 9 Cable fixing bracket xx1300000541 Remove the metal clamp on top of the arm house 10 Continues on next page 224 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 225: ...t xx1300000746 Person 1 working at side hole xx1300000745 Remove the cable harness out of the arm tube at the back of the upper arm Tip This step is best performed by two persons working together Person 1 Put one hand inside the side hole and take a hold of the cable harness Person 2 Take a hold on the cable harness at the back of the robot Together Move the cable harness out of the arm tube 12 Pe...

Page 226: ...sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1300000561 Remove the base cover 2 xx1300000591 Disconnect connectors R1 MP R1 SMB 3 xx1400000366 If used disconnect the DressPack hoses in the base 4 Continues on next page 226 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 1 Removing th...

Page 227: ...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 Disconnecting the axis 1 and axis 2 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 Product manual IRB 6700Inv 227 3HAC058254 001 Revision L Copyright 2017 ...

Page 228: ...e motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 228 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 229: ...urned off 1 ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 53 2 xx1300000829 Open the small cover on the SMB cover disconnect the battery cable and remove the battery 3 xx1300000669 Remove the SMB cover CAUTION Clean cover from metal residues before opening Metal residues can c...

Page 230: ...egard to the brake release board 3 xx1300000670 Remove the connectors X8 X9 and X10 from the brake release board 4 Removing the cable harness in the base Note Action If equipped with DressPack pull out the DressPack cables through the protection tube and place them carefully over the balancing device 1 xx1300000732 Pull out the robot cable harness through the protection tube 2 Place the cable harn...

Page 231: ...he metal clamp frame 1 xx1200001237 Cut the cable tie inside the frame recess 2 xx1300001114 Disconnect connectors on the SMB unit 3 Continues on next page Product manual IRB 6700Inv 231 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued ...

Page 232: ...ew the attachment screws that hold the SMB BU cover from inside the SMB recess 5 xx1300000560 Use caution and pull out the cable harness from the SMB recess Note The parts are sealed with Sikaflex Remove the part carefully 6 Continues on next page 232 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 1 Removing the cable harness Continued...

Page 233: ... arm Note Action xx1300000540 Loosen the axis 2 lower arm metal clamp and the axis 3 lower arm metal clamp loc ated on the inside of the lower arm by re moving the attachment screws Note The screws are reached from the outside of the lower arm 1 xx1300000733 Use caution and pull the cable harness out 2 Product manual IRB 6700Inv 233 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights rese...

Page 234: ...See Product manual spare parts IRB 6700 IRB 6700Inv Cable harness Product manual spare parts IRB 6790 Replace if damaged 3HAC048520 001 Cover insert Replace if damaged 3HAC055411 001 Cable protection PU rubber Continues on next page 234 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness ...

Page 235: ...ies 3HAC053986 001 Weatherstrip Robot position If the robot axes have been re positioned after the cable harness has been removed make sure to restore the initial robot position before refitting the cable harness See Preparations before removing the cable harness on page 212 Refitting the cable harness base frame and lower arm These procedures describes how to refit the cable harness in base frame...

Page 236: ... cable harness through the lower arm 3 xx1300000734 Secure the axis 2 lower arm cable bracket Note Do not secure the axis 3 lower arm cable bracket at this point Note Screws are reached from the outside of the lower arm 4 xx1300000735 Run the cable harness into the hole in the frame in this order R1 MP R1 SMB R2 MP2 R2 MP1 5 Continues on next page 236 Product manual IRB 6700Inv 3HAC058254 001 Revi...

Page 237: ...be in line with its position on the base plate Make sure that the R1 SMB cable will run on the correct side of the R1 MP1 see the figure 2 Make sure that the markings on the cables are facing the base cover when connected 3 Tightening torque for R1 SMB 10 Nm xx1300000591 Connect connectors R1 MP and R1 SMB 4 Continues on next page Product manual IRB 6700Inv 237 3HAC058254 001 Revision L Copyright ...

Page 238: ...ection tube in the base 7 Make sure that the hoses are running cor rectly and are not twisted xx1400000078 If used fit the bracket that hold the DressPack to the frame 8 xx1200000052 If used connect the DressPack cable package on the base plate 9 Continues on next page 238 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the ...

Page 239: ... figure shows the position of the o ring Wipe clean the contact surfaces of the cover as well as the hole it shall fit in 2 Apply Sikaflex on the o ring before as sembly 3 xx1300000560 Run the SMB BU cables into the SMB re cess 4 Continues on next page Product manual IRB 6700Inv 239 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Con...

Page 240: ...running through the hole in the frame by carefully moving the SMB BU cover on its screws while at the same time checking the position of the cable harness through the hole Note The cables must be placed so that they don t rub against any part of the robot 6 Screws 3 pcs xx1300000655 Secure the SMB BU cover with its attach ment screws from inside the SMB BU re cess 7 Continues on next page 240 Prod...

Page 241: ...l 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 The unit is sensitive to ESD on page 53 2 Continues on next page Product manual IRB 6700Inv 241 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 2 Re...

Page 242: ...position and fit the bracket that secures the SMB unit 5 X9 X8 X10 xx1700000978 If disconnected reconnect the connectors X8 X9 and X10 to the brake release board Be careful not to damage the sockets or pins Make sure the connector and its locking arms are snapped down properly 6 Continues on next page 242 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reser...

Page 243: ...s option refit the connector R2 FB7 to the SMB cover and tighten with 6 Nm 8 Reconnecting the axis 1 and axis 2 motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 Continues on next page Product manual IRB 6700Inv 243 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 244: ... O ring axis 1 3HAC054692 002 Inspect the o ring Note Replace if damaged 4 O ring axis 2 3HAC054692 002 O ring axis 3 3HAC054692 002 O ring axis 4 3HAC054692 001 xx1200001070 Wipe clean o ring and o ring groove 5 Continues on next page 244 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 245: ...ote Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Refitting the cable harness lower arm Note Action xx1300000668 Tip Use tape and tie the axis 5 and axis 6 connectors and carrier into a bundle if not already done This is done to facilitate the procedure and to avoid damaging the parts during the procedure This will also make it easier to run...

Page 246: ...e lower arm 3 xx1300000595 Before fitting the remaining axis 3 lower arm cable bracket inside the lower arm check that it will stay twisted a little between the metal clamps after fitting as shown in the figure Do not change the po sition of the brackets 4 Continues on next page 246 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 2 Refi...

Page 247: ... xx1700000269 Remove the yellow sleeve and transportation lock screw from the transportation and turning position 1 Tightening torque 70 Nm 15 Nm xx1700000270 Fasten the yellow sleeve and transportation lock screw in its parking position 2 Continues on next page Product manual IRB 6700Inv 247 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable h...

Page 248: ...een the cable clamps in the upper arm 3 xx1300000668 Tip Use tape and tie the axis 5 and axis 6 connectors and carrier into a bundle if not already done This is done to facilitate the procedure and to avoid damaging the parts during the procedure This will also make it easier to run the cable harness through the inside of the robot 4 Continues on next page 248 Product manual IRB 6700Inv 3HAC058254...

Page 249: ...sons working together Person 1 Put one hand inside the side hole of the arm tube 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 into the arm tube 6 Person 2 working at the back xx1400000356 Note The cable harness is best placed at the upper right hand side of the DressPack tube if used through ...

Page 250: ... a hold of the cable harness from inside the wrist Together Move the cable harness past the axis 5 motor and into the wrist 7 Person 2 working at the wrist xx1300000746 xx1700000340 Refit the metal clamp axis 4 inside the arm tube Note The screws are reached from outside the upper arm 8 xx1700000339 Continues on next page 250 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020...

Page 251: ...ide cover 9 xx1700000690 If used refit the insert that guides the DressPack cable package through the hole in the upper arm 10 xx1400000092 If used refit the tube containing the DressPack into the insert 11 Continues on next page Product manual IRB 6700Inv 251 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 252: ...00045 DressPack or Foundry Plus Refit the cover with the tube guiding ring fitted Note Foundry Plus Make sure the gasket is fitted cor rectly Use attachment screws made of stainless steel to fit the cover 13 Continues on next page 252 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 253: ...1973 14 Connecting the axis 3 and axis 4 motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page Product manual IRB 6700Inv 253 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 254: ...ing axis 4 3HAC054692 001 xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring Tip Lubricate the o ring with some grease for a better fitting in the groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page 254 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repa...

Page 255: ...ting the axis 5 motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 xx1200001016 Refit the cable gland cover by performing the following steps Slide the 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 Continues on next page Prod...

Page 256: ...1021 Make sure the o ring on the motor is undam aged Replace if damaged 4 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page 256 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 257: ...threads Replace with standard attachment screws Note Make sure the o ring is undamaged and properly fitted 6 xx1500001029 Secure the cable harness with cable straps to the heat protection plate 7 Screws M5x12 xx1500001030 Fit the heat protection plate with the screws 8 Continues on next page Product manual IRB 6700Inv 257 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repa...

Page 258: ... 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 xx1300000667 Push the cable harness into the wrist re cess and up into the axis 6 motor 3 xx1300001113 Push the carrier carefully into position 4 Continues on next page 258 Product manual IRB 6700Inv 3HAC058254 001 Revision L ...

Page 259: ... is level and completely pressed against the bottom 5 xx1300000484 Secure the cable bracket with its attach ment screws 6 xx1300000488 Reconnect the connectors to the axis 6 motor Note Place the resolver cable under the motor cable 7 Continues on next page Product manual IRB 6700Inv 259 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness...

Page 260: ...be dam aged 9 xx1200001080 Refit the motor cover 10 Concluding procedure Note Action xx1600002061 Make sure that the cable harness is placed in a way that it will not be damaged when the wrist cover is fitted 1 Continues on next page 260 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 2 Refitting the cable harness Continued ...

Page 261: ...ift the cover still tilted 4 Move the upper part of the cover into position 5 Secure the cover with its attachment screws 3 See figure above Foundry Plus 4 Refit protection plugs If used refit the DressPack cable package on the wrist 5 Axis Calibration is described in Calibrating with Axis Calibration method on page 683 Re calibrate the robot 6 General calibration information is included in sectio...

Page 262: ...v SMB unit DSQC633C Product manual spare parts IRB 6790 See Product manual spare parts IRB 6700 IRB 6700Inv Battery pack Product manual spare parts IRB 6790 Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 713 Standard toolkit Continues on next page 262 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB ...

Page 263: ...and remove the battery 3 xx1300000669 Remove the SMB cover CAUTION Clean cover from metal residues before opening Metal residues can cause shortage on the boards which can result in hazardous failures 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 uni...

Page 264: ...pper lip of the R2 G connector to release the lock while pulling the connector upwards 4 xx1700000993 xx1300000731 Pull out the SMB unit and put it 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 Continues on next page 264 Product manual IRB 6700Inv 3HAC058254 001 ...

Page 265: ...he SMB board R1 SMB1 3 R1 SMB4 6 and R2 SMB 4 xx1300000730 Push the SMB unit carefully into position and fit the bracket that secures the SMB unit 5 X9 X8 X10 xx1700000978 If disconnected reconnect the connectors X8 X9 and X10 to the brake release board Be careful not to damage the sockets or pins Make sure the connector and its locking arms are snapped down properly 6 Continues on next page Produ...

Page 266: ...he SMB battery Note Action ELECTROSTATIC DISCHARGE ESD The unit is sensitive to ESD Before handling the unit please read the safety information in the section The unit is sensitive to ESD on page 53 1 Reconnect the battery cable 2 xx1300000829 Place the battery in the recess 3 Refit the battery cover 4 Continues on next page 266 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2...

Page 267: ...page 680 Update the revolution counters 1 DANGER Make sure all safety requirements are met when performing the first test run 2 Product manual IRB 6700Inv 267 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 4 3 Replacing the SMB Continued ...

Page 268: ...ake release unit Product manual spare parts IRB 6790 See Product manual spare parts IRB 6700 IRB 6700Inv Battery pack Product manual spare parts IRB 6790 Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 713 Standard toolkit Continues on next page 268 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All...

Page 269: ... page 53 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 release 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 oth...

Page 270: ... the robot cabling is positioned in regard to the brake release board 3 xx1300000670 Remove the connectors X8 X9 and X10 from the brake release board 4 Removing the brake release unit Note Action xx1300000744 Unscrew the attachment screws that secure the brake release unit bracket 1 Remove the bracket with the brake release unit fitted 2 Remove the brake release unit from the bracket 3 Continues o...

Page 271: ...1700000978 Reconnect the connectors X8 X9 and X10 to the brake release unit Be careful not to damage the sockets or pins Make sure the connector and its locking arms are snapped down properly 4 Verify that the robot cabling is positioned correctly according to previously taken picture notes WARNING Screened cables must not get in contact with the brake release board after installation Eliminate al...

Page 272: ...at the buttons are moving freely and do not stay in any locked position 9 Reconnect the battery if it has been disconnected 10 See Updating revolution counters on page 680 Update the revolution counters if the battery has been disconnected 11 DANGER Make sure all safety requirements are met when performing the first test run 12 272 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 201...

Page 273: ...700Inv Upper arm Product manual spare parts IRB 6790 Consumables Parts needed to be replaced after removal Note Article number Equipment etc Shell Gadus S2 3HAC042536 001 Grease Used to lubricate o rings D 169 5x3 3HAC054692 002 O ring Used on axis 3 motor cover D 119x3 3HAC054692 001 Used on axis 4 motor cover D 119x3 3HAC054692 001 Used on axis 5 motor cover Continues on next page Product manual...

Page 274: ...ration tools 3HAC055412 001 Calibration tool box Axis Calibration Content is defined in section Standard toolkit on page 713 Standard toolkit Required documents Document number Document 3HAC060303 Directions for use Fork lift accessory for IRB 6700Inv User instructions for turning tool enclosed with the turning tool Deciding calibration routine Decide which calibration routine to be used based on ...

Page 275: ...new reference values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the upper arm Use these procedures to remove the upper arm Preparations before removing the upper arm Note Action Decide which calibration routine to use and take actions accordingly prio...

Page 276: ...fter removal On pallets as a sugges tion 7 Retrieving access to the wrist cabling Use this procedure to remove the wrist cover to retrieve access to the axis 5 and axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1400000355 If DressPack is installed Remove the bracket with the com plete ball joint housing...

Page 277: ...xx1300002247 Remove the wrist cover 4 xx1500001030 Remove the heat protection plates from the motor with the cabling still attached to the plate 5 Continues on next page Product manual IRB 6700Inv 277 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 278: ...ove the DressPack cable package is described in more detail in the product manual IRB 6700 DressPack For article number see References on page 10 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 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues o...

Page 279: ...or 2 Remove the outer screw 3 Slide the cable gland cover away from the inner screw Make sure the gasket is not damaged Tip Make a note in which direction the cable exit hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Continues on next page Product manual IRB 6700Inv 279 3HAC058254 001 Revision L Copyri...

Page 280: ...xx1200001080 Unscrew the attachment screws and re move the motor cover 2 xx1300000488 Disconnect the motor cables 3 xx1300000484 Unscrew the attachment screws that hold the cable bracket 4 Continues on next page 280 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 281: ...es by holding the cables with one hand at the motor and the other at the carrier 7 Disconnecting the axis 3 and axis 4 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page Product manual IRB 6700Inv 281 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 1 Replacin...

Page 282: ...the motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 282 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 283: ...s wrist and upper arm Note Action xx1200000045 Remove the cover Note Foundry Plus Use caution not to damage the gasket not to loose the washers on the cover sealing or not to loose the inserts fitted on the cover 1 xx1700001803 If the cabling is to be replaced by a new cable harness remove the cover insert to use it on the new cabling 2 Continues on next page Product manual IRB 6700Inv 283 3HAC058...

Page 284: ...rs and carrier into a bundle if not already done This is done to facilitate the removal and to avoid damaging the parts This will also make it easier to run the cable harness through the inside of the upper arm 5 Continues on next page 284 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 285: ...xis 4 metal clamp inside the arm tube Note The screw is reached from outside the up per arm 7 xx1700000339 xx1300000543 Remove the arm house metal clamp 8 Continues on next page Product manual IRB 6700Inv 285 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 286: ...acket is replaced by the cable guide xx1300001973 Cable guide 9 Cable fixing bracket xx1300000541 Remove the metal clamp on top of the arm house 10 Continues on next page 286 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 287: ...st xx1300000746 Person 1 working at side hole xx1300000745 Remove the cable harness out of the arm tube at the back of the upper arm Tip This step is best performed by two persons working together Person 1 Put one hand inside the side hole and take a hold of the cable harness Person 2 Take a hold on the cable harness at the back of the robot Together Move the cable harness out of the arm tube 12 P...

Page 288: ...um 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm xx1200001134 Roundsling 2 m Lifting capacity 2 000 kg 2 pcs xx1700000693 Attach a lifting sling to an overhead crane or similar and then to the lifting eye in the arm house 4 Attach a lifting sling to an overhead crane or similar and then to the lifting eye in the wrist Note Lifting slings are used instead of lifting chains to not damage th...

Page 289: ...he screws that hold the lower arm to the axis 3 gearbox that are removed 1 Guide pin M16x200 3HAC13120 3 Always use guide pins in pairs xx1700000457 Tip Lubricate the guide pins with some grease to make the upper arm slide better xx1700000458 Leave one of the remaining attachment screws fitted remove the other screws 2 Continues on next page Product manual IRB 6700Inv 289 3HAC058254 001 Revision L...

Page 290: ...ttachment screw and let the upper arm slide out from the lower arm with support from the guide pins 1 xx1700000459 Lift the upper arm and place it on the pre pared area 2 Continues on next page 290 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 291: ...f applicable 3 Refitting the upper arm Use these procedures to refit the upper arm Preparations before refitting the upper arm Note Action Wipe clean all contact surfaces 1 Rust preventive 3HAC034903 001 Mer casol 3110 Waxcoat Recommended drying time is 24h xx1700001880 Foundry Plus Apply Mercasol on the surface on the lower arm as shown in the figure CAUTION Keep the sealing surfaces clean from M...

Page 292: ...m and bring it towards the lower arm 3 24 VDC power supply If the axis 3 motor is installed to the upper arm 4 Rotation tool Connect the 24 VDC power supply to re lease the brakes Connect to R2 MP3 connector pin 2 pin 5 Use the rotation tool and rotate the axis 3 motor to find the correct position for the guide pins in the lower arm Disconnect and remove the 24 VDC power supply after finding the p...

Page 293: ...y tightening the at tachment screws 8 xx1700000694 Refit the axis 3 synchronization mark plate 9 Refitting the cable harness upper arm Note Action xx1300000541 Refit the metal clamp on top of the arm house 1 Continues on next page Product manual IRB 6700Inv 293 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 294: ...run the cable harness through the inside of the robot 4 A B C D xx1400000382 A Gasket B Cable guide C Washer D Cover Foundry Plus Make sure that the gasket underneath the cover is correctly fitted Replace if dam aged The gasket is covered with adhesive on the side facing the upper arm cover The three washers are pressed into the holes in the gasket Make sure all three washers are fitted 5 Continue...

Page 295: ... back of the robot Together Use caution and move the cable harness into the arm tube 6 Person 2 working at the back xx1400000356 Note The cable harness is best placed at the upper right hand side of the DressPack tube if used through the arm tube Do not run the cable harness into the DressPack tube Note Do not run the cable harness into the DressPack tube if one is fitted xx1300000820 Continues on...

Page 296: ...ke a hold of the cable harness from inside the wrist Together Move the cable harness past the axis 5 motor and into the wrist 7 Person 2 working at the wrist xx1300000746 xx1700000340 Refit the metal clamp axis 4 inside the arm tube Note The screws are reached from outside the upper arm 8 xx1700000339 Continues on next page 296 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 20...

Page 297: ... side cover 9 xx1700000690 If used refit the insert that guides the DressPack cable package through the hole in the upper arm 10 xx1400000092 If used refit the tube containing the DressPack into the insert 11 Continues on next page Product manual IRB 6700Inv 297 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 298: ...0000045 DressPack or Foundry Plus Refit the cover with the tube guiding ring fitted Note Foundry Plus Make sure the gasket is fitted cor rectly Use attachment screws made of stainless steel to fit the cover 13 Continues on next page 298 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 299: ...le 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 Connecting the axis 3 and axis 4 motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 Continues on next page Product manual IRB 6700Inv 299 3HAC058254 001 Revision L Copyright 2017 2020 ABB All...

Page 300: ... 3 O ring axis 1 3HAC054692 002 Inspect the o ring Note Replace if damaged 4 O ring axis 2 3HAC054692 002 O ring axis 3 3HAC054692 002 O ring axis 4 3HAC054692 001 xx1200001070 Wipe clean o ring and o ring groove 5 Continues on next page 300 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 301: ... reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Connecting the axis 5 motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 Continues on next page Product manual IRB 6700Inv 301 3HAC...

Page 302: ...x1200001015 Connect the connectors Connect in accordance with the markings on the connectors 3 O ring axis 5 3HAC054692 001 xx1200001021 Make sure the o ring on the motor is undam aged Replace if damaged 4 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page 302 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 20...

Page 303: ...e threads Replace with standard attachment screws Note Make sure the o ring is undamaged and properly fitted 6 xx1500001029 Secure the cable harness with cable straps to the heat protection plate 7 Screws M5x12 xx1500001030 Fit the heat protection plate with the screws 8 Continues on next page Product manual IRB 6700Inv 303 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Re...

Page 304: ...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 xx1300000667 Push the cable harness into the wrist re cess and up into the axis 6 motor 3 xx1300001113 Push the carrier carefully into position 4 Continues on next page 304 Product manual IRB 6700Inv 3HAC058254 001 Revision ...

Page 305: ...er is level and completely pressed against the bottom 5 xx1300000484 Secure the cable bracket with its attach ment screws 6 xx1300000488 Reconnect the connectors to the axis 6 motor Note Place the resolver cable under the motor cable 7 Continues on next page Product manual IRB 6700Inv 305 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm C...

Page 306: ...UTION When fitting the motor cover make sure that none of the cables inside will be dam aged 9 xx1200001080 Refit the motor cover 10 Continues on next page 306 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm Continued ...

Page 307: ...er not to dam age the cable harness when the wrist cover is refitted use this method 1 Hold the cover angled See figure 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 2 Remove the lifting accessories 3 Continues on next page Product manual IRB 6700Inv 307 3HAC0...

Page 308: ...n is described in Calibrating with Axis Calibration method on page 683 Re calibrate the robot 3 General calibration information is included in section Calibration on page 673 DANGER Make sure all safety requirements are met when performing the first test run 4 308 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 1 Replacing the upper arm...

Page 309: ...nder any circumstances open the cover on the axis 5 gearbox It is strictly forbidden to do any repair work on the axis 5 gearbox xx1300002248 Continues on next page Product manual IRB 6700Inv 309 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist ...

Page 310: ...t etc Cable tie Shell Gadus S2 3HAC042536 001 Grease Used to lubricate o rings D 119x3 3HAC054692 001 O ring Used on axis 5 motor cover Used on axis 6 motor cover 3HAC033489 001 Gasket Mercasol 3110 Waxcoat Re commended drying time is 24h 3HAC034903 001 Rust preventive Used on Foundry Plus Continues on next page 310 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All r...

Page 311: ...robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility t...

Page 312: ...ificance as long as the robot is secured to the founda tion Axis 2 0 Axis 3 0 Axis 4 90 Axis 5 90 Axis 6 no significance 4 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 5 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 6 Continues...

Page 313: ...alled Remove the bracket with the com plete ball joint housing still fitted as shown in the figure This is done to be able to reach the two hidden screws that secure the wrist cover 2 xx1400000206 If used open the ball joint housing on the arm tube and remove the DressPack cable package 3 xx1300002247 Remove the wrist cover 4 Continues on next page Product manual IRB 6700Inv 313 3HAC058254 001 Rev...

Page 314: ...or replacing the motor the cabling does not need to be loosened from the plate 6 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 314 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyrig...

Page 315: ...ld the cable bracket 4 xx1300000485 Unscrew the M4 screw that holds the carri er Note The screw is located at the bottom of the carrier 5 Continues on next page Product manual IRB 6700Inv 315 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 316: ...ting 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 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page 316 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continu...

Page 317: ...otor 2 Remove the outer screw 3 Slide the cable gland cover away from the inner screw Make sure the gasket is not damaged Tip Make a note in which direction the cable exit hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Continues on next page Product manual IRB 6700Inv 317 3HAC058254 001 Revision L Copy...

Page 318: ... balanced when it is removed Placed at a different position there is a risk of sudden change in the balance which can cause damage or injury Do not attach the roundsling around the axis 5 gearbox 2 Note Make sure the roundsling is stretched so it can carry the weight of the wrist 3 Removing the wrist Note Action xx1700000691 If used remove the bracket with the part of the ball joint housing still ...

Page 319: ...e remaining attachment screws 3 xx1300000750 Pull out the wrist a bit 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 4 xx1300000769 Use caution and pull out the cabling from the wrist unit 5 Continues on next page Product manual IRB 6700Inv 319 3HAC058254 001 Revision L Copyright 2017 2020...

Page 320: ...e are turned off 1 Wipe clean all contact surfaces 2 A B C xx1400000371 Foundry Plus Apply Mercasol on the surfaces shown in the figure 3 Guide pin M12x150 3HAC13056 2 Fit two guide pins in opposite holes in the wrist Tip Lubricate the guide pins with some grease to make the wrist slide better 4 Always use guide pins in pairs xx1700001595 Continues on next page 320 Product manual IRB 6700Inv 3HAC0...

Page 321: ... placed as shown in the figure to keep the wrist balanced when it is removed Placed at a different position there is a risk of sudden change in the balance which can cause damage or injury Do not attach the roundsling around the axis 5 gearbox 2 Note Make sure the roundsling is stretched so it can carry the weight of the wrist 3 Refitting the wrist Note Action xx1300000770 Lift the wrist and inser...

Page 322: ...1300000749 Fit 10 of the 12 attachment screws and washers 4 xx1300000748 Remove the guide pins and replace them with the remaining attachment screws and washers 5 Tightening torque 120 Nm Tighten the attachment screws 6 Continues on next page 322 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 323: ... 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 Product manual IRB 6700Inv 323 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 2 Replaci...

Page 324: ...efit the screws that will hold the heat protection plate at this point Note Do not reuse the self threading attachment screws it will damage the threads Replace with standard attachment screws Note Make sure the o ring is undamaged and properly fitted 6 xx1500001029 Secure the cable harness with cable straps to the heat protection plate 7 Continues on next page 324 Product manual IRB 6700Inv 3HAC0...

Page 325: ... floor if the robot is floor standing 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 xx1300000667 Push the cable harness into the wrist re cess and up into the axis 6 motor 3 Continues on next page Product manual IRB 6700Inv 325 3HAC058...

Page 326: ... The attachment screw securing the carrier may be difficult to fit Make sure the carrier is level and completely pressed against the bottom 5 xx1300000484 Secure the cable bracket with its attach ment screws 6 Continues on next page 326 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 327: ... Make sure the gasket is undamaged Replace if damaged 8 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 9 xx1200001080 Refit the motor cover 10 Continues on next page Product manual IRB 6700Inv 327 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 328: ...torque 10 Nm xx1300000772 Refit the wrist cover Use this method not to damage the cable harness 1 Hold the cover tilted See figure 2 Catch any part of the cable harness hanging down 3 Lift the cover still held tilted 4 Move the upper part of the cover into position 5 Secure the cover with its attachment screws 3 Foundry Plus 4 Refit protection plugs If used refit the DressPack cable package on the...

Page 329: ...obot 6 General calibration information is included in section Calibration on page 673 DANGER Make sure all safety requirements are met when performing the first test run 7 Product manual IRB 6700Inv 329 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 2 Replacing the wrist Continued ...

Page 330: ...nual spare parts IRB 6790 Consumables Note Article number Equipment etc Mercasol 3110 Waxcoat Re commended drying time is 24h 3HAC034903 001 Rust preventive Used on Foundry Plus Required tools and equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 713 Standard toolkit Continues on next page 330 Product manual IRB 6700Inv 3HAC058254 001 Revision L Cop...

Page 331: ... pressure supply air pressure supply to the robot before entering the safe guarded space 2 Remove any equipment fitted to the turning disc 3 Removing the turning disc Note Action xx1400002195 Remove the screws and washers that se cure the turning disc 1 xx1300000493 Remove the turning disc 2 Continues on next page Product manual IRB 6700Inv 331 3HAC058254 001 Revision L Copyright 2017 2020 ABB All...

Page 332: ...500000874 xx1500000873 Compatible synchronization mark plate is in stalled Incompatible synchronization mark plate is installed No action required Replace the plate Fitting the axis 6 synchronization mark plate There are different attachment holes on the plate used for different robot variants See table below IRB 6700 300 2 70 IRB 6700 245 3 00 IRB 6700 235 2 65 IRB 6700 205 2 80 IRB 6700 175 3 05...

Page 333: ... Foundry Plus Apply Mercasol on the surfaces on turning disc and axis 6 gearbox as shown in the figure 3 Tightening torque 70 Nm Secure the turning disc with its attachment screws and washers 4 Attachment screws M10x25 Steel 12 9 Gleitmo 603 21 pcs Washers Steel 21 pcs xx1400002195 Concluding procedure Note Action DANGER Make sure all safety requirements are met when performing the first test run ...

Page 334: ...onsumables Note Article number Equipment etc Mercasol used on Foundry Plus Rust preventive Removing the process turning disc Use these procedures to remove the process turning disc Preparations before removing the process turning disc Note Action Run the robot to a position most comfort able for the removal of the process turning disc 1 Continues on next page 334 Product manual IRB 6700Inv 3HAC058...

Page 335: ...sc 1 Remove the process turning disc 2 Refitting the process turning disc Use this procedure to refit the process turning disc Screw joint for refitting process turning disc Tightening torque Number of washers Number of screws Screw dimen sion Variant 70 Nm 21 pcs 21 pcs M10x25 IRB 6700Inv 300 2 60 70 Nm 21 pcs 21 pcs M10x25 IRB 6700Inv 245 2 90 Continues on next page Product manual IRB 6700Inv 33...

Page 336: ...me with process turning disc Tightening torque 70 Nm Secure the process turning disc with its attachment screws and washers 3 Attachment screws M10x25 Steel 12 9 Gleitmo 603 21 pcs Washers Steel 21 pcs Concluding procedure Note Action DANGER Make sure all safety requirements are met when performing the first test run 1 336 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 AB...

Page 337: ...tion lock screw before attempting to lift the robot Summary of the replacement procedure This is a brief summary of the replacement procedure containing the major actions to be performed 1 Lift down the robot to floor standing 2 Unload the balancing device 3 Remove the shaft in the balancing device front link ear 4 Remove the cabling from the upper and lower arm 5 Remove the upper arm 6 Replace th...

Page 338: ...uipment Contains fork lift pockets and all re quired hardware for installation User instructions are enclosed with the tool see Directions for use Fork lift accessory for IRB 6700Inv In order to rotate the robot either use the turning tool or a fork lift truck with a rotator attachment 3HAC058825 001 Fork lift accessory set User instructions are enclosed 3HAC061162 001 Turning tool Used for unload...

Page 339: ... defined in section Standard toolkit on page 713 Standard toolkit Required documents Document number Document 3HAC060303 Directions for use Fork lift accessory for IRB 6700Inv User instructions for turning tool enclosed with the turning tool Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action mig...

Page 340: ... fine calibration Remove all external cable packages DressPack and tools from the robot Removing the lower arm Use these procedures to remove the lower arm Preparations before removing the lower arm Note Action Decide which calibration routine to use and take actions accordingly prior to begin ning the repair procedure 1 DANGER Turn off all electric power supply hydraulic pressure supply air press...

Page 341: ...e the robot can be secured with the attachment bolts 1 M24x100 8 pcs For hole configuration see Hole configuration base on page 64 The robot must always be secured to the floor if any kind of repair or maintenance work is to be performed Verify that the lower arm is secured with the transportation lock screw 2 DressPack can stay fitted Remove any payload and tools from the robot 3 870 50 600 50 60...

Page 342: ...6 screws can be fitted to the fork lift pockets to press the forks against the pockets and make the lift more stable 9 See user instructions enclosed with the turning tool If lifting and turning with the turning tool and overhead crane 1 Install the turning tool to the fork lift pock ets Make sure to install the turning tool with correct side to front 2 Raise the overhead crane to take the weight ...

Page 343: ...tops in maintenance position 3 xx1700000347 Remove the transportation lock screw and yellow sleeve from locking position Note It is only allowed to remove the transportation lock screw and sleeve if the service stops are in maintenance position when the robot is floor standing 4 xx1700000348 Fit the transportation lock screw and the yellow sleeve in their parking position 5 Continues on next page ...

Page 344: ...Tightening torque 70 Nm 15 Nm Fit the relief screws to unload the balancing device DANGER Do not remove the relief screws when the balan cing device is removed from the robot 8 Relief screws 3HAC058129 001 xx1700000070 xx1700000560 Continues on next page 344 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Conti...

Page 345: ...to the balancing device Note Action CAUTION The weight of the balancing device excluding cradle is 305 kg All lifting accessories used must be sized accord ingly 1 SA 10 8 NA1 2 pcs xx1700000086 Fasten lifting shackles on the balancing device 2 Continues on next page Product manual IRB 6700Inv 345 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lo...

Page 346: ...t in the front link ear Note Action It is possible to drive a screwdriver or similar through the VK cover as close as possible to the center of the VK cover and pull it out xx1700000088 Remove the VK cover at the link ear Note Make sure that the lifting accessories hold the weight of the balancing device Tip Use high pressure air to remove the VK covers 1 Continues on next page 346 Product manual ...

Page 347: ...haft out 3 xx1700000322 Carefully lower the lifting device to let the balan cing device rest on the frame 4 Positioning the robot Note Action The upper arm needs to be in a horizontal position later on when the arm is lifted away from the ro bot Turn the power on temporarily and jog axis 3 so that the upper arm is horizontal Jog axis 5 to 90 1 Continues on next page Product manual IRB 6700Inv 347 ...

Page 348: ...l power hydraulic pressure and air pressure are turned off 1 xx1400000355 If DressPack is installed Remove the bracket with the com plete ball joint housing still fitted as shown in the figure This is done to be able to reach the two hidden screws that secure the wrist cover 2 xx1400000206 If used open the ball joint housing on the arm tube and remove the DressPack cable package 3 Continues on nex...

Page 349: ...e ties that hold the cable har ness to the plate Note Keep the heat protection plate until refitting Tip If removing the plate only for replacing the motor the cabling does not need to be loosened from the plate 6 Continues on next page Product manual IRB 6700Inv 349 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 350: ...e ball joint housings on the lower arm and remove the DressPack 2 xx1200001332 If used unscrew the screws that hold the connection plate and let the DressPack hang free 3 Continues on next page 350 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 351: ...turned off 1 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page Product manual IRB 6700Inv 351 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 352: ...ion and pull out the motor cables 6 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 xx1200001135 Unscrew the attachment screws and washers and remove the motor cover 2 Continues on next page 352 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserv...

Page 353: ...or 2 Remove the outer screw 3 Slide the cable gland cover away from the inner screw Make sure the gasket is not damaged Tip Make a note in which direction the cable exit hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Continues on next page Product manual IRB 6700Inv 353 3HAC058254 001 Revision L Copyri...

Page 354: ...xx1200001080 Unscrew the attachment screws and re move the motor cover 2 xx1300000488 Disconnect the motor cables 3 xx1300000484 Unscrew the attachment screws that hold the cable bracket 4 Continues on next page 354 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 355: ... Pull out the carrier from its position 6 xx1300000666 Pull out the axis 6 motor cables by holding the cables with one hand at the motor and the other at the carrier 7 Continues on next page Product manual IRB 6700Inv 355 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 356: ...g or not to loose the inserts fitted on the cover 1 xx1700001803 If the cabling is to be replaced by a new cable harness remove the cover insert to use it on the new cabling 2 xx1700000690 If used loosen the insert 3 Continues on next page 356 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 357: ...e This is done to facilitate the removal and to avoid damaging the parts This will also make it easier to run the cable harness through the inside of the upper arm 5 xx1300000557 Remove the side cover on the arm tube 6 Continues on next page Product manual IRB 6700Inv 357 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 358: ...e arm tube Note The screw is reached from outside the up per arm 7 xx1700000339 xx1300000543 Remove the arm house metal clamp 8 Continues on next page 358 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 359: ...acket is replaced by the cable guide xx1300001973 Cable guide 9 Cable fixing bracket xx1300000541 Remove the metal clamp on top of the arm house 10 Continues on next page Product manual IRB 6700Inv 359 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 360: ...st xx1300000746 Person 1 working at side hole xx1300000745 Remove the cable harness out of the arm tube at the back of the upper arm Tip This step is best performed by two persons working together Person 1 Put one hand inside the side hole and take a hold of the cable harness Person 2 Take a hold on the cable harness at the back of the robot Together Move the cable harness out of the arm tube 12 P...

Page 361: ...er minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm xx1200001134 Roundsling 2 m Lifting capacity 2 000 kg 2 pcs xx1700000693 Attach a lifting sling to an overhead crane or similar and then to the lifting eye in the arm house 4 Attach a lifting sling to an overhead crane or similar and then to the lifting eye in the wrist Note Lifting slings are used instead of lifting chains to not d...

Page 362: ...he screws that hold the lower arm to the axis 3 gearbox that are removed 1 Guide pin M16x200 3HAC13120 3 Always use guide pins in pairs xx1700000457 Tip Lubricate the guide pins with some grease to make the upper arm slide better xx1700000458 Leave one of the remaining attachment screws fitted remove the other screws 2 Continues on next page 362 Product manual IRB 6700Inv 3HAC058254 001 Revision L...

Page 363: ...ttachment screw and let the upper arm slide out from the lower arm with support from the guide pins 1 xx1700000459 Lift the upper arm and place it on the pre pared area 2 Continues on next page Product manual IRB 6700Inv 363 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 364: ...re removing the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Open the ball joint housings on the lower arm and remove the DressPack 2 xx1300000540 Loosen the axis 2 lower arm metal clamp and the axis 3 lower arm metal clamp loc ated on the inside of the lower arm by re moving the attachment screws Note The screws...

Page 365: ...ccessory to unload the lower arm 1 Guide pin M16x150 3HAC13120 2 Remove two attachment screws in opposite holes and replace them with guide pins Tip Lubricate the guide pins with some grease to make the lower arm slide better 2 Guide pin M16x200 3HAC13120 3 Always use guide pins in pairs xx1400002181 Continues on next page Product manual IRB 6700Inv 365 3HAC058254 001 Revision L Copyright 2017 202...

Page 366: ...arm Preparations before refitting the lower arm Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Rust preventive 3HAC034903 001 Mer casol 3110 Waxcoat Recommended drying time is 24h xx1700001879 Apply Mercasol on the surface on the lower arm as shown in the figure CAUTION Keep the sealing surfaces clean from Mer casol 2 Contin...

Page 367: ...pins and slide it into position 1 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 until the holes matches Connect 24 VDC the power supply to con nector R2 MP2 pin 2 pin 5 2 24 VDC power supply xx1300...

Page 368: ...002181 Remove the guide pins and replace them with the remaining attachment screws 6 Tightening torque M16 300 Nm Secure the remaining attachment screws 7 Remove the lifting accessory from the lower arm 8 Preparations before refitting the upper arm Note Action Wipe clean all contact surfaces 1 Continues on next page 368 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB A...

Page 369: ... arm slide better 3 Guide pin M16x200 3HAC13120 3 Always use guide pins in pairs xx1700000056 Securing the upper arm Note Action CAUTION The weight of the complete upper arm in cluding the wrist is 465 kg All lifting accessories used must be sized accordingly 1 See Attaching lifting accessories to the upper arm on page 204 Attach the lifting accessories if not already fitted 2 Lift the upper arm a...

Page 370: ...1 If the axis 3 motor is not installed to the upper arm 5 Use the pinion to rotate the axis 3 gearbox to find the correct position for the guide pins in the lower arm xx1700000460 Insert and tighten 20 of the 22 M16 screws 6 Remove the guide pins and fit the two re maining screws 7 M16 tightening torque 300 Nm Secure the upper arm by tightening the at tachment screws 8 xx1700000694 Refit the axis ...

Page 371: ...e it easier to run the cable harness through the inside of the robot 1 xx1300000733 Run the upper end of the cable harness up through the lower arm 2 xx1300000734 Refit the axis 2 lower arm metal clamp located on the inside of the lower arm Note The screws are reached from the outside of the lower arm 3 Continues on next page Product manual IRB 6700Inv 371 3HAC058254 001 Revision L Copyright 2017 ...

Page 372: ...ackets 4 xx1300000558 Refit the axis 3 lower arm metal clamp located on the inside of the lower arm Note The screws are reached from the outside of the lower arm 5 Refitting the cable harness upper arm Note Action xx1300000541 Refit the metal clamp on top of the arm house 1 Continues on next page 372 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4...

Page 373: ...run the cable harness through the inside of the robot 4 A B C D xx1400000382 A Gasket B Cable guide C Washer D Cover Foundry Plus Make sure that the gasket underneath the cover is correctly fitted Replace if dam aged The gasket is covered with adhesive on the side facing the upper arm cover The three washers are pressed into the holes in the gasket Make sure all three washers are fitted 5 Continue...

Page 374: ... back of the robot Together Use caution and move the cable harness into the arm tube 6 Person 2 working at the back xx1400000356 Note The cable harness is best placed at the upper right hand side of the DressPack tube if used through the arm tube Do not run the cable harness into the DressPack tube Note Do not run the cable harness into the DressPack tube if one is fitted xx1300000820 Continues on...

Page 375: ...ke a hold of the cable harness from inside the wrist Together Move the cable harness past the axis 5 motor and into the wrist 7 Person 2 working at the wrist xx1300000746 xx1700000340 Refit the metal clamp axis 4 inside the arm tube Note The screws are reached from outside the upper arm 8 xx1700000339 Continues on next page Product manual IRB 6700Inv 375 3HAC058254 001 Revision L Copyright 2017 20...

Page 376: ... side cover 9 xx1700000690 If used refit the insert that guides the DressPack cable package through the hole in the upper arm 10 xx1400000092 If used refit the tube containing the DressPack into the insert 11 Continues on next page 376 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 377: ...0000045 DressPack or Foundry Plus Refit the cover with the tube guiding ring fitted Note Foundry Plus Make sure the gasket is fitted cor rectly Use attachment screws made of stainless steel to fit the cover 13 Continues on next page Product manual IRB 6700Inv 377 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 378: ...001973 14 Connecting the axis 3 and axis 4 motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page 378 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 379: ... ring axis 4 3HAC054692 001 xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring Tip Lubricate the o ring with some grease for a better fitting in the groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page Product manual IRB 6700Inv 379 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Re...

Page 380: ...ecting the axis 5 motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 xx1200001016 Refit the cable gland cover by performing the following steps Slide the 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 Continues on next page 38...

Page 381: ...001021 Make sure the o ring on the motor is undam aged Replace if damaged 4 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page Product manual IRB 6700Inv 381 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 382: ...e threads Replace with standard attachment screws Note Make sure the o ring is undamaged and properly fitted 6 xx1500001029 Secure the cable harness with cable straps to the heat protection plate 7 Screws M5x12 xx1500001030 Fit the heat protection plate with the screws 8 Continues on next page 382 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Re...

Page 383: ...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 xx1300000667 Push the cable harness into the wrist re cess and up into the axis 6 motor 3 xx1300001113 Push the carrier carefully into position 4 Continues on next page Product manual IRB 6700Inv 383 3HAC058254 001 Revision ...

Page 384: ...er is level and completely pressed against the bottom 5 xx1300000484 Secure the cable bracket with its attach ment screws 6 xx1300000488 Reconnect the connectors to the axis 6 motor Note Place the resolver cable under the motor cable 7 Continues on next page 384 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm C...

Page 385: ...UTION When fitting the motor cover make sure that none of the cables inside will be dam aged 9 xx1200001080 Refit the motor cover 10 Continues on next page Product manual IRB 6700Inv 385 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 386: ...500001030 Fit the heat protection plate with the screws 2 xx1600002061 Make sure that the cable harness is placed so it will not be damaged when the wrist cover is fitted 3 Continues on next page 386 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 387: ...still tilted 4 Move the upper part of the cover into position 5 Secure the cover with its attachment screws 5 How to refit the DressPack cable package is described in the product manual IRB 6700 DressPack For article number see References on page 10 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 bra...

Page 388: ...e connection plate 8 xx1400000195 If used refit the DressPack in the ball joint housings on the lower arm 9 Continues on next page 388 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower arm Continued ...

Page 389: ...balancing device link ear with the hole in the lower arm Note Verify that the link ear is correctly turned 4 A B C A xx1400000368 A Front link ear B Shaft C Mercasol red dotted lines Foundry Plus Apply Mercasol on the surfaces on the shaft and front ear 5 xx1200001280 Lubricate the shaft and place it to the front ear Note Foundry Plus Do not lubricate surfaces where Mercasol is ap plied 6 Continue...

Page 390: ... 2701 xx1300000782 Apply locking liquid on the first threads of the screw 8 Tightening torque 180 Nm xx1200001279 Secure the shaft with screw and washer 9 xx1700000088 Fit the protection plug or a new VK cover de pends on shaft version 10 xx1900002311 Continues on next page 390 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing...

Page 391: ...k bracket if used 13 Restoring the balancing device Note Action Remove the lifting equipment from the balancing device 1 xx1700001406 Jog axis 2 to 4 to be able to remove the relief screws 2 xx1700000070 Remove the relief screws to activate the balancing device Note Axis 2 must be in 4 3 Continues on next page Product manual IRB 6700Inv 391 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rig...

Page 392: ... position Note Action 870 50 600 50 60 65 35 3 0 xx1600001371 Verify that the robot stands in position Axis 1 0 Axis 2 35 Axis 3 65 Axis 4 0 Axis 5 60 Axis 6 no significance 1 xx1700000348 Remove the transportation lock screw and the yellow sleeve from the parking position 2 Continues on next page 392 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved ...

Page 393: ...ning and floor standing 3 xx1600002114 Preparations before lifting up the robot to inverted position Note Action xx1700000068 Remove the two service stops from maintenance position if previously moved there 1 xx1700000067 Fit the service stops in their parking position 2 See user instructions enclosed with the fork lift accessory Fasten the fork lift accessory 3 Fork lift accessory set 3HAC058825 ...

Page 394: ...itable screws lightly lubricated M24x100 8 pcs 8 8 Fit the bolts and washers in the base attachment holes Note Lightly lubricate screws before assembly 5 Suitable washer 4 mm flat washer Screw tightening yield point utiliza tion factor v according to VDI2230 90 v 0 9 Tightening torque CAUTION If high stress on screws are suspected replace used screws with new ones 550 Nm screws lubricated with Mol...

Page 395: ...tion is described in Calibrating with Axis Calibration method on page 683 Re calibrate the robot 2 General calibration information is included in section Calibration on page 673 DANGER Make sure all safety requirements are met when performing the first test run 3 Product manual IRB 6700Inv 395 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 5 5 Replacing the lower ...

Page 396: ...procedure containing the major actions to be performed 1 Unload the balancing device 2 Replace the spherical roller bearing Spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 6700Inv via myABB Business Portal www abb com myABB Continues on next page 396 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 202...

Page 397: ...3HAC028920 001 Dismantle and mounting tool set To be used with the press tool 3HAC11731 1 Hydraulic cylinder To be used with the hydraulic cylinder 3HAC13086 1 Hydraulic pump 80 MPa SA 10 8 NA1 Lifting shackle 2 pcs Lifting capacity 1 000 kg Roundsling 1 m Content is defined in section Standard toolkit on page 713 Standard toolkit Consumables Note Article number Consumable 3HAA2166 12 VK cover 28x...

Page 398: ...r repair or maintenance 2 Tightening torque 70 Nm 15 Nm Fit the relief screws to unload the balancing device DANGER Do not remove the relief screws during replace ment of spherical roller bearing 3 Relief screws 3HAC058129 001 xx1700000699 xx1700000700 Jog the robot into position Axis 1 25 Axis 2 15 Axis 3 4 5 6 no significance 4 Continues on next page 398 Product manual IRB 6700Inv 3HAC058254 001...

Page 399: ... 8 NA1 xx1700000701 Fasten a lifting shackle on the rear lifting ear 2 Roundsling 1 m Lifting capacity 1 000 kg Fasten a lifting sling through the shackle and around the balancing device Note Put a cloth between the lifting equipment and the balancing device to avoid color scratches 3 xx1700000711 Fasten a lifting eye in the robot foot above the balancing device 4 Continues on next page Product ma...

Page 400: ...as possible to the center of the VK cover and pull it out xx1700000088 Remove the VK cover at the link ear Note Make sure that the lifting accessories hold the weight of the balancing device Tip Use high pressure air to remove the VK covers 1 xx1700000089 Remove the attachment screw and washer at the link ear CAUTION The balancing device is heavy at the back and will tip over when the link ear is ...

Page 401: ...tion Check that the link ear is in a position where it is possible to apply the dismantle and mounting tool If not adjust with the lifting accessory 1 xx1300000774 Unscrew the attachment screws securing the end cover remove end cover and radial sealing with a screwdriver 2 xx1300000775 Remove the o ring 3 Continues on next page Product manual IRB 6700Inv 401 3HAC058254 001 Revision L Copyright 201...

Page 402: ...ol DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool Refitting the spherical roller bearing Use these procedures to refit 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 402 Produ...

Page 403: ... set 3HAC028920 001 Press in the spherical roller bearing using the dismantle and mounting tool according to user instructions enclosed with the equipment xx0900000813 6 User instructions are enclosed with the tool Go to the user instructions enclosed with the press tool DANGER Handling the tool incorrectly will cause serious injury Read and follow enclosed user instructions for the tool Continues...

Page 404: ...elease the chain block Note Action xx1700000712 Release the chain block to raise the front link ear on the balancing device 1 Align the front link ear and the spherical roller bearing 2 Continues on next page 404 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 1 Replacing the spherical roller bearing Continued ...

Page 405: ...g device link ear with the hole in the lower arm Note Verify that the link ear is correctly turned 4 A B C A xx1400000368 A Front link ear B Shaft C Mercasol red dotted lines Foundry Plus Apply Mercasol on the surfaces on the shaft and front ear 5 xx1200001280 Lubricate the shaft and place it to the front ear Note Foundry Plus Do not lubricate surfaces where Mercasol is ap plied 6 Continues on nex...

Page 406: ...1300000782 Apply locking liquid on the first threads of the screw 8 Tightening torque 180 Nm xx1200001279 Secure the shaft with screw and washer 9 xx1700000088 Fit the protection plug or a new VK cover de pends on shaft version 10 xx1900002311 Continues on next page 406 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 1 Replacing the sph...

Page 407: ... 12 Refit the DressPack bracket if used 13 Remove lifting accessories Note Action Remove the chain block 1 xx1700000711 Remove the lifting eye in robot foot 2 Remove the lifting sling 3 xx1700000701 Remove the lifting shackle on the balancing device 4 Continues on next page Product manual IRB 6700Inv 407 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 1 Replacing...

Page 408: ...0 Remove the relief screws to activate the balancing device Note Axis 2 must be in 4 3 xx1700000451 Refit the covers Make sure that the o rings are still fitted Note Only manual force is required no tightening torque 4 408 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 1 Replacing the spherical roller bearing Continued ...

Page 409: ... arm using the yellow sleeve and transportation lock screw before attempting to lift the robot Summary of the replacement procedure This is a brief summary of the replacement procedure containing the major actions to be performed 1 Lift down the robot to floor standing 2 Unload the balancing device 3 Replace the balancing device 4 Lift up and rotate the robot to inverted position Continues on next...

Page 410: ...000 kg Roundsling 1 m SA 10 8 NA1 Lifting shackle 2 pcs Contains fork lift pockets and all re quired hardware for installation User instructions are enclosed with the tool see Directions for use Fork lift accessory for IRB 6700Inv In order to rotate the robot either use the turning tool or a fork lift truck with a rotator attachment 3HAC058825 001 Fork lift accessory set User instructions are encl...

Page 411: ...octite 243 3HAB7116 1 Locking liquid Shaft link ear versions Shaft link ear 3HAC044036 001 Shaft link ear 3HAC072597 001 xx1900002310 xx1900002309 Required documents Document number Document 3HAC060303 Directions for use Fork lift accessory for IRB 6700Inv User instructions for turning tool enclosed with the turning tool Removing the balancing device Use these procedures to remove the balancing de...

Page 412: ...fting down the robot from inverted position Note Action Suitable screws lightly lubricated If the robot is to be secured to the floor prepare an area where the robot can be secured with the attachment bolts 1 M24x100 8 pcs For hole configuration see Hole configuration base on page 64 The robot must always be secured to the floor if any kind of repair or maintenance work is to be performed Verify t...

Page 413: ... instructions enclosed with the fork lift accessory set Install the fork lift pockets to the robot if not already installed 8 Fork lift accessory set 3HAC058825 001 If lifting and turning with the fork lift rotator attach ment required 1 Insert the forks of the fork lift truck into the fork lift pockets as far as possible 2 Raise the forks of the fork lift truck to make sure that the weight of the...

Page 414: ...tructions enclosed with the turning tool Rotate the robot to floor standing position using the turning tool or using the fork lift truck with a rotator attachment 12 Attachment screws M24x100 8 pcs Lower and secure the robot to the floor 13 Unloading the balancing device Note Action Attachment screws M24x100 8 pcs Verify that the robot is secured to the foundation 1 xx1700000067 Remove the two ser...

Page 415: ...1700000348 Fit the transportation lock screw and the yellow sleeve in their parking position 5 xx1700001404 Jog axis 2 to 4 to be able to insert the relief screws 6 xx1700000451 Remove the covers on the balancing device Note The covers have to be refitted after repair or maintenance 7 Continues on next page Product manual IRB 6700Inv 415 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights...

Page 416: ...rews 3HAC058129 001 xx1700000070 xx1700000560 xx1700001405 Jog axis 2 to 15 9 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 10 Continues on next page 416 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing device Continued ...

Page 417: ...e sized accord ingly 1 SA 10 8 NA1 2 pcs xx1700000086 Fasten lifting shackles on the balancing device 2 Roundsling 1 m 2 pcs Lifting ca pacity 1 000 kg xx1700000087 Fasten the lifting slings 3 Continues on next page Product manual IRB 6700Inv 417 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing device Continued ...

Page 418: ...Loosen the DressPack bracket if mounted 1 It is possible to drive a screwdriver or similar through the VK cover as close as possible to the center of the VK cover and pull it out xx1700000088 Remove the protection plug or VK cover at the link ear depends on shaft version 2 xx1900002311 Continues on next page 418 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All right...

Page 419: ...se as possible to the center of the VK cover xx1700000091 Remove the VK covers at the cradle Tip Use high pressure air to remove the VK covers 4 Wipe off all residual grease inside the recess 5 xx1700000093 Loosen the attachment screws 6 Continues on next page Product manual IRB 6700Inv 419 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing...

Page 420: ...x1700000322 7 Dismantle and mounting tool set 3HAC028920 001 xx1700000090 Use the dismantle and mounting tool and pull the shaft out 8 xx1700000094 Remove attachment screws and washers at the cradle 9 Continues on next page 420 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing device Continued ...

Page 421: ...aring A B C 8 4 xx1700000384 12 Refitting the balancing device Use these procedures to refit the balancing device Attaching lifting accessories to the balancing device Note Action CAUTION The weight of the balancing device excluding cradle is 305 kg All lifting accessories used must be sized accord ingly 1 Continues on next page Product manual IRB 6700Inv 421 3HAC058254 001 Revision L Copyright 20...

Page 422: ...C059516 001 2 xx1600002060 Raise the lifting slings to take the weight of the balancing device CAUTION The balancing device is heavy at the back and will tip over when the link ear is loosened xx1700000322 4 Continues on next page 422 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing device Continued ...

Page 423: ...lancing device into position in the cradle 2 xx1700000096 Apply a big screwdriver between the cradle and the balancing device when the shafts are refitted 3 Dismantle and mounting tool set 3HAC028920 001 Press the shafts into position one at a time 4 K G C 8 xx1700000406 4 Continues on next page Product manual IRB 6700Inv 423 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 ...

Page 424: ... xx1300000837 Fit new VK covers 7 Shell Gadus S2 3HAC042536 001 xx1300000832 Unscrew both screws in the cradle and fill the bearing with grease from the inner hole until grease appears in the outer hole 8 Refit the screws 9 Wipe clean from residual grease 10 Continues on next page 424 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 2 Re...

Page 425: ...ncing device link ear with the hole in the lower arm Note Verify that the link ear is correctly turned 4 A B C A xx1400000368 A Front link ear B Shaft C Mercasol red dotted lines Foundry Plus Apply Mercasol on the surfaces on the shaft and front ear 5 xx1200001280 Lubricate the shaft and place it to the front ear Note Foundry Plus Do not lubricate surfaces where Mercasol is ap plied 6 Continues on...

Page 426: ...1 xx1300000782 Apply locking liquid on the first threads of the screw 8 Tightening torque 180 Nm xx1200001279 Secure the shaft with screw and washer 9 xx1700000088 Fit the protection plug or a new VK cover de pends on shaft version 10 xx1900002311 Continues on next page 426 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing the...

Page 427: ...racket if used 13 Restoring the balancing device Note Action Remove the lifting equipment from the balancing device 1 xx1700001406 Jog axis 2 to 4 to be able to remove the relief screws 2 xx1700000070 Remove the relief screws to activate the balancing device Note Axis 2 must be in 4 3 Continues on next page Product manual IRB 6700Inv 427 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights...

Page 428: ...ition Note Action 870 50 600 50 60 65 35 3 0 xx1600001371 Verify that the robot stands in position Axis 1 0 Axis 2 35 Axis 3 65 Axis 4 0 Axis 5 60 Axis 6 no significance 1 xx1700000348 Remove the transportation lock screw and the yellow sleeve from the parking position 2 Continues on next page 428 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Re...

Page 429: ... and floor standing 3 xx1600002114 Preparations before lifting up the robot to inverted position Note Action xx1700000068 Remove the two service stops from maintenance position if previously moved there 1 xx1700000067 Fit the service stops in their parking position 2 See user instructions enclosed with the fork lift accessory Fasten the fork lift accessory 3 Fork lift accessory set 3HAC058825 001 ...

Page 430: ...le screws lightly lubricated M24x100 8 pcs 8 8 Fit the bolts and washers in the base attachment holes Note Lightly lubricate screws before assembly 5 Suitable washer 4 mm flat washer Screw tightening yield point utiliza tion factor v according to VDI2230 90 v 0 9 Tightening torque CAUTION If high stress on screws are suspected replace used screws with new ones 550 Nm screws lubricated with Molykot...

Page 431: ...700000270 Fasten the yellow sleeve and transportation lock screw in its parking position 8 Product manual IRB 6700Inv 431 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 2 Replacing the balancing device Continued ...

Page 432: ...ore the balancing device 5 Lift up and rotate the robot to inverted position Required spare parts Note The spare part numbers that are listed in the table can be out of date See the latest spare parts of the IRB 6700Inv via myABB Business Portal www abb com myABB Note Article number Spare part The maintenance kit contains bearings radial sealings retain ing rings and VK covers 3HAC048834 001 Maint...

Page 433: ... Content is defined in section Standard toolkit on page 713 Standard toolkit Required consumables Note Article number Consumable Also included in the maintenance kit 3HAA2166 13 VK cover 100x10 2 pcs Shell Gadus S2 3HAC042536 001 Bearing grease Loctite 243 3HAB7116 1 Locking liquid Removing the rear bearings on the balancing device Use these procedures to remove the rear bearings Securing the lowe...

Page 434: ...n be secured with the attachment bolts 1 M24x100 8 pcs For hole configuration see Hole configuration base on page 64 The robot must always be secured to the floor if any kind of repair or maintenance work is to be performed Verify that the lower arm is secured with the transportation lock screw 2 DressPack can stay fitted Remove any payload and tools from the robot 3 870 50 600 50 60 65 35 3 0 xx1...

Page 435: ...e fitted to the fork lift pockets to press the forks against the pockets and make the lift more stable 9 See user instructions enclosed with the turning tool If lifting and turning with the turning tool and overhead crane 1 Install the turning tool to the fork lift pock ets Make sure to install the turning tool with correct side to front 2 Raise the overhead crane to take the weight of the robot 1...

Page 436: ...nance position 3 xx1700000347 Remove the transportation lock screw and yellow sleeve from locking position Note It is only allowed to remove the transportation lock screw and sleeve if the service stops are in maintenance position when the robot is floor standing 4 xx1700000348 Fit the transportation lock screw and the yellow sleeve in their parking position 5 Continues on next page 436 Product ma...

Page 437: ...que 70 Nm 15 Nm Fit the relief screws to unload the balancing device DANGER Do not remove the relief screws when the balan cing device is removed from the robot 8 Relief screws 3HAC058129 001 xx1700000070 xx1700000560 Continues on next page Product manual IRB 6700Inv 437 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 3 Replacing the rear bearings on the balancin...

Page 438: ...ng device Note Action CAUTION The weight of the balancing device excluding cradle is 305 kg All lifting accessories used must be sized accord ingly 1 SA 10 8 NA1 2 pcs xx1700000086 Fasten lifting shackles on the balancing device 2 Continues on next page 438 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 3 Replacing the rear bearings on...

Page 439: ...TION The balancing device is heavy at the back and will tip over when the link ear is loosened xx1700000322 4 Removing the shaft end and rear bearings Note Remove one shaft end and one bearing at a time Continues on next page Product manual IRB 6700Inv 439 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 3 Replacing the rear bearings on the balancing device Contin...

Page 440: ...pe off all residual grease inside the recess 2 xx1700000094 Remove attachment screws and washers 3 xx1700000343 Remove the retaining ring bore 4 xx1300000838 Put a big screw driver between the cradle and balancing device and use it as a distance tool 5 Continues on next page 440 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 3 Replacin...

Page 441: ...gs Note Action Wipe clean all contact surfaces from resid ual grease and other contamination inside the recess 1 A B C xx1400000367 A Mercasol red dotted lines B Balancing device C Shaft Foundry Plus Apply Mercasol on matching surfaces on the axis and balancing device See the fig ure 2 Continues on next page Product manual IRB 6700Inv 441 3HAC058254 001 Revision L Copyright 2017 2020 ABB All right...

Page 442: ...r refers to marking on the tool Apply a threaded bar into the hole in the balancing device 4 xx1300000830 Use caution and put sealing ring radial sealing spacer and groove ball bearing onto the shaft end manually 5 Continues on next page 442 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 3 Replacing the rear bearings on the balancing d...

Page 443: ...t radial sealing and groove ball bearing onto the shaft end manually 6 Put the shaft end with the fitted parts on the threaded bar 7 Manually press the shaft end into the cradle a little 8 Continues on next page Product manual IRB 6700Inv 443 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 3 Replacing the rear bearings on the balancing device Continued ...

Page 444: ...e cradle and balancing device and use it as a dis tance tool 10 Use caution and press the shaft end in po sition 11 Remove the press tool and the threaded bar 12 xx1700000343 Fit the retaining ring bore 13 Loctite 243 3HAB7116 1 Apply locking liquid on the attachment screw 14 Continues on next page 444 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved...

Page 445: ...ing the balancing device Note Action Remove the lifting equipment from the balancing device 1 xx1700001406 Jog axis 2 to 4 to be able to remove the relief screws 2 xx1700000070 Remove the relief screws to activate the balancing device Note Axis 2 must be in 4 3 Continues on next page Product manual IRB 6700Inv 445 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 3...

Page 446: ... Action 870 50 600 50 60 65 35 3 0 xx1600001371 Verify that the robot stands in position Axis 1 0 Axis 2 35 Axis 3 65 Axis 4 0 Axis 5 60 Axis 6 no significance 1 xx1700000348 Remove the transportation lock screw and the yellow sleeve from the parking position 2 Continues on next page 446 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 3...

Page 447: ... standing 3 xx1600002114 Preparations before lifting up the robot to inverted position Note Action xx1700000068 Remove the two service stops from maintenance position if previously moved there 1 xx1700000067 Fit the service stops in their parking position 2 See user instructions enclosed with the fork lift accessory Fasten the fork lift accessory 3 Fork lift accessory set 3HAC058825 001 Continues ...

Page 448: ...lightly lubricated M24x100 8 pcs 8 8 Fit the bolts and washers in the base attachment holes Note Lightly lubricate screws before assembly 5 Suitable washer 4 mm flat washer Screw tightening yield point utiliza tion factor v according to VDI2230 90 v 0 9 Tightening torque CAUTION If high stress on screws are suspected replace used screws with new ones 550 Nm screws lubricated with Molykote 1000 600...

Page 449: ...asten the yellow sleeve and transportation lock screw in its parking position 8 Product manual IRB 6700Inv 449 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 3 Replacing the rear bearings on the balancing device Continued ...

Page 450: ...d equipment Note Article number Equipment etc Content is defined in section Standard toolkit on page 713 Standard toolkit Required consumables Note Article number Consumable Loctite 243 3HAB7116 1 Locking liquid Mercasol 3110 Waxcoat Recom mended drying time is 24h 3HAC034903 001 Foundry plus Rust preventive Continues on next page 450 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright ...

Page 451: ...before entering the robot working area 1 xx1700000356 Hold the mechanical stop pin in a firm grip Remove the set screw cup point 2 xx1700000358 Remove the stop pin 3 Continues on next page Product manual IRB 6700Inv 451 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 4 Replacing the stop pin Continued ...

Page 452: ... surfaces shown in the figure on stop pin and in the hole as shown in the figure 1 xx1700000358 Fit the stop pin 2 Loctite 243 Apply locking liquid on the set screw and secure the stop pin 3 Set screw M10x20 xx1700000356 452 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 6 4 Replacing the stop pin Continued ...

Page 453: ... lifting tools 2 Replace the motor 3 Remove the lifting tools Spare parts Note Spare part number Spare part See Product manual spare parts IRB 6700 IRB 6700Inv Axis 1 motor Product manual spare parts IRB 6790 Consumables Note Article number Equipment etc Used to lubricate o rings Shell Gadus S2 3HAC042536 001 Grease Continues on next page Product manual IRB 6700Inv 453 3HAC058254 001 Revision L Co...

Page 454: ...7 1 Rotation tool Used to release the motor brakes 24 VDC power supply Leak down tester Delivered as a set of calibration tools 3HAC055412 001 Calibration tool box Axis Calibration Content is defined in section Standard toolkit on page 713 Standard toolkit Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is ch...

Page 455: ...be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the axis 1 motor These procedures describe how to remove the motor Preparations before removing the axis 1 motor Note Action Decide which calibration routine to use and take actions accordingly prior to begin ning the repair procedure 1 Jog the robot to the synchronization posi tion 2...

Page 456: ...e motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 456 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor Continued ...

Page 457: ...l out the motor cables 6 Attaching the removal tool Note Action xx1700000364 Foundry plus Remove the plastic plugs 1 xx1700000365 Revolving handle A Shelf B Bracket C Lower the revolving handle on the removal tool to be able to fit the shelf beneath the motor while fastening the tool 2 Continues on next page Product manual IRB 6700Inv 457 3HAC058254 001 Revision L Copyright 2017 2020 ABB All right...

Page 458: ...er 3HAC12342 1 xx1700000368 Remove the two shown motor screws and wash ers 1 xx1700000367 Raise the revolving handle to fit the motor on the tool shelf 2 Continues on next page 458 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor Continued ...

Page 459: ... be sized accord ingly 6 Disconnect the 24 VDC power supply 7 Lifting eye M12 3HAC16131 1 Fasten lifting eyes in two of the fastening holes on the motor 8 Use a roundsling to lift the motor off 9 Refitting the axis 1 motor These procedures describes how to refit the motor Preparations prior to refitting motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure an...

Page 460: ...e Tip Lubricate the o ring with some grease for a better fitting in the groove 4 xx1200001135 If the motor is a new spare part remove the cover 5 Continues on next page 460 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor Continued ...

Page 461: ...y Remove the protection filter and install the transparent plug sight glass On the axis 6 motor there are two protection filters that must be replaced with transparent plugs sight glasses xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard Attaching the removal tool Note Action xx1700000364 Foundry plus Remove the plastic plugs 1 Continues on next page Product manua...

Page 462: ...e 3 Securing the axis 1 motor Note Action CAUTION The weight of the motor is 27 kg All lifting accessories used must be sized accord ingly 1 Lifting eye M12 3HAC16131 1 Fasten lifting eyes in two of the fastening holes on the motor 2 Use a roundsling to lift the motor 3 Continues on next page 462 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Rep...

Page 463: ...s used 8 Raise the revolving handle to assemble motor Make sure that the motor pinion is properly mated into the hub Make sure that the motor pinion does not get damaged Make sure that the direction of the cable exit is facing the correct way 9 Bits extender 3HAC12342 1 Secure the motor with its attachment screws and washers 10 Tightening torque 50 Nm Use a bits extender to reach the screws Screw ...

Page 464: ...plus Refit the plastic plugs 2 Connecting the motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 Continues on next page 464 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor Continued ...

Page 465: ... O ring axis 1 3HAC054692 002 Inspect the o ring Note Replace if damaged 4 O ring axis 2 3HAC054692 002 O ring axis 3 3HAC054692 002 O ring axis 4 3HAC054692 001 xx1200001070 Wipe clean o ring and o ring groove 5 Continues on next page Product manual IRB 6700Inv 465 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 1 Replacing the axis 1 motor Continued ...

Page 466: ...maged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Concluding procedure Use this procedure for the concluding refitting Note Action Axis Calibration is described in Calibrating with Axis Calibration method on page 683 Re calibrate the robot 1 General calibration information is included in section Calibration on page 673 DANGER Make sur...

Page 467: ... 3 Replace the motor 4 Remove the lifting tools 5 Refill the axis 2 gearbox with oil Spare parts Note Spare part number Spare part See Product manual spare parts IRB 6700 IRB 6700Inv Axis 2 motor Product manual spare parts IRB 6790 Consumables Note Article number Equipment etc Shell Gadus S2 3HAC042536 001 Grease Used to lubricate o rings Continues on next page Product manual IRB 6700Inv 467 3HAC0...

Page 468: ... supply Used to secure lower arm Lock screw M16x120 Leak down tester Delivered as a set of calibration tools 3HAC055412 001 Calibration tool box Axis Calibration Content is defined in section Standard toolkit on page 713 Standard toolkit Deciding calibration routine Decide which calibration routine to be used based on the information in the table Depending on which routine is chosen action might b...

Page 469: ...e procedures describes how to remove the motor Preparations before removing the axis 2 motor Note Action Decide which calibration routine to use and take actions accordingly prior to begin ning the repair procedure 1 See Draining the axis 2 gearbox on page 152 Drain the oil from the gearbox 2 Jog the robot to the calibration position 3 DANGER Secure the weight of the lower arm with a lock screw be...

Page 470: ...ables 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 xx1200001070 Make sure the o ring is present 3 Continues on next page 470 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 2 Rep...

Page 471: ...e same position 5 Use caution and pull out the motor cables 6 Removing the axis 2 motor Note Action Before removing the motor make sure that the axis 2 gearbox is completely drained 1 To release the brake connect the 24 VDC power supply 2 Connect to connector R2 MP2 axis 2 mo tor pin 2 pin 5 Continues on next page Product manual IRB 6700Inv 471 3HAC058254 001 Revision L Copyright 2017 2020 ABB All...

Page 472: ...s used 5 Removal tool motor M12 3HAC14631 1 If required press the motor out of its posi tion by using the removal tool in opposite holes of the motor 6 Always use removal tools in pairs Disconnect the 24 VDC power supply 7 CAUTION The motor weighs 28 kg All lifting accessories used must be sized accordingly 8 Carefully lift the motor out on the guide pins in order to get the pinion away from the g...

Page 473: ...hat all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove any old paint residues or other contam ination from the contact surfaces on both the motor and the mating parts 2 Wipe clean the contact surfaces and the o ring groove xx1200001019 Check the o ring Replace if damaged 3 xx1200001020 Make sure the o ring is seated in the groove Tip Lubricate the o ring ...

Page 474: ...axis 6 motor there are two protection filters that must be replaced with transparent plugs sight glasses xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard 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 CAUTION The motor weighs 28 kg All lifting accessories used must be sized acc...

Page 475: ...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 Make sure that the motor pinion does not get damaged Make sure that the direction of the cable exit is facin...

Page 476: ...uality 12 9 Gleitmo 4 pcs xx1700000515 See Performing a leak down test on page 184 Perform a leak down test 14 Connecting the motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 Continues on next page 476 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 2 Replacing the axis 2 motor Continued ...

Page 477: ... O ring axis 1 3HAC054692 002 Inspect the o ring Note Replace if damaged 4 O ring axis 2 3HAC054692 002 O ring axis 3 3HAC054692 002 O ring axis 4 3HAC054692 001 xx1200001070 Wipe clean o ring and o ring groove 5 Continues on next page Product manual IRB 6700Inv 477 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 2 Replacing the axis 2 motor Continued ...

Page 478: ... reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Concluding procedure Note Action Use caution and jog axis 2 a little to facilit ate the removal of the lock screw 1 Continues on next page 478 Product manual IRB 6700Inv 3HAC058...

Page 479: ...l 4 Axis Calibration is described in Calibrating with Axis Calibration method on page 683 Re calibrate the robot 5 General calibration information is included in section Calibration on page 673 DANGER Make sure all safety requirements are met when performing the first test run 6 Product manual IRB 6700Inv 479 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 2 Repl...

Page 480: ...Grease Used to lubricate o rings D 169 5x3 3HAC054692 002 O ring Used on motor cover D 102x3 3HAB3772 107 O ring Used on motor flange Required tools and equipment Note Article number Equipment etc Used together with a lifting sling and a lifting eye for securing the weight The chain block included in the turning tool for the robot can be used Turning tool 3HAC061162 001 Chain block Continues on ne...

Page 481: ...te Action Decide which calibration routine to use for calibrating the robot Reference calibration External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is t...

Page 482: ...f these methods Use a fork lift to rest the upper arm onto Use lifting slings and an overhead crane to rest the upper arm onto Secure the upper arm with a lifting eye a lifting sling and a chain block Fit the lifting eye at the base of the robot the lifting sling around the wrist and the chain block in between Strain the lifting sling with the chain block until the weight of the upper arm is unloa...

Page 483: ...ables 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 xx1200001070 Make sure the o ring is present 3 Continues on next page Product manual IRB 6700Inv 483 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 3 Rep...

Page 484: ...Action Before removing the motor make sure that the axis 3 gearbox is completely drained 1 DANGER When releasing the holding brakes of the motor the upper arm will be movable and may fall down if not secured Verify that the upper arm is secured as previously described before continuing 2 To release the brakes connect the 24 VDC power supply 3 Connect to connector R2 MP3 pin 2 pin 5 Continues on ne...

Page 485: ...excess ive force is used 6 Removal tool motor M12 3HAC14631 1 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 CAUTION The motor weighs 26 kg All lifting accessorie...

Page 486: ...amaging the pinion and gear 11 Disconnect the 24 VDC power supply 12 Make sure the pinion is not damaged Remove the motor by lifting it straight out 13 Refitting the motor These procedures describes how to refit the motor Preparations prior to refitting motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove any old pain...

Page 487: ...is a new spare part the evacuation hole protection filter must be replaced with a transparent plug sight glass enclosed with the spare part delivery Remove the protection filter and install the transparent plug sight glass On the axis 6 motor there are two protection filters that must be replaced with transparent plugs sight glasses xx1800000102 Transparent plug Foundry Plus xx1800000101 Protectio...

Page 488: ...weighs 26 kg All lifting accessories used must be sized accordingly 2 Lifting accessory motor 3HAC15534 1 xx1700000273 Apply the lifting accessories to the motor Note Make sure the cable gland exit is turned ac cording to figure 3 Continues on next page 488 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 3 Replacing the axis 3 motor Con...

Page 489: ...connect the 24 VDC power supply 7 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 8 Use caution and push the motor in position while at the same time the motor pinion is slightly rotated 9 Pay attention to following points Mate the motor pinion properly to the gear of the gearbox Do not damage the motor p...

Page 490: ...ge 184 Perform a leak down test 15 Disconnect the 24 VDC power supply 16 Connecting the motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 xx1200001067 Refit the cable gland cover Note Replace the gasket if damaged 2 Continues on next page 490 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 3 R...

Page 491: ...ring axis 4 3HAC054692 001 xx1200001070 Wipe clean o ring and o ring groove 5 Refit the o ring Tip Lubricate the o ring with some grease for a better fitting in the groove 6 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 7 Continues on next page Product manual IRB 6700Inv 491 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Rep...

Page 492: ...ncluding refitting Note Action Remove the equipment used to unload the upper arm 1 See Filling oil into the axis 3 gearbox on page 159 Refill the gearbox with oil 2 Axis Calibration is described in Calibrating with Axis Calibration method on page 683 Re calibrate the robot 3 General calibration information is included in section Calibration on page 673 DANGER Make sure all safety requirements are ...

Page 493: ...v Axis 4 motor Product manual spare parts IRB 6790 Consumables Note Article number Equipment etc Shell Gadus S2 3HAC042536 001 Grease Used to lubricate o rings D 119x3 3HAC054692 001 O ring Used on motor cover D 102x3 3HAB3772 107 O ring Used on motor flange Continues on next page Product manual IRB 6700Inv 493 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 4 Re...

Page 494: ...on External cable packages DressPack and tools can stay fitted on the robot Fine calibration All external cable packages DressPack and tools must be removed from the robot 1 Follow the instructions given in the refer ence calibration routine on the FlexPendant to create reference values If the robot is to be calibrated with refer ence calibration Find previous reference values for the axis or crea...

Page 495: ... replaced 2 If there is no space to position the upper arm pointed straight up drain the axis 4 gearbox 3 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 4 Disconnecting the motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 ...

Page 496: ...ole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Removing the axis 4 motor Note Action CAUTION Use caution when releasing the brakes Axis 4 can move unexpectedly 1 Continues on next page 496 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 4 Rep...

Page 497: ... gears may be damaged if excess ive force is used 5 Removal tool motor 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 13 kg All lifting accessories used must be sized accordingly 7 Disconnect the 24 VDC power supply 8 Continues on next page Product manual IRB 6...

Page 498: ...re that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove any old paint residues or other contam ination from the contact surfaces on both the motor and the mating parts 2 Wipe clean the contact surfaces and the o ring groove xx1200001019 Check the o ring Replace if damaged 3 Continues on next page 498 Product manual IRB 6700Inv 3HAC058254 001 Revision L...

Page 499: ...laced with a transparent plug sight glass enclosed with the spare part delivery Remove the protection filter and install the transparent plug sight glass On the axis 6 motor there are two protection filters that must be replaced with transparent plugs sight glasses xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard Securing the axis 4 motor Note Action Guide pin M8...

Page 500: ... accordingly 4 Rotation tool 3HAB7887 1 Apply the rotation tool and use it to rotate the pinion when mating it into the gear 5 This requires two persons co operating if the motor is installed from above if the upper arm is pointing upwards Continues on next page 500 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 4 ...

Page 501: ...earbox Make sure that the motor pinion does not get damaged Make sure that the direction of the cable gland is facing the correct way 8 Remove the guide pins 9 Tightening torque 35 Nm Secure the motor with its attachment screws and washers 10 Screws M8x30 quality 12 9 Gleitmo 4 pcs xx1700000290 See Performing a leak down test on page 184 Perform a leak down test 11 Disconnect the 24 VDC power supp...

Page 502: ...he 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 502 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 4 motor Continued ...

Page 503: ...e sure that none of the cables inside will be dam aged 7 Attachment screws M5x12 8 8 7 pcs xx1200001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues on ...

Page 504: ...ng with Axis Calibration method on page 683 Re calibrate the robot 2 General calibration information is included in section Calibration on page 673 DANGER Make sure all safety requirements are met when performing the first test run 3 504 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 4 Replacing the axis 4 motor Continued ...

Page 505: ...r cover D 102x3 3HAB3772 107 O ring Used on motor flange Required tools Note Article number Equipment etc Used to push out the motor if neces sary Always use removal tools in pairs 3HAC14631 1 Removal tool motor M12 Length 140 mm Long Allen key socket IN19L 6 140 Always use guide pins in pairs 3HAC15520 1 Guide pin M8x100 300 mm bits 1 2 3HAC12342 1 Bits extender Used to rotate the motor pinion 3H...

Page 506: ...ious reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 684 If no previous reference values exist and no new reference values can b...

Page 507: ...e the wrist cover to retrieve access to the axis 5 and axis 6 motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 xx1400000355 If DressPack is installed Remove the bracket with the com plete ball joint housing still fitted as shown in the figure This is done to be able to reach the two hidden screws that secure the w...

Page 508: ...x1300002247 Remove the wrist cover 4 xx1500001030 Remove the heat protection plates from the motor with the cabling still attached to the plate 5 Continues on next page 508 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 5 motor Continued ...

Page 509: ...ned from the plate 6 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 Product manual IRB 6700Inv 509 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 5 Repl...

Page 510: ...r 2 Remove the outer screw 3 Slide the cable gland cover away from the inner screw Make sure the gasket is not damaged Tip Make a note in which direction the cable exit hole is facing if the motor will be re moved too The motor shall be refitted in the same position 5 Use caution and pull out the motor cables 6 Continues on next page 510 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyrig...

Page 511: ...e damaged if excess ive force is used 2 Removal tool motor M12 3HAC14631 1 If needed fit removal tools in opposite holes 3 Always use removal tools in pairs CAUTION The motor weighs 12 kg All lifting accessories used must be sized accordingly 4 Continues on next page Product manual IRB 6700Inv 511 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 5 Replacing the ax...

Page 512: ...reparations before refitting the axis 5 motor Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 1 Continues on next page 512 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 5 motor Continued ...

Page 513: ... sure the o ring is seated in the groove 5 Guide pin M8x100 3HAC15520 1 Apply two guide pins in opposite holes 6 Securing the axis 5 motor Note Action CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 1 Continues on next page Product manual IRB 6700Inv 513 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 5 Repl...

Page 514: ...l 3HAB7887 1 xx1200001018 Use caution and lower the motor into posi tion on the guide pins while at the same time rotating the motor pinion slightly Make sure that the motor pinion is properly mated to the gear of the gearbox the motor pinion does not get dam aged the direction of the cable exit is fa cing the same way as before remov al 5 Remove the guide pins 6 Continues on next page 514 Product...

Page 515: ...ak down test on page 184 Perform a leak down test 8 Disconnect the 24 VDC power supply 9 Connecting the motor cables Note Action xx1300000738 Push the motor cables in through the cable gland opening 1 Continues on next page Product manual IRB 6700Inv 515 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 5 motor Continued ...

Page 516: ...200001015 Connect the connectors Connect in accordance with the markings on the connectors 3 O ring axis 5 3HAC054692 001 xx1200001021 Make sure the o ring on the motor is undam aged Replace if damaged 4 CAUTION When fitting the motor cover make sure that none of the cables inside will be dam aged 5 Continues on next page 516 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020...

Page 517: ... threads Replace with standard attachment screws Note Make sure the o ring is undamaged and properly fitted 6 xx1500001029 Secure the cable harness with cable straps to the heat protection plate 7 Screws M5x12 xx1500001030 Fit the heat protection plate with the screws 8 Continues on next page Product manual IRB 6700Inv 517 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Rep...

Page 518: ...72 Refit the wrist cover In order not to dam age the cable harness when the wrist cover is refitted use this method 1 Hold the cover slightly tilted below the wrist 2 Put the cable harness inside the cover 3 Lift the cover still tilted 4 Move the upper part of the cover into position 5 Secure the cover with its attachment screws 3 Foundry Plus 4 Refit protection plugs If used refit the DressPack c...

Page 519: ...t 6 General calibration information is included in section Calibration on page 673 DANGER Make sure all safety requirements are met when performing the first test run 7 Product manual IRB 6700Inv 519 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 5 Replacing the axis 5 motor Continued ...

Page 520: ...te o rings Used on motor cover 3HAC033489 001 Gasket D 102x3 3HAB3772 107 O ring Used on motor flange Required tools and equipment Note Article number Equipment etc Used to push out the motor if neces sary Always use removal tools in pairs 3HAC14631 1 Removal tool motor M12 Used to rotate the motor pinion 3HAB7887 1 Rotation tool Used to release the motor brakes 24 VDC power supply Leak down teste...

Page 521: ... be calibrated with refer ence calibration Find previous reference values for the axis or create new reference values These val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 684 If no previous refe...

Page 522: ...lectric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 3 xx1300002247 Remove the wrist cover 4 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 522 Product manual IRB 6700Inv 3HAC058254 001 Revision L Co...

Page 523: ...1300000488 Disconnect the motor cables 3 xx1300000484 Unscrew the attachment screws that hold the cable bracket 4 Continues on next page Product manual IRB 6700Inv 523 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 524: ...or cables by holding the cables with one hand at the motor and the other at the carrier 7 Removing the axis 6 motor Note Action 24 VDC power supply To release the brakes connect the 24 VDC power supply 1 Connect to R2 MP6 connector pin 2 pin 5 Continues on next page 524 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 6 Replacing the axi...

Page 525: ...equired press the motor out of position by fitting the removal tool motor to the at tachment holes of the motor 4 Always use removal tools in pairs CAUTION The motor weighs 9 kg All lifting accessories used must be sized accordingly 5 Continues on next page Product manual IRB 6700Inv 525 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor...

Page 526: ...e 24 VDC power supply 7 Refitting the axis 6 motor Use this procedure to refit the motor Preparations prior to refitting motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 526 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 6 Replacing the...

Page 527: ...he o ring Replace if damaged 3 xx1200001020 Make sure the o ring is seated in the groove Tip Lubricate the o ring with some grease for a better fitting in the groove 4 xx1200001135 If the motor is a new spare part remove the cover 5 Continues on next page Product manual IRB 6700Inv 527 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor C...

Page 528: ... that must be replaced with transparent plugs sight glasses xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard Securing the axis 6 motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 To release the brakes connect the 24 VDC power supply 2 Connect to connector R2 MP6 pin 2 pin 5 CAUTION Whene...

Page 529: ... CAUTION The motor weighs 9 kg All lifting accessories used must be sized accordingly 5 Continues on next page Product manual IRB 6700Inv 529 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 530: ...ox Make sure the motor pinion is not dam aged 6 xx1200001097 Screws M8x25 Steel 8 8 A2F 4 pcs Check that the gasket is fitted correctly 7 Tightening torque 24 Nm xx1200001090 Secure the motor with its attachment screws Continues on next page 530 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 531: ...he screw is located at the bottom of the carrier 9 xx1300000484 Refit the cable bracket 10 See Performing a leak down test on page 184 Perform a leak down test 11 Disconnect the 24 V DC power supply 12 Continues on next page Product manual IRB 6700Inv 531 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 532: ...9 001 xx1200001095 Check the gasket Replace if damaged 14 xx1200001082 Refit the motor cover 15 Continues on next page 532 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 533: ...72 Refit the wrist cover In order not to dam age the cable harness when the wrist cover is refitted use this method 1 Hold the cover slightly tilted below the wrist 2 Put the cable harness inside the cover 3 Lift the cover still tilted 4 Move the upper part of the cover into position 5 Secure the cover with its attachment screws 3 Foundry Plus 4 Refit protection plugs If used refit the DressPack c...

Page 534: ...t 6 General calibration information is included in section Calibration on page 673 DANGER Make sure all safety requirements are met when performing the first test run 7 534 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 7 6 Replacing the axis 6 motor Continued ...

Page 535: ...e containing the major actions to be performed 1 Drain the oil in axis 1 2 Remove the axis 1 motor 3 Replace the hub 4 Refit the axis 1 motor 5 Fill oil in axis 1 Required spare parts Note Article number Spare part 3HAC058203 003 Hub with pinion Continues on next page Product manual IRB 6700Inv 535 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the h...

Page 536: ...supply Used for removal and refitting of the hub 3HAC071355 001 Hub tool Leak down tester Delivered as a set of calibration tools 3HAC055412 001 Calibration tool box Axis Calibra tion Content is defined in section Standard toolkit on page 713 Standard toolkit Required consumables Note Article number Consumable Castrol Molub Alloy 777 1 NG Grease Deciding calibration routine Decide which calibratio...

Page 537: ...t is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removing the hub Use these procedures to remove the hub Draining the axis 1 gearbox Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 1 WARNING Handling gearbox oil involves several saf...

Page 538: ...d fasten the extender screw in the fork lift pocket xx1700000314 Open the valve slowly to avoid air bubbles in the oil 7 Connect the oil dispenser to the oil level gauge 8 Suck out the oil with the oil dispenser Note There will be some oil left in the gear after drain ing 9 Continues on next page 538 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4...

Page 539: ...ke actions accordingly prior to begin ning the repair procedure 1 Jog the robot to the synchronization posi tion 2 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 3 Disconnecting the motor cables Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turn...

Page 540: ...ve the motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 540 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the hub Continued ...

Page 541: ... pull out the motor cables 6 Attaching the removal tool Note Action xx1700000364 Foundry plus Remove the plastic plugs 1 xx1700000365 Revolving handle A Shelf B Bracket C Lower the revolving handle on the removal tool to be able to fit the shelf beneath the motor while fastening the tool 2 Continues on next page Product manual IRB 6700Inv 541 3HAC058254 001 Revision L Copyright 2017 2020 ABB All r...

Page 542: ...tender 3HAC12342 1 xx1700000368 Remove the two shown motor screws and wash ers 1 xx1700000367 Raise the revolving handle to fit the motor on the tool shelf 2 Continues on next page 542 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the hub Continued ...

Page 543: ... Lower the revolving handle 5 Rotate the shelf to remove the motor CAUTION The weight of the motor is 27 kg All lifting accessories used must be sized accord ingly 6 Disconnect the 24 VDC power supply 7 Lifting eye M12 3HAC16131 1 Fasten lifting eyes in two of the fastening holes on the motor 8 Use a roundsling to lift the motor off 9 Removing the hub Note Action DANGER Make sure that all supplies...

Page 544: ...maged if excessive force is used 3 Hub tool 3HAC071355 001 xx2000001379 Fit the two threaded rods of the hub tool into the attachment holes in the hub 4 xx2000001380 Alternately thread the nuts clockwise on the two rods to pull out the hub from the gear 5 Continues on next page 544 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 1 Repla...

Page 545: ...l be refitted Wipe clean if needed 2 xx1500002039 Make sure the o ring on the hub is undam aged Note Replace if damaged 3 Apply some grease on the o ring for a bet ter fitting 4 xx1500002082 Examine the pinion and the splines in the hub for damages 5 Continues on next page Product manual IRB 6700Inv 545 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing ...

Page 546: ...071355 001 xx2000001377 Fit the hub tool 1 CAUTION Whenever parting mating the hub pinion and gearbox the gears may be damaged if excessive force is used 2 xx2000001381 Lift the hub to the gear and mate the pinon carefully into the gear 3 Continues on next page 546 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the hub Cont...

Page 547: ...ower hydraulic pressure and air pressure are turned off 1 Remove any old paint residues or other contam ination from the contact surfaces on both the motor and the mating parts 2 Wipe clean the contact surfaces and the o ring groove xx1200001019 Check the o ring Replace if damaged 3 xx1200001020 Make sure the o ring is seated in the groove Tip Lubricate the o ring with some grease for a better fit...

Page 548: ... enclosed with the spare part delivery Remove the protection filter and install the transparent plug sight glass On the axis 6 motor there are two protection filters that must be replaced with transparent plugs sight glasses xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard Attaching the removal tool Note Action xx1700000364 Foundry plus Remove the plastic plugs 1...

Page 549: ...frame 3 Securing the axis 1 motor Note Action CAUTION The weight of the motor is 27 kg All lifting accessories used must be sized accord ingly 1 Lifting eye M12 3HAC16131 1 Fasten lifting eyes in two of the fastening holes on the motor 2 Use a roundsling to lift the motor 3 Continues on next page Product manual IRB 6700Inv 549 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4...

Page 550: ...rce is used 8 Raise the revolving handle to assemble motor Make sure that the motor pinion is properly mated into the hub Make sure that the motor pinion does not get damaged Make sure that the direction of the cable exit is facing the correct way 9 Bits extender 3HAC12342 1 Secure the motor with its attachment screws and washers 10 Tightening torque 50 Nm Use a bits extender to reach the screws S...

Page 551: ...dry plus Refit the plastic plugs 2 Connecting the motor cables Note Action xx1300000738 Push the motor cables through the cable gland opening 1 Continues on next page Product manual IRB 6700Inv 551 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the hub Continued ...

Page 552: ...ors 3 O ring axis 1 3HAC054692 002 Inspect the o ring Note Replace if damaged 4 O ring axis 2 3HAC054692 002 O ring axis 3 3HAC054692 002 O ring axis 4 3HAC054692 001 xx1200001070 Wipe clean o ring and o ring groove 5 Continues on next page 552 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the hub Continued ...

Page 553: ...e threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Filling oil into axis 1 gearbox inverted Note Action DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 1 WARNING Handling gearbox oil involves several safety risks see Gearbox l...

Page 554: ... oil level gauge 5 If the Fork lift accessory set is as sembled fasten the extender screw in the fork lift pocket xx1700000314 Connect the oil dispenser to the Oil level gauge 6 Continues on next page 554 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the hub Continued ...

Page 555: ... level gauge 8 If the Fork lift accessory set is as sembled fasten the extender screw in the fork lift pocket xx1700000314 Remove the oil dispenser and the Oil level gauge 9 Tightening torque 24 Nm Refit the oil plug 10 Note After all repair and maintenance work involving oil always wipe the robot clean from all surplus oil 11 DANGER Make sure all safety requirements are met when performing the fi...

Page 556: ...ethod on page 683 Re calibrate the robot 1 General calibration information is included in section Calibration on page 673 DANGER Make sure all safety requirements are met when performing the first test run 2 556 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 1 Replacing the hub Continued ...

Page 557: ... before attempting to lift the robot Summary of the replacement procedure This is a brief summary of the replacement procedure containing the major actions to be performed 1 Lift down the robot to floor standing 2 Drain the axis 1 gearbox 3 Remove the cabling from the base 4 Remove the axis 1 motor 5 Remove the complete arm system including frame and balancing device as a package 6 Replace the axi...

Page 558: ...l tool motor M12 300 mm bits 1 2 3HAC12342 1 Bits extender 3HAC16131 1 Lifting eye M12 3HAC16131 1 Lifting eye M12 Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm Fender washer SA 10 8 NA1 Lifting shackle 2 pcs Lifting capacity 2 000 kg Roundsling 2 m Lifting instruction 3HAC15880 2 en closed 3HAC15556 1 Lifting accessory chain 3HAC14457 4 Lifting eye M16 3HAC14457 4 ...

Page 559: ...ated between the gearbox and the frame 3HAB3772 160 O ring 183 74x3 53 Located between the gearbox and the base 3HAB3772 150 O ring D 169 5x3 3HAC054692 002 O ring Used on motor cover D 102x3 3HAB3772 107 O ring Used on motor flange Located in the frame on top of the protection tube 3HAC047474 001 Sealing ring Located on the sealing ring 3HAB3772 57 O ring Located in the frame under neath the seal...

Page 560: ...e val ues are to be used after the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 684 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the robot is t...

Page 561: ...he robot can be secured with the attachment bolts 1 M24x100 8 pcs For hole configuration see Hole configuration base on page 64 The robot must always be secured to the floor if any kind of repair or maintenance work is to be performed Verify that the lower arm is secured with the transportation lock screw 2 DressPack can stay fitted Remove any payload and tools from the robot 3 870 50 600 50 60 65...

Page 562: ...crews can be fitted to the fork lift pockets to press the forks against the pockets and make the lift more stable 9 See user instructions enclosed with the turning tool If lifting and turning with the turning tool and overhead crane 1 Install the turning tool to the fork lift pock ets Make sure to install the turning tool with correct side to front 2 Raise the overhead crane to take the weight of ...

Page 563: ... of the complete arm system when it is resting by itself after it has been re moved Remove tools and other equipment fitted on the turning disc DressPack can stay fitted for the time being 2 xx1400002179 Hold the mechanical stop pin in a firm grip and remove it by unscrewing the attachment screw CAUTION The mechanical stop weighs 5 kg 3 See Draining the axis 1 gearbox floor standing on page 147 Be...

Page 564: ...dure contains two alternative methods for lifting the arm system either by using the turning tool or by using lifting chains Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 CAUTION The complete arm system weighs 1300 Kg All lifting accessories used must be sized accord ingly 2 Lifting eye M12 3HAC16131 1 Fit a lifting eye to ...

Page 565: ...se which lifting accessory to use Attach the lifting chains on page 566 Attach the Turning tool on page 567 Con venient if the tool is already partly mounted on the robot after rotation from inverted position to floor standing 5 Continues on next page Product manual IRB 6700Inv 565 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Con...

Page 566: ...t the roundsling from gliding A B C D A Upper arm B Shackle C Roundsling D Hole in frame 1 Lifting shackle 2 pcs SA 10 8 NA1 Connect the roundsling with a shackle 2 Use caution and jog axis 3 slowly to stretch the roundsling Note Make sure the roundsling is stretched so it can carry the weight of the frame The position of axis 3 will be approximately 45 3 Continues on next page 566 Product manual ...

Page 567: ...e this procedure to attach the Turning tool for lift of the arm system Note Action Turning tool 3HAC061162 001 Secure the turning tool chain block to the lifting eye in the wrist Shorten the chain to make the lift horizontal 1 Fit a roundsling between the overhead crane hook and the lifting eye in the arm house 2 Disconnecting the axis 1 motor cables Note Action DANGER Make sure that all supplies ...

Page 568: ... motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page 568 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 569: ...lectrical power hydraulic pressure and air pressure are turned off 1 Lifting accessory chain 3HAC15556 1 Attach the lifting accessories 2 Lifting accessory motor 3HAC14459 1 24 VDC power supply To release the brakes connect the 24 VDC power supply 3 Connect to R2 MP1 connector pin 2 pin 5 CAUTION The weight of the motor is 27 kg All lifting accessories used must be sized accordingly 4 Continues on...

Page 570: ...oval tool motor M12 3HAC14631 1 If needed use removal tools to help re move the motor 8 Used to push out the motor if necessary Always use removal tools in pairs Lifting accessory chain 3HAC15556 1 Use caution and lift the motor straight up to get the pinion parted from the gear 9 Lifting accessory motor 3HAC14459 1 xx1500002084 Disconnect the 24 VDC power supply 10 Continues on next page 570 Prod...

Page 571: ...e M6x16 torx pan head screws 2 CAUTION Whenever parting mating the hub pinion and gearbox the gears may be damaged if excessive force is used 3 Hub tool 3HAC071355 001 xx2000001379 Fit the two threaded rods of the hub tool into the attachment holes in the hub 4 Continues on next page Product manual IRB 6700Inv 571 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 2...

Page 572: ...e removing the cable harness in the base 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 572 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 573: ... earth cable 5 Washer dimension 6 4x17x3 xx1400000354 xx1400000078 If used remove the attachment screws that secure the bracket This is done to facilitate removal of the DressPack hoses 6 Continues on next page Product manual IRB 6700Inv 573 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 574: ...nd place them carefully over the balancing device 1 xx1300000732 Pull out the robot cable harness through the protection tube 2 Place the cable harness over the balancing device 3 Lifting away the complete arm system Note Action xx1700001256 Remove the cable guide in the frame by re moving the four attachment screws and pulling the guide upwards 1 Continues on next page 574 Product manual IRB 6700...

Page 575: ...the frame slide better 4 xx1700000321 Guide pin M16x120 3HAC062397 001 Always use guide pins in pairs xx1400002169 Unscrew the remaining attachment screws as far as it is possible at this point 5 Note It will not be possible to remove the screws completely at this point CAUTION The complete arm system weighs 1300 Kg All lifting accessories used must be sized accordingly 6 Continues on next page Pr...

Page 576: ...ot change the position of the axes from the position de scribed earlier 9 Removing the gearbox Note Action xx1400002171 Remove the back plate 1 Lifting eye M16 3HAC14457 4 xx1700000323 Fit two lifting eyes 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 whic...

Page 577: ...0324 Attach the lifting accessory 4 xx1400002180 Unscrew the attachment screws that hold the base to the foundation and lift base and gearbox up high enough to be able to fit the four support legs 5 Continues on next page Product manual IRB 6700Inv 577 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 578: ...rocedure is best performed by two persons working together one underneath the robot base making sure that the bit is being fitted into the screw head holes all the way until they reach the bottom one using the torque wrench tighten ing the screws from beside the base 8 xx1700000561 Remove the protection tube from the base by removing the two attachment screws and pulling the tube downwards 9 Conti...

Page 579: ...is 140 kg All lifting accessories used must be sized accordingly 11 xx1700000566 Lift away the gearbox 12 xx1700001378 Remove the old o ring to use it as aid in holding the screws during fitting of the new gearbox A new o ring must be installed to the new gearbox 13 Continues on next page Product manual IRB 6700Inv 579 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair ...

Page 580: ...base on top of the legs 1 A Support legs 3HAC15535 1 xx1700001369 Remove the three VK covers from the new gearbox by driving a screwdriver or similar through the VK cover as close as possible to the center of the cover The covers must not be installed in the gearbox for IRB 6700Inv WARNING Be careful not to damage the gearbox during removal of the covers Remove any residuals 2 Continues on next pa...

Page 581: ...e the surface of the gearbox which is a sealing surface 3 CAUTION The weight of the gearbox is 140 kg All lifting accessories used must be sized accordingly 4 Lifting accessory chain 3HAC15556 1 xx1700000326 Attach the lifting accessory and lift the gear box 5 Continues on next page Product manual IRB 6700Inv 581 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 2 ...

Page 582: ...B3772 150 xx1700001376 Check the o ring on the base Replace if damaged 7 Flange sealant Loctite 574 12340011 116 xx1700001377 Apply flange sealant to the mounting interface on the base between the groove and the screw holes 8 Continues on next page 582 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Contin...

Page 583: ...er when the gearbox is resting on the base xx1400002176 Before the gearbox is being fitted place the attachment screws that will secure the gear box to the frame temporarily in their holes and lock screws with the old o ring This is done to prevent the screws from falling out Note Do not use the new o ring 1 xx1400002177 Make sure that the locating pin in the base will match its hole in the gearbo...

Page 584: ...ersons working together one underneath the robot base making sure that the bit is being fitted into the screw head holes all the way until they reach the bottom one using the torque wrench tighten ing the screws from beside the base 7 xx1700000568 Check the protection tube for damages Especially inspect the surface for the sealing ring Replace if damaged 8 Wipe the surfaces of the protection tube ...

Page 585: ...box to the founda tion 5 M24x100 8 pcs Secure the base to the foundation 6 550 Nm screws lubricated with Molykote 1000 600 725 Nm typical 650 Nm screws none or lightly lubricated Preparations before refitting the arm system Note Action Remove old residues of flange sealant and other contamination from the contact sur faces on the gearbox 1 Wipe clean the contact surfaces from any remaining contami...

Page 586: ...ccording to the figure 5 Apply some grease on the outside of the bearing the guiding part of the bearing the edge of the protection tube the edge around the gearbox 6 Guide pin M16x120 3HAC062397 001 2 pcs Apply guide pins in the guide pin holes in the gearbox Tip Lubricate the guide pins with some grease to make the frame slide better 7 Always use guide pins in pairs xx1700000329 Continues on nex...

Page 587: ...the upper arm lifting accessory chain to an overhead crane or similar and then to the lifting eye in the arm house and to the lifting eye in the wrist Adjust the lengths of the chains so that the lifting hook is located in line with the center of gravity when the robot arm system is lifted as shown in the figure 3 xx1700000319 WARNING The angle between the two chains may not exceed 90 4 Continues ...

Page 588: ...the base Note Make sure that none of the screws are miss ing or in the wrong position 9 Lift the complete arm system and lower it slowly down over the guide pins until it is possible to insert the attachment screws manually CAUTION Do not lower the arm system completely at this stage The attachment screws must be fitted in two steps If not the complete arm system will risk resting on the attachmen...

Page 589: ...ly rotate axis 1 to a position where the remaining attachment screw can be secured 15 xx1700000320 Remove the guide pins and refit the two plastic protection plugs or the two M16 screws 16 xx1700000321 Screws M6x10 4 pcs Refit the cable guide in the frame 17 Locking liquid Loctite 243 3HAB7116 1 Secure with the four attachment screws Tightening torque 10 Nm xx1700001256 Apply locking liquid on the...

Page 590: ... xx1500002039 Make sure the o ring on the hub is undam aged Note Replace if damaged 3 Apply some grease on the o ring for a bet ter fitting 4 xx1500002082 Examine the pinion and the splines in the hub for damages 5 Continues on next page 590 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 591: ...5 001 xx2000001377 Fit the hub tool 1 CAUTION Whenever parting mating the hub pinion and gearbox the gears may be damaged if excessive force is used 2 xx2000001381 Lift the hub to the gear and mate the pinon carefully into the gear 3 Continues on next page Product manual IRB 6700Inv 591 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbo...

Page 592: ...ccessory motor 3HAC14459 1 Apply the lifting accessory 3 Rotation tool 3HAB7887 1 Fit the rotation tool 4 Grease Castrol Molub Alloy 777 1 NG xx1500002346 Make sure that there is enough grease on the splines before fitting If not apply 1 gram of grease 5 Connect the 24 VDC power supply to re lease the brakes 6 To release the brakes connect the 24 VDC power supply as described in the list Connect t...

Page 593: ...0002084 Bits extender 3HAC12342 1 Secure the motor with its attachment screws and washers 9 Tightening torque 50 Nm Use a bits extender to reach the screws Screws M10x40 quality 12 9 Gleitmo 4 pcs xx1500002083 See Performing a leak down test on page 184 Perform a leak down test if not already done 10 Disconnect the 24 VDC power supply 11 Continues on next page Product manual IRB 6700Inv 593 3HAC05...

Page 594: ... 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 594 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 595: ... sure that none of the cables inside will be dam aged 7 Attachment screws M5x12 8 8 7 pcs xx1200001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues on n...

Page 596: ...the protection tube in this order R1 MP R1 SMB If necessary lubricate the cables with grease to make them run more smoothly 1 xx1300000736 Make sure that the cables are not twisted Each cable must be in line with its position on the base plate Make sure that the R1 SMB cable will run on the correct side of the R1 MP1 see the figure 2 Make sure that the markings on the cables are facing the base co...

Page 597: ...he protection tube in the base 6 If used run the DressPack hoses through the protection tube in the base 7 Make sure that the hoses are running cor rectly and are not twisted xx1400000078 If used fit the bracket that hold the DressPack to the frame 8 Continues on next page Product manual IRB 6700Inv 597 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing ...

Page 598: ...stop and remaining cable brackets Note Action xx1400000378 Foundry Plus Apply Mercasol on the surfaces shown in the figure on stop pin and in the hole as shown in the figure 1 Continues on next page 598 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 599: ... Loctite 243 on screw 2 xx1200001237 Secure the cable harness inside the frame hole with a cable strap 3 xx1200001246 Refit the cable bracket on the frame 4 Continues on next page Product manual IRB 6700Inv 599 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 2 Replacing the axis 1 gearbox Continued ...

Page 600: ...ctions enclosed with the fork lift accessory Lift the robot using the fork lift accessory 1 Move the robot close to its installation location 2 See user instructions enclosed with the turning tool Rotate the robot into inverted position using the turning tool or using a fork lift truck with a rotator attachment DANGER Make sure that there is enough space underneath the robot See user instructions ...

Page 601: ...hat the base is not distorted 6 xx1700000269 Remove the yellow sleeve and transportation lock screw from the transportation and turning position 7 Tightening torque 70 Nm 15 Nm xx1700000270 Fasten the yellow sleeve and transportation lock screw in its parking position 8 Concluding procedure Note Action Axis Calibration is described in Calibrat ing with Axis Calibration method on page 683 Re calibr...

Page 602: ...equired space DANGER The base shall be fitted to the foundation when performing this procedure Valid in both examples described below Note Using this method to replace the gearbox with cable harness and DressPack fitted is only a recommendation If it is not possible to put the arm system close enough to the robot and keep the cable harness partly fitted it is necessary to remove the cable harness ...

Page 603: ...ticle 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 142 Oil dispenser 3HAC16131 1 Lifting eye M12 3HAC14457 4 Lifting eye M16 300 mm bits 1 2 3HAC12342 1 Bits extender Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 ...

Page 604: ...ed with the hydraulic cylinder 3HAC13086 1 Hydraulic pump 80 MPa Threaded bar M16x340 Leak down tester Delivered as a set of calibration tools 3HAC055412 001 Calibration tool box Axis Calibration Content is defined in section Standard toolkit on page 713 Standard toolkit Consumables Note Article number Equipment etc Shell Gadus S2 3HAC042536 001 Grease Used to lubricate o rings D 102x3 3HAB3772 10...

Page 605: ...fter the repair proced ure is completed for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 684 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the robot is to be calibrated with fine ...

Page 606: ...ifting down the robot from inverted position Note Action Suitable screws lightly lubricated If the robot is to be secured to the floor prepare an area where the robot can be secured with the attachment bolts 1 M24x100 8 pcs For hole configuration see Hole configuration base on page 64 The robot must always be secured to the floor if any kind of repair or maintenance work is to be performed Verify ...

Page 607: ...r instructions enclosed with the fork lift accessory set Install the fork lift pockets to the robot if not already installed 8 Fork lift accessory set 3HAC058825 001 If lifting and turning with the fork lift rotator attach ment required 1 Insert the forks of the fork lift truck into the fork lift pockets as far as possible 2 Raise the forks of the fork lift truck to make sure that the weight of th...

Page 608: ...using the fork lift truck with a rotator attachment 12 Attachment screws M24x100 8 pcs Lower and secure the robot to the floor 13 Preparations before replacing the axis 2 gearbox Note Action Decide which calibration routine to use and take actions accordingly prior to begin ning the repair procedure 1 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the ro...

Page 609: ...locking position Note It is only allowed to remove the transportation lock screw and sleeve if the service stops are in maintenance position when the robot is floor standing 4 xx1700000348 Fit the transportation lock screw and the yellow sleeve in their parking position 5 Continues on next page Product manual IRB 6700Inv 609 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 R...

Page 610: ...ghtening torque 70 Nm 15 Nm Fit the relief screws to unload the balancing device DANGER Do not remove the relief screws when the balan cing device is removed from the robot 8 Relief screws 3HAC058129 001 xx1700000070 xx1700000560 Continues on next page 610 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Co...

Page 611: ... the balancing device Note Action CAUTION The weight of the balancing device excluding cradle is 305 kg All lifting accessories used must be sized accord ingly 1 SA 10 8 NA1 2 pcs xx1700000086 Fasten lifting shackles on the balancing device 2 Continues on next page Product manual IRB 6700Inv 611 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis...

Page 612: ...in the front link ear Note Action It is possible to drive a screwdriver or similar through the VK cover as close as possible to the center of the VK cover and pull it out xx1700000088 Remove the VK cover at the link ear Note Make sure that the lifting accessories hold the weight of the balancing device Tip Use high pressure air to remove the VK covers 1 Continues on next page 612 Product manual IR...

Page 613: ...ut 3 xx1700000322 Carefully lower the lifting device to let the balan cing device rest on the frame 4 Robot position Note Action See Replacing the axis 2 gearbox on page 602 Follow the procedure of replacing the axis 2 gearbox to get the robot prepared for at tachment of the lifting accessories for lift of the un separated lower and upper arm 1 Continues on next page Product manual IRB 6700Inv 613...

Page 614: ... supply air pressure supply to the robot before entering the safe guarded space 3 Attaching lifting accessories to the lower and upper arm Use this procedure to attach the lifting accessories Note Action CAUTION The lower and upper arms together weigh accord ing to variants 650 kg All lifting accessories used must be sized accord ingly 1 Continues on next page 614 Product manual IRB 6700Inv 3HAC05...

Page 615: ...1700000377 Attach the Lifting accessory chain to an over head crane or similar then to the lifting eye in the arm house 3 Raise the overhead crane to stretch the chain 4 To release the brake connect the 24 VDC power supply 5 Connect to connector R2 MP2 axis 2 motor pin 2 pin 5 Continues on next page Product manual IRB 6700Inv 615 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserve...

Page 616: ...int housings from the lower arm and lift away the cabling from the ball joint housings 1 xx1300000540 Unscrew the attachment screws that secure the axis 2 lower arm metal clamp and the axis 3 lower arm metal clamp located on the inside of the lower arm by removing the attachment screws Note The screws are reached from outside the lower arm 2 Continues on next page 616 Product manual IRB 6700Inv 3H...

Page 617: ... 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 M16x200 3HAC13120 3 Always use guide pins in pairs xx1400002181 xx1400002182 Remove all but one of the remaining attach ment screws that secure the lower arm to the axis 2 gearbox 2 Continues on next page Product manual IRB 6700Inv 617 3HAC058254 001 Revision L Copyr...

Page 618: ... xx1700000442 Remove the remaining screw and lift away the lower and upper arm together Let the cabling run in the lower arm Make sure not to stretch any cabling Note Two persons required One person to oper ate the overhead crane and one person to handle the arm system 3 Use a piece of wood or similar as a support under the arm house when the arm system is put down on the pallets 4 This is done in...

Page 619: ... motor cover 2 xx1200001070 Make sure the o ring is present 3 xx1200001066 Disconnect the motor cables 4 Continues on next page Product manual IRB 6700Inv 619 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 620: ...motor Note Action Before removing the motor make sure that the axis 2 gearbox is completely drained 1 To release the brake connect the 24 VDC power supply 2 Connect to connector R2 MP2 axis 2 mo tor pin 2 pin 5 Bits extender 3HAC12342 1 xx1700000515 Remove the attachment screws Use a bits extender in order to reach the screws 3 Continues on next page 620 Product manual IRB 6700Inv 3HAC058254 001 R...

Page 621: ...e 24 VDC power supply 7 CAUTION The motor weighs 28 kg All lifting accessories used must be sized accordingly 8 Carefully lift the motor out on the guide pins in order to get the pinion away from the gear and let it rest on the guide pins 9 Lifting accessory motor 3HAC15534 1 Fasten the lifting accessory Attach the lifting chain to the accessory and an over head crane 10 Lifting accessory chain 3H...

Page 622: ... M12x200 3HAC13056 3 Always use guide pins in pairs xx1700000443 xx1700000444 Leave one of the upper attachment screws and remove the rest The remaining screw is used to prevent the gearbox from falling down 2 CAUTION The gearbox weighs 110 kg All lifting accessories used must be sized accordingly 3 Continues on next page 622 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020...

Page 623: ...e the gearbox 8 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 the utmost caution not to cause any damage to the cable harness Continues on next page Product manual IRB 6700Inv...

Page 624: ...lean Note This must also be done on a new spare part 4 Wipe clean the contact surfaces from any contamination Note Also wipe clean the o ring groove 5 Check the condition of the o ring 6 Replace if damaged Lubricate the o ring with some grease for a better fitting in the groove 7 Fit the o ring in the groove 8 xx1400000374 Foundry Plus Apply Mercasol on the surfaces shown in the figure 9 Continues...

Page 625: ...the gearbox into position 12 xx1400002188 Fit the attachment screws now accessible 13 Screw dimension M12x90 Screw quality 12 9 Gleitmo totally 32 pcs Remove the lifting accessory 14 Remove the guide pins and fit the remain ing attachment screws 15 Tightening torque 120 Nm Secure the gearbox with its attachment screws 16 Continues on next page Product manual IRB 6700Inv 625 3HAC058254 001 Revision...

Page 626: ...ipe clean the contact surfaces and the o ring groove xx1200001019 Check the o ring Replace if damaged 3 xx1200001020 Make sure the o ring is seated in the groove Tip Lubricate the o ring with some grease for a better fitting in the groove 4 xx1200001135 If the motor is a new spare part remove the cover 5 Continues on next page 626 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017...

Page 627: ... Plus xx1800000101 Protection filter Stand ard 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 CAUTION The motor weighs 28 kg All lifting accessories used must be sized accordingly 2 Lifting accessory motor 3HAC15534 1 Apply the lifting accessory 3 Lifting accessory chain 3HAC15556 1 xx1700000517 Note Make sure t...

Page 628: ...rly mated to the gear of 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 10 Screws M10x40 quality 12 9 Gleitmo Fit two of the attachment screws and washers 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 was...

Page 629: ...airs xx1400002189 CAUTION The lower and upper arms together weigh 650 kg All lifting accessories used must be sized accordingly 4 Apply the lifting accessories if not already fitted 5 Lift the lower and upper arm 6 Make sure not to stretch any of the cables that the arm package is level when lifted xx1700000692 Align the lower arm with the gearbox in height Match the upper edge of the gear box wit...

Page 630: ...ox until the hole pattern is matching the holes in the lower arm Fit one attachment screw in one of the up per holes using it for security and lower the lifting accessory a little 12 xx1400002190 Fit all now accessible attachment screws 13 Remove the two guide pins and fit the re maining attachment screws 14 Tightening torque M16 300 Nm Secure the lower arm to the axis 2 gearbox with its attachmen...

Page 631: ... the cable gland cover Note Replace the gasket if damaged 2 xx1200001066 Connect the motor cables Connect in accordance with the markings on the connectors 3 Continues on next page Product manual IRB 6700Inv 631 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 632: ... sure that none of the cables inside will be dam aged 7 Attachment screws M5x12 8 8 7 pcs xx1200001135 Refit the motor cover with its attachment screws Note Do not reuse the self threading attachment screws Replace with standard attachment screws or the threads will be damaged Note Make sure the o ring is undamaged and properly fitted 8 Make sure that the covers are tightly sealed 9 Continues on n...

Page 633: ...al clamp and 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 xx1200001283 Refit the cable bracket on the frame 3 Continues on next page Product manual IRB 6700Inv 633 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2 gearbox Continued ...

Page 634: ... hydraulic pressure supply air pressure supply to the robot before entering the safeguarded space 1 Remove all residues of Loctite in the screw hole of the shaft 2 Wipe all contact surfaces inside the recess clean from residual grease or other contamination 3 xx1300000784 Align the balancing device link ear with the hole in the lower arm Note Verify that the link ear is correctly turned 4 Continue...

Page 635: ...ol is ap plied 6 Hydraulic pressure 250 bar Press the shaft in with the hydraulic press tool 7 Hydraulic pump 80 MPa 3HAC13086 1 Hydraulic cylinder 3HAC11731 1 Dismantle and mounting tool set 3HAC028920 001 Press tool M Loctite 2701 xx1300000782 Apply locking liquid on the first threads of the screw 8 Continues on next page Product manual IRB 6700Inv 635 3HAC058254 001 Revision L Copyright 2017 20...

Page 636: ...1 xx1300000783 Unscrew both screws in link ear Fill the bearing 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 Refit the DressPack bracket if used 13 Continues on next page 636 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 3 Replacing the axis 2...

Page 637: ...rding to given axis degrees further on Restoring the balancing device Note Action Remove the lifting equipment from the balancing device 1 xx1700001406 Jog axis 2 to 4 to be able to remove the relief screws 2 xx1700000070 Remove the relief screws to activate the balancing device Note Axis 2 must be in 4 3 Continues on next page Product manual IRB 6700Inv 637 3HAC058254 001 Revision L Copyright 201...

Page 638: ...sition Note Action 870 50 600 50 60 65 35 3 0 xx1600001371 Verify that the robot stands in position Axis 1 0 Axis 2 35 Axis 3 65 Axis 4 0 Axis 5 60 Axis 6 no significance 1 xx1700000348 Remove the transportation lock screw and the yellow sleeve from the parking position 2 Continues on next page 638 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 R...

Page 639: ...g and floor standing 3 xx1600002114 Preparations before lifting up the robot to inverted position Note Action xx1700000068 Remove the two service stops from maintenance position if previously moved there 1 xx1700000067 Fit the service stops in their parking position 2 See user instructions enclosed with the fork lift accessory Fasten the fork lift accessory 3 Fork lift accessory set 3HAC058825 001...

Page 640: ...ble screws lightly lubricated M24x100 8 pcs 8 8 Fit the bolts and washers in the base attachment holes Note Lightly lubricate screws before assembly 5 Suitable washer 4 mm flat washer Screw tightening yield point utiliza tion factor v according to VDI2230 90 v 0 9 Tightening torque CAUTION If high stress on screws are suspected replace used screws with new ones 550 Nm screws lubricated with Molyko...

Page 641: ...e axis 2 gearbox on page 155 Refill oil to the axis 2 gearbox 2 Axis Calibration is described in Calibrating with Axis Calibration method on page 683 Re calibrate the robot 3 General calibration information is included in section Calibration on page 673 DANGER Make sure all safety requirements are met when performing the first test run 4 Product manual IRB 6700Inv 641 3HAC058254 001 Revision L Cop...

Page 642: ...distance exceeds 2 1 m the cabling in the upper arm and the wrist must be removed Removal of the cabling in the upper arm and wrist is detailed in the procedures found in Removing the cable harness upper arm and wrist on page 214 2 Replace the axis 3 gearbox Spare parts Note Spare part number Spare parts See Product manu al spare parts IRB 6700 IRB 6700Inv Axis 3 gearbox Required tools and equipme...

Page 643: ...al tool motor M12 Used to push out the gearbox if neces sary ScrewsM8x75 fully threaded Always use guide pins in pairs 3HAC13056 2 Guide pin M12x150 Always use guide pins in pairs 3HAC13120 2 Guide pin M16x150 Always use guide pins in pairs 3HAC13120 3 Guide pin M16x200 Used for rotating the axis 3 gearbox when refitting upper arm 3HAC067545 001 Pinion Used to release the motor brakes 24 VDC power...

Page 644: ...leted for calibration of the ro bot Creating new values requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 684 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external ca...

Page 645: ... sling around the upper arm and fasten to the balancing device shackle 6 DANGER When releasing the holding brakes of the motor the upper arm will be movable and may fall down if not secured Verify that the upper arm is secured as previously de scribed before continuing 7 Release the holding brakes for the axis 3 motor to give the weight of the upper arm to the roundsling attached to the balancing ...

Page 646: ...the screw DANGER Always use the transportation lock screw and sleeve to lock the lower arm at transportation turning and floor standing 3 xx1600002114 Removing the axis 3 motor Note Action Before removing the motor make sure that the axis 3 gearbox is completely drained 1 DANGER When releasing the holding brakes of the motor the upper arm will be movable and may fall down if not secured Verify tha...

Page 647: ...x1700000346 CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 6 Removal tool motor M12 3HAC14631 1 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 l...

Page 648: ...upply 12 Make sure the pinion is not damaged Remove the motor by lifting it straight out 13 Removing the cable harness from the upper arm and wrist The upper arm cabling can stay fitted if the distance between the axis 3 rotation centre and the floor does not exceed 2 1 m If the distance exceeds 2 1 m the cabling in the upper arm and the wrist must be removed Removal of the cabling in the upper ar...

Page 649: ...700000693 Attach a lifting sling to an overhead crane or similar and then to the lifting eye in the arm house 4 Attach a lifting sling to an overhead crane or similar and then to the lifting eye in the wrist Note Lifting slings are used instead of lifting chains to not damage the balancing device surface 5 Raise the lifting accessories to take the weight of the upper arm 6 Continues on next page P...

Page 650: ...screws that hold the lower arm to the axis 3 gearbox that are removed 1 Guide pin M16x200 3HAC13120 3 Always use guide pins in pairs xx1700000457 Tip Lubricate the guide pins with some grease to make the upper arm slide better xx1700000458 Leave one of the remaining attachment screws fitted remove the other screws 2 Continues on next page 650 Product manual IRB 6700Inv 3HAC058254 001 Revision L Co...

Page 651: ...achment screw and let the upper arm slide out from the lower arm with support from the guide pins 1 xx1700000459 Lift the upper arm and place it on the pre pared area 2 Continues on next page Product manual IRB 6700Inv 651 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 652: ...Note Action Guide pin M12x150 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 xx1700000370 xx1700000371 Remove all but one of the remaining attach ment screws 2 ScrewsM8x75 fully threaded Used to push out the gearbox if necessary Fit three full...

Page 653: ...ow the gearbox 8 With the gearbox attached to the lifting ac cessory remove the gearbox by letting it slide out on the guide pins 9 Remove the gearbox 10 Refitting the axis 3 gearbox Use these procedures to refit the axis 3 gearbox Preparations before refitting the axis 3 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off ...

Page 654: ...guide pins in opposite holes Tip Lubricate the guide pins with some grease to make the gearbox slide better 10 Always use guide pins in pairs Lift the gearbox to the upper arm and let it rest on the guide pins 11 Securing the axis 3 gearbox Note Action Tightening torque 120 Nm Secure the gearbox with 28 of the 30 attach ment screws 1 M12x70 xx1400002193 Continues on next page 654 Product manual IR...

Page 655: ...tion Wipe clean all contact surfaces 1 Rust preventive 3HAC034903 001 Mer casol 3110 Waxcoat Recommended drying time is 24h xx1700001880 Foundry Plus Apply Mercasol on the surface on the lower arm as shown in the figure CAUTION Keep the sealing surfaces clean from Mer casol 2 Continues on next page Product manual IRB 6700Inv 655 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved...

Page 656: ...nd bring it towards the lower arm 3 24 VDC power supply If the axis 3 motor is installed to the upper arm 4 Rotation tool Connect the 24 VDC power supply to re lease the brakes Connect to R2 MP3 connector pin 2 pin 5 Use the rotation tool and rotate the axis 3 motor to find the correct position for the guide pins in the lower arm Disconnect and remove the 24 VDC power supply after finding the posi...

Page 657: ...r to refitting motor Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Remove any old paint residues or other contam ination from the contact surfaces on both the motor and the mating parts 2 Wipe clean the contact surfaces and the o ring groove Continues on next page Product manual IRB 6700Inv 657 3HAC058254 001 Revision L Cop...

Page 658: ... Tip Lubricate the o ring with some grease for a better fitting in the groove 4 xx1200001135 If the motor is a new spare part remove the cover 5 Continues on next page 658 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 659: ...tor there are two protection filters that must be replaced with transparent plugs sight glasses xx1800000102 Transparent plug Foundry Plus xx1800000101 Protection filter Stand ard Securing the axis 3 motor Use this procedure to secure the motor Note Action Guide pin M10x150 3HAC15521 2 Fit guide pins in opposite holes 1 Always use guide pins in pairs xx1700000272 CAUTION The motor weighs 26 kg All...

Page 660: ...he axis 4 motor still fitted 4 Remove the lifting accessory and allow the motor to rest on the guide pins 5 Rotation tool 3HAB7887 1 Apply the rotation tool and use it to rotate the pinion when mating it into the gear 6 To release the brakes connect the 24 VDC power supply 7 Connect to connector R2 MP3 pin 2 pin 5 CAUTION Whenever parting mating motor and gearbox the gears may be damaged if excess...

Page 661: ... Perform a leak down test 15 Disconnect the 24 VDC power supply 16 Refitting the cable harness to the upper arm and wrist If the cabling in the upper arm and wrist has been removed refit it as described in Refitting the cable harness upper arm and wrist on page 248 and continue with the concluding procedure below Note Action Refit the cabling as described in Refitting the cable harness upper arm a...

Page 662: ...t the cover still tilted 4 Move the upper part of the cover into position 5 Secure the cover with its attachment screws 5 See figure above Foundry Plus 6 Refit protection plugs If used refit the DressPack cable package on the wrist 7 Concluding procedure Note Action See Filling oil into the axis 3 gearbox on page 159 Refill oil in the gearbox 1 Axis Calibration is described in Calibrating with Axi...

Page 663: ...ure all safety requirements are met when performing the first test run 3 Product manual IRB 6700Inv 663 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 4 Replacing the axis 3 gearbox Continued ...

Page 664: ...ed on motor flange Used on motor cover 3HAC033489 001 Gasket Used on gearbox 3HAB3772 161 O ring Required tools and equipment Note Article number Equipment etc Used to rotate the motor pinion 3HAB7887 1 Rotation tool Used to release the motor brakes 24 VDC power supply Leak down tester Delivered as a set of calibration tools 3HAC055412 001 Calibration tool box Axis Calibration Content is defined i...

Page 665: ... requires possibility to move the robot Read more about reference calibration for Axis Calibration in Reference calibration routine on page 684 If no previous reference values exist and no new reference values can be created then reference calibration is not possible If the robot is to be calibrated with fine calibration Remove all external cable packages DressPack and tools from the robot Removin...

Page 666: ...no significance Axis 3 no significance Axis 4 0 Axis 5 55 Axis 6 10 6 DANGER Turn off all electric power supply hydraulic pressure supply air pressure supply to the robot before entering the safe guarded space 7 Continues on next page 666 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 6 gearbox Continued ...

Page 667: ... Action xx1400002195 Remove the screws and washers that se cure the turning disc 1 xx1300000493 Remove the turning disc 2 Continues on next page Product manual IRB 6700Inv 667 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 4 Repair 4 8 5 Replacing the axis 6 gearbox Continued ...

Page 668: ...ox If required fit two attachment screws and press out the gearbox 3 Refitting the axis 6 gearbox Use these procedures to refit the gearbox Preparations before refitting the axis 6 gearbox Note Action DANGER Make sure that all supplies for electrical power hydraulic pressure and air pressure are turned off 1 Continues on next page 668 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright ...

Page 669: ... o ring Fit the o ring in the groove of the gearbox 2 xx1400000717 Foundry Plus Apply Loctite 574 on the surface shown in the figure 3 Refitting the axis 6 gearbox Note Action CAUTION Whenever parting mating motor and gear box the gears may be damaged if excess ive force is used 1 xx1700001601 Fit the gearbox to the wrist CAUTION Be careful not to damage motor pinion or gears 2 Continues on next p...

Page 670: ...ing disc Note Action See Replacing the synchronization mark plate on page 332 If new turning disc spare part is installed verify that the correct synchronization mark plate for axis 6 is installed on the wrist 1 Wipe clean the contact surfaces 2 A B xx1400000385 Foundry Plus Apply Mercasol on the surfaces on turning disc and axis 6 gearbox as shown in the figure 3 Continues on next page 670 Produc...

Page 671: ...nization plate axis 6 1 Axis Calibration is described in Calibrating with Axis Calibration method on page 683 Re calibrate the robot 2 General calibration information is included in section Calibration on page 673 DANGER Make sure all safety requirements are met when performing the first test run 3 Product manual IRB 6700Inv 671 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved...

Page 672: ...This page is intentionally left blank ...

Page 673: ...eric term for all calibration methods that aim to move the robot to calibration position Standard calibration A calibration routine that generates a new zero posi tion of the robot Fine calibration A calibration routine that in the first step generates a reference to current zero position of the robot The same calibration routine can later on be used to re calibrate the robot back to the same posi...

Page 674: ...n is a standard calibration method for calibration of IRB 6700Inv and is the most accurate method for the standard calibration It is the recommended method in order to achieve proper performance The following routines are available for the Axis Calibration method Fine calibration Update revolution counters Reference calibration The calibration equipment for Axis Calibration is delivered as a toolk...

Page 675: ...t You will be guided through the calibration procedure step by step References Article numbers for the calibration tools are listed in the section Special tools on page 714 Product manual IRB 6700Inv 675 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 5 Calibration 5 1 2 Calibration methods Continued ...

Page 676: ...t If the revolution counter memory is lost the counters must be updated See Updating revolution counters on page 680 This will occur when The battery is discharged A resolver error occurs The signal between a resolver and measurement board is interrupted A robot axis is moved with the control system disconnected The revolution counters must also be updated after the robot and controller are connec...

Page 677: ...onization marks and the synchronization position for each axis Synchronization marks IRB 6700Inv Axis 2 xx1300000869 Axis 1 xx1300000868 Axis 4 xx1300000871 Axis 3 xx1300000870 Continues on next page Product manual IRB 6700Inv 677 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes ...

Page 678: ... plates xx1300000873 Axis 5 xx1300000872 xx1500000845 678 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 5 Calibration 5 2 1 Synchronization marks and synchronization position for axes Continued ...

Page 679: ...s will handle the calibration movements automatically and these might be different from the positive directions shown below Manual movement directions 6 axes Note The graphic shows an IRB 7600 The positive direction is the same for all 6 axis robots except the positive direction of axis 3 for IRB 6400R which is in the opposite direction xx0200000089 Product manual IRB 6700Inv 679 3HAC058254 001 Re...

Page 680: ...ion marks and synchron ization position for axes on page 677 Jog the manipulator to align the synchron ization marks 2 Step 2 Updating the revolution counter with the FlexPendant on page 680 When all axes are positioned update the revolution counter 3 Step 2 Updating the revolution counter with the FlexPendant Use this procedure to update the revolution counter with the FlexPendant IRC5 Action On ...

Page 681: ...obotWare 6 02 and later 3 Calibration method used at factory for each axis is shown as well as calibration method used during last field calibration Tap Manual Method Advanced xx1500000944 Continues on next page Product manual IRB 6700Inv 681 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 5 Calibration 5 3 Updating revolution counters Continued ...

Page 682: ... 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 selected revolution counters and removes the tick from the list of axes 7 CAUTION If a revolution counter is incorrectly updated it will cause incorrect manipulator posi tioning which in turn may...

Page 683: ...le calibration tool is inserted by the operator into a calibration bushing on the axis chosen for calibration according to instructions on the FlexPendant WARNING Calibrating the robot with Axis Calibration requires special calibration tools from ABB Using other pins in the calibration bushings may cause severe damage to the robot and or personnel WARNING The calibration tool must be fully inserte...

Page 684: ... factory The reference value will be named according to tool name date etc Follow the instructions given in the reference calibration routine on the FlexPendant to create reference values When reference calibration is performed the robot is restored to the status given by the reference values Update revolution counters Choose this routine to make a rough calibration of each manipulator axis by upd...

Page 685: ...Axis 3 Axis 2 Axis 1 Required position of axis Axis 1 0 0 Axis 2 0 0 Axis 3 Axis 4 Axis 5 Axis 6 Axis to be calibrated Unrestricted Axis is allowed to be jogged to other position than 0 degrees Axis must be put in position 0 degrees 0 How to calibrate an inverted robot The IRB 6700Inv is calibrated inverted in factory prior to shipping To recalibrate an inverted robot use either fine calibration o...

Page 686: ... other pins in the calibration bushings may cause severe damage to the robot and or personnel Note Article number Equipment etc Delivered as a set of calibration tools 3HAC055412 001 Calibration tool box Axis Calibration Examining the calibration tool Check prior to usage Before using the calibration tool make sure that the tube insert the plastic protection and the steel spring ring are present W...

Page 687: ...lution Note Action It is possible to use any RFID solution with the correct dimensions ABB has verifed function on some suppliers fulfilling the requirements of NFC compatible devices 13 56 Mhz according to ISO 14443 or ISO 15693 Note The maximum dimensions on the RFID chip must not exceed Ø7 9 mm x 8 0 mm Ø5 9 mm x 8 0 mm or Ø3 9 mm x 8 0 mm depending on calibra tion tool size 1 There is a cavity...

Page 688: ...as follows xx1700000514 Spare parts When calibration is not being performed a protective cover and an o ring should always be installed on the fixed calibration pin as well as a protective plug included a sealing in the bushing Replace damaged parts with new Note Article number Spare part Contains replacement calibration pin covers and protective plugs for the bushing 3HAC056806 001 Protection cov...

Page 689: ... procedure and what to do at each step is given on the FlexPendant You will be guided through the calibration procedure step by step Use the following list to learn about the calibration procedure before running the RobotWare program on the FlexPendant It gives you a brief overview of the calibration procedure sequence After the calibration method has been called for on the FlexPendant the followi...

Page 690: ...he robot s working area is empty as the robot can make unpredictable movements 1 Use a clean cloth Wipe the calibration tool clean Note The calibration method is exact Dust dirt or color flakes will affect the calibration value 2 If the data is optimized the calibra tion routine Wrist Optimization must be re run after standard calib ration Check if the standard calibration data for axes 4 or 5 are...

Page 691: ... xx1500000942 1 All mechanical units connected to the system are shown with their calibration status 2 Tap the mechanical unit in question xx1500000943 Continues on next page Product manual IRB 6700Inv 691 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 5 Calibration 5 4 4 Axis Calibration Running the calibration procedure Continued ...

Page 692: ...ce and press Play The three position enabling device on the FlexPendant has been released during robot movement Remove the calibration tool if it is installed and restart the calibration procedure from the beginning See Starting the calibration procedure on page 691 The RobotWare program is terminated with PP to Main If the calibration tool is in contact the robot axis needs to be jogged in order ...

Page 693: ...th new spare part if missing or damaged 2 Protection cover and plug set 3HAC056806 001 xx1500000952 Reinstall the protective plug and sealing in the bushing on each axis directly after the axis has been calibrated Ensure that the sealing is not damaged Replace the plug and the sealing with new spare part if missing or damaged 3 Protection cover and plug set 3HAC056806 001 See Calibrating with Wris...

Page 694: ... save reference values for all axes that is to be replaced Make sure that the values are saved in RobotStudio or FTP program The files are located in Active system folder name HOME RefCalibFiles 7 Perform the repair 8 Make sure that the tooling and process equipment are the same as when creating the reference Use Reference calibration to update the system with new calibration offset value for the ...

Page 695: ...e 96 3 94 2 2 1 degrees 8 Manually jog axis 4 the calculated angle difference 2 1 NOTE The direction shall be the same direction as the direction used when axis 4 was manually jogged to coincide with the verification process In the example 2 1 degrees 9 Make a new manual fine calibration of axis 4 with axis in 2 1 degrees position 10 Check again against the verification position 11 Repeat the manu...

Page 696: ...will be run 1 Choose calibration routine Wrist Optimization 2 Modify targets for 4 point tool frame definition in Wrist Optimization routine en0400000906 a Jog the robot to an appropriate position A for the first approach point Use small increments to accurately posi tion the tool tip as close to the reference point as possible b Tap Modify Position to define the point c Repeat for each approach p...

Page 697: ...n program twice Do not change the position of the robot axes after running the program 1 This is detailed in section Synchronization marks and synchronization position for axes on page 677 Adjust the synchronization marks when the calibration is done if necessary 2 Write down the values on a new label and stick it on top of the calibration label 3 The label is located on the lower arm Product manu...

Page 698: ...age 677 and Updating revolution counters on page 680 Check that the synchronization marks for the axes align correctly If they do not update the revolu tion counters 6 Using the jogging window Use this procedure to jog the robot to the synchronization position of all axes Note Action On the ABB menu tap Jogging 1 Tap Motion mode to select group of axes to jog 2 Tap to select the axis to jog axis 1...

Page 699: ...es motors Copper Base lower arm upper arm Cast iron nodular iron Gears screws base frame and so on Steel Brakes motors Neodymium Cables connectors drive belts and so on Plastic rubber Gearboxes Oil grease Covers synchronization brackets Aluminium Oil and grease Where possible arrange for oil and grease to be recycled Dispose of via an authorized person contractor in accordance with local regulatio...

Page 700: ... organisms Oxygen transfer could also be impaired Spillage can penetrate the soil causing ground water contamination 700 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 6 Decommissioning 6 1 Environmental information Continued ...

Page 701: ...tery is exposed to heat for example from a blow torch it will explode Always remove all oil grease in gearboxes If exposed to heat for example from a blow torch the oil grease will catch fire When motors are removed from the robot the robot will collapse if it is not properly supported before the motor is removed Product manual IRB 6700Inv 701 3HAC058254 001 Revision L Copyright 2017 2020 ABB All ...

Page 702: ...R 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 decommissioned Note Action Detailed in section Replacing the balan cin...

Page 703: ...m a safe distance and somewhat from above 2 DANGER The hole must be cut as specified in the figure Pieces of the spring can be thrown out from the cylinder at high speed if the hole is cut larger than specified 3 Use a cutting torch with a long shaft xx1600002062 Cut a hole in the housing as shown in the figure 4 Use a cutting torch with a long shaft Cut all the coils of the springs inside the hou...

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Page 705: ...ter includes general information complementing the more specific information in the different procedures in the manual Product manual IRB 6700Inv 705 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 7 Reference information 7 1 Introduction ...

Page 706: ...ces Coordinate systems and motion nomenclatures ISO 9787 2013 Manipulating industrial robots performance criteria and related test methods ISO 9283 1998 Classification of air cleanliness EN ISO 14644 1 2015i Ergonomics of the thermal environment Part 1 EN ISO 13732 1 2008 EMC Generic emission EN 61000 6 4 2007 A1 2011 IEC 61000 6 4 2006 A1 2010 option 129 1 EMC Generic immunity EN 61000 6 2 2005 I...

Page 707: ...cts Principles for design EN 574 1996 A1 2008 UL ANSI and other standards Description Standard Safety requirements for industrial robots and robot systems ANSI RIA R15 06 Safety standard for robots and robotic equipment ANSI UL 1740 Industrial robots and robot Systems General safety require ments CAN CSA Z 434 14 Product manual IRB 6700Inv 707 3HAC058254 001 Revision L Copyright 2017 2020 ABB All ...

Page 708: ... 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 708 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 7 Reference information 7 3 Unit conversion ...

Page 709: ... 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 wrench Screw dimensions of...

Page 710: ...ir maintenance or installation procedure overrides the standard torque 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 f...

Page 711: ...ing torque for water and air connectors when one or both connectors are made of brass Note A special torque specified in the repair maintenance or installation procedure overrides the standard torque 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 Product manual IRB 6700Inv 711 3HAC058254 001 R...

Page 712: ...sory when handling components with a weight exceeding 22 kg A wide range of lifting accessories and devices are available for each manipulator model Example Following is an example of a weight specification in a procedure Note Action CAUTION The arm weighs 25 kg All lifting accessories used must be sized accord ingly 712 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB ...

Page 713: ... Comment Tool Qty Ring open end spanner 8 19 mm 1 Socket head cap 2 5 17 mm 1 Torx socket no 20 60 1 Box spanner set 1 Torque wrench 10 100 Nm 1 Torque wrench 75 400 Nm 1 Ratchet head for torque wrench 1 2 1 Hexagon headed screw M10x100 2 Hexagon headed screw M16x90 1 Hex bit socket head cap no 14 socket 40 mm L 100 mm 1 To be shortened to 12 mm Hex bit socket head cap no 14 socket 40 mm L 20 mm 1...

Page 714: ...sum of standard tools defined in the section Standard toolkit on page 713 and of special tools listed directly in the instructions and also gathered in this section Special tools Continues on next page 714 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 7 Reference information 7 7 Special tools ...

Page 715: ...12x150 3HAC13056 2 2 Guide pin M12x200 3HAC13056 3 2 2 2 2 Guide pin M16x150 3HAC13120 2 2 2 2 2 Guide pin M16x200 3HAC13120 3 Lifting accessories x x x x x x x xx1200001241 Lifting accessory chain 3HAC15556 1 x x Lifting accessory motor Note Floor standing robot 3HAC14459 1 x x x x Lifting accessory motor 3HAC15534 1 x x xx1700000365 Revolving handle A Shelf B Bracket C Removal tool axis 1 motor ...

Page 716: ...x x 2 xx1200001242 Lifting eye M16 3HAC14457 4 x x x x x x xx1200001243 Lifting shackle 2 pcs SA 10 8 NA1 x x x x x Fender washer Outer diameter minimum 26 mm maximum 30 mm hole diameter 13 mm thickness 3 mm x Roundsling 1 5 m Lifting capacity 2 000 kg x x x x x x x x x x Roundsling 1 m Lifting capacity 1 000 kg x x x x x xx1700000762 Fork lift accessory set 3HAC058825 001 x x x x x xx1700000761 T...

Page 717: ...Threaded bar M16x340 Removal tools 3 ScrewsM8x75 fully threaded x x x x x x x x x x Removal tool motor M12 3HAC14631 1 x xx2000001378 Hub tool 3HAC071355 001 Other tools x x x x x x x x x x x x x x x 24 VDC power supply x x Aligning tool 3HAC046645 003 x x x Long Allen key socket IN19L 6 140 x x x x x x x x Bits extender 3HAC12342 1 x x x x x x x x x x x x x x x Calibration tool box Axis Calibrati...

Page 718: ...ipment with spare part number These tools can be ordered from ABB x Lock screw M16x120i x x x x x x Service stop i 3HAC058167 001 Screws 3HAB3409 88 x x x x x x Oil collecting vessel x x x x x x x Oil dispenser x xx1800001147 Pinion 3HAC067545 001 x x x x x x x x x x x x x Rotation tool 3HAB7887 1 i The tools are mounted on the robot at delivery Continues on next page 718 Product manual IRB 6700In...

Page 719: ...ng accessories is not detailed in the activity procedure but in the instruction delivered with each piece of lifting accessories This implies that the instructions delivered with the lifting accessories should be stored for later reference Product manual IRB 6700Inv 719 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 7 Reference information 7 8 Lifting accessories and lifting...

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Page 721: ...ws are not included in the manual but delivered as a separate document for registered users on myABB Business Portal www mypo rtal abb com Product manual IRB 6700Inv 721 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 8 Spare parts 8 1 Spare part lists and illustrations ...

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Page 723: ...C025611 001 Circuit diagram IRB 260 3HAC028647 009 Circuit diagram IRB 360 3HAC036446 005 Circuit diagram IRB 460 3HAC025691 001 Circuit diagram IRB 660 3HAC025691 001 Circuit diagram IRB 760 3HAC046307 003 Circuit diagram IRB 1200 3HAC2800 3 Circuit diagram IRB 1410 3HAC021351 003 Circuit diagram IRB 1600 1660 3HAC039498 007 Circuit diagram IRB 1520 3HAC6670 3 Circuit diagram IRB 2400 3HAC029570 ...

Page 724: ...ircuit diagram IRB 6700 IRB 6790 3HAC13347 1 Circuit diagram IRB 7600 3HAC025744 001 3HAC050778 003 Circuit diagram IRB 14000 3HAC056159 002 Circuit diagram IRB 910SC 724 Product manual IRB 6700Inv 3HAC058254 001 Revision L Copyright 2017 2020 ABB All rights reserved 9 Circuit diagrams 9 1 Circuit diagrams Continued ...

Page 725: ...ing 268 brakes testing function 37 BRU replacing 268 buttons for brake release 68 C cabinet lock 30 cable harness replacing 211 234 cable harness attachments 122 cabling robot 82 cabling between robot and controller 82 calibrating robot 683 roughly 680 calibrating robot 683 696 calibration rough 680 standard type 674 verification 697 when to calibrate 676 calibration manuals 675 calibration marks ...

Page 726: ...is 5 113 axis 6 115 installation mechanical stop axis 1 80 installation procedure 58 installing motor cooling fan 86 instructions for assembly 41 integrator responsibility 29 intervals for maintenance 95 L labels robot 21 leak down test 184 lifting lower and upper arm together 201 robot 59 60 robot down 207 upper arm 204 lifting accessory 712 limitation of liability 17 Lithium disposal 699 loads o...

Page 727: ...ments on foundation 44 responsibility and validity 17 restricting working range axis 1 80 revolution counters storing on FlexPendant 680 updating 680 risk of tipping 50 robot labels 21 lifting 59 60 lifting down from inverted position 207 protection class 45 protection types 45 symbols 21 rotating robot 64 roundslings lifting the robot 60 rubber disposal 699 S safety brake testing 37 ESD 53 fire e...

Page 728: ...turning disc replacing 330 U updating revolution counters 680 upper arm replacing 273 users requirements 18 V validity and responsibility 17 velocity adjusting 92 verifying calibration 697 W weight 43 axis 1 gearbox 579 581 axis 1 gearbox and base 577 585 axis 1 motor 459 462 543 549 569 592 balancing device 345 399 417 421 438 611 robot 62 209 342 413 435 562 575 587 607 upper arm complete 205 28...

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Page 730: ... 47 22 87 2000 ABB Engineering Shanghai Ltd Robotics Discrete Automation No 4528 Kangxin Highway PuDong District SHANGHAI 201319 China Telephone 86 21 6105 6666 ABB Inc Robotics Discrete Automation 1250 Brown Road Auburn Hills MI 48326 USA Telephone 1 248 391 9000 abb com robotics 3HAC058254 001 Rev L en Copyright 2017 2020 ABB All rights reserved Specifications subject to change without notice ...

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